DF200A - 99500-96L00-01E Service Manual

99500-96L00-01E
99500-96L00-01E
2014
No.55-800 99500-96L00-01E DF200A Service Manual Cover for PS printing (XXmm) 5/1 2014/7/29 DIC619 Pantone 303C Pantone 485 Pantone 294 Black
IMPORTANT NOTICE
WARNING / CAUTION / NOTICE / NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and
the words ! WARNING , ! CAUTION , NOTICE and NOTE have special meanings.
Pay special attention to the messages highlighted by these signal words.
! WARNING
Indicates a potential hazard that could result in death or serious injury.
! CAUTION
Indicates a potential hazard that could result in minor or moderate injury.
NOTICE
Indicates a potential hazard that could result in damage to the motor or boat.
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 poten-
tial hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the ! WARNING ,
! CAUTION , and NOTICE stated, you must also use good judgment and observe basic mechanical safety prin-
ciples.
! WARNING
This service manual is intended for authorized Suzuki outboard motor dealers and qualified service
technicians only.
Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment
may not be able to properly perform the services described in this manual. Improper repair may result
in injury to the mechanic and may render the engine unsafe for the boat operator and passengers.
FOREWORD
This manual contains an introductory description of the SUZUKI DF200A Outboard motors and procedures for
inspection, service and overhaul of their main components.
General knowledge information is not included.
Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning this
motor. Read and refer to the other sections in this manual for information regarding proper inspection and service
procedures.
This manual will help you better understand these outboard motors, assisting you in providing your customers
with optimum and quick service.
* This manual has been prepared using the latest information available at the time of publication. Differences
may exist between the content of this manual and the actual outboard motor.
* Illustrations in this manual are used to show the basic principles of operation and work procedures and may
not represent the actual outboard motor in exact detail.
* This manual is intended for use by technicians who already possess the basic knowledge and skills to ser-
vice SUZUKI Outboard motors. Persons without such knowledge and skills should not attempt to service
Suzuki Outboard engines by relying on this manual only and should contact an authorized SUZUKI Out-
board motor dealer.
NOTE:
This manual is compiled with the production model manufactured in October, 2014.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2014

00
TABLE OF CONTENTS
Precautions............................................................... 00-i
Precautions ............................................................ 00-1 1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Tune-Up..................................... 0B-1
Power Head................................................................. 1-i 2
Precautions .............................................................. 1-1
Engine Control ....................................................... 1A-1
Engine Electrical Devices.......................................1C-1
Power Unit Mechanical ..........................................1D-1 3
Power Unit Lubrication ........................................... 1E-1
Power Unit Cooling System ................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System.......................................................1H-1
Starting System....................................................... 1I-1 4
Charging System.................................................... 1K-1
Mid Unit ....................................................................... 2-i
Precautions .............................................................. 2-1
Housing and Bracket.............................................. 2A-1 5
Power Trim and Tilt ................................................ 2B-1
Lower Unit................................................................... 3-i
Precautions .............................................................. 3-1
Right Hand Rotation Unit ....................................... 3A-1 6
Left Hand Rotation Unit.......................................... 3B-1
Wire / Hose Routing ................................................... 4-i
Precautions .............................................................. 4-1
Wire Routing .......................................................... 4A-1 7
Fuel / Water Hose Routing..................................... 4B-1
10
11
12
Table of Contents 00- i
Section 00
00
Precautions
CONTENTS
Precautions ...............................................00-1 Precautions........................................................... 00-1

General Precautions ........................................... 00-1
00-1 Precautions:
Precautions
Precautions
Precautions
General Precautions
CENFH5110000001
The WARNING, CAUTION and NOTICE messages below describe some general precautions that you should observe
when servicing the outboard motor. These general precautions apply to many of the service procedures, but they will
not necessarily be repeated for every procedure to which they apply.
! WARNING
Failure to take proper precautions when servicing the outboard motor can cause severe personal
injury.
• To avoid eye injury, always wear protective glasses when filing metals, working on a grinder, or
doing other work, which could cause debris.
• When two or more persons work together, pay attention to the safety of each other.
• When it is necessary to run the outboard motor indoors, make sure that exhaust gas is vented
outdoors.
• When testing an outboard motor in the water, ensure that the necessary safety equipment is on
board.
Such equipment includes: flotation aids for each person, fire extinguisher, distress signals, anchor,
paddles, bilge pump, first aid kit, emergency starter rope, etc.
• Whenever handling toxic or flammable materials, wear safety glasses to protect your eyes. Any
toxic or flammable materials getting into your eye may cause inflammation. Also wear
moistureproof gloves to protect your skin.
• Do not swallow any toxic or flammable materials. Swallowing them could cause diarrhea, nausea or
other health problems. Be especially careful not to allow children and pets to swallow these
materials.
• Keep all toxic or flammable materials out of reach of children and pets.
• When working with toxic or flammable materials, make sure that the area you work in is well
ventilated and that you follow all of the material manufacturer’s instructions.
• Never use gasoline as a cleaning solvent.
• To avoid getting burned, do not touch the engine, engine oil or exhaust system during or shortly
after engine operation.
• Avoid contact with new and used oil. Prolonged contact with used oil has been shown to cause skin
cancer in laboratory animals. Brief contact with used oil may irritate the skin. Keep new and used oil
away from children and pets. To minimize your exposure to oil, wear a long sleeve shirt and
moisture - proof gloves (such as latex gloves) when changing oil. If oil contacts your skin, wash
thoroughly with soap and water. Launder any clothing or rags if wet with oil. Recycle or properly
dispose of used oil.
• Never disconnect any of the fuel lines between the fuel pump and injectors without first releasing
the fuel pressure, or fuel can be sprayed out under pressure.
• After servicing the fuel, lubrication, cooling and/or the exhaust system, check all lines and fittings
related to the system for leaks.
• Carefully adhere to the battery handling instructions laid out by the battery supplier.
Precautions: 00-2
NOTICE
Failure to take proper precautions when servicing the outboard motor can cause damage to the parts
or the outboard motor.
To prevent the parts or the outboard motor from damage, be sure to take the following precautions:
• When removing parts that are to be reused, keep them arranged in an orderly manner so that they
may be reinstalled in the proper order and orientation.
• Be sure to use special tools where instructed.
• Make sure that all parts used in assembly are clean and also lubricated when specified.
• When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified
type.
• When removing the battery, disconnect the negative cable first and then the positive cable. When
reconnecting the battery, connect the positive cable first and then the negative cable.
• When performing service to electrical parts, if the service procedures do not require using battery
power, disconnect the negative cable at the battery.
• Do not expose connectors and electrical parts to water, which will cause electrical systems
problems.
• Always be careful not to drop electrical components (ECM, relays, etc.) or handle them in a rough
manner.
• Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, locking nuts, cotter
pins, circlips, and certain other parts as specified, always replace them with new ones. Also, before
installing these new parts, be sure to remove any left over material from the mating surfaces.
• Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than
required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely
seated in its groove and securely fitted.
• Use a torque wrench to tighten fasteners to the torque values when specified.
• Remove grease or oil from screw / bolt threads unless a lubricant is specified.
• After assembly, check parts for tightness and proper operation.
NOTE
• To protect the environment, do not unlawfully dispose of used motor oil, other fluids or batteries.
• To protect the Earth’s natural resources, properly dispose of used motor parts.
Replacement Parts
NOTICE
Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to
performance problems and damage.
Use only genuine SUZUKI replacement parts or their equivalent. Genuine SUZUKI parts are high
quality parts which are designed and built specially for SUZUKI outboard motors.
If parts replacement is necessary, Suzuki strongly recommends that you use genuine Suzuki parts or their equivalent.
They are precision-made to ensure high quality and correct fit.
00-3 Precautions:
Section 0
General Information
0
CONTENTS
General Information ................................ 0A-1 Periodic Maintenance Schedule Chart................0B-1

General Description .............................................0A-1 Lubrication Point .................................................0B-2
Symbols .............................................................. 0A-1 Service Instructions .............................................0B-3
Abbreviations ...................................................... 0A-1 Engine Oil Level Check.......................................0B-3
Wire Color Symbols ............................................ 0A-2 Engine Oil Change and Engine Oil Filter
Warning, Caution and Information Label Replacement .....................................................0B-3
Locations........................................................... 0A-2 Gear Oil Change .................................................0B-6
Outboard Motor Identification Number Spark Plug Removal and Installation ..................0B-7
Location ............................................................ 0A-3 Spark Plug Inspection and Cleaning ...................0B-8
Fuel and Oil Recommendations.......................... 0A-3 Tappet Clearance Inspection and Adjustment ....0B-9
Break-In Procedures ........................................... 0A-4 Idle Speed and Idle Air Control (IAC) Duty
Propeller Selection Guide ................................... 0A-5 Inspection........................................................0B-14
Battery Requirement ........................................... 0A-5 Ignition Timing Inspection .................................0B-16
Powerhead Direction of Rotation Description ..... 0A-5 Breather Line and Fuel Line Inspection ............0B-17
Specifications.......................................................0A-6 Low Pressure Fuel Filter Inspection..................0B-18
Specifications ...................................................... 0A-6 High Pressure Fuel Filter Replacement ............0B-19
Service Data ....................................................... 0A-9 Water Pump and Water Pump Impeller
Tightening Torque Specifications...................... 0A-14 Inspection........................................................0B-19
Propeller / Propeller Nut and Cotter Pin
Special Tools and Equipment ...........................0A-15
Inspection........................................................0B-20
Recommended Service Material ....................... 0A-15
Anode Inspection ..............................................0B-20
Special Tool ...................................................... 0A-16
Bonding Wire Inspection ...................................0B-21
Maintenance and Tune-Up...................... 0B-1 Battery Inspection .............................................0B-22
Balancer Chain Replacement ...........................0B-23
Precautions...........................................................0B-1
Thermostat Inspection.......................................0B-23
Precautions for Maintenance .............................. 0B-1
Bolts and Nuts Inspection .................................0B-23
General Description .............................................0B-1 Oil Pressure Check ...........................................0B-24
Recommended Oil and Lubricants...................... 0B-1 Cylinder Compression Pressure Check ............0B-25
Scheduled Maintenance ......................................0B-1
0A-1 General Information:
General Information
General Information
General Description
Symbols
CENFH5110101001
Listed in the table below are the symbols indicating instructions and other important information necessary for proper
servicing.
Please note the definition for each symbol. You will find these symbols used throughout this manual.
Refer back to this table if you are not sure of any symbol(s) meanings.
Symbol Definition
Torque control required.
Data beside it indicates specified torque.
Apply oil.
Use engine oil unless otherwise specified.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1)
Apply SUZUKI Outboard Motor Gear Oil.
Apply SUZUKI Super Grease A.
Apply SUZUKI Moly Paste.
99000-25140
Apply SUZUKI Water Resistant Grease.
Apply SUZUKI Bond 1207B.
Apply SUZUKI Silicone Seal.
Apply SUZUKI Thread Lock 1342.
Apply SUZUKI Thread Lock Super 1333B.
Use special tool.
Do not reuse.
Note on reassembly.
Use peak voltmeter Stevens CD-77.
Abbreviations I:
CENFH5110101002 IAT: Intake Air Temperature
Abbreviations used in this service manual are as follows:
IG: Ignition
A:
Ign.: Ignition
ATDC: After Top Dead Center
IN (In.): Intake
AC: Alternating Current
L:
B:
LPS: Lever Position Sensor
BCM: Boat Control Module
M:
BTDC: Before Top Dead Center
MAP: Manifold Absolute Pressure
C:
O:
CKP Sensor: Crankshaft Position sensor
OCV: Oil Control Valve
CMP Sensor: Camshaft Position sensor
P:
D:
PCV: Positive Crankcase Ventilation
DBW: Drive By Wire
PORT: Port
DC: Direct Current
PTT: Power Trim and Tilt
DOHC: Double Over Head Camshaft
S:
E:
SPC System: Suzuki Precision Control System
ECM: Engine Control Module
SPS: Shift Position Sensor
ETV: Electronic Throttle Valve
STBD: Starboard
ESA: Electronic Shift Actuator
SIGP: Start-In-Gear Protection
EX (Ex.): Exhaust
T:
F:
TPS: Throttle Position Sensor
FP: Fuel Pump
V:
G:
VSV: Vacuum Switching Valve
GND: Ground
VVT: Variable Valve Timing
General Information: 0A-2
Wire Color Symbols

CENFH5110101003
There are two kinds of colored wire used in this product.
One is single colored wire and the other is dual colored (striped) wire.
The single colored wire uses only one color symbol. example: B (Black).
The dual colored wire uses two color symbols. example: Bl/B.
The first symbol represents the base color of the wire and the second symbol represents the color of the stripe.
Example: Bl/B (Blue with Black stripe).
Symbol Wire color Symbol Wire color
B Black Lg Light green
Bl Blue O Orange
Br Brown P Pink
Dg Dark green R Red
G Green V Violet
Gr Gray W White
Lbl Light blue Y Yellow
B (Base Color: Black)
Bl (Base Color: Blue) Bl/B

B (Stripe Color: Black)
IEH511010001-01
Warning, Caution and Information Label Locations

CENFH5110101004
The figure shows main labels among others that are attached to outboard motor.
When servicing outboard motor, refer to WARNING/CAUTION instructions printed on labels.
If any WARNING/CAUTION label is found stained or damage, clean or replace it as necessary.
Do not reuse a label after it has been removed. Always use new label.
3
1
8 WARNING
AVERTISSEMENT
• Fuel can leak creating a fire hazard if
you lay motor on its side. Drain fuel
completely from vapor separator or
carburetor before laying motor on its side.
• See owner’s manual for details.
• Le carburant risque de fuir et de
présenter un danger d’incendie si le
moteur est placé sur le côté.
Vidanger entièrement le carburant du
séparateur de vapeurs ou du
carburateur avant de procéder.
• Pour plus de détail, voir le manuel
du propriétaire.
IFH511010003-06
1. Label, engine cover 2. Label, mag cover 3. Label S.I.G.P.

Outboard Motor Identification Number Location Fuel and Oil Recommendations

CENFH5110101005 CENFH5110101006
Model, Pre-Fix, Serial Number Gasoline
The Model, Pre-fix and Serial number of motor are
stamped on a plate attached to the clamp bracket. NOTICE
Use of leaded gasoline can cause engine
damage.
Use of improper or poor quality fuel can
affect performance and may damage the
motor and fuel system.
Use only unleaded gasoline. Do not use fuel

having lower than the recommended octane,
1
or fuel that may be stale or contaminated by
dirt/water etc.
IEH511010002-03 Suzuki highly recommends that you use alcohol-free

1. Identification number plate
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
Example
equivalent octane content may be used.
1 Allowable maximum blend of a single additive (Not
combination)
&(# 5% Methanol, 10% Ethanol, 15% MTBE
20003F-XXXXXX Engine Oil

57<7-+/1614%14214#6+10
/#&'+0,#2#0 NOTICE
(#$4+37'#7,#210 Use of a poor quality engine oil can adversely
2 3 affect engine performance and life.
IFH511010001-01
1. Model 2. Pre-fix 3. Serial number Suzuki recommends that you use Suzuki
Marine 4-Cycle Engine Oil or its equivalent.
Engine Serial Number Location
A second engine serial number plate is pressed into a Oil quality is a major contributor to your engine’s
boss on the cylinder block. performance and life. Always select good quality engine
oil.
Suzuki recommends the use of SAE 10W-40 or 10W-30
SUZUKI MARINE 4-CYCLE ENGINE OIL.
1
If SUZUKI MARINE 4-CYCLE ENGINE OIL is not
available, select a NMMA certified FC-W oil or good
quality 4-cycle motor oil from the following chart
XXXXXX according to the average temperatures in your area.
API Classification SAE Viscosity Grade
SG
SH 10W–40
SJ
IFH511010002-01
SL
10W–30
1. Serial number plate SM
C –20 –10 0 10 20 30 40
TEMP.
F –4 14 32 50 68 86 104
I9J011010003-02
Gear Oil
Suzuki recommends the use of SUZUKI Outboard Motor
Gear Oil. If it is not available, use SAE 90 hypoid gear oil
which is rated GL-5 under the API classification system.
Break-In Procedures Throttle Recommendation

CENFH5110101007
NOTICE NOTE
Failure to follow the break-in procedures Avoid maintaining a constant engine speed
described below can result in severe engine for an extended period at any time during the
damage. engine break-in period by varying the throttle
position occasionally.
Be sure to follow the engine break-in
procedures described below. First 2 hours
For the first 15 minutes, operate the engine in-gear at
The first 10 hours are critically important to ensure idling speed. During the remaining 1 hour and 45
correct running of either a brand new motor or a motor minutes, operate the engine in-gear at less than 1/2
that has been reconditioned or rebuilt. How the motor is (half) throttle (3 000 r/min).
operated during this time will have direct bearing on its
life span and long-term durability. NOTE
Break-in period The throttle may be briefly opened beyond

10 hours the recommended setting to plane the boat,
but must be reduced to the recommended
Warm-Up Recommendation setting immediately after planning.
NOTICE
Next 1 hour
Running at high speed without sufficient
Operate the engine in-gear at less than 3/4 (three -
warm-up may cause severe engine damage
quarter) throttle (4 000 r/min).
such as piston seizure.
Last 7 hours
Always allow sufficient idling time (5
Operate the engine in-gear at a desired engine speed.
minutes) for the engine to warm-up before
However, do not operate continuously at full throttle for
running at high speed.
more than 5 minutes.
Allow sufficient idling time (more than 5 minutes) for the NOTICE
engine to warm up after cold engine starting.
Running continuously at full throttle for more
than 5 minutes at a time during the last 7
hours of break-in operation may cause
severe engine damage such as seizure.
During the last 7 hours of break-in operation,

do not operate at wide open throttle for more
than 5 minutes at a time.
Propeller Selection Guide Battery Requirement

CENFH5110101008 CENFH5110101009
An outboard motor is designed to develop its rated Suzuki recommends a 12 V cranking type lead acid
power within a specified engine speed range. The battery for the DF200A.
maximum rated power delivered by the DF200A models Minimum battery requirement for starting the engine is
are shown below. provided below.
The battery must satisfy one of the specifications
Recommended full throttle speed range described below.
DF200AT/Z 5 500 – 6 100 r/min
NOTE
NOTICE • The specifications listed below are the
Installing a propeller with either too much or minimum battery rating requirements for
too little pitch will cause incorrect maximum starting the engine.
engine speed, which may result in severe • If your boat application requires additional
damage to the motor. battery loads, it is recommended that an
auxiliary battery or batteries be installed.
Select a propeller that will allow the engine to • Dual-purpose (Cranking/Deep Cycle)
reach the recommended operating range at batteries can be used if they meet the
full throttle with the maximum boat load. minimum specifications listed below
(MCA, CCA, or RC).
If the standard propeller fails to meet the above
requirement, use another pitch propeller to hold the • Do not use a Deep Cycle battery for the
engine speed within the range specified above. main cranking battery.
• The use of Maintenance-Free, sealed, or
Propeller size chart Gel-Cell batteries is not recommended
Right-hand rotation propeller because they may not be compatible with
Blade x Dia. (in.) x Pitch (in.) Suzuki’s charging system.
3 x 15 and 1/2 x 17 • When connecting batteries in parallel, they
3 x 15 and 1/4 x 19 must be of the same type, capacity,
3 x 15 x 21 manufacturer, and of similar age. When
3 x 14 and 3/4 x 23 replacement is necessary, they should be
3 x 14 and 1/2 x 25 replaced as a set.
3 x 14 and 1/2 x 27
• It is recommended that the battery be
3 x 16 x 15
installed in an enclosed case.
3 x 16 x 17
3 x 16 x 18 and 1/2 • When connecting batteries, hexagon nuts
3 x 16 x 20 must be used to secure battery leads to
3 x 16 x 21 and 1/2 battery terminals.
3 x 16 x 23
Battery specification
3 x 16 x 24 and 1/2
850 Marine Cranking Amps (MCA)/ABYC, or 670 Cold
3 x 16 x 26
Cranking Amps (CCA)/SAE or 180 Reserve Capacity
3 x 16 x 27 and 1/2
(RC) Minutes/SAE or 12 V 100 AH
Left-hand rotation propeller
Blade x Dia. (in.) x Pitch (in.) Powerhead Direction of Rotation Description
CENFH5110101010
3 x 15 and 1/2 x 17 This outboard motor is designed with a L.H. (left hand)
3 x 15 and 1/4 x 19 rotation powerhead utilizing an offset crankshaft. This
3 x 15 x 21 design has the advantage of reducing the size of the
3 x 14 and 3/4 x 23 motor and keeping the overall motor’s weight closer to
3 x 14 and 1/2 x 25 the boat transom and therefore closer to the boat C/G
3 x 14 and 1/2 x 27 (Center of Gravity).
3 x 16 x 17 Rotation of the driveshaft is accomplished through a
3 x 16 x 18 and 1/2 crankshaft drive gear and a driveshaft driven gear.
3 x 16 x 20 These gears are located beneath the powerhead in the
3 x 16 x 21 and 1/2 same oil bath location as the camshaft chain.
3 x 16 x 23 As the rotational direction of the driven gear will be
3 x 16 x 24 and 1/2 opposite of the drive gear, a left hand rotation
3 x 16 x 26 powerhead design was adopted to retain a conventional,
standard rotation (right hand) propeller shaft output.
Specifications
Specifications
CENFH5110107001
NOTE
These specifications are subject to change without notice.
Model Pre-Fix
Data
Item Unit
DF200AT DF200AZ
PRE-FIX 20003F 20003Z
Dimensions and Weight

Data
Item Unit
DF200AT DF200AZ
Overall length (front to back) mm (in.) 899 (35.4)
Overall width (side to side) mm (in.) 547 (21.5)
L mm (in.) 1 772 (69.8)
Overall height
X mm (in.) 1 899 (74.8)
L kg (lbs) 226 (498)
Weight (without engine oil)
X kg (lbs) 231 (509)
L mm (in. type) 502 (20)
Transom height
X mm (in. type) 629 (25)
Performance
Data
Item Unit
DF200AT DF200AZ
Maximum output kW (PS) 147 (200)
Recommended operating range r/min 5 500 – 6 100
Idle speed r/min 650 ± 50 (in-gear: Approx. 600 – 700)
Powerhead
Data
Item Unit
DF200AT DF200AZ
Engine type 4-stroke DOHC
Number of cylinders 4
Bore mm (in.) 97 (3.82)
Stroke mm (in.) 97 (3.82)
Total displacement cm3 (cu. in) 2 867(174.9)
Compression ratio :1 10.2
Spark plug NGK LKR6E
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
Fuel and Oil

Data
Item Unit
DF200AT DF200AZ
Suzuki highly recommends the use of alcohol-free
unleaded gasoline with a minimum pump octane rating of
Fuel 87 (R/2+M/2 method) or 91 (Research method). However,
blends of unleaded gasoline and alcohol with equivalent
octane content may be used.
• API classification: SG, SH, SJ, SL, SM or NMMA
certified FC-W oil
Engine oil
• Viscosity rating: SAE 10W-40 or 10W-30,
NMMA FC-W 10W-40 or 10W-30
8.0 (8.5/7.0): Oil change only
Engine oil amounts L (US/lmp. qt)
8.5 (9.0/7.5): Oil filter change
SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear
Gear oil
oil, API classification GL-5.
Gearcase oil capacity ml (US/lmp. oz) 1 100 (37.2/38.7)
Bracket
Data
Item Unit
DF200AT DF200AZ
Trim angle degree 0 – 21 (–6 to 15)
Number of trim position PTT system
Maximum tilt angle degree 75 (–6 to 69)
Lower Unit
Data
Item Unit
DF200AT DF200AZ
Reversing system Gear
Transmission Forward-Neutral-Reverse
Reduction system Bevel gear
Gear ratio 12 : 25 (2.08)
Drive line impact protection Spline drive rubber hub
DF200AT: Clockwise
Propeller shaft rotation (When shift into forward)
DF200AZ: Counterclockwise
Right-hand rotation propeller
Blade x Dia. (in.) x Pitch (in.)
3 x 15 and 1/2 x 17
3 x 15 and 1/4 x 19
3 x 15 x 21
3 x 14 and 3/4 x 23
3 x 14 and 1/2 x 25
3 x 14 and 1/2 x 27
3 x 16 x 15
3 x 16 x 17
3 x 16 x 18 and 1/2
3 x 16 x 20
3 x 16 x 21 and 1/2
3 x 16 x 23
3 x 16 x 24 and 1/2
3 x 16 x 26
Propeller
3 x 16 x 27 and 1/2
Left-hand rotation propeller
Blade x Dia. (in.) x Pitch (in.)
3 x 15 and 1/2 x 17
3 x 15 and 1/4 x 19
3 x 15 x 21
3 x 14 and 3/4 x 23
3 x 14 and 1/2 x 25
3 x 14 and 1/2 x 27
3 x 16 x 17
3 x 16 x 18 and 1/2
3 x 16 x 20
3 x 16 x 21 and 1/2
3 x 16 x 23
3 x 16 x 24 and 1/2
3 x 16 x 26
Reduction System
Data
Item
DF200AT DF200AZ
1st reduction gear ratio
30 : 36 (1.20)
(Crankshaft drive gear: Driven gear)
2nd reduction gear ratio (Lower unit gear) 12 : 25 (2.08)
Total reduction gear ratio 2.50 (36/30 x 25/12)
Service Data
CENFH5110107002
NOTE
These service data are subject to change without notice.
Powerhead
Data
Item Unit
DF200AT DF200AZ
Recommended operating range r/min 5 500 – 6 100
Idle speed r/min 600 – 700 (in-gear: 600 – 700)
kPa
**Cylinder compression pressure 1 100 – 1 700 (11 – 17, 156 – 242)
(kgf/cm2, psi.)
**Cylinder compression pressure max. kPa
100 (1.0, 14)
difference between cylinders (kgf/cm2, psi.)
kPa 400 – 600 (4.0 – 6.0, 57 – 85) at 3 000 r/min
**Engine oil pressure
(kgf/cm2, psi.) (at normal operating temp.)
• API classification: SG, SH, SJ, SL, SM
or NMMA certified FC-W oil
Engine oil
• Viscosity rating: SAE 10W-40 or 10W-30,
8.0 (8.5/7.0): Oil change only
Engine oil amounts L (US/lmp. qt)
8.5 (9.0/7.5): Oil filter change
Thermostat operating temperature °C (°F) 48 – 52 (118 – 125)
**Figures shown are guidelines only, not absolute service limits.
Cylinder Head / Camshaft

Data
Item Unit
DF200AT DF200AZ
Cylinder head distortion Limit mm (in.) 0.05 (0.002)
Manifold seating faces distortion Limit mm (in.) 0.10 (0.004)
std. mm (in.) 45.330 – 45.490 (1.7846 – 1.7909)
IN
Limit mm (in.) 45.230 (1.7807)
Cam height
std. mm (in.) 44.420 – 44.580 (1.7488 – 1.7551)
EX
Limit mm (in.) 44.320 (1.7449)
Top, std. mm (in.) 0.043 – 0.085 (0.0017 – 0.0033)
2nd,
Camshaft journal oil
3rd,
clearance Limit mm (in.) 0.120 (0.0047)
4th,
5th
Top, std. mm (in.) 26.000 – 26.021 (1.0236 – 1.0244)
2nd,
Camshaft journal (housing)
3rd,
inside diameter Limit mm (in.) —
4th,
5th
Top, std. mm (in.) 25.936 – 25.957 (1.0211 – 1.0219)
2nd,
Camshaft journal outside
3rd,
diameter Limit mm (in.) —
4th,
5th
Camshaft runout Limit mm (in.) 0.10 (0.004)
Cylinder head bore to tappet std. mm (in.) 0.025 – 0.066 (0.0010 – 0.0026)
clearance Limit mm (in.) 0.150 (0.0059)
Tappet outer diameter std. mm (in.) 33.959 – 33.975 (1.3370 – 1.3376)
Cylinder head tappet bore std. mm (in.) 34.000 – 34.025 (1.3386 – 1.3396)
Valve / Valve Guide

Data
Item Unit
DF200AT DF200AZ
IN mm (in.) 37.9 (1.49)
Valve diameter
EX mm (in.) 31.4 (1.2)
Tappet clearance IN std. mm (in.) 0.23 – 0.27 (0.009 – 0.011)
(Cold engine condition) EX std. mm (in.) 0.30 – 0.34 (0.012 – 0.013)
IN — 30°, 45°, 60°
Valve seat angle
EX — 30°, 45°, 60°
std. mm (in.) 0.020 – 0.047 (0.0008 – 0.0019)
IN
Valve guide to valve stem Limit mm (in.) 0.070 (0.0028)
clearance std. mm (in.) 0.045 – 0.072 (0.0018 – 0.0028)
EX
Limit mm (in.) 0.090 (0.0035)
IN,
Valve guide inside diameter std. mm (in.) 5.500 – 5.512 (0.2165 – 0.2170)
EX
IN,
Valve guide protrusion std. mm (in.) 11.4 – 11.8 (0.45 – 0.46)
EX
IN std. mm (in.) 5.465 – 5.480 (0.2152 – 0.2157)
Valve stem outside diameter
EX std. mm (in.) 5.440 – 5.455 (0.2142 – 0.2148)
IN Limit mm (in.) 0.14 (0.006)
Valve stem deflection
EX Limit mm (in.) 0.18 (0.007)
IN,
Valve stem runout Limit mm (in.) 0.05 (0.002)
EX
IN,
Valve head radial runout Limit mm (in.) 0.08 (0.003)
EX
std. mm (in.) 1.1 (0.04)
IN
Limit mm (in.) 0.7 (0.03)
Valve head thickness
std. mm (in.) 1.0 (0.04)
EX
Limit mm (in.) 0.7 (0.03)
IN std. mm (in.) 1.1 – 1.3 (0.04 – 0.05)
Valve seat contact width
EX std. mm (in.) 1.1 – 1.3 (0.04 – 0.05)
std. mm (in.) 39.75 (1.56)
Valve spring free length
Limit mm (in.) 38.20 (1.50)
std. N (kg, lbs) 147 – 173 (14.7 – 17.3, 32.4 – 38.1) at 31.1 mm (1.22 in.)
Valve spring preload
Limit N (kg, lbs) 136 (13.6, 30.0) at 31.1 mm (1.22 in.)
Valve spring squareness Limit mm (in.) 2.0 (0.08)
Cylinder / Piston / Piston Ring

Data
Item Unit
DF200AT DF200AZ
Cylinder distortion Limit mm (in.) 0.05 (0.002)
std. mm (in.) 0.045 – 0.065 (0.0018 – 0.0026)
Piston to cylinder clearance
Limit mm (in.) 0.10 (0.0039)
Cylinder bore std. mm (in.) 97.000 – 97.020 (3.8189 – 3.8197)
Cylinder measuring position mm (in.) 50 (2.0) from cylinder top surface
Piston skirt diameter std. mm (in.) 96.945 – 96.965 (3.8167 – 3.8175)
Piston measuring position mm (in.) 12 (0.47) from piston skirt end
Cylinder bore wear Limit mm (in.) 0.10 (0.0039)
std. mm (in.) 0.20 – 0.30 (0.008 – 0.012)
1st
Limit mm (in.) 0.70 (0.028)
Piston ring end gap
std. mm (in.) 0.30 – 0.45 (0.012 – 0.018)
2nd
Limit mm (in.) 1.00 (0.039)
std. mm (in.) Approx. 13.5 (0.53)
1st
Limit mm (in.) 10.8 (0.43)
Piston ring free end gap
std. mm (in.) Approx. 13.6 (0.54)
2nd
Limit mm (in.) 10.9 (0.43)
std. mm (in.) 0.030 – 0.070 (0.0012 – 0.0028)
1st
Piston ring to groove Limit mm (in.) 0.12 (0.005)
clearance std. mm (in.) 0.020 – 0.060 (0.0008 – 0.0024)
2nd
Limit mm (in.) 0.10 (0.004)
1st std. mm (in.) 1.22 – 1.24 (0.048 – 0.049)
Piston ring groove width 2nd std. mm (in.) 1.21 – 1.23 (0.048 – 0.048)
Oil std. mm (in.) 2.51 – 2.53 (0.099 – 0.100)
1st std. mm (in.) 1.17 – 1.19 (0.046 – 0.047)
Piston ring thickness
2nd std. mm (in.) 1.17 – 1.19 (0.046 – 0.047)
std. mm (in.) —
Pin clearance in piston pin hole
Limit mm (in.) —
std. mm (in.) 21.995 – 22.000 (0.8659 – 0.8661)
Piston pin outside diameter
Limit mm (in.) —
std. mm (in.) 22.006 – 22.014 (0.8664 – 0.8667)
Piston pin hole diameter
Limit mm (in.) —
std. mm (in.) —
Pin clearance in conrod small end
Limit mm (in.) —
Crankshaft / Conrod
Data
Item Unit
DF200AT DF200AZ
Conrod small end inside diameter std. mm (in.) 21.968 – 21.979 (0.8649 – 0.8653)
std. mm (in.) 0.045 – 0.063 (0.0018 – 0.0025)
Conrod big end oil clearance
Limit mm (in.) 0.080 (0.0031)
Conrod big end inside diameter std. mm (in.) 57.000 – 57.018 (2.2441 – 2.2448)
Crank pin outside diameter std. mm (in.) 53.982 – 54.000 (2.1253 – 2.1260)
Crank pin outside diameter
Limit mm (in.) 0.010 (0.0004)
difference (Out-of-round and taper)
Conrod bearing thickness std. mm (in.) 1.482 – 1.497 (0.0583 – 0.0589)
std. mm (in.) 0.300 – 0.450 (0.0118 – 0.0177)
Conrod big end side clearance
Limit mm (in.) 0.550 (0.0217)
Conrod big end width std. mm (in.) 22.750 – 22.800 (0.8957 – 0.8976)
Crank pin width std. mm (in.) 23.100 – 23.200 (0.9094 – 0.9134)
Crankshaft center journal runout Limit mm (in.) 0.04 (0.002)
std. mm (in.) 0.030 – 0.050 (0.0012 – 0.0020)
Crankshaft journal oil clearance
Limit mm (in.) 0.065 (0.0026)
Crankcase bearing holder inside
std. mm (in.) 70.000 – 70.018 (2.7559 – 2.7566)
diameter
Crankshaft journal outside diameter std. mm (in.) 64.982 – 65.000 (2.5583 – 2.5591)
Data
Item Unit
DF200AT DF200AZ
Crankshaft journal outside diameter
Limit mm (in.) 0.010 (0.0004)
difference (Out-of-round and taper)
Crankshaft bearing thickness std. mm (in.) 2.497 – 2.512 (0.0983 – 0.0989)
std. mm (in.) 0.11 – 0.31 (0.004 – 0.012)
Crankshaft thrust play
Limit mm (in.) 0.35 (0.014)
Crankshaft thrust bearing thickness std. mm (in.) 2.425 – 2.475 (0.0955 – 0.0974)
Electrical
Data
Item Unit
DF200AT DF200AZ
Ignition timing Degree 0° ± 6° BTDC – 26° BTDC
Over revolution limiter r/min 6 300
CKP sensor resistance Ω at 20 °C 168 – 252
CMP sensor resistance Ω at 20 °C —
Primary Ω at 20 °C —
Ignition coil resistance
Secondary kΩ at 20 °C —
Battery charge coil resistance Ω at 20 °C 0.14 – 0.30
Battery charge coil output (12 V) Watt 528
Type NGK LKR6E
Standard spark plug
Gap mm (in.) 0.8 – 0.9 (0.031 – 0.035)
Main fuse: 60
Starter motor: 30
Ignition coil, Injector, ECM, F/P: 30
Fuse amp. rating A
PTT switch: 10
IAC valve, VSV, VVT: 10
Isolator: 30
Recommended battery capacity (12 V) Ah (kC) 100 (360) or larger
Fuel injector resistance Ω at 20 °C 10 – 14
IAC valve resistance Ω at 20 °C 25 – 34
IAT sensor/Cylinder temp. sensor/Ex.
mani. temp. sensor (Thermistor kΩ at 25 °C 1.8 – 2.3
characteristic)
ECM main relay coil resistance Ω at 20 °C 145 – 190
Starter motor relay coil resistance Ω at 20 °C 145 – 190
PTT motor relay coil resistance Ω at 20 °C 16 – 24
Starter Motor
Data
Item Unit
DF200AT DF200AZ
Max. continuous time of use Sec. 30
Motor output kW 1.4
std. mm (in.) 16.0 (0.63)
Brush length
Limit mm (in.) 12.0 (0.47)
std. mm (in.) 0.5 – 0.8 (0.02 – 0.03)
Commutator undercut
Limit mm (in.) 0.2 (0.01)
std. mm (in.) 29.0 (1.14)
Commutator outside diameter
Limit mm (in.) 28.0 (1.10)
PTT Motor
Data
Item Unit
DF200AT DF200AZ
std. mm (in.) 9.8 (0.39)
Brush length
Limit mm (in.) 5.5 (0.22)
std. mm (in.) 22.0 (0.87)
Commutator outside diameter
Limit mm (in.) 21.0 (0.83)
Self-Diagnostic Code
0: OFF, 1: ON
Fail-safe system
Failed item Code Lamp flashing pattern
activating
1
MAP sensor 1 3–4 0

YES
MCODE00D34-0-01
1
Cylinder temp. sensor 1–4 0

YES
MCODE00D14-0-01
1
IAT sensor 2–3 0

YES
MCODE00D23-0-01
1
CKP sensor 4–2 0

NO
MCODE00D42-0-01
1
CMP sensor #1 2–4 0

NO
MCODE00D24-0-01
1
Air intake system 2–2 0

YES
MCODE00D22-0-01
1
MAP sensor 2 3–2 0

NO
MCODE00D32-0-01
1
Exhaust manifold temp. sensor 1–5 0

YES
MCODE00D15-0-01
1
Fuel injector 4–3 0

NO
MCODE00D43-0-01
1
Throttle position sensor 2–1 0

YES
MCODE00D21-0-01
1
Shift position sensor 1–2 0

YES
MCODE00D12-0-01
1
CMP sensor #2 (VVT) 2–6 0

YES
MCODE00D26-0-01
1
VVT advance 5–1 0

YES
MCODE00D51-0-01
1
Neutral switch 3–3 0

NO
MCODE00D33-0-01
1
Oil control valve 6–1 0

NO
MCODE00D61-0-01
1
Rectifier/Regulator (Over-charging) 1–1 0

NO
MCODE00D11-0-01
1
Oil pressure switch 5–3 0

NO
MCODE00D53-0-01
1
Trim sensor 3–7 0

NO
MCODE00D37-0-01
1
Knock sensor 5–4 0

YES
MCODE00D54-0-01
1
O2 sensor 3–6 0
YES
MCODE00D36-0-04
1
O2 sensor heater 6–3 0

YES
MCODE00D63-0-01
Tightening Torque Specifications

CENFH5110107003
NOTICE
Failure to use the correct fasteners or to properly use fasteners can cause parts or system damage.
• When fasteners are removed, always reinstall them at the locations from which they were removed.
• All fasteners must be replaced with fasteners having the same part number.
If a fastener of the correct part number is not available, a fastener of the same size having equal or
higher strength may be used.
Important Fasteners
Thread Tightening torque
Item
diameter Nm kgf-m lbf-ft
Cylinder head cover bolt 6 mm 11 1.1 8.0
8 mm 23 2.3 16.5
Cylinder head bolt
12 mm 86 8.6 62.0
Outside 10 mm 37 3.7 27.0
Crankcase bolt
Inside 11 mm 58 5.8 42.0
Crankshaft drive gear bolt 10 mm 48 4.8 34.5
30 Nm (3.0 kgf-m, 21.5 lb-ft), then plus turn in 60
Conrod cap bolt 9 mm
degrees.
Camshaft housing bolt 6 mm 12 1.2 8.5
Oil pump bolt 8 mm 23 2.3 16.5
IN. camshaft timing sprocket — 60 6.0 43.5
EX. camshaft timing sprocket — 78 7.8 56.5
OCV bolt 6 mm 12 1.2 8.5
Chain tensioner adjuster bolt 6 mm 11 1.1 8.0
Timing chain guide bolt 8 mm 23 2.3 16.5
Intake manifold bolt/nut 8 mm 23 2.3 16.5
Oil pressure switch — 13 1.3 9.5
Fuel delivery pipe bolt 8 mm 23 2.3 16.5
Fuel delivery pipe plug/union Upper 14 mm 35 3.5 25.5
bolt Lower 14 mm 35 3.5 25.5
Low pressure fuel pump bolt 6 mm 10 1.0 7.0
Thermostat cover bolt 6 mm 11 1.1 8.0
Flywheel bolt 12 mm 118 11.8 85.5
Starter motor mounting bolt 8 mm 23 2.3 16.5
Engine oil filter — 14 1.4 10.0
Engine oil drain plug 12 mm 13 1.3 9.5
8 mm 23 2.3 16.5
Power unit mounting bolt
10 mm 50 5.0 36.0
Driveshaft housing bolt 10 mm 50 5.0 36.0
Upper mount nut 14 mm 100 10.0 72.5
Upper mount cover bolt 10 mm 50 5.0 36.0
Lower mount bolt 14 mm 100 10.0 72.5
Clamp bracket shaft nut 7/8-14 UNF 43 4.3 31.0
Water pump case bolt 8 mm 17 1.7 12.5
Driveshaft oil seal housing — 100 10.0 72.5
10 mm 55 5.5 40.0
Gearcase bolt
12 mm 83 8.3 60.0
Propeller shaft bearing housing bolt 8 mm 23 2.3 16.5
Pinion nut 16 mm 145 14.5 105.0
Propeller nut 18 mm 55 5.5 40.0
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

Type of bolt
diameter Nm kgf-m lbf-ft
5 mm 2–4 0.2 – 0.4 1.5 – 3.0
6 mm 4–7 0.4 – 0.7 3.5 – 5.0
8 mm 10 – 16 1.0 – 1.6 7.0 – 11.5
I9J011010014-01 10 mm 22 – 35 2.2 – 3.5 16.0 – 25.5

(Conventional or “4” marked bolt)
5 mm 2–4 0.2 – 0.4 1.5 – 3.0
6 mm 6 – 10 0.6 – 1.0 4.5 – 7.0
8 mm 15 – 20 1.5 – 2.0 11.0 – 14.5
I9J011010015-01 10 mm 34 – 41 3.4 – 4.1 24.5 – 29.5

(Stainless steel bolt)
5 mm 3–6 0.3 – 0.6 2.0 – 4.5
6 mm 8 – 12 0.8 – 1.2 6.0 – 8.5
8 mm 18 – 28 1.8 – 2.8 13.0 – 20.0
I9J011010016-01 10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5

(“7” marked bolt)
Special Tools and Equipment

Recommended Service Material
CENFH5110108001
93691–80030 99000–22B22 99000–25350 99000–31140 99000–32050

SUZUKI Silicone Seal SUZUKI Outboard SUZUKI Water SUZUKI Bond 1207B SUZUKI Thread Lock
(100 g) Motor Gear Oil Resistant Grease EP2 (100 g) 1342 (50 g)
(250 g)
99000–22810
PTT Fluid
Special Tool
CENFH5110108002
09900–20101 09900–20202 09900–20203 09900–20204 09900–20205

Vernier calipers (150 Micrometer (25 – 50 Micrometer (50 – 75 Micrometer (75 – 100 Micrometer (0 – 25
mm) mm) mm) mm) mm)
09900–20602 09900–20605 09900–20606 09900–20607 09900–20701

Dial gauge Dial calipers (10 – 34 Dial gauge Dial gauge Magnetic stand
mm)
09900–20803 09900–21304 09900–22301 09900–22302 09900–25008

Thickness gauge Steel “V” block set Plastigauge (0.025 – Plastigauge (0.051 – Multi circuit tester set
0.076 mm) 0.125 mm)
09900–28403 09910–39610 09912–58432 09912–58442 09912–58490

Hydrometer Piston pin remover Fuel pressure hose Fuel pressure gauge 3-way joint & hose
and installer
09913–50121 09915–47341 09915–64512 09915–64530 09915–64550

Oil seal remover Oil filter wrench Compression gauge Compression gauge Compression gauge
hose hose attachment
09915–77311 09915–78211 09916–10911 09916–14521 09916–19030

Oil pressure gauge Oil pressure gauge Valve lapper Valve lifter attachment Valve lifter
adapter
09916–34542 09916–34550 09916–37320 09916–44310 09916–56011

Valve guide reamer Valve guide reamer (ø Valve guide reamer (ø Valve guide remover Valve guide installer
handle 5.5 mm) 10.5 mm) attachment
09916–57330 09916–69310 09916–77310 09916–84511 09916–99312

Valve guide installer Tappet holder Piston ring Tweezers Flywheel holder
compressor
09917–47011 09917–49610 09917–98221 09921–29410 09922–59410

Vacuum pump gauge Vacuum pump adapter Valve guide stem seal Driveshaft holder Propeller shaft
installer attachment housing installer
09922–59420 09922–89810 09923–73210 09926–29310 09930–30104

Housing installer Shift lock pin remover Bearing remover Driveshaft housing Sliding hammer
handle remover
09930–30161 09930–76310 09930–88730 09930–89260 09933–39810

Propeller shaft Timing light 36-pin test cord set Injector test cord (A) O2 sensor socket
remover
09940–44121 09940–44130 09944–09810 09944–09820 09945–79310

Air pressure gauge Attachment PTT trim cap tool PTT cylinder cap tool PTT cable extension
09950–69512 09951–09310 09951–09530 09951–99310 09952–09310

Gearcase oil leakage Gear adjust spring set Gear adjusting gauge Gear holder Backlash indicator tool
tester
09952–99320 Stevens peak reading

Hand air pump voltmeter CD-77
0B-1 Maintenance and Tune-Up:
Maintenance and Tune-Up

General Information
Precautions
Precautions for Maintenance
CENFH5110200001
The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work
necessary to keep the motor operating at peak performance and economy.
Maintenance intervals should be judged by number of hours or months, whichever comes first.
NOTE
More frequent servicing should be performed on outboard motors that are used under severe
conditions.
General Description
Recommended Oil and Lubricants
CENFH5110201001
Refer to “Fuel and Oil Recommendations” in Section 0A (Page 0A-3).
Scheduled Maintenance
Periodic Maintenance Schedule Chart
CENFH5110205001
NOTE
I = Inspect and clean, adjust, lubricate or replace, if necessary
T = Tighten
R = Replace
Interval
Item to be serviced Initial 20 hrs. Every 100 hrs. Every 200 hrs. Every 300 hrs.
or 1 month or 12 months or 12 months or 36 months
Spark plug — I — —
Breather & Fuel line I I — —
Engine oil R R — —
Gear oil R R — —
Lubrication I I — —
Anodes (External) I I — —
Anodes (Internal powerhead) — I — —
Bonding wires I I — —
Battery I I — —
Engine oil filter R — R —
High pressure fuel filter Replace every 1 000 hours.
I I — —
Low pressure fuel filter
Replace every 400 hours or 2 years.
Ignition timing — — I —
Idle speed I — I —
Balancer chain Replace every 1 600 hours.
Tappet clearance — — — I
Water pump — — I —
Water pump impeller — — I R
Propeller nut & pin I I — —
Bolt & Nuts T T — —
Thermostat — I — —
Maintenance and Tune-Up: 0B-2
Lubrication Point
CENFH5110205002
Proper lubrication is important for the safe, smooth operation and long life of each working part of the outboard motor.
Apply Suzuki Water Resistant Grease to the following point.
Lubricate
Initially after 20 hours (1 month) and every 100 hours (12 months)
: Grease 99000–25350 (SUZUKI Water Resistant Grease EP2 (250 g))
4
1
3 2
4 6
5
7
IFH511020001-03
1. Throttle cable 3. Clutch lever shaft 5. Trim ram pad 7. Propeller shaft
2. Shift/clutch link 4. Grease nipple, swivel bracket 6. Grease nipple, steering bracket
Service Instructions
Engine Oil Level Check
CENFH5110206001
Inspect oil level

Before every use
1) Place outboard motor upright on a level surface.
2) Remove motor cover.
3) Remove the oil level dipstick (1) and wipe it clean.
IEH511020004-01
Engine Oil Change and Engine Oil Filter

Replacement
CENFH5110206002
Change engine oil

1 Initially after 20 hours (1 month) and every 100 hours
(12 months)
IEH511020002-01
Replace engine oil filter
4) Reinsert dipstick fully into dipstick tube, then remove Initially after 20 hours (1 month) and every 200 hours
it to check oil level. (12 months)
5) Oil level should be between full level Max. mark
(hole) and low level Min. mark (hole). NOTE
If level is low, add recommended oil to full level Max. • Engine oil should be changed while engine
mark. is warm.
Recommended engine oil • When replacing engine oil filter, change
• 4 stroke motor oil engine oil at the same time.
• NMMA certified FC-W oil.
Engine Oil Change
or API classification:
SG, SH, SJ, SL, SM. 1) Place outboard motor upright on a level surface.
• Viscosity rating: 2) Remove oil filler cap (1).
SAE 10W-40 or 10W-30,
“A”
“B” IEH511020005-01
IEH511020003-01
“A”: Max. mark (hole) “B”: Min. mark (hole)

3) Place a container under engine oil drain plug. 6) Pour recommended engine oil into oil filler opening,
4) Remove engine oil drain plug (2) and gasket (3) to then install oil filler cap.
drain engine oil. Recommended engine oil
• 4 stroke motor oil
• NMMA certified FC-W oil.
3 or API classification:
2 SG, SH, SJ, SL, SM.
• Viscosity rating:
SAE 10W-40 or 10W-30,
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)
IEH511020006-01
5) Install new gasket and oil drain plug.

Tighten engine oil drain plug to specified torque.
NOTICE
A previously-used gasket may leak, resulting
in engine damage.
To avoid water entry into oil pan or oil

leakage into the environment do not reuse
gasket once removed.
IEH511020004-01
Always use a new one.
7) Reset oil change reminder system’s operation time
Tightening torque to zero (cancellation).
Engine oil drain plug (a): 13 N·m (1.3 kgf-m, 9.5
NOTE
lbf-ft)
Refer to “Oil Change Reminder System
Description” in Section 1A (Page 1A-14).
(a) 8) Start engine and allow it to run for several minutes at

idle speed.
Check oil drain plug for oil leakage.
Turn off engine and wait for approx. two minutes,
then recheck engine oil level.
IEH511020007-01
Engine Oil Filter Replacement 5) Screw the new filter on by hand until filter O-ring
1) Drain engine oil in the same manner of engine oil contacts the mounting surface.
change procedure. 6) Tighten the filter 3/4 turn from the point of contact
2) Remove STBD lower side cover. with mounting surface using the oil filter wrench.
Refer to “Lower Side Cover Removal and Tightening torque
Installation” in Section 2A (Page 2A-3). Engine oil filter (a): 14 N·m (1.4 kgf-m, 10.0 lbf-ft)
3) Place a shop cloth under the oil filter before removal
to absorb any oil released.
4) Using the oil filter wrench to loosen the oil filter, then (A)
(a)
remove the filter and O-ring.
Special tool
(A): 09915–47341 (Oil filter wrench)
(A)
IFH511020004-01
7) Install STBD lower side cover.

Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
8) Pour the recommended engine oil into the oil filler
opening, then install oil filler cap. Check the oil level
IFH511020003-01
in the same manner of engine oil change procedure.
NOTE Recommended engine oil

• 4 stroke motor oil
Before fitting a new oil filter, be sure to oil the
O-ring. • NMMA certified FC-W oil.
or API classification:
SG, SH, SJ, SL, SM.
• Viscosity rating:
SAE 10W-40 or 10W-30,
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)
9) Reset oil change reminder system’s operation time
to zero (cancellation).
I9J011020004-01 NOTE
Refer to “Oil Change Reminder System
Description” in Section 1A (Page 1A-14).
10) 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.
Gear Oil Change 5) Install air vent plug before removing oil filler tube
CENFH5110206003 from drain hole.
Change gear oil 6) Install oil drain plug.
Initially after 20 hours (1 month) and every 100 hours
(12 months) NOTICE
1) Place outboard motor upright on a level surface. An used gasket may leak and allow water to
enter the gearcase causing severe damage.
2) Place a container under the lower unit.
3) Remove lower gear oil drain plug (1) first, then Do not reuse gaskets once removed.
remove air vent plug (2) and drain gear oil. Always use new gaskets.
NOTE
To avoid a possible low gear oil level,
2 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 (3).
b) If oil can be seen at oil level plug level, the unit is
1
full.
IEH511020010-01
4) Fill with recommended gear oil through oil drain hole c) If oil level is low, re-fill with gear oil through oil
until oil just starts to flow out from air vent hole. level hole.
d) Install oil level plug.
Recommended gear oil
• Suzuki Outboard Motor Gear Oil or API
classification GL5, Viscosity rating SAE # 90
Hypoid gear oil.
Gear oil amount
1 100 ml (37.2/38.7 US/Imp. oz)
IEH511020012-01
IEH511020011-01
Spark Plug Removal and Installation 2) Remove the spark plugs (3) with spark plug wrench.
CENFH5110206004
Inspect spark plug

Every 100 hours (12 months)
3
Standard spark plug
NGK LKR6E
NOTICE
Non-resistor types of spark plugs will
interfere with the function of the electronic
ignition, causing misfiring, or causing
problems with other electronic boat
equipment and accessories. IFH511020006-01
Only resistor (R) type spark plugs must be Installation

used with this engine. Installation is reverse order of removal.
Pay attention to the following:
Removal • Tighten the spark plug to specified torque.
! WARNING Tightening torque

Spark plug (a): 17 N·m (1.7 kgf-m, 12.3 lbf-ft)
The hot engine can burn you.
Wait until the engine is cool enough to touch.
1) Disconnect the ignition coil connectors (1). (a)

Remove the bolts and ignition coils (2).
IFH511020007-01
IFH511020005-01
Spark Plug Inspection and Cleaning Spark Plug Gap

CENFH5110206005 Measure spark plug gap with a thickness gauge. Adjust
NOTICE to within specified range if gap is out of specification.
Non-resistor types of spark plugs will
Special tool
interfere with the function of the electronic
: 09900–20803 (Thickness gauge)
ignition, causing misfiring, or causing
problems with other electronic boat Spark plug gap “a” (Standard)
equipment and accessories. 0.8 – 0.9 mm (0.031 – 0.035 in.)
Only resistor (R) type spark plugs must be

used with this engine.
Inspect spark plug

Standard spark plug
NGK LKR6E
“a”
Carbon Deposits
Inspect for carbon deposits on spark plug base.
I9J011020007-01
If carbon is present, remove it with a spark plug cleaning
machine or by carefully using a pointed tool.
Condition of Electrodes
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.
NOTICE
Use of improper spark plugs can cause
severe engine damage.
If the reach is too short, carbon will be
I9J011020005-01 deposited on the threaded portion of the plug
hole resulting in possible engine damage.
Confirm the thread size and reach when

replacing the plug.
IDG211020060-01
Tappet Clearance Inspection and Adjustment

CENFH5110206006
Inspect tappet clearance

2
Inspection
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 IFH511020009-01
mechanism and will deliver full power. In this engine, the 5) Rotate crankshaft counterclockwise to bring cam
tappet clearance is increased or decreased by replacing nose vertical to shim surface.
the shim disc, made of a special wear resistant material,
fitted to the top of the tappet. Using the proper tools NOTE
provides for easy removal and installation of the shim This is a left hand (LH) rotation powerhead.
disc.
Tappet clearance adjustment should be checked and NOTICE
adjusted: Turning of the engine in clockwise can cause
• During scheduled periodic inspection. water pump impeller damage.
• When valve mechanism is serviced.
• When camshafts are disturbed by removing them for Rotate the crankshaft in the normal running
inspection. direction only (counterclockwise) to prevent
water pump impeller damage.
1) Remove the lower side covers.
Refer to “Lower Side Cover Removal and 6) Measure tappet clearances by inserting thickness
Installation” in Section 2A (Page 2A-3). gauge between cam and shim surface.
2) Remove the ring gear cover and air intake silencer
case (1). NOTE
Refer to “Air Intake Silencer Case Removal and • Rotate crankshaft and measure clearance
Installation” in Section 1D (Page 1D-2). for each tappet respectively by bringing
cam nose vertical to shim surface.
1 • All tappet clearances can be measured
during two crankshaft rotations.
Special tool
(A): 09900–20803 (Thickness gauge)
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.)
IFH511020008-01
3) Remove all spark plugs.

“a”
Refer to “Spark Plug Removal and Installation”
(Page 0B-7).
4) Remove the cylinder head cover (2).
Refer to “Cylinder Head Cover Removal and
Installation” in Section 1D (Page 1D-17).
(A)
I9J011020008-01
“a”: 90°
7) If out of specification, adjust tappet clearance by

changing shim.
Adjustment 4) Rotate top of cam 90 degree clockwise and remove

Tappet clearances are adjusted by replacing tappet shim from cut-away at tappet.
shim. (Two tappets can be adjusted at the same time)
1) With cam nose vertical to valve, turn tappet cut-away
towards center of cylinder head as shown in figure. 4
2 1 “A” IEH511020021-01
IEH511020019-01
1. Shim 4. Magnet
1. Shim “A”: Cut section of the tappet
2. Spark plug hole NOTE
When installing shim, identification mark on
2) Rotate crankshaft to open (lift up) valve and then
the shim should face down (towards tappet).
remove camshaft housing bolts where shim is to be
replaced. 5) After removing shim, measure thickness of original
3) Install special tool with camshaft housing bolts as shim and determine correct thickness of shim for
shown in figure. proper tappet clearance as calculated by following
Special tool formula.
(A): 09916–69310 (Tappet holder) Special tool
(B): 09900–20205 (Micrometer (0 – 25 mm))
3
(B)
(A)
IEH511020020-01
IEH511020022-01
3. Camshaft housing bolt
Tappet clearance specifications
IN. side: A = B + (C – 0.25 mm)
! WARNING EX. side: A = B + (C – 0.32 mm)
A: Correct thickness of shim for proper tappet
Failure to take proper precautions when
clearance (mm)
installing or removing the tappet shim can
B: Thickness of original shim (mm)
result in severe personal injury.
C: Original tappet clearance (mm)
When installing or removing the tappet shim:
“B”
• Never put in the hand between camshaft
and tappet.
• Use a magnet to remove and install shim. 250 “b”
IEH511020023-01
“B”: I.D No. “b”: 2.50 mm

Shim size chart 9) Recheck tappet clearance.

Thickness Thickness
I.D. No. I.D. No. NOTE
(mm) (mm)
218 2.18 260 2.60 After completing tappet clearance
220 2.20 263 2.63 adjustment and securing camshaft housing
223 2.23 265 2.65 bolts, inspect tappet clearance again.
225 2.25 268 2.68
228 2.28 270 2.70 10) After checking and adjusting all valves, reinstall parts
230 2.30 273 2.73 removed earlier.
233 2.33 275 2.75 Installation is reverse order of removal.
235 2.35 278 2.78 a) Cylinder Head Cover.
238 2.38 280 2.80 • Install the cylinder head cover.
240 2.40 283 2.83 Refer to “Cylinder Head Cover Removal and
243 2.43 285 2.85 Installation” in Section 1D (Page 1D-17).
245 2.45 288 2.88
248 2.48 290 2.90 NOTE
250 2.50 293 2.93 Examine cylinder head cover gasket (7) for
253 2.53 295 2.95 damage. Always replace gasket if sealing
255 2.55 298 2.98 performance is suspect.
258 2.58 300 3.00
6) Install shim with the identification number facing

down (towards tappet).
7) Rotate crankshaft clockwise to open (lift up) valve.
NOTE
This step only;
Rotate the crankshaft clockwise, otherwise
the valves may contact with the piston head.
8) Remove special tool and tighten camshaft housing 7

bolts (a) to specified torque.
IEH511020025-01
Tightening torque b) OCV
Camshaft housing bolt (a): 12 N·m (1.2 kgf-m, • Install OCV.
8.5 lbf-ft) Refer to “OCV (Oil Control Valve) Removal
and Installation” in Section 1D (Page 1D-19).
5
(A)
NOTICE
An used gasket may leak, resulting in engine
damage.
(a)
Do not reuse gasket once removed.
Always use a new gasket.
6
IFH511020028-03
c) Final assembly check
5. Tappet 6. Camshaft • All parts removed have been returned to their
original positions.
• Check hose and wire routing.
Refer to “Wiring Harness Routing Diagram” in
Section 4A (Page 4A-2).
• Check oil leakage.
TAPPET SHIM SELECTION CHART [IN. side]
Shim
I.D. No.
218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
Present shim
size (mm)
Tappet 2.18 2.20 2.23 2.25 2.28 2.30 2.33 2.35 2.38 2.40 2.43 2.45 2.48 2.50 2.53 2.55 2.58 2.60 2.63 2.65 2.68 2.70 2.73 2.75 2.78 2.80 2.83 2.85 2.88 2.90 2.93 2.95 2.98 3.00
clearance
(mm)
0.00 – 0.04 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278
0.05 – 0.09 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283
0.10 – 0.14 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288
0.15 – 0.19 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293
0.20 – 0.22 220 223 225 225 228 230 233 235 240 240 245 245 250 250 255 255 260 260 263 265 270 270 273 278 280 280 283 285 290 290 293 295
0.23 – 0.27 SPECIFIED CLEARANCE / NO. ADJUSTMENT REQUIRED

0.28 – 0.32 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.33 – 0.37 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.38 – 0.42 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.43 – 0.47 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.48 – 0.52 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.53 – 0.57 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
Tappet shim selection chart (IN. side)
0.58 – 0.62 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
1. Measure tappet clearance “Engine cold”.
2. Measure present shim size.
0.63 – 0.67 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
3. Match clearance in vertical column with
0.68 – 0.72 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300 present shim size in horizontal column.
0.73 – 0.77 268 270 273 275 278 280 283 285 288 290 293 295 298 300
[ EXAMPLE ]
0.78 – 0.82 273 275 278 280 283 285 288 290 293 295 298 300 Tappet clearance is — 0.35 mm
0.83 – 0.87 278 280 283 285 288 290 293 295 298 300 Present shim size — 2.40 mm
Shim size to be used — 2.50 mm
Maintenance and Tune-Up:
0.88 – 0.92 283 285 288 290 293 295 298 300
IEH511020026-01
0B-12
TAPPET SHIM SELECTION CHART [EX. side]
Shim
ID No.
218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
Present shim
size (mm)
Tappet 2.18 2.20 2.23 2.25 2.28 2.30 2.33 2.35 2.38 2.40 2.43 2.45 2.48 2.50 2.53 2.55 2.58 2.60 2.63 2.65 2.68 2.70 2.73 2.75 2.78 2.80 2.83 2.85 2.88 2.90 2.93 2.95 2.98 3.00
clearance
(mm)
0.00 – 0.04 218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270
0.05 – 0.09 218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275
0.10 – 0.14 218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280
0.15 – 0.19 218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285
0.20 – 0.24 218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290
0.25 – 0.29 218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295
0.30 – 0.34 SPECIFIED CLEARANCE / NO. ADJUSTMENT REQUIRED

0.35 – 0.39 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.40 – 0.44 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.45 – 0.49 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.50 – 0.54 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.55 – 0.59 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.60 – 0.64 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
Tappet shim selection chart (EX. side)
0.65 – 0.69 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300 1. Measure tappet clearance “Engine cold”.
2. Measure present shim size.
0.70 – 0.74 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
3. Match clearance in vertical column with
0.75 – 0.79 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300 present shim size in horizontal column.
0.80 – 0.84 268 270 273 275 278 280 283 285 288 290 293 295 298 300
[ EXAMPLE ]
0.85 – 0.89 273 275 278 280 283 285 288 290 293 295 298 300 Tappet clearance is — 0.40 mm
0.90 – 0.94 278 280 283 285 288 290 293 295 298 300 Present shim size — 2.40 mm
Shim size to be used — 2.50 mm
IEH511020027-01
Idle Speed and Idle Air Control (IAC) Duty 2) Adjust engine speed by the IAC duty fixed mode.
Inspection In IAC duty fixed mode, engine speed can be
CENFH5110206007 adjusted while monitoring engine speed by
Inspect idle speed and IAC duty tachometer.
(12 months)
NOTE
Before checking idle speed/IAC duty, make
sure of the following.
• Engine must be warmed up.
• Check idle speed after engine speed has
stabilized.
• Check throttle link mechanism and throttle I9J011020033-01
valve for smooth operation.

SDS tool is used
• Lead wires and hoses of electronic fuel
To perform the idle speed and IAC duty inspection, use
injection and engine control systems are
personal computer and the SDS tool.
connected securely.
1) Connect the SDS tool to engine.
• Ignition timing is within specification.
Refer to the step 1 on the SDS operation manual.
• Tappet clearance is checked according to
2) Start the engine and allow to warm up.
maintenance schedule.
3) Check the engine speed and IAC duty by using
• No abnormal air drawn in from air intake
“Service data/Engine data” mode in the SDS.
system.
After all items are confirmed, check idle Idle speed in neutral gear (IAC duty)
speed and IAC duty. Standard: 600 – 700 r/min (Duty: Approx. 15%)
There are two methods available for performing the idle NOTE
speed / IAC duty inspection and adjustment; During the period of idling or trolling, the IAC
1) Using a personal computer and the SDS (Suzuki duty is approx. 15%, however it varies by the
Diagnostic System) software. load, the climate, water condition etc. to keep
Suzuki recommends using this method as it is the engine speed at preset value.
possible to monitor the inspection data.
4) If engine idle speed/IAC duty is out of the
specification, the following adjustment must be
performed.
1 NOTE
To access the by-pass air screw, there is the
access hole on the fuel hose guard as shown
in the figure below.
IFH511020010-01
1. SDS service connector

a) Turn the by-pass air screw in an appropriate Adjust engine speed by the IAC duty fixed mode
direction to bring it to the standard specification. Checking and adjustment of idle speed / IAC duty by IAC
duty fixed mode are as follows;
NOTE
1) Start engine and allow to warm up.
Idling/trolling speed is controlled by the IAC
system. NOTE
Do not attempt to adjust the throttle valve To access the by-pass air screw, there is the
opening by turning the throttle stop screw. access hole on the fuel hose guard as shown
in the figure below.
2) Shift into Neutral and close the throttle fully (this will
cause a full close throttle signal to be input to the
ECM).
3) To set the IAC valve duty to constant 13.8%, turn the
1
ignition key from ON 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
IFH511020011-01 While IAC duty is at a fixed 13.8% duty, the
“Check Engine” lamp will flash.
This function is added to “caution buzzer
sound”.
NOTE
• The ignition key operation to set the IAC
valve into the fixed mode should be
performed with the engine running at idle.
2 • While IAC valve duty is at a fixed 13.8%
duty, the caution buzzer will sound in a
repeating pattern of 0.5 second on with an
IFH511020012-02
interval of 3 seconds off.
1. Access hole 2. By-pass air screw
• The 13.8% fixed mode of IAC valve duty
will continue for 5 minutes after which it
b) Shift into forward, check in-gear idle speed.
will automatically cancel.
NOTE
• The IAC duty at the trolling speed will be
increased more than that at idle speed due
to the load.
• Trolling speed (in-gear idle speed) is the
same as engine idle speed.
• Idling/trolling speed of 600 – 700 r/min. is
controlled by the IAC system.
If engine speed can not be controlled to
the specification, IAC passage may be
clogged or IAC system may not operate
correctly.
See “Idle Air Control System Description”
in Section 1G (Page 1G-10).
Idle speed in gear (IAC duty)

600 – 700 r/min (Duty: Approx. 10 – 40%)
4) During this fixed mode of IAC valve duty, adjust Ignition Timing Inspection
engine speed to 650 ± 50 r/min. by turning by-pass CENFH5110206008
air screw. Inspect ignition timing

Turning air screw counterclockwise: Every 200 hours (12 months)
Engine speed will increase.
Turning air screw clockwise: NOTE
Engine speed will decrease. 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.
Special tool
1 (A): 09930–76310 (Timing light)
IFH511020013-02
(A)
IFH511020015-01
2 3) Check the ignition timing while operating the engine
in neutral gear at 1 000 r/min.
IFH511020014-02 Ignition timing

1. Access hole 2. By-pass air screw
Approx. 4° BTDC at 1 000 r/min
5) When finished adjusting the idle speed, opening the (A)
throttle will automatically cancel the IAC fixed mode.
NOTE
The fixed mode of IAC can also be canceled
manually by shifting to Forward or Reverse
or raising the engine speed (changes the TPS
full close throttle signal to OFF).
6) Return the throttle to full close and check engine

speed. IFH511020016-01
It should now be stable at 600 – 700 r/min.
NOTE
Idling/trolling speed of 600 – 700 r/min. is
controlled by IAC (idle air control) system.
If engine speed does not return to
specification, IAC passage may be clogged
or IAC system may not be operating
correctly. See “Idle Air Control System
Description” in Section 1G (Page 1G-10).
NOTE
Trolling speed (in-gear idle speed) is same as
idle speed.
Breather Line and Fuel Line Inspection

CENFH5110206009
Inspect breather line and fuel line

Initially after 20 hours (1 month) and every 100 hours (12 months)
If leakage, cracks, swelling or other damage is found, replace the breather hose and/or fuel line.
Fuel line check point
IFH511020017-02
Low Pressure Fuel Filter Inspection 3) Remove the bolts securing resonator (1), then
CENFH5110206010 remove the resonator.
Inspect low pressure fuel filter
(12 months)
Replace low pressure fuel filter
Every 400 hours or 2 years
If water accumulation, sediment, leakage, cracks or
other damage is found, replace the low pressure fuel
filter.
1 1
IFH511020019-02
4) Remove the nut (2) securing the low pressure fuel

filter to filter bracket.
1
2
IFH511020018-02
1. Low pressure fuel filter
! WARNING
Gasoline is extremely flammable and toxic. IFH511020020-02
It can cause a fire and can be hazardous to
people and pets. NOTICE
Improperly loosening the filter cup can cause
Always take the following precautions when switch lead wires damage.
servicing the fuel filter
• Be careful not to twist the switch lead wire
• Stop the motor before cleaning the low when removing the filter cup.
pressure fuel filter.
• Disconnect the lead wire connector before
• Be careful not to spill fuel. If you do, wipe it removing the filter cup.
up immediately.
• Do not smoke, and keep away from open 5) Push the connector lock tab “A”, then disconnect the
flames and sparks. switch lead wire connector (3).
1) Turn the engine off and allow it to cool.

Make sure that the ignition key is in the OFF
position.
2) Remove STBD lower side cover. 3
“A”
IFH511020021-02
6) Place a rag under the filter before removal to catch High Pressure Fuel Filter Replacement
any spilled fuel. CENFH5110206011
7) Separate the fuel filter cup (4) from the fuel filter Replace high pressure fuel filter
body (5) by turning the fuel filter cup Every 1 000 hours
counterclockwise. SUZUKI recommends that replacing the high pressure
fuel filter every 1 000 operating hours.
For high pressure fuel filter replacement procedure, refer
5 to “High Pressure Fuel Filter Removal and Installation” in
Section 1G (Page 1G-30).
IFH511020022-02
8) Drain fuel and water in the fuel filter cup (4) into a
1
suitable container.
9) Pull out the filter element (6).
10) Inspect the filter element (6), O-ring (7) and seal ring IFH511020023-01
(8) for damage. 1. High pressure fuel filter

If they are damaged, replace them.
Water Pump and Water Pump Impeller
5 Inspection
CENFH5110206012
Inspect water pump/pump impeller

8 Every 200 hours (12 months)
7
6
Replace water pump impeller
4
1) Remove the lower unit and water pump case.
Refer to “Water Pump Removal and Installation” in
IFH511020027-01 Section 3A (Page 3A-7).
11) Wash the filter element (6) with clean solvent and dry 2) Inspect water pump case, inner sleeve and under
it. panel. Replace if wear, cracks, distortion or corrosion
12) Assemble the seal ring (8) and filter element (6) in is found.
their original positions. 3) Inspect water pump impeller.
13) Verify that the O-ring (7) is in place in the top of the Replace if vanes are cut, torn or worn.
filter cup (4) and screw the filter cup back into place. SUZUKI recommends that replacing the water pump
14) Connect the switch lead wire connector (3). impeller every 300 hours (36 months).
15) Reinstall the fuel filter and resonator.
16) Restart the engine and check that there are no leaks
around the fuel filter.
IEH511020034-01
4) Assemble the water pump related items. Anode Inspection

Refer to “Water Pump Removal and Installation” in CENFH5110206014
Section 3A (Page 3A-7). Inspect anodes (External)

5) Install the lower unit assembly. Initially after 20 hours (1 month) and every 100 hours
Refer to “Lower Unit Removal and Installation” in (12 months)
Section 3A (Page 3A-6). Inspect anodes (Internal powerhead)
Propeller / Propeller Nut and Cotter Pin
If 2/3 of zinc anode has corroded away, replace anode.
Inspection
CENFH5110206013 The anode should be periodically cleaned with a wire
brush to ensure maximum effectiveness.
Inspect propeller/propeller nut and cotter pin
Initially after 20 hours (1 month) and every 100 hours NOTICE
(12 months).
If anodes are not properly maintained,
1) Inspect propeller for bent, chipped or broken blades. underwater aluminum surfaces (such as the
Replace propeller if damage noticeably affects lower unit) will suffer galvanic corrosion
operation. damage.
2) Remove the propeller. • Periodically inspect anodes to make sure
Refer to “Propeller Removal and Installation” in they have not become detached.
Section 3A (Page 3A-5). • Do not paint anodes, as this will render
3) Inspect propeller splines. Replace propeller if splines them ineffective.
are worn, damaged or twisted. • Periodically clean anodes with a wire
4) Inspect propeller bush for slippage. brush to remove any coating which might
Replace if necessary. decrease their protective ability.
IEH511020035-01
IEH511020036-01
IEH511020057-01
5) Install the propeller and related parts.

Refer to “Propeller Removal and Installation” in
Section 3A (Page 3A-5). IEH511020037-01
6) Make sure that propeller nut is torqued to

specification and cotter pin is installed securely.
Tightening torque
Propeller nut: 55 N·m (5.5 kgf-m, 40.0 lbf-ft)
NOTE Bonding Wire Inspection

CENFH5110206015
The anode cover (1) may be separated from
the power unit body by inserting and turning Inspect bonding wires
a 10 mm bolt (2) to function as a screw jack. Initially after 20 hours (1 month) and every 100 hours
(12 months)
If breakage or other damage is found on bonding wire,
2 replace the wire.
If rust, corrosion or other damage is found on terminal,
1
clean with cleaning solvent or replace the wire.
IEH511020038-01
IEH511020042-01
IEH511020039-01
IEH511020043-01
IEH511020040-01
NOTE
The anode securing bolt should be covered
with suzuki silicone seal.
: Sealant 93691–80030 (SUZUKI Silicone Seal

(100 g))
IEH511020041-01
Battery Inspection Connecting Battery

CENFH5110206016
Inspect battery ! WARNING

Initially after 20 hours (1 month) and every 100 hours Battery posts, terminals, and related
(12 months) accessories contain lead and lead
compounds that may be hazardous.
! WARNING
Failure to take proper precautions when Wash hands after handling.
handling the battery may cause severe injury.
NOTICE
Be sure to take the following precautions
Failure at the battery connection will cause
when handling the battery:
incorrect operation of the engine control
• Never expose the battery to open flames or system.
electric sparks as batteries generate gas
which is flammable and explosive. Be sure to take the following precautions:
• Do not place the battery near the fuel tank. • Ensure battery cable connections are
• Battery acid is poisonous and corrosive. clean and secure.
Avoid contact with eyes, skin, clothing, • Be sure to use hexagon nuts to secure
and painted surfaces. battery cables to the battery terminals to
If you come in contact with battery acid, avoid loss of electrical power.
flush immediately with large amounts of Do not use wing nuts to secure the battery
water and seek immediate medical cables.
attention.
• Check the nuts periodically for proper
• Batteries should always be kept out of tightness.
reach of children.
• Do not disconnect battery leads from the
• When checking or servicing battery, battery while the engine is running.
disconnect the negative (black) cable.
Be careful not to cause a short circuit by How to connect
allowing metal objects to contact the 1) Connect positive (+) terminal first.
battery posts and motor at the same time.
2) Connect negative (–) terminal second.
• Wear approved eye protection.
3) Upon completion of connection, lightly apply grease
to battery terminals.
Recommended battery
12 V 100 AH (360 kC) or larger 1
Refer to “Battery Requirement” in Section 0A (Page 0A- 3
5).
2
IFH511020002-01
1. Red lead 2. Sub battery cable 3. Black lead

How to disconnect Balancer Chain Replacement

CENFH5110206017
1) Disconnect negative (–) terminal first.
2) Disconnect positive (+) terminal second. Replace balancer chain
Every 1 600 hours
1 SUZUKI recommends replacing the balancer chain,
3
chain tensioner and chain guide every 1 600 hours.
For balancer chain replacement procedure, refer to
2
“Timing Chain, Camshaft Sprocket, Balancer Chain
Removal and Installation” in Section 1D (Page 1D-29).
Thermostat Inspection
CENFH5110206018
IFH511020024-01
Inspect thermostat
1. Red lead 2. Sub battery cable 3. Black lead
Inspect thermostat every 100 hours (12 months).
Battery Solution Level Check Refer to “Thermostat Removal and Installation” in
Section 1F (Page 1F-3) and “Thermostat Inspection” in
NOTICE Section 1F (Page 1F-4).
If you add diluted sulphuric acid to the
battery after it has been initially serviced, you Bolts and Nuts Inspection
will damage the battery. CENFH5110206019
Inspect bolts and nuts

Never add diluted sulphuric acid to the Initially after 20 hours (1 month) and every 100 hours
battery after it has been initially serviced. (12 months)
Follow the battery manufacturer’s
instructions for specific maintenance Check that all bolts and nuts listed below are tightened
procedures. to their specified torque.
Refer to “Tightening Torque Specifications” in Section 0A
Battery solution level should be between UPPER level (Page 0A-14).
and LOWER level. • Cylinder head cover bolts
If level is low, add distilled water only. • Intake manifold bolts and nuts
• Flywheel bolt
• Power unit mounting bolts
• Clamp bracket shaft nut
• Lower mount bolts
• Gearcase bolts
• Propeller nut
I9J011020031-01
Battery Solution Specific Gravity Check

Measure the specific gravity of battery solution using a
hydrometer.
Battery solution specific gravity (Temperature)
1.28 (20 °C)
Special tool
: 09900–28403 (Hydrometer)
I9J011020032-01
Oil Pressure Check 6) After warming up, shift into forward gear and
CENFH5110206020 increase engine speed to 3 000 r/min., then compare
! CAUTION pressure indicated on gauge to specifications.
Engine oil can be hot enough to burn you. NOTE
Do not remove the oil pressure gauge The figure shown below is a guideline only,
adapter when the engine is hot. Wait until not an absolute service limit.
engine cools.
Oil pressure
400 – 600 kPa (4.0 – 6.0 kg/cm2, 57 – 85 psi.)
Check the engine oil pressure periodically.
1) Check the engine oil level. If oil pressure is lower or higher than specification,
2) Remove STBD lower side cover. the following causes may be considered.
Refer to “Lower Side Cover Removal and Low oil pressure
Installation” in Section 2A (Page 2A-3). • Clogged oil filter
3) Remove the plug (1) for oil pressure service port. • Leakage from oil passages
• Defective oil pump
• Defective oil pressure regulator
• Damaged O-ring
• Combination of above items
High oil pressure
• Using an engine oil of too high viscosity
1 • Clogged oil passage
• Clogged oil pressure regulator
• Combination of above items
7) Apply thread lock to the oil pressure service port
IEH511020045-02
plug (1).
4) Install oil pressure gauge in place of service port.
: Thread lock cement 99000–32050
Special tool
(SUZUKI Thread Lock 1342 (50 g))
(A): 09915–77311 (Oil pressure gauge)
(B): 09915–78211 (Oil pressure gauge 8) Tighten the oil pressure service port plug (1) to
adapter) specified torque.
Tightening torque
(A)
Oil pressure service port plug (a): 13 N·m (1.3
kgf-m, 9.5 lbf-ft)
(B)
IEH511020046-02
1 (a)
IEH511020055-01
9) Reinstall STBD lower side cover.

I9J011020033-01
Cylinder Compression Pressure Check 7) While cranking engine with starter motor, note
CENFH5110206021 maximum compression pressure reading on gauge
The compression pressure reading of cylinder is good for each cylinder.
indicator of its internal condition.
The decision to overhaul the power unit is often based NOTE
on the results of a compression test.
Figures shown are guidelines only, not
Periodic maintenance records kept at your dealership
absolute service limits.
should include compression readings for each
maintenance service. Cylinder compression pressure
1) Start engine and allow to warm up, then shut engine Standard: 1 100 – 1 700 kPa (11 – 17 kgf/cm2, 156
off. – 242 psi.)
2) Disconnect all fuel injector connectors at fuel Cylinder compression pressure max. difference
injector. between cylinders
3) Remove all spark plugs. 100 kPa (1.0 kgf/cm2, 14 psi.)
Refer to “Spark Plug Removal and Installation”
(Page 0B-7).
4) Install compression gauge hose attachment into
spark plug hole, then connect compression gauge
hose to gauge hose attachment and compression
gauge.
Special tool
(A): 09915–64512 (Compression gauge)
(B): 09915–64530 (Compression gauge
hose)
(C): 09915–64550 (Compression gauge
hose attachment) IFH511020026-01
Low compression pressure can indicate one or more

of following:
• Excessively worn cylinder wall
• Worn piston or piston rings
• Stuck piston rings
(A) • Poor seating of valves
• Ruptured or otherwise damaged cylinder head
(B) (C)
gasket
8) Reinstall parts removed earlier.
IEH511020049-01
5) Disconnect remote control throttle cable from throttle

lever.
6) Move and hold throttle lever in full-open position.
IFH511020025-01
Section 1
Power Head
CONTENTS
Precautions .................................................1-1 Self-Diagnostic Code “2 – 2” Air Intake

Precautions............................................................. 1-1 System ............................................................1A-35
Precautions for Powerhead................................... 1-1 Self-Diagnostic Code “3 – 2” MAP Sensor 2.....1A-36
Self-Diagnostic Code “3 – 3” Neutral Switch.....1A-38
Engine Control......................................... 1A-1 Self-Diagnostic Code “5 – 1” VVT Advance ......1A-39
Precautions...........................................................1A-1 Self-Diagnostic Code “5 – 3” Oil Pressure
Precautions on Engine Control Diagnosis........... 1A-1 Switch..............................................................1A-40
Self-Diagnostic Code “6 – 1” OCV (Oil Control
General Description .............................................1A-2
Valve) ..............................................................1A-41
Engine Control System Description .................... 1A-2
Self-Diagnostic Code “5 – 4” Knock Sensor......1A-41
Engine Control Module (ECM) ............................ 1A-3
Self-Diagnostic Code “3 – 6” O2 Sensor...........1A-42
Caution System Description................................ 1A-6
Self-Diagnostic Code “6 – 3” O2 Sensor
Self-Diagnostic System Description .................... 1A-9
Heater .............................................................1A-43
Fail-Safe System Description............................ 1A-12
Troubleshooting Without Self-Diagnostic
Operating Hour Indication System
Code................................................................1A-44
Description ...................................................... 1A-13
IAC System Troubleshooting ............................1A-45
Oil Change Reminder System Description........ 1A-14
Water in Fuel Alert System Description ............ 1A-15 Service Instructions ...........................................1A-46
Troll Mode System Description ......................... 1A-15 How to Use the 36-Pin Test Cord Set ...............1A-46
Multi-Stage Induction Description ..................... 1A-16 Inspection of the ECM and Its Circuit................1A-47
VVT (Variable Valve Timing) System ECM Main Relay Inspection..............................1A-50
Description ...................................................... 1A-19 ECM Removal and Installation..........................1A-50
Component Location .........................................1A-21 Engine Electrical Devices ....................... 1C-1
Engine Control System Components / Engine
Electrical Device Location ............................... 1A-21 Precautions...........................................................1C-1
Precaution for Engine Electrical Device ..............1C-1
Diagnostic Information and Procedures..........1A-21
ECM Power and Ground Circuit Check............. 1A-21 General Description .............................................1C-1
Troubleshooting with Self-Diagnostic Code ...... 1A-23 Sensor and Switch Description ...........................1C-1
Self-Diagnostic Code “3 – 4” MAP Sensor........ 1A-23 ECM Power Source Line.....................................1C-6
Self-Diagnostic Code “1 – 4” Cylinder Temp. Component Location ...........................................1C-7
Sensor............................................................. 1A-24 Location of Sensor and Switch............................1C-7
Self-Diagnostic Code “2 – 3” IAT Sensor .......... 1A-25 Service Instructions .............................................1C-7
Self-Diagnostic Code “1 – 5” Ex. Manifold Resistance Check ...............................................1C-7
Temp. Sensor ................................................. 1A-26 Cylinder Temp. Sensor Removal and
Self-Diagnostic Code “3 – 7” Trim Sensor ........ 1A-27 Installation .........................................................1C-8
Self-Diagnostic Code “2 – 1” TPS (Throttle Cylinder Temp. Sensor Inspection ......................1C-9
Position Sensor).............................................. 1A-28 Ex. Manifold Temp. Sensor Removal and
Self-Diagnostic Code “1 – 2” SPS (Shift Installation .........................................................1C-9
Position Sensor).............................................. 1A-29 Ex. Manifold Temp. Sensor Inspection .............1C-10
Self-Diagnostic Code “1 – 1” Rectifier / CKP Sensor Removal and Installation ..............1C-10
Regulator (Over Charging).............................. 1A-30 CKP Sensor Inspection .....................................1C-11
Self-Diagnostic Code “4 – 3” Fuel Injector ........ 1A-31 IAT Sensor Removal and Installation................1C-11
Self-Diagnostic Code “4 – 2” CKP Sensor ........ 1A-32 IAT Sensor Inspection.......................................1C-11
Self-Diagnostic Code “2 – 4” CMP Sensor #1... 1A-33 CMP Sensor Removal and Installation .............1C-12
Self-Diagnostic Code “2 – 6” CMP Sensor #2 CMP Sensor Inspection ....................................1C-12
(VVT)............................................................... 1A-34 MAP Sensor Removal and Installation..............1C-13
1-ii Table of Contents
MAP Sensor Output Voltage Inspection............1C-14 Cylinder Head Components Inspection and
O2 Sensor Removal and Installation.................1C-15 Servicing .........................................................1D-46
O2 Sensor Output Voltage Inspection...............1C-15 Counter-Balancer Mechanism Removal and
O2 Sensor Heater Inspection............................1C-16 Installation .......................................................1D-52
Knock Sensor Removal and Installation ...........1C-17 Counter-Balancer Mechanism Disassembly
Knock Sensor Inspection ..................................1C-17 and Assembly..................................................1D-53
OCV (Oil Control Valve) Inspection...................1C-18 Counter-Balancer Mechanism Component
VSV (Vacuum Switching Valve) Removal and Inspection........................................................1D-55
Installation .......................................................1C-19 Pistons, Piston Rings, Connecting Rods,
VSV (Vacuum Switching Valve) Inspection.......1C-19 Cylinder and Crankshaft Components ............1D-56
IAC Valve Removal and Installation..................1C-20 Pistons, Piston Rings, Connecting Rods,
IAC Valve Inspection.........................................1C-20 Cylinder and Crankshaft Disassembly and
TPS Inspection..................................................1C-21 Assembly.........................................................1D-56
Shift Position Sensor Removal and Cylinder, Piston and Piston Ring Inspection
Installation .......................................................1C-21 and Servicing ..................................................1D-66
Shift Position Sensor Inspection .......................1C-23 Piston Pin and Conrod Inspection .....................1D-68
Trim Sensor Removal and Installation ..............1C-24 Crank Pin and Conrod Bearing Inspection ........1D-69
Trim Sensor Inspection .....................................1C-25 Crankshaft Inspection .......................................1D-71
Emergency Stop Switch Inspection...................1C-26 Crankshaft Main Bearing Inspection .................1D-72
Crankshaft Drive Gear Inspection .....................1D-75
Power Unit Mechanical ........................... 1D-1 Crankshaft Oil Seal Inspection ..........................1D-75
General Description .............................................1D-1 Oil Filter Stand Seal Ring Inspection ................1D-75
Power Unit Construction Description ..................1D-1
Diagnostic Information and Procedures............1D-1 Power Unit Lubrication ........................... 1E-1
Cylinder Compression Check..............................1D-1 General Description .............................................1E-1
Oil Pressure Check .............................................1D-1 Engine Lubrication Description ...........................1E-1
Service Instructions.............................................1D-2 Schematic and Routing Diagram ........................1E-2
Tappet Clearance Inspection ..............................1D-2 Engine Oil Lubrication Chart ...............................1E-2
Ring Gear Cover Removal and Installation.........1D-2 Diagnostic Information and Procedures ............1E-3
Air Intake Silencer Case Removal and Oil Pressure Check .............................................1E-3
Installation .........................................................1D-2 Oil Change Reminder System.............................1E-3
Electric Parts Holder Removal and Installation ....1D-3 Low Oil Pressure Caution System ......................1E-3
Intake Manifold and Throttle Body Powerhead Lubrication System Diagnosis..........1E-3
Components......................................................1D-7 Service Instructions .............................................1E-4
Intake Manifold Removal and Installation ...........1D-8 Oil Pump Removal and Installation .....................1E-4
Throttle Control Cable Installation and Oil Pump Disassembly and Assembly ................1E-5
Adjustment ......................................................1D-11 Oil Pump Component Parts Inspection ...............1E-6
Throttle Link Rod Adjustment............................1D-13 Oil Pressure Switch Removal and Installation ....1E-7
Intake Manifold Disassembly and Assembly.....1D-13 Oil Pressure Switch Inspection ...........................1E-8
Intake Manifold Component Inspection.............1D-15 Oil Strainer Removal and Installation ..................1E-8
Throttle Body Removal and Installation ............1D-16 Oil Strainer Related Parts Inspection ..................1E-8
Throttle Body Inspection ...................................1D-16 Piston Cooling Jet Removal and Installation .......1E-9
Cylinder Head Cover Removal and Piston Cooling Jet Inspection..............................1E-9
Installation .......................................................1D-17
OCV (Oil Control Valve) Removal and Power Unit Cooling System.....................1F-1
Installation .......................................................1D-19 General Description ............................................. 1F-1
OCV (Oil Control Valve) Inspection...................1D-20 Water Cooling System Description ..................... 1F-1
Power Unit Removal and Installation ................1D-20 Displacement Type Water Pump Description ..... 1F-1
Timing Chain, Camshaft Sprocket, Balancer Water Pressure Valve Description ...................... 1F-1
Chain Components .........................................1D-28 Schematic and Routing Diagram ........................ 1F-2
Timing Chain, Camshaft Sprocket, Balancer Cooling Water Circulation Chart.......................... 1F-2
Chain Removal and Installation ......................1D-29
Diagnostic Information and Procedures ............ 1F-3
Timing Chain, Camshaft Sprocket, Balancer
Powerhead Cooling System Diagnosis ............... 1F-3
Chain Related Parts Inspection ......................1D-36
Service Instructions ............................................. 1F-3
Camshaft, Tappet and Shim Removal and
Thermostat Removal and Installation.................. 1F-3
Installation .......................................................1D-38
Thermostat Inspection......................................... 1F-4
Camshaft, Tappet and Shim Inspection ............1D-40
Water Pressure Valve Removal and
Cylinder Head Removal and Installation ...........1D-43
Installation ......................................................... 1F-5
Cylinder Head Disassembly and Assembly ......1D-44
Table of Contents 1-iii
Water Pressure Valve Related Item Component Location ...........................................1H-4

Inspection.......................................................... 1F-6 Ignition System Components Location................1H-4
Water Pump Removal and Installation................ 1F-6 Diagnostic Information and Procedures ............1H-4
Water Pump Related Item Inspection ................. 1F-6 Ignition System Symptom Diagnosis...................1H-4
Water Tube Removal and Installation ................. 1F-6 Ignition System Troubleshooting.........................1H-5
Water Tube Related Item Inspection .................. 1F-6 Service Instructions .............................................1H-6
Spark Plug Removal and Installation ..................1H-6
Fuel System ............................................. 1G-1 Spark Plug Inspection .........................................1H-6
Precautions...........................................................1G-1 Ignition Coil Removal and Installation .................1H-6
Precautions on Fuel System Service ..................1G-1 Ignition Coil Inspection ........................................1H-6
General Description .............................................1G-1 Ignition Coil Operating Signal Inspection ............1H-7
Electronic Fuel Injection System Description ......1G-1 CKP Sensor Inspection .......................................1H-8
Fuel Delivery System Component Description ....1G-4 CMP Sensor Inspection ......................................1H-8
High Pressure Fuel Pump Control System Ignition Switch Inspection....................................1H-8
Description ........................................................1G-7 ECM Main Relay Inspection................................1H-8
Air Intake Components Description.....................1G-8
Idle Air Control System Description ..................1G-10 Starting System .........................................1I-1
Diagnostic Information and Procedures..........1G-12 General Description .............................................. 1I-1
Fuel Pressure Inspection ..................................1G-12 Electric Starter System Description...................... 1I-1
Fuel System Diagnosis .....................................1G-14 Starter Motor Operation Condition
Fuel Injection System Troubleshooting .............1G-15 Description ......................................................... 1I-2
Service Instructions...........................................1G-16 Start-In-Gear Protection System Description ....... 1I-2
Fuel Pressure Relief Procedure ........................1G-16 Component Location ............................................ 1I-3
Fuel Line Removal and Installation ...................1G-16 Starting System Components Location................ 1I-3
Fuel Line Inspection ..........................................1G-17 Diagnostic Information and Procedures ............. 1I-3
Fuel Leakage Check Procedure .......................1G-17 Starter System Troubleshooting........................... 1I-3
Inspection of Fuel Hose Connections ...............1G-17 Service Instructions .............................................. 1I-4
High Pressure Fuel Pump Operating Sound Starter Motor Removal and Installation................ 1I-4
Inspection........................................................1G-18 Starter Motor Test ................................................ 1I-5
Fuel Vapor Separator Removal and Starter Motor Components................................... 1I-7
Installation .......................................................1G-18 Starter Motor Disassembly and Assembly ........... 1I-7
Fuel Vapor Separator Disassembly and Starter Motor Components Inspection and
Assembly ........................................................1G-19 Servicing ............................................................ 1I-9
Inspection of Fuel Vapor Separator Ignition Switch Inspection................................... 1I-13
Component Parts ............................................1G-23 Starter Motor Relay Inspection........................... 1I-14
Fuel Injector Inspection with Injector in Place ...1G-24 Neutral Switch Removal and Installation............ 1I-14
Individual Fuel Injector Operating Sound Neutral Switch Inspection................................... 1I-16
Inspection........................................................1G-24
Fuel Injector Operating Signal Inspection .........1G-25 Charging System ..................................... 1K-1
Fuel Injector Removal and Installation ..............1G-26 General Description .............................................1K-1
Low Pressure Fuel Pump Removal and Charging System Description..............................1K-1
Installation .......................................................1G-28 Battery Requirement Description ........................1K-3
Low Pressure Fuel Pump Inspection ................1G-29
Component Location ...........................................1K-3
Low Pressure Fuel Line Components ...............1G-29
Charging System Components Location.............1K-3
Low Pressure Fuel Filter / Fuel Hose
Diagnostic Information and Procedures ............1K-3
Inspection........................................................1G-30
Charging System Diagnosis................................1K-3
High Pressure Fuel Filter Removal and
Installation .......................................................1G-30 Service Instructions .............................................1K-4
Water Detection Switch Inspection ...................1G-31 Charging System Construction ...........................1K-4
Flywheel Removal and Installation......................1K-5
Ignition System........................................ 1H-1 Battery Charge Coil Removal and Installation ....1K-7
General Description .............................................1H-1 Battery Charge Coil Inspection ...........................1K-8
Ignition System Description ................................1H-1 Rectifier / Regulator Removal and Installation ....1K-8
Ignition Control Description .................................1H-2 Rectifier / Regulator Inspection ...........................1K-9
Main Fuse Inspection ........................................1K-10
1-1 Precautions:
Precautions
Power Head
Precautions
Precautions for Powerhead
CENFH5111000001
Refer to “General Precautions” in Section 00 (Page 00-1).
NOTICE
If the electrical circuits is shorted while servicing the power head, the powerhead electrical circuit
could be damage seriously.
When the intended service operation does not require electric power supply from the battery, be sure
to disconnect the negative cable at the battery before starting the service work.
Engine Control: 1A-1
Engine Control
Power Head
Precautions
Precautions on Engine Control Diagnosis
CENFH5111100001
! WARNING
Service operation of any type performed on engine control system involves a risk of fire and personal
injury if proper precaution are not taken.
To prevent any unexpected engine starting, perform the following before proceeding with any
CRANKING tests.
• When performing tests not related to fuel injector operation:
– Disconnect all fuel injector wire connectors.
• When performing tests related to fuel injector operation:
– Relieve the fuel pressure in the fuel lines.
Refer to “Fuel Pressure Relief Procedure” in Section 1G (Page 1G-16).
– Disconnect the high pressure fuel pump wire connector located on the fuel vapor separator.
! CAUTION
If you do not disconnect the battery before disconnecting or connecting the wiring harness, you could
get an electrical shock.
Always turn the ignition switch “OFF” and disconnect the battery cables when wires are being
disconnected or connected.
NOTICE
Failure to take proper precaution when disconnecting the harness connector can cause damage to the
wiring harness.
Hold and pull the connectors when disconnecting.

Do not pull the wires.
NOTE
• To troubleshoot the ECM and the engine control system, consisting of sensors and actuators, use
the Suzuki Diagnostic System.
• The self-diagnostic codes memory in the ECM will remain even if the battery is disconnected.
• Each electrical circuit is affected by battery voltage, always use a full-charged battery.
• Make sure all ground points have good electrical contact.
• Make sure all wires/cables are securely connected.
1A-2 Engine Control:
General Description
Engine Control System Description
CENFH5111101001
The DF200AT/AZ 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).
System Structure
INPUT CONTROL OUTPUT

(sensor/switch) (ECM) (actuator etc.)
CKP sensor Fuel injection system Fuel injector
CMP sensor #1 Ignition system Ignition coil
CMP sensor #2 VVT system OCV (Oil Control Valve)
Idle air control system IAC valve
MAP sensor
Fuel pump system High pressure fuel pump
IAT sensor
Cylinder temp. sensor Multi-stage induction system VSV (Vacuum Switching Valve)
Ex. manifold temp. sensor
Caution system Caution Buzzer

Throttle position sensor
Water in fuel alert system
Water detection switch
Self diagnostic system
Neutral switch Monitor-tachometer
Fail safe system
Knock sensor
Operating hour indication system
Shift position sensor Oil changing reminder system
Oil pressure switch Starer motor relay,

Start-in-gear protection system (Starter motor)
Emergency stop switch
Starter motor relay control system
Power trim and tilt relay PTT motor relay

Ignition switch control system
PTT switch Trim gauge
Tilt & Trim sensor
O2 sensor
Troll mode switch
IFH511110001-04
Engine Control Module (ECM)

CENFH5111101002
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 the intake air volume
through the IAC valve.
VVT system • Controls intake cam valve timing through OCV (Oil Control
Valve).
Fuel pump control • Controls high pressure fuel pump drive.
Multi-stage induction system • Changing the length of intake manifold pipes according to engine
speed.
Caution system control • Informs operator of abnormal engine condition.
• Controls engine speed, if activated.
Self-diagnostic system control • Informs operator of sensor/switch malfunction.
Fail-safe system control • Allows engine operation with a back-up system during sensor/
switch malfunction.
Total operating hour indication system control • Informs operator of total operating time.
Oil changing reminder system control • Informs operator of time for replacing engine oil on the basis of
the maintenance schedule.
Start-in-gear protection system control • Prevents engine start when shift is positioned in forward or
reverse.
Starter motor relay control system • Prevents starter motor operation when engine is already
operating.
Power trim and tilt relay control system • Controls On/Off for the PTT relay’s up and down circuits.
Water in fuel alert system • Informs operator of water accumulates in the low pressure fuel
filter.
NOTE
Information related to the caution system, self-diagnostic system and total operating hour indication
system is retained in ECM memory.
IFH511110027-01
1. ECM
ECM Input / Output Circuit Diagram
MAIN RELAY
IG SW ECM POWER 2 FUEL INJ #1

12 41
BATTERY ECM
FUEL INJ #2
POWER 1 43
36
FUEL INJ #3
46
MAIN RELAY
24 FUEL INJ #4
39
NEUTRAL
SW
33
NEUTRAL STARTER STARTER
SW RELAY
RELAY
10 HIGH PRESSURE
START START FUEL PUMP
SW 72 M
SW
32
PTT SW RESET SW BUZZER RESET
SW
19
OIL CONTROL
VALVE
PTT SW 44
PTT UP SW
23
VACUUM
SWITCHING
PTT DN SW
22 VALVE
49
PTT
RELAY UP
M PTT 27
PTT
RELAY
26 RELAY DN O2 SENSOR
CKP HEATER
SENSOR 60
4
CMP
SENSOR #1
69
IAC1
CMP 59 M
SENSOR #2 IAC2
70 47
IAC3
50
IAC4
38
SENSOR
PWR (5V)
7
MAP
SENSOR
6 IGN COIL #1
68
SPS
8
IGN COIL #2
54
TPS
5
TRIM & TILT

SENSOR IGN COIL #3
28 66
IGN COIL #4
O2 SENSOR 53
3
IAT SENSOR
14 PWR GND
55
67
CYL TEMP SENSOR PWR GND
15 BUZZER 57
IPS
EX-MANI TEMP OVER HEAT
SENSOR LED
63
17
DIAG LED
62
SENSOR GND
31 OIL PRESSURE
WATER LED 64
DETECTION
SWITCH
21
TRIM GAUGE
IPS 58
OIL PRESSURE
SW
11
OVER REV LED
65
EMERGENCY
STOP SW
9
TACHO METER
1
TROLL MODE
SW
2 COMMUNICATION LINE A 34
SDS TOOL
COMMUNICATION LINE B 35
KNOCK SENSOR ECM GND

56 61
IFH511110002-05
ECM Connector / Terminals Layout
48 47 46 45 44 43 42 41 40 39 38 37 12 11 10 9 8 7 6 5 4 3 2 1
60 59 58 57 56 55 54 53 52 51 50 49 24 23 22 21 20 19 18 17 16 15 14 13
72 71 70 69 68 67 66 65 64 63 62 61 36 35 34 33 32 31 30 29 28 27 26 25
“A” “B”
IFH511110003-01
“A”: Gray connector “B”: Black connector
Terminal Wire color Circuit Terminal Wire color Circuit

1 Y/B Tachometer 37 — —
2 V Troll mode switch 38 W/Bl IAC valve No.4
3 Gr/Bl O2 sensor 39 Lg No.4 fuel injector
4 R/B CKP sensor 40 — —
5 Br/Y Throttle position sensor 41 O/B No.1 fuel injector
6 W MAP sensor 42 — —
7 R Power source for sensors 43 B/Br No.2 fuel injector
8 P/Bl Shift position sensor 44 Br/R OCV
9 Bl/R Emergency stop switch 45 — —
10 G Starter relay control 46 R/W No.3 fuel injector
11 Bl Oil pressure switch 47 R/Y IAC valve No.2
12 B/Bl Power source No.2 for ECM 48 — —
13 — — 49 Gr/G VSV
14 Lg/B IAT sensor 50 O/Bl IAC valve No.3
15 Lg/W Cylinder temp. sensor 51 — —
16 — — 52 — —
17 V/W EX. manifold temp. sensor 53 Lg/R No.4 ignition coil
18 — — 54 Bl/Y No.2 ignition coil
19 O/W Buzzer cancel 55 B Ground for power
20 — — 56 P/Y Knock sensor
21 R/Bl Water detection switch 57 Bl/W Buzzer
22 P PTT switch (DOWN) 58 W/Y Trim gauge
23 Lbl PTT switch (UP) 59 W/B IAC valve No.1
24 P/B Ground for main relay 60 Lg/Bl O2 sensor heater
25 — — 61 B Ground for ECM
26 P PTT relay (DOWN) 62 G/W CHECK ENGINE lamp
27 Lbl PTT relay (UP) 63 G/Y TEMP lamp
28 W/Y Trim and tilt sensor 64 Bl/B Oil lamp
29 — — 65 P/W REV-LIMIT lamp
30 — — 66 Gr/Y No.3 ignition coil
31 B/W Ground for sensors 67 B Ground for power
32 Br Starter switch 68 O No.1 ignition coil
33 Y/G Neutral switch 69 Y/Bl CMP sensor No.1
34 O/Y PC Communication line (A) 70 O/G CMP sensor No.2
35 Y PC Communication line (B) 71 — —
36 Gr Power source No.1 for ECM 72 B/R High pressure fuel pump
Caution System Description

CENFH5111101006
The following four caution systems alert the operator when an abnormality occurs on the engine.
• OVER-REVOLUTION CAUTION
• LOW OIL PRESSURE CAUTION
• OVERHEAT CAUTION
• LOW BATTERY VOLTAGE CAUTION
Monitor-Tachometer
“A”
“D”
“C” “B”
I9J011110004-02
“A”: “REV LIMIT” lamp “C”: “TEMP” lamp

“B”: “OIL” lamp “D”: “CHECK ENGINE” lamp
Caution type Caution lamp Caution buzzer Engine RPM limited

Over-revolution Yes “A” No Yes
Low oil pressure Yes “B” (“A”) Yes Yes
Overheat Yes “C” (“A”) Yes Yes
Low battery voltage Yes “D” Yes No
Lamp Check / Buzzer Check

When the ignition key is turned to the “ON” position:
• Four Caution lamps turns on for two seconds.
• Caution buzzer sounds for two seconds.
Over-Revolution Caution System

Condition:
The ECM controlled 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
DF200A: 6 300 r/min.
Action:
Engine speed • Automatically reduced to approx. 3 000 r/min. by an intermittent fuel injection signal.
• If the operator decreases the engine speed below the over revolution system maximum
preset value, within 10 seconds, the over-revolution caution control will be canceled.
Caution lamp “REV-LIMIT” lamp lights continuously.
Caution buzzer No buzzer sounds.
Reset:
Close the throttle to reduce the engine speed below approx. 3 000 r/min for one second.
Low Oil Pressure Caution System

Condition:
Immediate activation of the system when the oil pressure switch is turned “ON” due to an engine oil pressure drop
below 100 kPa (1.0 kg/cm2, 14 psi.) while the engine is running.
Action:
Engine speed • Automatically reduced to approx. 1 000 r/min. maximum by an intermittent fuel
injection signal.
• The engine automatically stops 3 minutes after the caution system is activated.
Caution lamp • “OIL” lamp lights continuously.
• “REV-LIMIT” lamp lights continuously during engine speed rev-limiter
activation (1 000 r/min, or higher).
Caution buzzer • Sounds in a series of long (1.5 sec.) beeps.
NOTE
If the engine is automatically stopped due to the caution system, the engine can be started again.
However, the caution system will repeatedly activate until the cause is eliminated.
Reset:
Stop the engine and check the engine oil level. Refill the engine oil to the correct level if it is below the low oil level
mark.
If the engine oil level is correct, the following causes may be considered:
• Improper oil viscosity.
• Malfunctioning oil pressure switch.
• Clogged oil strainer or oil filter.
• Worn oil pump relief valve.
• Oil leakage from the oil passage.
• Excessive wear/damage of oil pump.
NOTE
The low oil pressure caution system will reset when the oil pressure is restored to over 100 kPa (1.0
kg/cm2, 14 psi.) at approx. 1 000 r/min. or less engine speed operation.
The engine must be stopped and checked immediately once the system is activated.
Overheat Caution System

Condition 1 (Maximum temperature)
Immediate activation of the system when:
• Cylinder temperature reaches 110 °C (230 °F)
• Exhaust manifold temperature reaches 104 °C (219 °F)
Condition 2 (Gradient temperature – Temp. rise vs. Time)
Immediate activation of the system when:
• The average temperature difference between three consecutive 10 second measurement periods of the cylinder
temperature sensor, at engine speeds of 500 r/min or higher, exceeds the limits as shown below.
Temperature range Temperature difference
80 – 89 °C (176 – 192 °F) Approx. 6 °C (10 °F)
90 °C – (194 °F –) Approx. 1.0 °C (1.8 °F)
• The average temperature difference between 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
72 – 84 °C (161 – 183 °F) Approx. 11 °C (20 °F)
85 °C – (185 °F –) Approx. 1.0 °C (1.8 °F)
Action:
Engine speed • Automatically reduced to approx. 3 000 r/min. maximum by intermittent fuel
injection and ignition signals.
• The engine automatically stops 3 minutes after the caution system is
activated.
Caution lamp • “TEMP” lamp lights continuously.
• “REV-LIMIT” lamp lights continuously during engine speed rev-limiter
activation (3 000 r/min. or higher).
NOTE
If the engine is automatically stopped due to the caution system, the engine can be started again.
The caution system will repeatedly activate until the cause is eliminated.
Reset:
Close the throttle completely and then shift into neutral.
System reset will occur when the cylinder temperature drops below the limits shown below. However, the system may
be activated again unless the cause for overheat (such as insufficient water) is removed.
Caution cause Reset temperature
Condition 1 (Maximum temperature) Approx. 70 – 78 °C (158 – 172 °F)
Condition 2 (Gradient temp. – Temp. rise vs. Time) Approx. 68 – 76 °C (154 – 169 °F)
Low Battery Voltage Caution System

Condition 1:
The system is activated when the battery voltage decreases to less than 9 V for 30 seconds.
Condition 2:
The system is activated if the battery voltage is less than 2 V for more than 2 seconds with the ignition switch is turned
“ON” and the engine not running.
Action:
Engine speed • No engine speed limiter is activated.
Caution lamp • “CHECK ENGINE” lamp lights continuously.
Reset:
Condition 1:
The caution system is automatically reset when battery voltage increases to more than 9 V.
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 this condition possibilities such as a deteriorated battery, poor battery cable
connection, battery switch in the OFF position, etc, must be inspected.
To cancel the caution system activation for these conditions, check all power source related items and eliminate the
problem.
Self-Diagnostic System Description

CENFH5111101007
The self-diagnostic system alerts the operator when an abnormality occurs in a signal from a sensor, or 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 the engine is running, the buzzer sounds a series of short (0.2 sec.) beeps. When the engine is not running, the
buzzer sounds according to each code pattern, but not simultaneously with the flashing lamp. The buzzer sound can
be temporally canceled by pushing the ignition key in.
Monitor-Tachometer
“A”
I9J011110005-01
“A”: “CHECK ENGINE” lamp

Priority / Code / Pattern for Self-Diagnostic System Operation

0: OFF, 1: ON
Priority Failed item Code Lamp flashing pattern Fail-Safe system active
1
1 MAP sensor 1 3–4 0

Yes
MCODE00D34-0-01
1
2 Cylinder temp. sensor 1–4 0

Yes
MCODE00D14-0-01
1
3 IAT sensor 2–3 0

Yes
MCODE00D23-0-01
1
4 CKP sensor 4–2 0

No
MCODE00D42-0-01
1
5 CMP sensor #1 2–4 0

No
MCODE00D24-0-01
1
6 Air intake system 2–2 0

Yes
MCODE00D22-0-01
1
7 MAP sensor 2 3–2 0

No
MCODE00D32-0-01
1
8 Exhaust manifold temp. sensor 1–5 0

Yes
MCODE00D15-0-01
1
9 Fuel injector 4–3 0

No
MCODE00D43-0-01
1
10 Throttle position sensor 2–1 0

Yes
MCODE00D21-0-01
1
11 Shift position sensor 1–2 0

Yes
MCODE00D12-0-01
1
12 CMP sensor #2 (VVT) 2–6 0

Yes
MCODE00D26-0-01
1
13 VVT advance 5–1 0

Yes
MCODE00D51-0-01
1
14 Neutral switch 3–3 0

No
MCODE00D33-0-01
1
15 Oil control valve 6–1 0

No
MCODE00D61-0-01
1
16 Rectifier/Regulator (Over-charging) 1–1 0

No
MCODE00D11-0-01
1
17 Oil pressure switch 5–3 0

No
MCODE00D53-0-01
1
18 Trim sensor 3–7 0

No
MCODE00D37-0-01
1
19 Knock sensor 5–4 0

Yes
MCODE00D54-0-01
1
20 O2 sensor 3–6 0
Yes
MCODE00D36-0-04
1
21 O2 sensor heater 6–3 0

Yes
MCODE00D63-0-01
NOTE
• If two or more items fail at once, the self-diagnostic indication appears according to the priority
order. The indication repeats three times.
• If the failed item remains, the self-diagnostic indication appears again after turning the ignition
switch “ON”.
• After correcting failed item, the self-diagnostic indication appears until the ECM receives the proper
signal with the engine running or turn on the ignition switch from OFF.
• It is the basic theory that the cancellation of self-diagnostic indication is automatically performed
when the failure is corrected and then supplying power to the ECM or operating the motor to receive
a normal signal from sensor, switch, etc. by the ECM.
However, in addition to the above, it has to meet the following conditions.
– The period of 20 – 30 seconds which is necessary for the ECM to decide the signal is normal.
– In the case of the codes 5-1 “VVT advance” or 6-1 “oil control valve”, it is necessary to operate
the VVT system actually.
So it is required to operate the motor at around 3 500 r/min for a certain period.
However, the self-diagnostic code remains until the ECM decides the input signal during cruising.
• The Rectifier/Regulator self-diagnostic indication may not be displayed when the ignition switch is
turned “ON” because the ECM cannot detect rectifier/regulator charging output if the engine is not
running.
Under this condition, the buzzer will not sound a 1 – 1 code.
However, if the rectifier/regulator has failed, the self diagnostic indication will appear again after
starting the engine.
Condition for Self-Diagnostic System Operation

Failed item Condition
• No signal (With engine running).
MAP sensor 1 • Receiving an out of range “37 – 860 mmHg (1.45 – 33.86 inHg) (0.2 – 4.84
V)” signal (With the engine running.).
• No signal.
Cylinder temp. sensor • Receiving an out of range “– 46 to + 170 °C (– 50.8 – +338 °F) (0.10 – 4.6
V)” signal.
• No signal.
IAT sensor • Receiving an out of range “– 46 to + 169 °C (– 50.8 – +336.2 °F) (0.10 –
4.6 V)” signal.
• During the rotation of the predetermined crankshaft angle, the normal CKP
CKP sensor
sensor signal pattern is not received by the ECM.
• During four crankshaft rotations, the normal CMP sensor signal pattern is
CMP sensor #1
not received by the ECM.
• During the ECM’s receiving input of the complete close signal from the
Air intake system throttle position sensor, the engine operates at an abnormally high speed.
(Criterion: 2 100 r/min minimum)
• Receiving unchanging signal regardless engine speed change.
MAP sensor 2
(Pressure detect passage) • From TPS sensor, the full close signal is inputted, but from the MAP
sensor, the signal voltage exceeds 2.0 V.
• No signal.
Exhaust manifold temp. sensor • Receiving an out of range “– 46 to + 170 °C (– 50.8 – +338 °F) (0.10 – 4.6
V)” signal.
Fuel injector • No operation signal from the ECM.
• No signal.
Throttle position sensor
• Receiving an out of range “0.2 – 4.8 V” signal.
Rectifier/Regulator (Over-charging) • Receiving 16 V or higher signal.
• While the engine is stopped and the ignition switch is on, the ECM receives
Oil pressure switch
an “OFF” signal from the oil pressure switch.
CMP sensor (VVT) • During two crankshaft rotation, 4 signals are not input to ECM.
• There is a large difference between the target advance angle and the
VVT advance
actual advance angle.
Failed item Condition

• While the shift sensor outputs the forward or reverse signal, the ECM
Neutral switch
receives input of the neutral signal from the neutral switch.
Oil control valve • OCV not operating.
Trim sensor • Receiving an out of range “0.2 – 4.8 V” signal.
• No signal
Knock sensor
• Receiving an out of range “0.55 – 4.39 V” signal.
• The compensation value of fuel injection amount is more than the
predetermined value while the O2 feedback is executed.
O2 sensor
• The compensation value of fuel injection amount is below the
predetermined value while the O2 feedback is executed.
• No operation signal comes from the ECM. (Open or short in O2 sensor
O2 sensor heater
heater circuit)
Fail-Safe System Description

CENFH5111101008
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 value for the failed sensors.
This allows the engine to continue running under the fail-safe condition.
Pre-Programmed Value for Fail-Safe System

Failed item Pre-Programmed value
• 240 – 760 mmHg (9.4 – 30 inHg)
MAP sensor 1 (The control takes place in accordance with the engine speed.)
• VVT advance is fixed at the most retarded angle.
Air intake system • The control is executed with the maximum engine speed of 2 000 r/min.
Cylinder temp. sensor 60 °C (140 °F)
IAT sensor 45 °C (113 °F)
Exhaust manifold temp. sensor 60 °C (140 °F)
Throttle position sensor • The control is executed with the throttle opening at 30 degrees.
• The shift position (Fwd/Neu/Rev) is detected with the neutral switch signal.
Shift position sensor
• The IAC control follows the forward gear map.
CMP sensor (VVT) • VVT advance is fixed at the most retarded angle.
• VVT advance is fixed at the most retarded angle.
VVT advance • 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.
Trim sensor • The control is continued with fixed sensor output as 3.5 V.
Knock sensor • The ignition timing delays with the predetermined amount.
• The fuel injection amount is controlled with the base map.
O2 sensor
(The O2 feedback can not be executed.)
• The fuel injection amount is controlled with the base map.
O2 sensor heater
(The O2 feedback can not be executed.)
NOTE
There is no back-up system for the ECM itself. The engine will stop if it has failed.
Operating Hour Indication System Description

CENFH5111101013
When the ignition switch is initially turned “ON” (from “OFF”), the ECM tests the caution system by turning on all four
lamps in the monitor-tachometer and sounding the caution buzzer for an initial two seconds.
For the next three seconds, the ECM indicates the total operating hours, using a combination of the tachometer needle
and “REV-LIMIT” lamp flash.
NOTE
The total operating hours displayed are those of the actual engine operation, not the ignition switch
“ON” time.
Monitor-Tachometer
“B”
“A”
I9J011110006-01
“A”: Needle “B”: “REV-LIMIT” lamp
Chart of Total Operating Hours Indication

Monitor-Tachometer
Total operating hours
Needle “A” indication REV-LIMIT lamp “B” flashing*
0 h – (49 h) No
50 h 500 r/min.
60 h 600 r/min. No
↓ ↓
540 h 5 400 r/min.
550 h 500 r/min.
560 h 600 r/min.
1 time
↓ ↓
1 040 h 5 400 r/min.
1 050 h 500 r/min.
↓ ↓ 2 times
1 540 h 5 400 r/min.
1 550 h 500 r/min.
↓ ↓ 3 times
2 030 h 5 300 r/min.
2 040 h or over 5 400 r/min. 3 times
*: One lamp flash corresponds to 500 hours.

Oil Change Reminder System Description Cancellation Procedure

CENFH5111101009
This system informs the operator that it is time to change 1) Turn the ignition key to the “ON” position.
the ENGINE OIL based on the recommended 2) Remove the emergency stop switch plate (1).
maintenance schedule. 3) Pull out the emergency stop switch knob (2) three
When the total motor operating hours has reached the times in ten seconds.
pre-programmed hours, the “OIL” lamp will flash, and the A short beep will be heard if the cancellation is
buzzer will begin a series of double beeps if the engine successful.
is not running (but ignition switch is “ON”). 4) Turn the ignition key to the “OFF” position.
The above mentioned indication will repeat until the
activated system is manually canceled. 5) Set the emergency stop switch plate (1) into the
original position.
NOTE
This system will activate up to 2 100 hour’s
operation.
Indication of System Activation

1
Buzzer
2
I9J011110007-02
NOTE
I9J011110008-01
• Cancellation of the system is possible
whether or not the engine oil has been
Oil lamp
replaced.
Once the system has been activated,
SUZUKI strongly recommends that the
engine oil be replaced before canceling the
system.
• If the engine oil has been replaced with the
system not activated, it is still necessary to
I9J011110009-01 perform the cancellation procedure to
reset the Oil Change Reminder System.
Action
Starting operation
(*1) (*4)
Indication Cancellation
(*2) (*4)
(*3) (*4)
(*3) (*4)
Repeat
I9J011110010-03
*1: Lapse of initial 20 hour’s operation

*2: Lapse of 80 hour’s operation
*3: Lapse of 100 hour’s operation
*4: When performing cancellation before system activation
Water in Fuel Alert System Description During Troll mode, ECM will control the engine speed as
CENFH5111101014 follows:
This engine is equipped with an integral fuel filter/water ECM calculates the target engine speed with the input
separator and associated alert system. signal from the switch, then controls the IAC valve and
The alert system will activate if water separated from the the trolling speed is made to become to the target speed.
fuel exceeds a specific volume.
If this system activates, the red REV-LIMIT lamp will Setting The Troll Mode:
flash and a buzzer will begin a series of triple beeps
when the engine is in neutral only. 1) Shift into forward or reverse gear and make sure that
the throttle is fully closed (in-gear idle speed).
If this system activates, stop the engine, and check the 2) Press the “UP” or “DN” position of the troll mode
fuel filter/water separator for water. switch, until you hear one beep.
For inspection and cleaning of the fuel filter, refer to the The REV/TRL (or REV) lamp on the monitor gauge
“Low Pressure Fuel Filter Inspection” in Section 0B will flash indicating that the motor has been set to the
(Page 0B-18) and “Water Detection Switch Inspection” in troll mode. The REV/TRL (or REV) lamp will
Section 1G (Page 1G-31). continue to flash while the motor is in the troll mode.
Monitor-Tachometer
NOTE
The troll mode system will not operate if the
switch is depressed when the remote control
lever is in the neutral position.
Adjusting Trolling Speed:

1 • When pressing the “UP” switch, one short beep
sounds and the engine speed increases by 50 r/min.
• When pressing the “DN” switch, one short beep
IDG211110030-02
sounds and the engine speed decreases by 50 r/min.
1. “REV-LIMIT” lamp
NOTE
Troll Mode System Description • When pressing the “DN” switch at the
CENFH5111101010
lower limit of trolling speed, the engine
The troll mode system consists of the optional troll mode
speed will not change and three long (0.8
switch, ECM, tachometer/monitor gauge and related
sec.) beeps will sound.
electrical wiring.
The “Troll Mode System” is activated by pressing the troll • When pressing the “UP” switch at the
mode switch, when the motor is running at in-gear idle upper limit of trolling speed, the engine
speed. By using this system, you can set and maintain a speed will not change and three long (0.8
desired engine speed with the control switch in a range sec.) beeps will sound.
from in-gear idle speed (Approx. 650 r/min) to 1 200 r/ • Shift operation and throttle control remain
min. operational, even in troll mode.
5V Cancelling The Troll Mode:

1
The troll mode can be cancelled by shifting the remote
control lever to the neutral position, or by increasing the
2 engine speed to 3 000 r/min or more. In both cases, two
TROLL SW short (0.1 sec.) beeps sound when cancelling the troll
mode.
2
IDG211110031-01
1. ECM 2. Troll mode switch

Multi-Stage Induction Description Vacuum tank

CENFH5111101011 The vacuum tank stores vacuum created during engine
Outline operation. The vacuum tank’ purpose is to supply a
The multi-stage induction system is designed to improve stable vacuum to the depression chamber under the
the intake efficiency by changing the intake tract volume varying vacuum conditions normally occurring within the
in accordance with the engine speed. intake manifold, thereby making it possible to control the
This system improves low and mid range torque and shut off valve accurately.
increases power output at the higher rpm ranges.
A hose and check valve connects one side of the
vacuum tank to the intake manifold. The other side of the
System Composition
tank is connected to the VSV with a hose.
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), vacuum 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 vacuum passage.
1
IFH511110029-01
1. Vacuum tank
VSV (Vacuum Switching Valve)

One side of the VSV is connected via hose to the
vacuum tank, the other side is connected via hose to the
2 depression chamber.
IFH511110028-02
The VSV receives operating signals from the ECM.
When the ECM signals OFF, the VSV releases vacuum
1. Intake manifold assembly 2. Check valve
to the atmosphere.
When the ECM signals ON, the VSV supplies vacuum to
the depression chamber.
IFH511110030-01
1. VSV (Vacuum switching valve)

Depression chamber System operation

The depression chamber is designed to open/close the This system is operated by the vacuum created during
shut off valve. engine operation and controlled by the ECM.
When vacuum is applied to the depression chamber, the To operate the system (open/close the shut off valve to
rod in the chamber is pulled in closing the shut off valve. change the intake tract), the intake manifold, check
When vacuum is not applied to the chamber, the rod valve, vacuum tank, VSV and depression chamber are
returns to the original position, opening the shut off connected with hoses as shown in the illustration.
valve. A rod is used to connect the shut off valve and
depression chamber for opening and closing the valve.
2 1
IFH511110031-01
1. Depression chamber
6
5
4
IFH511110022-02
1. Intake manifold 4. Check valve

2. Throttle body 5. Depression chamber
3. VSV 6. Vacuum tank
Low & mid speed range High speed range

When engine speed is below the preset value (*), the When the engine speed is above the preset value (*),
ECM generates a signal to turn the VSV ON, applying the ECM generates a signal to turn the VSV OFF, and
vacuum to the depression chamber which closes the vacuum is no longer applied to the depression chamber.
shut off valve. Without vacuum the shut off valve return spring returns
With the valve closed during the engines low to mid and holds the valve in its normal open position.
speed range, intake air is supplied through the low and In this operating mode, intake air is supplied to the
mid speed intake tract only. engine through the high speed intake tract only.
In this operating mode, intake air speed is boosted and, This enlarges the intake tract volume, improves intake
combined with the inertia effect to the long intake tract, inertia and efficiency, which increases the engines
increases low and mid speed range engine torque. output power.
High speed
*: Preset value;
DF200A: Approx. 4 700 r/min 1
Low and Mid speed
1
“A”
IEH511140007-06
1. Shut off valve “A”: Air flow

1
“A”
IEH511140006-06
1. Shut off valve “A”: Air flow

VVT (Variable Valve Timing) System Description

CENFH5111101012
• The VVT system is designed to continuously vary intake valve timing to best fit the engines current operating
condition.
• The intake cam timing sprocket assembly (VVT actuator) is located at the front end of the intake camshaft. The
timing sprocket’ internal rotor is operated by engine oil pressure. Since the 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.
• The ECM determines the optimum valve timing (advance angle) under various operating conditions based on
engine speed, manifold pressure (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.
16
“E”
6 2
3 “F”
“G”
4
15 14
“H”
ECM
5
“D”
9 “A”
8 12
7 13
11 “C”
10
“B” “I”
ECM +12 V
“J” “M”
17
19 20
12
“K”
“44”
18
“55”
“L”
IFH511110023-01
1. Ex. camshaft 10. MAP sensor 19. Ex. valve “H”: Drain
2. In. camshaft 11. Manifold pressure signal 20. In. valve “I”: Engine oil pressure
3. Crankshaft 12. Oil control valve (OCV) “A”: Target advance “J”: Advance
4. CKP sensor 13. Oil pan “B”: Actual valve timing “K”: Retard
5. Crank position 14. Oil pump “C”: Feed back “L”: Valve overlap
6. CMP sensor #2 15. Oil filter “D”: Duty control “M”: 40° movable angle
7. Cam position signal 16. VVT actuator “E”: Rotation direction
8. Cylinder temp. sensor 17. Valve lift “F”: Retard pressure
9. Cylinder temp. signal 18. Crank angle “G”: Advance pressure
OCV (Oil Control Valve) Retaining Operation

The OCV is used to regulate oil flow and is installed on When the duty ratio of the ECM is medium, the OCV coil’
the lower camshaft housing. magnetic and return spring forces are equal. This
positions the spool valve between the advance and
Retard Operation retard chamber, closing both oil passages.
When the duty ratio of the ECM is small, the OCV spool
valve is pushed away from the coil by spring force and Intake Cam Timing Sprocket Assembly
engine oil pressure is applied to the retard chamber. Inside the intake cam timing sprocket assembly (VVT
Engine oil remaining in the advance chamber is drained actuator), there are separate advance and retard
out through the spool valve. chambers formed by a partition of the rotor.
The rotor moves inside the housing as engine oil
“C” pressure is applied to the advance or retard chamber.
“A” The intake cam timing sprocket is part of the sprocket
“B” “D”
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
1 2 3 lock pin which engages with the housing when spring
force is greater than oil pressure, locking the rotor in the
IEH511140010-03 most retarded position. This prevents a change of phase
1. Coil “A”: Engine oil pressure “D”: Drain angle between the intake camshaft and intake cam
2. Spool valve “B”: To retard chamber timing sprocket when the engine oil pressure is low at
3. Spring “C”: To advance chamber engine start.
When the engine is started and the engine oil pressure is
Advance Operation applied to the advance chamber, the lock pin is forced
When the duty ratio of the ECM is large, the spool valve up, compressing the return spring, releasing the rotor
is pulled towards the coil by magnetic force, and allowing the VVT actuator to function.
compressing the spring and applying engine oil pressure
to the advance chamber side. 7 2
Engine oil remaining in the retard chamber side is
8
drained out through the spool valve. 1
5
4 6
3
IEH511140011-03
1. Intake cam timing sprocket 5. Rotor

2. Housing 6. Seal
3. Lock pin 7. Advance chamber
4. Spring 8. Retard chamber
Component Location
Engine Control System Components / Engine Electrical Device Location
CENFH5111103001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-2).
Diagnostic Information and Procedures

ECM Power and Ground Circuit Check
CENFH5111104001
Wiring Diagram
9
R
R
6 5
Gr 36
R/W
B/Bl 12
2 8
P/B 24
3
1
BATT W
IG Gr Gr
GND B B
IFH511110004-02
1. Battery 4. Main battery cable 7. ECM main relay

2. Sub battery cable 5. Fuse (60 A) 8. ECM
3. Fuse (15 A) 6. Fuse (30 A) 9. Starter motor
Circuit Description NOTE

The ECM is battery dependent and must be provided Ensure battery cable connections are clean
with its own dedicated 12 V power supply. The electrical and secure.
circuits which provide this supply are: Failure at the battery connection will cause
1) The sub battery cable to the white lead wire in the incorrect operation of the ECM and starter
remote control extension harness to the ignition motor cranking system.
switch.
When the ignition switch is turned ON, battery power 2) The engine wiring harness to the main relay. When
passes from the white lead wire, through the ignition the ECM main relay is energized by turning the
switch contacts to the gray output lead wire to the ignition switch ON, a circuit is formed which supplies
No.12 terminal of ECM. battery voltage to the No.36 terminal of ECM.
Troubleshooting Step 5
Step 1 1) Turn the ignition switch “OFF”.
2) Connect the 36-pin test cord set between the
Is operation of the main relay heard when the
ECM and the main wire harness.
ignition switch is turned “ON”?
3) Turn the ignition switch “ON”.
Yes Go to step 4. 4) Measure the voltage between the No.24 terminal
No Go to step 2. and body ground.
Is the voltage approx. 0.8 V?
Step 2
Yes Go to step 6.
Are the main fuses (60 A and 30 A, for ignition and
ECM) and sub battery cable fuse (15 A) in good No • “P/B” wire open, shorted or poor
condition? connection.
Yes Go to step 3. • If the wiring and connection is OK,
intermittent trouble or a faulty ECM may
No Replace. be the cause.
Step 3 Step 6
1) Disconnect the ECM connectors at the ECM with 1) Turn the ignition switch “ON”.
the ignition switch “OFF”. 2) Measure the voltage between the No.36 terminal
2) Measure the voltage between the No.24 terminal and body ground.
of the ECM connector and body ground.
Is the voltage 12 V (Battery Voltage)?
Yes ECM power and ground circuit are in good
Yes Go to step 4. condition.
No • Check the ECM main relay. No • “Gr” wire open, shorted or poor
Refer to “ECM Main Relay Inspection” connection.
(Page 1A-50). • Faulty ECM main relay.
• Poor ECM main relay connection.
• “P/B” wire open, shorted or poor
connection.
Step 4
1) Turn the ignition switch “OFF”.
2) Connect the 36-pin test cord set between the
ECM and the main wire harness.
3) Turn the ignition switch “ON”.
4) Measure the voltage between the No.12 terminal
and body ground.
Yes Go to step 5.
No • Check the ignition switch.

Refer to “Ignition Switch Inspection” in
Section 1I (Page 1I-13).
• “Gr”, “B/Bl” wire open circuit or poor
connection.
Troubleshooting with Self-Diagnostic Code

CENFH5111104002
! WARNING
Before troubleshooting, read and follow the “Precautions on Engine Control Diagnosis” (Page 1A-1).
In this section, troubleshooting procedures are based on the assumption that the “low pressure fuel system” and
“mechanical components (power unit, lower unit, etc.)” are normal.
Self-Diagnostic Code “3 – 4” MAP Sensor

CENFH5111104003
Wiring Diagram
ECM
5V
1
C
W
P
B/W U
5V
IEH511110028-01
1. MAP sensor
Step 1 1) Check the MAP sensor output voltage change.
Refer to “MAP Sensor Output Voltage Inspection”
1) Remove the fuel hose guard.
in Section 1C (Page 1C-14).
2) With the ignition switch “OFF”, disconnect the
MAP sensor connector. Is it in good condition?
3) With the ignition switch “ON”, check the voltage at Yes • Substitute a good ECM and recheck.
the “R” wire terminal of the MAP sensor
connector. No • Faulty MAP sensor.
Is the voltage approx. 4 – 5 V? • “R” wire shorted to “W” wire, “B/W” wire
open, poor “B/W” wire connection, poor
Yes Go to step 2. “W” wire connection, “W” wire open or
poor MAP sensor connection.
No • “R” wire open, “R” wire shorted to
ground or a poor wire connection. • If the wiring and connection is OK,
• If the wiring and connection is OK, be the cause.
substitute a known-good ECM and
recheck.
For step 1
B/W
R
IDG211110010-02
Self-Diagnostic Code “1 – 4” Cylinder Temp. Sensor

CENFH5111104004
Wiring Diagram
ECM
5V
C
B Lg/W
1 P
B B/W
U
IFH511110005-01
1. Cylinder temp. sensor
Troubleshooting
Step 1
1) With the ignition switch “OFF”, disconnect the cylinder temp. sensor lead wire connector.
2) With the ignition switch “ON”, check the voltage at the “Lg/W” wire terminal of the cylinder temp. sensor
connector.
Is the voltage 4 V or more?
Yes Go to step 2.
No • “Lg/W” wire shorted to the “B/W” wire or ground circuit.

• If the wiring is OK, substitute a known-good ECM and recheck.
Step 2
1) Check the cylinder temp. sensor.
Refer to “Cylinder Temp. Sensor Inspection” in Section 1C (Page 1C-9).
Is it in good condition?
Yes Poor cylinder temp. sensor connection, intermittent trouble or a faulty ECM may be the cause.
No Faulty cylinder temp. sensor.
For step 1
I9J011110045-02
Self-Diagnostic Code “2 – 3” IAT Sensor

CENFH5111104005
Wiring Diagram
ECM
5V
C
Lg/B
1 P
B/W
U
I9J011110024-03
1. IAT sensor
Troubleshooting
Step 1
1) With the ignition switch “OFF”, disconnect the IAT sensor connector.
2) With the ignition switch “ON”, check the voltage at the “Lg/B” wire terminal of the IAT sensor connector.
Yes Go to step 2.
No • “Lg/B” wire shorted to “B/W” wire or ground circuit.

Step 2
1) Check the IAT sensor.
Refer to “IAT Sensor Inspection” in Section 1C (Page 1C-11).
Yes Poor IAT sensor connection, intermittent trouble or a faulty ECM may be cause.
No Faulty IAT sensor.
For step 1
I9J011110046-01
Self-Diagnostic Code “1 – 5” Ex. Manifold Temp. Sensor

CENFH5111104006
Wiring Diagram
ECM
5V
C
1 B V/W
P
B B/W
U
I9J011110030-02
1. Ex. manifold temp. sensor
Troubleshooting
Step 1
1) With the ignition switch “OFF”, disconnect the Ex. manifold temp. sensor lead wire connector.
2) With the ignition switch “ON”, check the voltage at the “V/W” wire terminal of the Ex. manifold temp. sensor
connector.
Yes Go to step 2.
No • “V/W” wire shorted to “B/W” wire or ground circuit.

Step 2
1) Check the Ex. manifold temp. sensor.
Refer to “Ex. Manifold Temp. Sensor Inspection” in Section 1C (Page 1C-10).
Yes Poor Ex. manifold temp. sensor connection, intermittent trouble or a faulty ECM may be the cause.
No Faulty Ex. manifold temp. sensor.
For step 1
I9J011110049-01
Self-Diagnostic Code “3 – 7” Trim Sensor

CENFH5111104007
Wiring Diagram
ECM
1
5V
R R
C
W/Y W/Y P
U
B/W B/W
IEH511110029-01
1. Trim sensor
Troubleshooting
Step 1
1) With the ignition switch “OFF”, disconnect trim sensor connector.
2) With the ignition switch “ON”, check the voltage at the “R” wire terminal of trim sensor connector.
Is the voltage approx. 4 – 5 V?
Yes Go to step 2.
No • “R” wire open, “R” wire shorted to ground circuit or poor wire connection.
• If the wire and connection is OK, substitute a known-good ECM and recheck.
Step 2
1) Check the trim sensor output voltage change.
Refer to “Trim Sensor Inspection” in Section 1C (Page 1C-25).
Yes Poor trim sensor connection, intermittent trouble or a faulty ECM.
No • “R” wire shorted to “W/Y” wire, “B/W” wire open, poor “B/W” wire connection, poor “W/Y” wire
connection, “W/Y” wire open or poor trim sensor connection.
• If the wire and connection is OK, intermittent trouble or a faulty ECM may be the cause.
• Faulty trim sensor.
For step 1
W/Y
B/W
R
IDG211110015-04
Self-Diagnostic Code “2 – 1” TPS (Throttle Position Sensor)

CENFH5111104008
Wiring Diagram
1 ECM
5V
Br/Y
C
P
B/W U
I9J011110059-01
1. TPS
Troubleshooting
Step 1
2) With the ignition switch “OFF”, disconnect the TPS connector.
3) With the ignition switch “ON”, check the voltage at the “R” wire terminal of the TPS connector.
Yes Go to step 2.
No • “R” wire open, “R” wire shorted to ground circuit or poor connection.
• If the wiring and connection is OK, substitute a known-good ECM and recheck.
Step 2
1) Check the TPS output voltage change.
Refer to “TPS Inspection” in Section 1C (Page 1C-21).
Yes Substitute a known-good ECM and recheck.
No • Faulty TPS.
• “R” wire shorted to “Br/Y” wire, “B/W” wire open, poor “B/W” wire connection, poor “Br/Y” wire
connection, “Br/Y” wire open or poor TPS connection.
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.
For step 1
B/W
Br/Y
IDG211110013-01
Self-Diagnostic Code “1 – 2” SPS (Shift Position Sensor)

CENFH5111104009
Wiring Diagram
1 ECM
5V
Bl R
C
Y P/Bl P
B B/W
U
IFH511110006-01
1. SPS
Troubleshooting
Step 1
1) Remove lower side covers.
2) With the ignition switch “OFF”, disconnect the SPS lead wire connector.
3) With the ignition switch “ON”, check the voltage at the “R” wire terminal of the SPS lead wire connector.
Yes Go to step 2.
No • “R” wire open, “R” wire shorted to ground circuit or poor connection.
Step 2
1) Check the SPS output voltage change.
Refer to “Shift Position Sensor Inspection” in Section 1C (Page 1C-23).
Yes Poor shift position sensor connection, intermittent trouble or a faulty ECM may be the cause.
No • Faulty SPS.
• “R” or “Bl” wire shorted to “P/Bl” or “Y” wire, “B/W” or “B” wire open, poor “B/W” or “B” wire connection,
poor “P/Bl” or “Y” wire connection, “P/Bl” or “Y” wire open or poor SPS connection.
For step 1
P/Bl
R
B/W
IFH511110007-01
Self-Diagnostic Code “1 – 1” Rectifier / Regulator (Over Charging)

CENFH5111104010
NOTE
• This self-diagnostic code indication may be canceled when turning the ignition switch “ON” (engine
not running), because ECM detects battery voltage.
• It is difficult to thoroughly check the rectifier/regulator. Before replacing it with new one, check that
the ground point has good electrical contact.
Troubleshooting
Step 1
1) Check the rectifier/regulator.
Refer to “Rectifier / Regulator Inspection” in Section 1K (Page 1K-9).
Is the result OK?
Yes Go to step 2.
No Faulty rectifier/regulator.
Step 2
1) With the engine running, check charging voltage at idle speed.
Is the result 16 V or higher?
Yes Faulty rectifier/regulator.
No Faulty ECM or wire continuity/connection failure.

Self-Diagnostic Code “4 – 3” Fuel Injector

CENFH5111104011
Wiring Diagram
12 V (From main relay)
1 ECM
#1
O/B
#2
B/Br
#3
C
R/W
#4
P
Lg
U
IEH511110033-01
1. Fuel injector
Step 1 1) Disconnect the ECM connectors with the ignition
switch “OFF”, and check all of the injectors for
1) Using a sound scope, check that each injector has
resistance.
an operating sound when the engine is cranking.
Refer to “Resistance Check” in Section 1C (Page
Do all injectors make an operating sound? 1C-7).
Yes Fuel injector and its circuit are in good Is the resistance 10 – 14 Ω for each injector?
condition.
Yes Substitute a known-good ECM and
No Go to step 2. recheck.
Step 2 No Faulty injector or its circuit.

1) Check the fuel injector, the wiring connection and
the wire harness of the fuel injector not making the For step 3
operating sound.
Are all of the above OK?
Yes Substitute a known-good ECM and

recheck.
No • Faulty injector or its circuit. Gr

• Go to step 3.
Step 3 I9J011110023-02
1) With the ignition switch “OFF”, disconnect the

connectors from the fuel injectors.
2) Check the voltage at “Gr” wire terminal with the
ignition switch “ON”.
Is the voltage 12 V (battery voltage)?
Yes Go to step 4.
No Power circuit open.

Self-Diagnostic Code “4 – 2” CKP Sensor

CENFH5111104012
Wiring Diagram
ECM
C
R/B R/B
P
B/G B/W U
IEH511110034-02
1. CKP sensor
Troubleshooting
Step 1
1) Check the CKP sensor air gap.
Refer to “CKP Sensor Removal and Installation” in Section 1C (Page 1C-10).
Yes Go to step 2.
No Incorrectly adjusted air gap.
Step 2
1) Check the CKP sensor resistance.
Refer to “Resistance Check” in Section 1C (Page 1C-7).
Yes Open wire between the CKP sensor and the ECM, poor lead wire connection or sensor lead wires are
shorted to each other. If lead wire and connection are OK, intermittent trouble or a faulty ECM may be
the cause.
No Faulty CKP sensor.

Self-Diagnostic Code “2 – 4” CMP Sensor #1

CENFH5111104013
Wiring Diagram
ECM
1 2
B/Bl
Y/Bl
C
P
B/W U
IFH511110008-01
1. CMP sensor #1 2. + 12 V (From ignition switch)
Step 1 Was terminal “B/Bl” voltage in step 2 within
specification?
Is the CMP sensor #1 installed properly and the
wire harness connected securely? Yes Go to step 5.
Yes Go to step 2. No “B/Bl” wire open circuit. If the wiring and
connection is OK, substitute a known-
No Correct.
good ECM and recheck.
Step 2
Step 5
1) With the ignition switch “OFF”, disconnect the Check the CMP sensor #1 and sensor trigger vane.
connector from the CMP sensor #1. Refer to “CMP Sensor Inspection” in Section 1C (Page
2) Check for proper connection to the CMP sensor 1C-12).
#1 at “B/Bl”, “Y/Bl” and “B/W” wire terminals.
Is check result satisfactory?
3) If OK, turn the ignition switch “ON” and check the
voltage at the “B/Bl”, “Y/Bl” and “B/W” wire Yes Substitute a known-good ECM and
terminals of the CMP sensor #1 connector. recheck.
CMP sensor #1 voltage No Replace CMP sensor #1.
Terminal “B/Bl”: 10 – 14 V
Terminal “Y/Bl”: 4 – 5 V
Terminal “B/W”: 0 V For step 2
Is the voltage satisfactory?
Yes Go to step 5.
B/W
No Go to step 3.
Y /Bl
Step 3 B/B l
IFH511110009-01
Was terminal “Y/Bl” voltage in step 2 within
specification?
Yes Go to step 4.
No “Y/Bl” wire open or shorted to ground/

power supply circuit. If the wiring and
Self-Diagnostic Code “2 – 6” CMP Sensor #2 (VVT)

CENFH5111104014
Wiring Diagram
ECM
1 2
B/Bl
O/G
C
P
B/W U
IFH511110010-01
1. CMP sensor #2 2. + 12 V (From ignition switch)
Step 1 Was terminal “B/Bl” voltage in step 2 within
specification?
Is the CMP sensor #2 installed properly and the
wire harness connected securely? Yes Go to step 5.
Yes Go to step 2. No “B/Bl” wire open circuit. If the wiring and
No Correct.
Step 2
Step 5
1) With the ignition switch “OFF”, disconnect the Check the CMP sensor #2 and sensor trigger vane.
connector from the CMP sensor #2. Refer to “CMP Sensor Inspection” in Section 1C (Page
2) Check for proper connection to the CMP sensor 1C-12).
#2 at “B/Bl”, “O/G” and “B/W” wire terminals.
Is check result satisfactory?
3) If OK, turn the ignition switch “ON” and check the
voltage at the “B/Bl”, “O/G” and “B/W” wire Yes Substitute a known-good ECM and
terminals of the CMP sensor #2 connector. recheck.
CMP sensor #2 voltage No Replace CMP sensor #2.
Terminal “B/Bl”: 10 – 14 V
Terminal “O/G”: 4 – 5 V
Terminal “B/W”: 0 V For step 2
Is the voltage satisfactory?
Yes Go to step 5.
B /W
No Go to step 3.
O/G
Step 3 B /Bl
IFH511110011-01
Was terminal “O/G” voltage in step 2 within
specification?
Yes Go to step 4.
No “O/G” wire open or shorted to ground/

power supply circuit. If the wiring and
Self-Diagnostic Code “2 – 2” Air Intake System

CENFH5111104015
Wiring Diagram
1 ECM
5V
Br/Y
C
P
B/W U
I9J011110057-01
1. TPS
Step 1 1) Check the MAP sensor, IAC system and intake
manifold (system) for air leakage.
2) With the ignition switch “OFF”, disconnect the Is the result OK?
TPS connector.
Yes Intermittent trouble or faulty ECM.
3) With the ignition switch “ON”, check the voltage at Substitute a known-good ECM and
the “R” wire terminal of TPS connector. recheck.
Is the voltage approx. 4 – 5 V? No Faulty air intake system.
Yes Go to step 2.
No • “R” wire open, “R” wire shorted to For step 1

ground circuit or poor wire connection.
• If the wiring and connection is OK,
substitute a known-good ECM and
recheck. R
Step 2
Refer to “TPS Inspection” in Section 1C (Page 1C- B/W
Br/Y
21). IDG211110013-01
Yes Go to step 3.
No • Faulty TPS.
• “R” wire shorted to “Br/Y” wire, “B/W”
wire open, poor “B/W” wire connection,
poor “Br/Y” wire connection, “Br/Y” wire
open or poor TPS connection.
• If the wiring and connection is OK,
be the cause.
Self-Diagnostic Code “3 – 2” MAP Sensor 2

CENFH5111104016
Wiring Diagram
ECM
1 +5 V
R 5V
Br/Y
B/W
C
P
2 U
W
B/W 5V
R
IDG211110032-01
1. TPS 2. MAP sensor
Troubleshooting
Step 1
2) With the ignition switch “OFF”, disconnect the MAP sensor connector.
3) With the ignition switch “ON”, check the voltage at the “R” wire terminal of the MAP sensor connector.
Yes Go to step 2.
Step 2
1) Check the MAP sensor output voltage change.
Refer to “MAP Sensor Output Voltage Inspection” in Section 1C (Page 1C-14).
Yes Go to step 3.
No Faulty MAP sensor.
Step 3
1) With the ignition switch “OFF”, disconnect the TPS connector.
2) With the ignition switch “ON”, check the voltage at the “R” wire terminal of the TPS connector.
Yes Go to step 4.
Step 4
Refer to “TPS Inspection” in Section 1C (Page 1C-21).
Yes Intermittent trouble, substitute a known-good ECM and recheck.
No • Faulty TPS.
• “R” wire shorted to “Br/Y” wire, “B/W” wire open, poor “B/W” wire connection, poor “Br/Y” wire
connection, “Br/Y” wire open or poor TPS connection.
For step 1
B/W
R
IDG211110010-02
For step 3
B/W
Br/Y
IDG211110013-01
Self-Diagnostic Code “3 – 3” Neutral Switch

CENFH5111104017
Wiring Diagram
12 V (From ignition switch)
ECM
1
C
Br B/Bl
P
Y/G Y/G
U
IFH511110012-03
1. Neutral switch
Troubleshooting
Step 1
1) Remove the lower side covers and front panel.
2) With the ignition switch “OFF”, disconnect the neutral switch connector.
3) With the ignition switch “ON”, check the voltage at the “B/Bl” wire terminal of the neutral switch connector.
Yes Go to step 2.
No • “B/Bl” wire shorted to “Y/G” wire or ground circuit.

Step 2
1) Check the neutral switch.
Refer to “Neutral Switch Inspection” in Section 1I (Page 1I-16).
Yes • Poor neutral switch connection, intermittent trouble or a faulty ECM.

• Shift position sensor lever damage.
No Faulty neutral switch.
For step 1
Y/G
B/Bl
IFH511110013-02
Self-Diagnostic Code “5 – 1” VVT Advance

CENFH5111104018
Wiring Diagram
+12 V (From main relay) ECM
Gr/R
Br/R
CPU
IFH511110014-01
1. OCV
Troubleshooting
Step 1
1) With the ignition switch “OFF”, disconnect the connector from OCV.
2) Check the voltage at “Gr/R” wire terminal with the ignition switch “ON”.
Is the voltage 12 V (battery voltage)?
Yes Go to step 2.
No • Power circuit open.

• “Gr/R” wire shorted to “Br/R” wire or ground circuit.
• If the wiring and connection is OK, substitute known-good ECM and recheck.
Step 2
1) Inspect OCV and OCV gasket filter condition.
Refer to “OCV (Oil Control Valve) Inspection” in Section 1C (Page 1C-18).
Is the result OK?
Yes • Poor OCV connection, intermittent trouble or a faulty ECM.

• Clogged OCV oil passage.
No Faulty OCV.
Self-Diagnostic Code “5 – 3” Oil Pressure Switch

CENFH5111104019
Wiring Diagram
ECM
1
Bl
C
P
U
I9J011110063-01
1. Oil pressure switch
Troubleshooting
Step 1
1) With the ignition switch “OFF”, remove the oil pressure switch wire.
2) With the ignition switch “ON”, check the voltage between the oil pressure switch wire terminal and body ground.
Is the voltage approx. 5 V?
Yes Go to step 2.
No • Oil pressure switch wire open or poor connection.

• If wire and connection are OK, substitute a known-good ECM and recheck.
Step 2
1) Check the oil pressure switch operation.
Refer to “Oil Pressure Switch Inspection” in Section 1E (Page 1E-8).
Yes Poor oil pressure switch wire connection, intermittent trouble or a faulty ECM may be the cause.
No Faulty oil pressure switch.
For step 1
I9J011110064-01
Self-Diagnostic Code “6 – 1” OCV (Oil Control Valve)

CENFH5111104020
Wiring Diagram
+12 V (From main relay) ECM
Gr/R
Br/R
CPU
IFH511110014-01
1. OCV
Troubleshooting
Step 1
1) Inspect OCV.
Refer to “OCV (Oil Control Valve) Inspection” in Section 1D (Page 1D-20).
Is the result OK?
Yes Poor OCV wire connection, intermittent trouble or a faulty ECM may be the cause.
No Faulty OCV.
Self-Diagnostic Code “5 – 4” Knock Sensor

CENFH5111104030
Wiring Diagram
ECM
1
C
R P/Y P
U
IFH511110015-01
1. Knock sensor
Troubleshooting
Step 1
1) Inspect knock sensor.
Refer to “Knock Sensor Inspection” in Section 1C (Page 1C-17).
Yes Poor knock sensor connection, intermittent trouble or a faulty ECM may be the cause.
No Faulty knock sensor.

Self-Diagnostic Code “3 – 6” O2 Sensor

CENFH5111104031
Wiring Diagram
OX 12 V
GND
1 ECM
Gr
W
Gr B/W
C
B Gr/Bl P
W
U
Lg/Bl
+B
OXH
IFH511110016-01
1. O2 sensor
Troubleshooting For step 1
Step 1 ?
Gr/Bl
1) With the ignition switch “OFF”, disconnect the O2
sensor connector.
2) Check continuity between Gr/Bl terminal of O2
B/W
sensor connector and ground, also between Gr/Bl
and B/W terminals of O2 sensor connector.
Make sure there are not continuity.
3) Disconnect ECM connectors. IFH511110017-01
Refer to “ECM Removal and Installation” (Page

1A-50). Gr/Bl
4) Check continuity between Gr/Bl terminal of O2
sensor connector (harness side) and No.3
terminal of ECM connector (harness side), also
between B/W terminal and No.31 terminal.
B/W
Make sure there are continuity.
Are they in good condition?
“3”
Yes Go to step 2.
“31”
No Gr/Bl wire shorted, or Gr/Bl or B/W wire
open. Black connector side
IFH511110018-05
Step 2
1) Check the O2 sensor output voltage.
Refer to “O2 Sensor Output Voltage Inspection” in
Section 1C (Page 1C-15).
Is each voltage OK?
Yes Poor O2 sensor connection, intermittent

trouble or a faulty ECM may be the cause.
No Faulty O2 sensor.
Self-Diagnostic Code “6 – 3” O2 Sensor Heater

CENFH5111104032
Wiring Diagram
OX 12 V
GND
1 ECM
Gr
W
Gr B/W
C
B Gr/Bl P
W
U
Lg/Bl
+B
OXH
IFH511110019-01
1. O2 sensor
NOTE
Temperature of the sensor affects resistance value largely.
Make sure that the sensor heater is in atmospheric temperature.
Troubleshooting
Step 1
1) With the ignition switch “OFF”, disconnect the O2 sensor connector.
2) Measure the resistance between W terminals of O2 sensor.
Is the resistance 5.5 – 8.5 Ω at 20 °C (68 °F)?
Yes Go to Step 2.
No Faulty O2 sensor.
Step 2
1) Check the O2 sensor heater voltage.
Refer to “O2 Sensor Heater Inspection” in Section 1C (Page 1C-16).
Is the voltage OK?
Yes • Gr or Lg/Bl wire open or shorted to ground, or poor No.60 terminal connection.
• If wires and their connection are OK, intermittent trouble or a faulty ECM may be the cause.
No • Gr or Lg/Bl wire shorted or open.

• Poor connection on O2 sensor or ECM connector.
For step 1
W W
IFH511110024-01
Troubleshooting Without Self-Diagnostic Code

CENFH5111104029
Before troubleshooting, make sure that there is not a self-diagnostic code indication.
Condition Possible cause Correction / Reference Item

Unstable idling/trolling (or Clogged MAP sensor vacuum passage. Check the vacuum passage.
engine tends to stall) Malfunctioning TPS. Check the TPS.
Faulty IAC system Check the IAC system.
Fuel pressure out of specification. Check the fuel pressure.
Faulty injector or its circuit. Check the injector and its circuit.
Poor performance of the IAT sensor, Check each sensor.
TPS or MAP sensor.
Faulty ECM. Replace.
Faulty spark plug. Replace.
Faulty ignition coil or its circuit. Check the ignition coil and its circuit.
Faulty wire continuity / connection Correct or replace.
IAC System Troubleshooting

CENFH5111104033
Wiring Diagram
12V (From Main relay) ECM
1
2
5 3
IFH511110026-01
1. IAC valve
Troubleshooting
Step 2
Step 1 1) Disconnect the IAC connector at the IAC valve
with ignition switch “OFF”.
1) Warm up the engine to normal operating
temperature and keep it idling. 2) Check the resistance between following terminals.
/ IAC “1” terminal – “2” terminal
2) Using the SDS tool, check the IAC duty cycle and
idle speed.
Idle speed (IAC duty cycle): / IAC “6” terminal – “5” terminal
600 – 700 r/min (approx. 10 – 20%)
Is the resistance 25 – 34 Ω for each test?
Is result OK?
Yes Proceed to “Unstable Idling/Trolling” in
Yes IAC system is in good condition. “Troubleshooting Without Self-Diagnostic
Code” (Page 1A-44) and check items
No Go to step 2. except for “Faulty IAC System”.
No • Faulty IAC valve.

• Poor connection.
• Open wire harness.
For step2
1
2
3
4
5 6
IFH511110025-01
How to Use the 36-Pin Test Cord Set
CENFH5111106001
This test cord is used when checking a circuit for voltage, etc. and is connected between the ECM and the wiring
harness.
To take a measurement, connect the tester probe to the relevant terminal of the test cord.
Special tool
(A): 09930–88730 (36-pin test cord set)
3 2
(A) (A)
(White connector)
37 38 39 40 41 42 43 44 45 46 47 48 49 55 56 57 58 59 60 61 62 63 64 65 66 67
50 51 52 53 54 68 69 70 71 72
(Black connector) (Black connector)
1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31
14 15 16 17 18 32 33 34 35 36
(White connector)
4
IFH511110020-02
1. ECM 2. Black connector side 3. Gray connector side 4. Wire harness

Inspection of the ECM and Its Circuit

CENFH5111106002
NOTICE
If you connect a voltmeter or ohmmeter directly to ECM terminals by removing ECM connector, you
can damage the control module.
Never connect a voltmeter or an ohmmeter directly to any terminal of ECM by disconnecting control
module connector.
Special tool
: 09900–25008 (Multi circuit tester set)
Tester knob indication
DC Voltage ( )
1) Turn ignition switch OFF.
2) Connect the 36-pin test cord set 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 the voltage according to the “ECM Circuit
Voltage Table” (Page 1A-48).
3 2
(A) (A)
(White connector)
37 38 39 40 41 42 43 44 45 46 47 48 49 55 56 57 58 59 60 61 62 63 64 65 66 67
50 51 52 53 54 68 69 70 71 72
(Black connector) (Black connector)
1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31
14 15 16 17 18 32 33 34 35 36
(White connector)
4
IFH511110021-01
1. ECM 2. Black connector side 3. Gray connector side 4. Wire harness

ECM Circuit Voltage Table
48 47 46 45 44 43 42 41 40 39 38 37 12 11 10 9 8 7 6 5 4 3 2 1
“B” 60 59 58 57 56 55 54 53 52 51 50 49 24 23 22 21 20 19 18 17 16 15 14 13 “A”
72 71 70 69 68 67 66 65 64 63 62 61 36 35 34 33 32 31 30 29 28 27 26 25
IFH511110035-01
“A”: Black connector “B”: Gray connector
Wire
Terminal Circuit Standard voltage Condition/Remarks
color
1 Y/B Tachometer — —
Ignition switch “ON”, troll mode switch “UP” side
Approx. 12 V
push.
2 V Troll mode switch Approx. 2.6 V Ignition switch “ON”, troll mode switch free.
Ignition switch “ON”, troll mode switch “DOWN”
Approx. 0 V
side push.
Approx. 0 – 1 V While engine idling after warming up.
3 Gr/Bl O2 sensor
0.2 V or less Engine stopped (ignition switch “ON”).
4 R/B CKP sensor — —
Approx. 4.1 V Ignition switch “ON”, Throttle WOT.
5 Br/Y Throttle position sensor
Approx. 0.7 V Ignition switch “ON”, Throttle FCT.
6 W MAP sensor 0.2 – 4.5 V Ignition switch “ON”.
7 R Power source for sensors Approx. 5 V Ignition switch “ON”.
Approx. 2 V Ignition switch “ON”, shift into neutral.
8 P/Bl Shift position sensor Approx. 4 V Ignition switch “ON”, shift into forward.
Approx. 0.6 V Ignition switch “ON”, shift into reverse.
Approx. 5 V Ignition switch “ON”, stop switch plate in.
9 Bl/R Emergency stop switch
Approx. 0 V Ignition switch “ON”, stop switch plate out.
Approx. 0.8 V Ignition switch “ON”, cranking.
Approx. 12 V Ignition switch “ON”, Normal (Neutral).
10 G Starter relay control
Ignition switch “ON”, Normal (Shift into Forward
Approx. 0 V
or Reverse).
Approx. 5 V While engine running.
11 Bl Oil pressure switch
Approx. 0 V Engine stopped (ignition switch “ON”).
12 B/Bl Power source No.2 for ECM Approx. 12 V Ignition switch “ON”.
13 — — — —
14 Lg/B IAT sensor 0.1 – 4.6 V Ignition switch “ON”.
15 Lg/W Cylinder temp. sensor 0.1 – 4.6 V Ignition switch “ON”.
16 — — — —
17 V/W EX. manifold temp. sensor 0.1 – 4.6 V Ignition switch “ON”.
18 — — — —
Approx. 12 V Ignition switch “ON”, key pushed in.
19 O/W Buzzer cancel
Approx. 0 V Ignition switch “ON”, key not pushed in.
20 — — — —
Ignition switch “ON”, water detection switch
Approx. 12 V
“OFF”.
21 R/Bl Water detection switch
Ignition switch “ON”, water detection switch
Approx. 0 V
“ON”.
Ignition switch “ON”, PTT switch “DN”
Approx. 12 V
22 P PTT switch (DOWN) depressed.
Approx. 0 V Ignition switch “ON”, PTT switch not depressed.
Ignition switch “ON”, PTT switch “UP”
Approx. 12 V
23 Lbl PTT switch (UP) depressed.
Approx. 0 V Ignition switch “ON”, PTT switch not depressed.
Approx. 12 V Ignition switch “OFF”.
24 P/B Ground for ECM main relay
Approx. 0.8 V Ignition switch “ON”.
Wire
Terminal Circuit Standard voltage Condition/Remarks
color
25 — — — —
Approx. 0 V PTT switch not depressed.
26 P PTT relay (DOWN)
Approx. 12 V PTT switch “DN” depressed.
Approx. 0 V PTT switch not depressed.
27 Lbl PTT relay (UP)
Approx. 12 V PTT switch “UP” depressed.
28 W/Y Trim and tilt sensor 0.2 – 4.0 V Ignition switch “ON”.
29 — — — —
30 — — — —
31 B/W Ground for sensors — —
32 Br Starter switch
Approx. 12 V Ignition switch “START” position.
Approx. 12 V Ignition switch “ON”, shift into neutral.
33 Y/G Neutral switch
Approx. 0 V Ignition switch “ON”, shift into forward or reverse.
34 O/Y PC Communication line (A) — —
35 Y PC Communication line (B) — —
36 Gr Power source No.1 for ECM Approx. 12 V Ignition switch “ON”.
37 — — — —
38 W/Bl IAC valve No.4 Approx. 0 V or 12 V Ignition switch “ON”.
39 Lg No.4 fuel injector Approx. 12 V Ignition switch “ON”.
40 — — — —
41 O/B No.1 fuel injector Approx. 12 V Ignition switch “ON”.
42 — — — —
43 B/Br No.2 fuel injector Approx. 12 V Ignition switch “ON”.
44 Br/R OCV Approx. 12 V Ignition switch “ON”.
45 — — — —
46 R/W No.3 fuel injector Approx. 12 V Ignition switch “ON”.
47 R/Y IAC valve No.2 Approx. 0 V or 12 V Ignition switch “ON”.
48 — — — —
49 Gr/G VSV Approx. 12 V Ignition switch “ON”.
50 O/Bl IAC valve No.3 Approx. 0 V or 12 V Ignition switch “ON”.
51 — — — —
52 — — — —
53 Lg/R No.4 ignition coil Approx. 0 V Ignition switch “ON”.
54 Bl/Y No.2 ignition coil Approx. 0 V Ignition switch “ON”.
55 B Ground for power — —
56 P/Y Knock sensor
Approx. 2.5 V While engine running at idle speed.
57 Bl/W Buzzer — —
58 W/Y Trim gauge — —
59 W/B IAC valve No.1 Approx. 0 V or 12 V Ignition switch “ON”.
Approx. 12 V Engine stopped (ignition switch “ON”).
60 Lg/Bl O2 sensor heater
Approx. 0 V While engine running, after engine warmed up.
61 B Ground for ECM — —
62 G/W CHECK ENGINE lamp — —
63 G/Y TEMP lamp — —
64 Bl/B Oil lamp — —
65 P/W REV-LIMIT lamp — —
66 Gr/Y No.3 ignition coil Approx. 0 V Ignition switch “ON”.
67 B Ground for power — —
68 O No.1 ignition coil Approx. 0 V Ignition switch “ON”.
69 Y/Bl CMP sensor No.1 Approx. 0.3 V or 5 V Ignition switch “ON”.
70 O/G CMP sensor No.2 Approx. 0.3 V or 5 V Ignition switch “ON”.
71 — — — —
• Stop switch plate in, shift into neutral, for 3
Approx. 0 V sec. after ignition switch “ON”.
72 B/R High pressure fuel pump • While engine running.
Engine stopped, ignition switch “ON”, stop switch
Approx. 12 V
plate “IN”, shift into neutral.
ECM Main Relay Inspection 4) Measure the resistance between relay terminals (4)
CENFH5111106005 and (5).
Inspect the ECM main relay using the following
If out of specification, replace ECM main relay.
procedures:
1) Turn the ignition switch “OFF”. Tester knob indication
Resistance (Ω)
2) Disconnect the ECM main relay (1) from the fuse
box. ECM main relay solenoid coil resistance
Standard: 145 – 190 Ω
(A)
1 I9J011110039-01
IFH511110032-01
ECM Removal and Installation
1. ECM main relay CENFH5111106006
Removal
3) Check continuity between terminal (2) and (3) each 1) Turn the ignition switch “OFF”.
time 12 V power supply is applied to terminal (4) and 2) Remove the lower side covers.
(5). Refer to “Lower Side Cover Removal and
Connect the positive (+) lead to terminal (5), and Installation” in Section 2A (Page 2A-3).
negative (–) lead to terminal (4). 3) Disconnect lead wire connectors (1) from ECM, then
NOTICE remove ECM (2).
If the 12 V power supply wire is connected to

2
wrong terminal or touched to each other, the
power supply wire, tester may be damaged.
Be careful not to touch 12 V power supply

wires to each other or with other terminals.
Special tool
(A): 09900–25008 (Multi circuit tester set)
Tester knob indication 1
Continuity ( ) IFH511110033-01
ECM main relay function

Installation
Continuity
Installation is reverse order of removal.
12 V power applied Yes
12 V power not applied No
2 3
5
12 V
CONT
4
(A)
I9J011110038-02
Engine Electrical Devices: 1C-1
Engine Electrical Devices

Power Head
Precautions
Precaution for Engine Electrical Device
CENFH5111300001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions on Engine Control Diagnosis” in Section
1A (Page 1A-1).
General Description
Sensor and Switch Description CMP Sensor #1
CENFH5111301001
CKP Sensor • CMP sensor #1 is mounted on the cylinder head cover
with trigger vanes pressed onto the end of the exhaust
• There is one CKP sensor installed below the flywheel
camshaft.
rotor.
This sensor detects piston position.
When the reluctor bars on the flywheel pass the
sensor, a signal (voltage pulse) is generated and sent • Signals received from this sensor are also used by the
to the ECM. ECM to determine sequential fuel injection and
This is the fundamental signal used to judge engine ignition control.
speed and crankshaft angle. • The 12 V power to the CMP sensor is supplied
• There are 32 reluctor bars. They are located 10 through the Ign. (Gr) line of the ignition switch.
degrees apart, except at two positions where they are
30 degrees apart.
During one crankshaft rotation, 32 signals are input to
the ECM.
• Failure symptom:
Without the CKP sensor signal input, the ECM does
not output the ignition and fuel injection signals.
1
IFH511130056-02
1. CMP sensor #1
1 2
IFH511130024-02
1. CKP sensor 2. Reluctor bar

1C-2 Engine Electrical Devices:
• The CMP sensor is a GMR (Giant Magnet Resistive) • The six camshaft trigger vanes provide six high
semiconductor type sensor. voltage signals from the CMP sensor to the ECM
The GMR semiconductor has the property of varying during one camshaft rotation (two rotations of
the electrical resistance depending on the intensity of crankshaft).
the magnetic force applied.
When the line of magnetic force from the magnet to 1
the GMR semiconductor is increased or decreased,
the electrical resistance of the GMR semiconductor 2
will change. The changes in resistance as the 3
magnets pass create the sensors waveform.
When a trigger vane on the camshaft reluctor aligns 4
with the sensors internal magnet, the electrical
resistance of the GMR will decrease. “A”
When a trigger vane moves away from the sensor, the “B”
electrical resistance of the GMR will increase. 6 5
IEH511130109-02
When the GMR semiconductor voltage becomes
higher than the standard value, the sensors signal will 1. Camshaft 5. CMP sensor
be lower. And when the voltage becomes lower than 2. Trigger vane 6. Signal
3. Magnet resistive semiconductor “A”: High voltage
the standard value, the sensors signal will be higher.
4. Magnet “B”: Low voltage
• Failure symptom:
Without the CMP sensor signal input, the ECM does
not output the ignition and fuel injection signals.
ECM cylinder identification

Cylinders are identified by a calculation combined from two signals; one from the CKP sensor and one from the CMP
sensor.
TDC TDC
No.1 cylinder Cm Ep Ex In Cm Ep
TDC TDC
No.3 cylinder In Cm Ep Ex In Cm
TDC TDC
No.4 cylinder Ex In Cm Ep Ex In
TDC TDC
No.2 cylinder Ep Ex In Cm Ep Ex
32 signals / crankshaft 1 rotation

CKP sensor
signal
10° 30°
140° 220° 40° 180° 100° 40° 140°
CMP sensor
#1 signal 6 signal / 720˚ (Crankshaft 2 rotation)
CMP sensor
Cm.: Compression, Ep.: Explosion, Ex.: Exhaust, In.: Intake, TDC: Top Dead Center
IFH511130025-02
CMP Sensor #2
• CMP sensor #2 is mounted on the cylinder head cover (kΩ)
with trigger vanes pressed onto the end of the intake
camshaft.
This sensor detects camshaft position.
Resistance
• 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).
Temperature (C˚)
IEH511130007-01
1
Exhaust Manifold Temperature Sensor
The exhaust manifold temperature sensor is installed on
the exhaust manifold and used to detect exhaust
manifold temperature.
This sensor is the same type as the cylinder temperature
sensor, and inputs a signal to the ECM as a voltage
value.
This signal is also used to detect engine over-heat.
IFH511130057-02
1. CMP sensor #2
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 1
changes depending on temperature) and inputs a signal
to the ECM as a voltage value. This signal is used to
compensate the fuel injection time duration, ignition
timing, etc.
IFH511130027-02
This sensor is also used to detect engine over-heat as
the ECM detects both the temperature and temperature 1. EX. manifold temp. sensor
change gradient (temperature rise vs time).

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
sensor, and inputs a signal to the ECM as a voltage
1 value.
This signal is used to compensate the fuel injection time
duration.
IFH511130026-02
1. Cylinder temp. sensor

1
IFH511130028-02
1. IAT sensor 2. Air intake silencer case

MAP (Manifold Absolute Pressure) Sensor Neutral Switch

The MAP sensor is installed on the intake manifold and The neutral switch is installed on the clutch lever holder
used to detect the intake manifold pressure. and used to detect the shift position.
This sensor inputs the intake manifold pressure to the This switch is “ON” in neutral and “OFF” in forward or
ECM as a voltage value. reverse.
This input signal is used as the fundamental signal to Based on the switch’ shift position signal input, the ECM
determine fuel injection time duration, ignition timing, performs the following controls:
VVT system control, etc. • 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.
Refer to “Start-In-Gear Protection System Description”
1 in Section 1I (Page 1I-2).
IFH511130029-01
1. MAP sensor 1
TPS (Throttle Position Sensor)

The TPS is installed on the throttle body and detects the IFH511130031-02
degree of throttle opening. The throttle shaft is 1. Neutral switch
interlocked with the TPS shaft.
This sensor is a variable resistor, changing resistance SPS (Shift Position Sensor)
(Ohms) in accordance with the throttle opening. The SPS is installed on the throttle lever holder and
The varying resistance value is converted to voltage and detects the shift position with the clutch lever operation
input to the ECM. interlocked.
Based on the TPS voltage, the ECM calculates the idle This sensor is a variable resistor that changes resistance
position and throttle opening and determines the control (ohms) in accordance with the shift position.
modes of the various controls systems (Idle air control, The varying resistance value is converted to voltage and
VVT system control, fuel injection control system, etc.). 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 is controlled
1
to prevent engine speed from exceeding 3 000 r/min.
• After shifting into forward or reverse from neutral, the
IAC valve is controlled to increase intake air to
prevent unstable engine idle or stalling.
IFH511130030-02
1. TPS
IFH511130032-02
1. SPS
Knock Sensor Trim Sensor

Knock sensor uses a piezoelectric ceramics element The trim sensor is variable resistor type.
which converts engine vibration into voltage signals and With the sensor signal received, the ECM performs the
detects knocking from them. learning of the trim position and it controls the position of
Receiving signals from the knock sensor, ECM controls trim down limit.
the ignition timing to prevent knocking. The trim sensor signal also operates the trim meter
through the ECM.
NOTE
When the ECM has been replaced, the trim
sensor removed/reinstalled, or the mid unit
1
overhauled, re-setting the trim down limit
position must be performed.
IFH511130058-01
1. Knock sensor 1
O2 Sensor with Heater

The O2 sensor is install on the top of the cylinder.
O2 sensor detects the oxygen concentration in the
exhaust gas and feed it back to the ECM, compensating
the fuel injection duration.
IEH511130014-01
The fuel injection amount is compensated based on the
oxygen density in the exhaust gas detected with the O2 1. Trim sensor
sensor by the value programmed based on this data,
engine speed, etc. ECM Main Relay
To make the O2 sensor function properly, a built-in The ECM main relay is installed in the fuse box. When
heater is equipped in O2 sensor. energized by turning the ignition switch ON, a circuit is
The built-in heater is turned on or off by ECM. formed which supplies battery voltage to the ECM, fuel
injector, ignition coil, IAC valve, high pressure fuel pump,
OCV (Oil Control Valve) and VSV (Vacuum Switching
Valve).
With the ignition switch in the “OFF” position, and the UP
or DOWN button of the PTT switch pressed, the main
relay turns “ON” to supply 12 V power to the ECM, which
then performs the on/off control of the PTT motor relay.
IFH511130033-02
1. O2 sensor
2
IFH511130001-04
1. ECM main relay 2. Fuse box

Cranking Switch Signal ECM Power Source Line

The ECM detects if the engine is being started by the CENFH5111301003
position of ignition switch. When the ignition key is The ECM is battery dependent and must be provided
turned to ST position, a voltage (12 V) signal is input to with its own dedicated 12V power supply. The electrical
the ECM. circuits which provide this supply are:
The ECM in turn sets the ignition, fuel injection, IAC, etc. 1) The sub battery cable to the white lead wire in the
to the starting mode. remote control extension harness to the ignition
When the key is turned to the IG position after the switch.
engine has been started, the input voltage becomes When the ignition switch is turned ON, battery power
approx. 2.5 V. passes from the white lead wire, through the ignition
switch contacts to the gray output lead wire to the
2 3 No.12 terminal of ECM.
+12V 1
NOTE
Ensure battery cable connections are clean
OFF
and secure.
IG Failure at the battery connection will cause
ST incorrect operation of the ECM and starter
motor cranking system.
ECM
2) The engine wiring harness to the main relay. When
the ECM main relay is energized by turning the
ignition switch ON, a circuit is formed which supplies
I9J011130004-03
battery voltage to the No.36 terminal of ECM.
1. Ignition switch 3. To starter motor relay
2. Neutral switch
4
9
Emergency Stop Switch R
When the cord from the plate of the switch is secured to R

the operator, the plate will be pulled off if the operator is 6 5
suddenly thrown overboard.
The circuit of emergency stop switch will be closed when 7
the plate is removed.
Then the ECM does not provide fuel injector operating
signal, ignition signal, fuel pump operating signal and
starter motor relay operating signal.
W
Gr 36
Failure symptoms: R/W
B/Bl 12
A switch short circuit will not allow the motor to start. 2
8
P/B 24
3
1
BATT W
IG Gr Gr
1 GND B B
1
IFH511130003-03
1. Battery 6. Fuse (30 A)

2. Sub battery cable 7. ECM main relay
3. Fuse (15 A) 8. ECM
4. Main battery cable 9. Starter motor
IAJ611130015-01 5. Fuse (60 A)
1. Emergency stop switch

Component Location
Location of Sensor and Switch
CENFH5111303001
Resistance Check
CENFH5111306001
Special tool
Resistance (Ω)
NOTE
Make sure ignition switch is always OFF when measuring resistance.

2) Disconnect battery cables from battery.
3) Disconnect wire harness connectors from ECM.
4) Connect the tester probes to terminal (wire harness side) and measure resistance according to the “Resistance
Table” (Page 1C-8).
37 38 39 40 41 42 43 44 45 46 47 48 1 2 3 4 5 6 7 8 9 10 11 12
49 50 51 52 53 54 55 56 57 58 59 60 13 14 15 16 17 18 19 20 21 22 23 24
61 62 63 64 65 66 67 68 69 70 71 72 25 26 27 28 29 30 31 32 33 34 35 36
3 1 2
IFH511130004-01
1. Wire harness 2. Black connector 3. Gray connector
NOTE
Disconnect remote control wire harness and connect tester probe to terminal (“A”, White wire) in
engine main wiring harness connector.
“A”
IFH511130054-02
Resistance Table
Circuit Terminal for tester probe connection Standard resistance at 20 °C (68 °F)
CKP sensor 4 (R/B) to 31 (B/W) 168 – 252 Ω
Fuel injector No.1 41 (O/B) to 36 (Gr)
Fuel injector No.2 43 (B/Br) to 36 (Gr)
10 – 14 Ω
Fuel injector No.3 46 (R/W) to 36 (Gr)
Fuel injector No.4 39 (Lg) to 36 (Gr)
IAC Valve #1 59 (W/B) to 36 (Gr)
IAC Valve #2 47 (R/Y) to 36 (Gr)
25 – 34 Ω
IAC Valve #3 50 (O/Bl) to 36 (Gr)
IAC Valve #4 38 (W/Bl) to 36 (Gr)
OCV (Oil control valve) 44 (Br/R) to 36 (Gr) 6.0 – 8.3 Ω
VSV 49 (Gr/G) to 36 (Gr) 34 – 46 Ω
IAT sensor 14 (Lg/B) to 31 (B/W) 0 °C (32 °F): 5.3 – 6.6 kΩ
Cylinder temperature sensor 15 (Lg/W) to 31 (B/W) 25 °C (77 °F): 1.8 – 2.3 kΩ
50 °C (122 °F): 0.73 – 0.96 kΩ
Ex. manifold temperature sensor 17 (V/W) to 31 (B/W) 75 °C (135 °F): 0.33 – 0.45 kΩ
(Thermistor characteristic)
ECM main relay 24 (P/B) to Terminal “A” (W) 145 – 190 Ω
Cylinder Temp. Sensor Removal and Installation

Installation Installation is reverse order of removal.
CENFH5111306002
• Clean mating surface of sensor and cylinder.
Removal
• Tighten sensor to specified torque.
1) Disconnect the cylinder temp. sensor lead wire
connector (1). Tightening torque
Cylinder temp. sensor (a): 8 N·m (0.8 kgf-m, 5.8
lbf-ft)
(a)
IFH511130059-01
2) Remove the bolt and harness clamp (2)

3) Loosen and remove the cylinder temp. sensor (3). IFH511130036-04
• Check wire routing.

Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-2).
IFH511130035-03
Cylinder Temp. Sensor Inspection Ex. Manifold Temp. Sensor Removal and
CENFH5111306003
Installation
1) Remove the cylinder temperature sensor. CENFH5111306004
Refer to “Cylinder Temp. Sensor Removal and Removal
Installation” (Page 1C-8). 1) Disconnect the Ex. manifold temp. sensor lead wire
2) Immerse temperature sensing part of cylinder temp. connector (1).
sensor in water. Unfasten the cable tie (2) binding lead wire.
3) Measure resistance between sensor terminals while 2) Loosen and remove the Ex. manifold temp. sensor
heating water gradually. (3).
4) If measured resistance does not change in the
proportion indicated, replace sensor.
Cylinder temp. sensor specification
Water 2 3
temperature: 0 (32) 25 (77) 50 (122) 75 (135)
°C (°F)
Resistance 0.73 – 0.33 –
5.3 – 6.6 1.8 – 2.3
(kΩ) 0.96 0.45
1
1
IFH511130037-03
Installation
• Clean mating surface of sensor and exhaust cover.
• Tighten sensor to specified torque.
Tightening torque
Ex. manifold temp. sensor (a): 8 N·m (0.8 kgf-m,
2 5.8 lbf-ft)
I9J011130051-01
1. Thermometer 2. Heater
(a)
Resistance
IFH511130038-02
• Check wiring harness routing.

4A (Page 4A-2).
Temperature
I9J011130008-02
5) Reinstall the cylinder temp. sensor.

Refer to “Cylinder Temp. Sensor Removal and
Installation” (Page 1C-8).
Ex. Manifold Temp. Sensor Inspection CKP Sensor Removal and Installation
CENFH5111306005 CENFH5111306006
1) Remove the Ex. manifold temp. sensor. Removal
Refer to “Ex. Manifold Temp. Sensor Removal and 1) Remove the ring gear cover.
Installation” (Page 1C-9). Refer to “Ring Gear Cover Removal and Installation”
2) Immerse temperature sensing part of Ex. manifold in Section 1D (Page 1D-2).
temp. sensor in water. 2) Remove the ring gear under cover bolts (1).
3) Measure resistance between sensor terminals while
heating water gradually.
proportion indicated, replace sensor.
Ex. manifold temp. sensor specification
Water
temperature: 0 (32) 25 (77) 50 (122) 75 (135)
°C (°F)
Resistance 0.73 – 0.33 –
5.3 – 6.6 1.8 – 2.3 1
(kΩ) 0.96 0.45
IFH511130060-01
3) Remove the clamp and disconnect CKP sensor lead

1
wire connector (2).
2 2
I9J011130051-01
IFH511130039-02
4) Remove two screws and CKP sensor (3).

Resistance
Temperature
I9J011130008-02
IFH511130061-01
5) Reinstall the Ex. manifold temp. sensor.
Refer to “Ex. Manifold Temp. Sensor Removal and
Installation” (Page 1C-9).
Installation IAT Sensor Removal and Installation

Installation is reverse order of removal with special CENFH5111306008
attention to the following steps. Removal

Disconnect the sensor lead wire connector (1) and
• Apply thread lock to the sensor mounting screws. remove IAT sensor from air intake silencer case.
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
IFH511130042-02
IFH511130040-02
Installation
• Install CKP sensor with air gap of 0.75 mm (0.030 in) Installation is reverse order of removal.
between sensor and reluctor bar on flywheel, then
tighten sensor mounting screws securely. IAT Sensor Inspection
CENFH5111306009
CKP sensor air gap 1) Remove the IAT sensor.
0.75 mm (0.030 in) Refer to “IAT Sensor Removal and Installation”
(Page 1C-11).
2) Immerse temperature sensing part of IAT sensor in
water.
3) Measure resistance between sensor terminals while
heating water gradually.
2 proportion indicated, replace sensor.
IAT sensor specification
“a” Water
1 temperature: 0 (32) 25 (77) 50 (122) 75 (135)
IFH511130041-02 °C (°F)
1. CKP sensor “a”: 0.75 mm (0.030 in) Resistance 0.73 – 0.33 –
5.3 – 6.6 1.8 – 2.3
2. Reluctor bar (kΩ) 0.96 0.45
• Check to ensure that all removed parts are back in

original position.
1
4A (Page 4A-2).
CKP Sensor Inspection

CENFH5111306007
Inspect the CKP sensor.
Refer to “Resistance Check” (Page 1C-7).
2
I9J011130007-03
Installation
• Install CMP sensor (1) and sensor cover (2), then
tighten sensor mounting screw securely.
Resistance • Connect sensor lead wire connector to CMP sensor.
Temperature
I9J011130008-02 1
5) Reinstall the IAT sensor.
Refer to “IAT Sensor Removal and Installation”
(Page 1C-11).
IFH511130064-01
CMP Sensor Removal and Installation

CENFH5111306010 CMP Sensor Inspection
Removal CENFH5111306011
1) For the CMP sensor #2; 1) Turn ignition switch OFF.

remove the air intake silencer case (1). 2) Remove the bolt and CMP sensor.
Refer to “Air Intake Silencer Case Removal and 3) Connect the 36-pin test cords between ECM and
Installation” in Section 1D (Page 1D-2). wire harness as shown in figure.
Special tool
1
(A)
(A)
3
37 38 39 40 41 42 43 44 45 46 47 48 49
50 51 52 53 54
55 56 57 58 59 60 61 62 63 64 65 66 67
68 69 70 71 72
4
1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31
14 15 16 17 18 32 33 34 35 36
IFH511130062-02
2) Disconnect the CMP sensor lead wire connector (2)

at sensor.
3) Remove the bolt, CMP sensor (3) and sensor cover 2
IFH511130021-02
(4).
1. ECM 3. Black connector
2. Wire harness 4. Black connector
4 4) Connect the tester probe (“+”, Red) to each terminal.

CMP sensor Terminal Wire color
No.1 69 Y/Bl
No.2 (VVT) 70 O/G
3
5) Connect the tester probe (“–”, Black) to No.31
terminal (or to body ground).
2
Special tool
IFH511130063-04
DC voltage ( )
36-pin test cord (Black connector) MAP Sensor Removal and Installation
CENFH5111306012
3 Removal
1) Loosen the three bolts and remove fuel hose guard
(1).
69 70
IFH511130005-01
36-pin test cord (Black connector)

4
IFH511130065-01
31
2) Disconnect lead wire connector (2) at MAP sensor.
3) Remove bolts and MAP sensor (3) from intake
manifold.
IFH511130006-01
6) Turn ignition switch ON. 3

7) Measure the voltage when the tip of a steel
screwdriver is brought near and then pulled away
from the sensor tip.
2
When screwdriver is brought near
Approx. 5.0 V
When screwdriver is pulled away
IEH511130038-02
Approx. 0.3 V
If the voltage does not change in the above test, Installation
check wire harnesses for open and short. Installation is reverse order of removal.
If wire harnesses are in good condition, replace CMP • Install MAP sensor, then tighten mounting screw
sensor and recheck. securely.
• Connect sensor lead wire connector to MAP sensor.
• Install fuel hose guard.
5
4
IEH511130036-05
4. Screw driver 5. CMP sensor
8) Reinstall the CMP sensor.

MAP Sensor Output Voltage Inspection 6) Turn ignition switch ON.

CENFH5111306013
7) While applying negative pressure (vacuum) to MAP
sensor, measure “6” terminal voltage.
2) Connect the 36-pin test cord between ECM and wire
harness as shown in figure. MAP sensor output voltage change
Negative pressure: 0 40 80
Special tool kPa (kg/cm2, mmHg) (0, 0) (0.4, 300) (0.8, 600)
(A): 09930–88730 (36-pin test cord set) “6” terminal voltage (V) 4.00 2.42 0.84
1 (At 759.8 mmHg, 101.3 kPa, 29.91 inHg
(A) barometric pressure.)
(A)
36-pin test cord (White connector)

37 38 39 40 41 42 43 44 45 46 47 48 49 55 56 57 58 59 60 61 62 63 64 65 66 67
50 51 52 53 54 68 69 70 71 72
3
3
1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31
14 15 16 17 18 32 33 34 35 36
2
IFH511130022-03
1. ECM 3. White connector

2. Wire harness
3) Remove the bolts and MAP sensor (4). IFH511130007-02
Special tool
4
DC voltage ( )
If out of specification, check wire harnesses for open
and short. If wire harnesses are in good condition,
replace MAP sensor and recheck.
8) Reinstall MAP sensor.
Refer to “MAP Sensor Removal and Installation”
(Page 1C-13).
IEH511130113-01
4) Install MAP sensor into special tool.

5) Connect vacuum pump gauge (with hose) to MAP
sensor (special tool) as shown in figure.
Special tool
(B): 09917–49610 (Vacuum pump adapter)
(C): 09917–47011 (Vacuum pump gauge)
(C)
(B)
IFH511130043-01
O2 Sensor Removal and Installation

CENFH5111306032
Removal
1) Unfasten the cable tie (3) binding lead wire and
disconnect the O2 sensor lead wire connector (2).
2) Using special tool, remove the O2 sensor (1).
Special tool 1 (a)
(A): 09933–39810 (O2 sensor socket)
IFH511130046-02
3
O2 Sensor Output Voltage Inspection

CENFH5111306033
2) Connect the 36-pin test cord set between ECM and
2 wiring harness as shown in figure.
Special tool
IFH511130045-02 (A): 09930–88730 (36-pin test cord set)
(A)
1
IFH511130066-01 IFH511130044-02
1. O2 sensor
Installation
Installation is reverse order of removal with special
attention to the following steps. 2
• Tighten the O2 sensor (1) to the specified torque.
(A)
(A)
Tightening torque
O2 sensor (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)
37 38 39 40 41 42 43 44 45 46 47 48 49 55 56 57 58 59 60 61 62 63 64 65 66 67 5
NOTE 50 51 52 53 54 68 69 70 71 72 4
• Always keep the O2 sensor away from any 1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31

14 15 16 17 18 32 33 34 35 36
grease and oil.
• Examine O2 sensor gasket for damage.
Always replace O2 sensor assembly if
sealing performance is suspect. 3
IFH511130008-01

3) Connect the tester probe (“+”, Red) to No.3 terminal. O2 Sensor Heater Inspection
CENFH5111306034
4) Connect the tester probe (“–”, Black) to No.31
1) Turn the ignition switch OFF.
terminal (or to body ground).
2) Disconnect O2 sensor lead wire connector.
Special tool
3) Measure resistance between sensor terminals (1)
and (2).
O2 Sensor heater resistance at 20 °C (68 °F)
DC voltage ( )
5.5 – 8.5 Ω
1 2
4
IFH511130011-02
1. Heater (+) 2. Heater (–)

IFH511130009-01
4) If measurement exceeds specification, replace O2
36-pin test cord (Black connector) sensor.
5) Connect O2 sensor lead wire connector to wire
5
harness.
31
wiring harness as shown in figure.
Special tool
3
5
IFH511130010-02 (A)
(A)
5) Turn ignition switch ON.
6) Measure the O2 sensor output voltage.
37 38 39 40 41 42 43 44 45 46 47 48 49 55 56 57 58 59 60 61 62 63 64 65 66 67
O2 sensor output voltage 50 51 52 53 54 68 69 70 71 72
0.2 V or less 1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31
14 15 16 17 18 32 33 34 35 36
8) After warming up, measure the O2 sensor output
voltage while holding the engine speed at idling.
4
IFH511130012-02
NOTE
3. ECM 5. Black connector
The O2 sensor outputs 0 volt to 1.0 volt 4. Wire harness
according to the oxygen concentration in
exhaust gas.
O2 sensor output voltage at idling

0.7 V or more
9) If the voltage does not change in the above test,
check wiring harness for open and short.
If wiring harness is in good condition, replace O2
sensor and recheck.
7) Connect the tester probe (“+”, Red) to No.60 Installation

terminal. Installation is reverse order of removal with special
8) Connect the tester probe (“–”, Black) to body ground. attention to the following steps.
• Tighten the knock sensor (1) to the specified torque.
Special tool
: 09900–25008 (Multi circuit tester set) Tightening torque
Knock sensor (a): 22 N·m (2.2 kgf-m, 16.0 lbf-ft)
DC voltage ( )

5 1 (a)
60
IFH511130068-01
IFH511130013-02
• Install the intake manifold.
Refer to “Intake Manifold Removal and Installation” in
9) Turn the ignition switch “ON” and measure the O2 Section 1D (Page 1D-8).
sensor heater voltage.
O2 sensor heater voltage Knock Sensor Inspection
Approx. 12 V (Battery voltage) CENFH5111306036
11) After warming up, measure the O2 sensor heater wire harness as shown in figure.
voltage while holding the engine speed at idling.
Special tool
O2 sensor heater voltage at idling (A): 09930–88730 (36-pin test cord set)
Approx. 0 – 0.3 V
12) If inspection in step 9 and/or step 11 out of 1 3
specification, check wiring harness for open and
(A)
short. (A)
If wire harnesses are in good condition, replace O2

sensor and recheck.
37 38 39 40 41 42 43 44 45 46 47 48 49 55 56 57 58 59 60 61 62 63 64 65 66 67
50 51 52 53 54 68 69 70 71 72
Knock Sensor Removal and Installation 1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31

CENFH5111306035
14 15 16 17 18 32 33 34 35 36
Removal
1) Remove the intake manifold.
Refer to “Intake Manifold Removal and Installation”
2
in Section 1D (Page 1D-8). IFH511130014-03
2) Disconnect the sensor lead wire connector. 1. ECM 3. Black connector
Remove the knock sensor (1). 2. Wire harness
1
3) Connect the tester probe (“+”, Red) to No.56
terminal.
IFH511130067-01
4) Connect the tester probe (“–”, Black) to No.61 2) Check for operating sound (ticking sound) when
terminal (or to body ground). battery voltage applied to and removed from the
terminals of oil control valve.
Special tool
DC Voltage ( )

3
56 61 12 V
IEH511130043-01
3) Check resistance between the two OCV terminals.

Special tool
IFH511130015-03 Tester knob indication

5) Check for sensor output voltage. Resistance (Ω)
Sensor output voltage OCV resistance

6.0 – 8.3 Ω
Ignition switch ON Approx. 2.5 V
Engine running at idle speed Approx. 2.5 V
6) If out of specification, check wire harnesses for open

replace knock sensor and recheck.
OCV (Oil Control Valve) Inspection

CENFH5111306015
1) Remove the OCV (1).
Refer to “OCV (Oil Control Valve) Removal and
IEH511130044-01
If out of specification, replace the OCV with a new

1
one.
4) Install OCV.
IFH511130069-01
VSV (Vacuum Switching Valve) Removal and VSV (Vacuum Switching Valve) Inspection
CENFH5111306017
Installation
CENFH5111306016 1) With ignition switch OFF, remove the VSV.
Removal Refer to “VSV (Vacuum Switching Valve) Removal
1) Turn the ignition switch OFF. and Installation” (Page 1C-19).
2) Remove the air intake silencer case. 2) Check resistance between VSV terminals.
Refer to “Air Intake Silencer Case Removal and
Special tool
3) Disconnect the vacuum hoses (1).
NOTE Resistance (Ω)
Before removing hoses to check VSV, mark VSV resistance
each hose for position to ensure correct hose 34 – 46 Ω
connection on assembly.
4) Remove the screw (2) securing VSV to the bracket.

5) Disconnect the VSV connector (3).
(A)
3 IEH511130106-01
3) With 12 V applied between the VSV terminals, check

that port “A” connects to port “B” but not to the filter
1 section “C”.
IFH511130047-03
“C”
Installation
attention to the following step.
• Connect the vacuum hoses properly to VSV.
“A”
“B”
2 IEH511130045-02
1
“A”: Port (to depression chamber) “C”: Filter
“B”: Port (to vacuum tank)
4) Without voltage applied to the VSV terminals, check

that port “A” connects to the filter section “C” but not
IFH511130048-02 to port “B”.
1. Vacuum hose (Vacuum 2. Vacuum hose (VSV to
tank to VSV) depression chamber) Passage continuity
between ports “A” “B” “C”
VSV electrical power
Power ON
Power OFF
: Air passage
IEH511130046-02
IAC Valve Removal and Installation IAC Valve Inspection

CENFH5111306037 CENFH5111306038
Removal 1) Disconnect connector from IAC valve.
1) Remove the flywheel. 2) Check each coil of IAC valve for resistance.
Refer to “Flywheel Removal and Installation” in
Section 1K (Page 1K-5). IAC valve resistance
2) Disconnect IAC valve lead wire connector at IAC Terminals Resistance
valve (1). Between “1” to “2”
Between “3” to “2”
3) Remove screws (2) and IAC valve. 25 – 34 Ω
If out of specification, replace IAC valve.

1 2
1
2
3
4
5 6
IFH511130070-01
Installation IFH511130049-01
Installation is reverse order of removal. 3) Remove the flywheel.
• Install IAC valve, then tighten mounting screw Refer to “Flywheel Removal and Installation” in
securely. Section 1K (Page 1K-5).
• Connect IAC valve lead wire connector to IAC valve. 4) Remove the screws securing IAC valve, then detach
• Install flywheel and tighten flywheel bolts to specified the IAC valve from intake manifold.
torque. 5) Connect the connector to IAC valve.
Refer to “Flywheel Removal and Installation” in 6) When the ignition switch is turned “ON” and “OFF”,
Section 1K (Page 1K-5). check that the rotary valve turns to open and returns
to closed.
I9J011130018-01
7) If the valve does not turn, check the wiring harness

for continuity (between ECM and IAC valve and
connector contact condition.
8) Reinstall IAC valve.
Refer to “IAC Valve Removal and Installation” (Page
1C-20).
TPS Inspection 36-pin test cord (Black connector)

CENFH5111306039
1) Turn ignition switch OFF. 5
wire harness as shown in figure. 31
Special tool
IFH511130018-01
1 5) Turn the ignition switch ON.
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 opening angle.
Sensor output voltage
FCT position: Approx. 0.7 V
IFH511130050-02 WOT position: Approx. 4.1 V
1. TPS
Special tool
2 Tester knob indication
DC Voltage ( )
(A)
(A)
NOTICE
The throttle body will lose its original
37 38 39 40 41 42 43 44 45 46 47 48 49 55 56 57 58 59 60 61 62 63 64 65 66 67
5 performance if it has been disassembled and
50 51 52 53 54 68 69 70 71 72 4
reassembled.
1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31
14 15 16 17 18 32 33 34 35 36
Do not try to adjust or remove any of the

throttle body component parts (Throttle
position sensor, throttle valve, throttle stop
3
IFH511130055-01
screw, etc.).
These components have been factory
adjusted to precise specifications.
7) If out of specification, check wire harnesses for open

3) Connect tester probe (“+”, Red) to No. 5 terminal. and short. If wire harnesses are in good condition,
4) Connect tester probe (“–”, Black) to No. 31 terminal replace the throttle body and recheck.
(or to body ground).
36-pin test cord (White connector) Shift Position Sensor Removal and Installation
CENFH5111306041
4 Removal
5 Refer to “Lower Side Cover Removal and
2) Remove the fuel delivery pipe and intake manifold
assembly.
in Section 1D (Page 1D-8).
IFH511130017-01
3) Disconnect the neutral switch lead wire connector 7) Remove the sensor lever (8).
(1) and shift position sensor lead wire connector (2).
1 8
8
IFH511130076-02
IFH511130071-03 8) Remove the screw and shift position sensor (9).

4) Remove E-ring (3) from clutch lever shaft (4).
NOTE
Prior to removing sensor, mark the sensor’s
original position with a paint or scribe for
3 accurate reinstallation.
IFH511130073-02
5) Remove the two bolts (5) securing throttle/clutch

lever holder (6). 9
Remove the throttle/clutch lever holder with neutral
switch and shift position sensor.
IFH511130075-02
Installation
5 Installation is reverse order of removal with special
6 attention to the following steps.
• Place the shift position sensor (1) in position, then
tighten sensor mounting screw securely.
IFH511130072-02
6) Remove the screws and plate (7).
IFH511130077-02
IFH511130074-02
• Install the sensor lever (2) and plate (3), then tighten Shift Position Sensor Inspection
screws securely. CENFH5111306040
• Ensure that the tip “B” of sensor lever (2) fits firmly
into the sensor’s groove “A”. 2) Connect the 36-pin test cord set between ECM and
• Secure lead wire with lead wire clamps (4), then wire harness as shown in figure.
check that lead wire routed properly. Special tool
1
“A”
(A)
(A)
“B” 37 38 39 40 41 42 43 44 45 46 47 48 49 55 56 57 58 59 60 61 62 63 64 65 66 67
4
50 51 52 53 54 68 69 70 71 72 3
1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31
2 14 15 16 17 18 32 33 34 35 36
2
IFH511130078-03
2
IFH511130016-03
4 1. ECM 3. White connector

3) Connect tester probe (“+”, Red) to No. 8 terminal.

4 4) Connect tester probe (“–”, Black) to No. 31 terminal
3 3
IFH511130079-03
• Install the throttle/clutch lever holder with neutral 8

switch and shift position sensor, then tighten bolts
securely.
• Install the fuel delivery pipe and intake manifold
assembly.
Section 1D (Page 1D-8). IFH511130051-02

place. 36-pin test cord (Black connector)
• Check fuel and water hose routing. 4
Refer to “Fuel Hose Routing” in Section 4B (Page 4B-
1) and “Water Hose Routing” in Section 4B (Page 4B-
6). 31

4A (Page 4A-2).
• Check for fuel leakage.
• Check for water leakage. IFH511130052-02
5) Turn the ignition switch ON. 5) Remove the pin (3) securing side cover seal.
6) Check for sensor output voltage while operating Remove the trim sensor lead wire (4) from side
remo-con handle. cover seal.

Shift position Output voltage
Forward Approx. 4 V
Neutral Approx. 2 V 3
Reverse Approx. 0.6 V
Special tool
4
DC voltage ( )
IFH511130082-02
If out of specification: 6) Raise the engine to the full tilt up position and lower
• 1st check, sensor mount position, readjust if the manual tilt lock lever (5).
necessary.
• 2nd check, wire harnesses for open and short.
! WARNING
If wire harnesses are in good condition, replace shift Failure to take proper precaution when
position sensor and recheck. servicing trim sensor can cause severe
personal injury.
Trim Sensor Removal and Installation
CENFH5111306029 During the removal or installation of trim
Removal
sensor, the engine must be firmly secured
1) Turn the ignition switch OFF. and its weight fully supported by the hoist.
2) Remove lower side covers. (See below)
3) Remove the bolts (1) securing front panel.
5
IEH511130114-01
1
IFH511130080-01
4) Disconnect the trim sensor lead wire connector (2).
IEH511220010-01
IFH511130081-01
7) Remove the bolts and trim sensor (6) from clamp Trim Sensor Inspection
bracket. CENFH5111306030
Inspect trim sensor in the following procedures:
2) Connect the 36-pin test cord between ECM and wire
harness as shown in figure.
Special tool
6 (A): 09930–88730 (36-pin test cord set)
(A)
(A)
IEH511130089-02
37 38 39 40 41 42 43 44 45 46 47 48 49 55 56 57 58 59 60 61 62 63 64 65 66 67
3
Installation 50 51 52 53 54 68 69 70 71 72
Installation is reverse order of removal with special 1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31
attention to the following step. 14 15 16 17 18 32 33 34 35 36
• Tighten the sensor mounting bolts, pre-coated with

thread lock, to the specified torque.
2
Tightening torque IFH511130023-01
Trim sensor bolt (a): 6 N·m (0.6 kgf-m, 4.3 lbf-ft) 1. ECM 3. Black connector
: Thread lock cement 99000–32050 (SUZUKI 2. Wire harness

3) Connect tester probe (“+”, Red) to No.28 terminal.
4) Connect tester probe (“–”, Black) to No.31 terminal
(a)
3
28 31
IFH511130053-01
• Route and clamp the trim sensor lead wire properly.

Refer to “Wiring Harness Routing Diagram” in Section IFH511130020-02
4A (Page 4A-2). Special tool

• Perform the full trim down limit position setting. : 09900–25008 (Multi circuit tester set)
DC voltage ( )
5) Turn the ignition switch ON.
6) Check for sensor output voltage.
Operate the PTT switch, and check if voltage
changes linearly within specification, according to
trim/tilt position.
Trim/Tilt position Output voltage
Full trim down Approx. 0.2 V
Full tilt up Approx. 4 V
If out of specification, check wire harnesses for open

replace trim sensor and recheck.
Emergency Stop Switch Inspection

CENFH5111306031
1) Disconnect the emergency stop switch lead wire.
2) Check the continuity/infinity between the wiring leads
under the condition shown below.
Special tool
Continuity ( )
Tester probe connection Tester
Red (+) Black (–) indicates
Lock plate
Infinity
installed
Black Black
Lock plate
Continuity
removed
(A)
IDG211130064-01
(A)
B
IDG211130065-01
3) If out of specification, replace the emergency stop

switch.
Power Unit Mechanical: 1D-1
Power Unit Mechanical

Power Head
General Description
Power Unit Construction Description
CENFH5111401001
The power unit is direct water cooled, in line 4 cylinder, 4 stroke gasoline unit with its DOHC (Double overhead
camshaft) valve mechanism for “V” type valve configuration and 16 valves (4 valves/one cylinder).
The double overhead camshaft is mounted over the cylinder head, it is driven from crankshaft through driven gear and
timing chain, and no pushed rods are provided in the valve train system.
Powerhead Direction of Rotation
NOTE
This is a left hand (LH) rotation powerhead.
Cylinder Number
Cylinder number is as mentioned in figure.
No.1
No.2
No.3
No.4
IEH511140373-06

Cylinder Compression Check
CENFH5111404001
Refer to “Cylinder Compression Pressure Check” in Section 0B (Page 0B-25).
Oil Pressure Check

CENFH5111404002
Refer to “Oil Pressure Check” in Section 0B (Page 0B-24).
1D-2 Power Unit Mechanical:
Tappet Clearance Inspection Air Intake Silencer Case Removal and
CENFH5111406001
Refer to “Tappet Clearance Inspection and Adjustment”
Installation
CENFH5111406038
in Section 0B (Page 0B-9). Removal
Ring Gear Cover Removal and Installation 2) Remove the lower side covers.
CENFH5111406002
Removal Refer to “Lower Side Cover Removal and
3) Remove the three bolts (1) securing resonator (2),
2) Loosen and remove the four bolts securing ring gear
then remove the resonator.
cover (1).
2
1
IFH511140032-02
IFH511140030-01
3) Remove the ring gear cover.
Installation
• Check that lead wire is routed properly. 2
IFH511140033-01
4) Remove ring gear cover (3).

Refer to “Ring Gear Cover Removal and Installation”
(Page 1D-2).
IFH511140031-02
3
IFH511140034-01
5) Disconnect IAT sensor lead wire connector (4) at IAT Installation

sensor. Installation is reverse order of removal.
Check that all removed parts are back in original
position.
IFH511140035-01
6) Remove the two bolts (5) securing air intake silencer

case (6). IFH511140038-01
7) Remove the air intake silencer case.

Electric Parts Holder Removal and Installation
CENFH5111406003
Removal
6 1) Disconnect battery cables from battery.
5
! CAUTION
Failure to take proper precaution when
removing electrical parts may result in
personal injury and/or damage to electronic
components.
5
Prior to removing electrical parts, disconnect
IFH511140036-01
battery cables from battery.
8) Loosen the clamp securing breather hose (7), then
remove the breather hose from cylinder head cover. 2) Remove the lower side covers. Refer to “Lower Side
Cover Removal and Installation” in Section 2A (Page
2A-3).
3) Remove two bolts (1) securing front panel.
IFH511140037-01
1
IFH511140039-01
4) Disconnect lead wire connectors (2) from ECM (3), 8) Disconnect the evaporation hose (10) from outlet
then remove ECM. union.
3
10
IFH511140040-01 IFH511140043-02
5) Remove the nut (4), positive (+) battery cable (5) and 9) Cut the cable tie (11) binding battery cable and main
positive lead wire (R) from magnetic switch (6) of harness.
starter motor.
6) Remove the bolt (7) securing negative (–) battery
cable (8) and main harness GND.
6
11
7
IFH511140044-01
8
10) Pull the battery cables (12) out from electric parts
holder.
IFH511140041-01
7) Disconnect red lead wire (9) from magnetic switch

terminal “S”.
9 12
IFH511140045-01
11) Remove the SDS service connector (13) and main

harness connector (14) from electric parts holder.
IFH511140042-01 12) Disconnect the gauge connector (15).
13
15
14
IFH511140046-01
13) Remove the isolator wire connector (16) from 16) Remove the two bolts (23) securing electric parts
electric parts holder. holder (24).
Remove the cable clamp (17) from electric parts Slide the electric parts holder upward, then remove it
holder by releasing clamp’s lock. from cylinder block.
23
17
24
16
23
IFH511140047-01 IFH511140050-02
14) Disconnect PTT motor cable connector (18).

Disconnect PTT relay lead wire connectors (19) at
PTT relay.
24
19
24
IFH511140051-01
17) To free the electric parts holder;

18 a) Remove the cable clamp (25) and (26) from
IFH511140048-01
electric parts holder by releasing clamps’ lock.
15) Disconnect tilt limit switch lead wire connector (21)
and trim sensor lead wire connector (22).
25 26
22
21
IFH511140052-01
b) Push and remove the fuse box (27) from electric

IFH511140049-01
parts holder.
27
IFH511140053-01
c) Remove the PTT motor relay (28) from parts g) Disconnect the neutral switch lead wire
holder. connector (32) and sift position sensor connector
(33).
Cut the cable tie (34) binding battery cable and
lead wire.
28
33
34
IFH511140054-01
d) Remove the joint connector (29) from parts 32

holder.
IFH511140058-03
h) Remove the all wiring harness from electric parts

holder.
29 Installation
attention to the following steps.
• Tighten the main harness ground lead terminal
together with part-holder bolt “A”.
IFH511140055-01
e) Cut the cable tie (30) binding battery cable and

lead wires.
“A”
30
IFH511140059-02
• All parts removed have been returned to their original

position.
IFH511140056-01 4A (Page 4A-2).
f) Remove the screws (31) securing hose and
harness holder.
31
IFH511140057-01
Intake Manifold and Throttle Body Components

CENFH5111406004
(a)
6
7
5 8
(a)
(a)
10
9
11
1
13
12
IFH511140001-01
1. Intake manifold assembly 5. Seal ring 9. VSV 13. Clamp bracket

2. Seal ring 6. MAP sensor 10. VSV bracket : 23 Nm (2.3 kgf–m, 16.5 lbf-ft)
3. Throttle body 7. IAC valve 11. Check valve
4. Throttle body bracket 8. O-ring 12. Vacuum tank
Intake Manifold Removal and Installation 7) Remove the bolts and high pressure fuel filter (4).
CENFH5111406005 Refer to “High Pressure Fuel Filter Removal and
Removal
Installation” in Section 1G (Page 1G-30).
1) Relieve fuel pressure.
Refer to “Fuel Pressure Relief Procedure” in Section
1G (Page 1G-16).
3) Remove both side covers.
Installation” in Section 2A (Page 2A-3). 4
4) Remove ring gear cover and air intake silencer case
(1).
(Page 1D-2) and “Air Intake Silencer Case Removal
and Installation” (Page 1D-2). IFH511140062-01
5) Loosen the three bolts and remove the fuel hose 8) Remove fuel injectors and fuel delivery pipe (5).
guard (2). Refer to “Fuel Injector Removal and Installation” in
1
IFH511140060-02
IFH511140063-01
6) Remove fuel vapor separator (3).
Refer to “Fuel Vapor Separator Removal and 9) Remove the throttle link rod (6) from throttle drum
Installation” in Section 1G (Page 1G-18). (7).
Remove the bolts securing throttle drum to intake
manifold.
IFH511140061-01 6
IFH511140064-01
10) Disconnect the throttle position sensor lead wire 13) Disconnect the vacuum hose (VSV to depression
connector (8) at sensor. chamber) (14) from VSV.
Disconnect the IAC valve lead wire connector (9) at
IAC valve.
14
9
8 IFH511140068-01
14) Disconnect the vacuum hose (intake manifold to

IFH511140065-02 vacuum tank) (15) from vacuum tank.
11) Disconnect water inlet hose (10) from fuel cooler. 15) Remove the bolt (16) securing water return union
(17), then detach the union from engine holder.
10
16
17
IFH511140066-01
15
12) Disconnect MAP sensor connector (11) at sensor. IFH511140069-01
Disconnect water outlet hose (12) from fuel cooler. 16) Remove the bolts securing throttle body bracket (18)
Disconnect fuel hose (13) from 3-way joint. to cylinder.
13
18
12
11
IFH511140067-01 IFH511140070-01
17) Remove the engine oil dipstick (19). • Install intake manifold assembly, then tighten bolts
18) Remove eight bolts and two nuts and then remove and nuts in the indicated order.
intake manifold assembly (20). Tightening torque
Intake manifold bolt & nut (a): 23 N·m (2.3 kgf-m,
16.5 lbf-ft)
20
“8” “5”
“9”
“4”
“2” “1” (a)
19 “3”
IFH511140071-01 “10”
“6” “7”
2
Installation IFH511140072-02
NOTICE
Air leakage will induce a lean air/fuel mix (a)
which will result in severe engine damage.
Do not reuse gasket once removed. Always

use a new one.
• Install gaskets (1) into groove of intake manifold 2

assembly.
IFH511140073-01
• Connect the check valve (2) between vacuum hoses

as shown in the figure.
NOTE
The check valve is directional.
1 Refer to figure when connecting check valve
between vacuum hoses.
2
IEH511140040-06 “B”
“D” “C”
“A”
IEH511140042-08
2. Check valve “C”: From intake manifold assembly

“A”: Green side “D”: To vacuum tank
“B”: Black side
• Install fuel injectors and fuel delivery pipe (3). Throttle Control Cable Installation and
Refer to “Fuel Injector Removal and Installation” in Adjustment
Section 1G (Page 1G-26). CENFH5111406039
Installation and adjustment procedures of the throttle
control cables are as follows;
On throttle body side:

1) Install the open side throttle cable (1) to the throttle
drum and cable holder (2).
3
Secure the cable by tightening the cable lock nut (3).
2) Install the close side throttle cable (4) to the throttle
drum and cable holder (2).
Secure the cable by tightening the cable lock nut (5).
Throttle body side
IFH511140074-01
• Install fuel vapor separator (4).

Refer to “Fuel Vapor Separator Removal and
4
2
4
1
IFH511140076-01 3 5
• Install high pressure fuel filter (5).
IFH511140027-01
Refer to “High Pressure Fuel Filter Removal and
IFH511140077-01

place.
• Check fuel and water hose routing.
1) and “Water Hose Routing” in Section 4B (Page 4B-
6).
4A (Page 4A-2).
• Check for water leakage.
On throttle cable bracket side:

1) Bind the open/close cables with the clamp (6) and secure them on the intake manifold (7) at the location as shown
in the illustration.
NOTE
To ensure smooth operation of the throttle control system, the throttle cables must be positioned at
the location as shown in the illustration prior to installing them on the throttle drum on the throttle
cable bracket side.
2) Remove the throttle rod (8) from the throttle drum (9).
3) Remove the two bolts securing throttle cable bracket (10) to the intake manifold.
4) Install the close side throttle cable (4) to the throttle drum (9) and throttle cable bracket (10).
Adjust the position of cable lock nuts (11) so that the alignment mark “A” on the throttle drum (9) is positioned 2
mm away from the alignment mark “B” on the throttle cable bracket (10) as shown in the illustration.
Then secure the throttle cable (4) on the bracket by tightening the lock nuts (11).
5) Install the open side throttle cable (1) to the throttle drum (9) and throttle cable bracket (10).
Adjust the position of cable lock nuts (12) so that the alignment mark “A” on the throttle drum (9) aligns with the
alignment mark “B” on the throttle cable bracket (10) as shown in the illustration.
Then secure the throttle cable (1) on the bracket by tightening the lock nuts (12).
6) Tighten the throttle cable bracket (10) to the intake manifold with two bolts.
7) Connect the throttle rod (8) to the throttle drum (9).
8) Operate the throttle lever (13) and check that the throttle valve opens and closes completely without interference.
NOTE
If the throttle valve does not operate smoothly or open/close completely, check for the throttle cable
routing or inner cable tension.
Throttle cable bracket side
Step 4
“B” “a”
10
9
10
Step 5 “A”
“B”
10
6
7 9
9
13 8
“A”
9
10
1 12
11
IFH511140028-04
“a”: 2 mm (0.08 in.)

Throttle Link Rod Adjustment 3) Remove the screws and IAC valve (3).
CENFH5111406040
When replacing a link rod and/or connector, see the
illustration below to adjust the link rod length to
specification.
3
NOTE
Tighten lock nut against the connector after
adjusting the link rod length.
Throttle link rod length “L”

136 mm (5.4 in.)
IFH511140080-01
4) Remove flame arrester (4).

Remove bolts and throttle body assembly (5).
“L”
IFH511140029-02 4 5
Intake Manifold Disassembly and Assembly

CENFH5111406006
Disassembly
1) Remove bolts and fuel cooler (1).
1
IFH511140081-01
NOTICE
Do not attempt to remove bolts and
depression chamber (6).
If any repair is required on depression
chamber, replace it as an intake manifold
assembly.
IFH511140078-01
2) Remove screws and MAP sensor (2).
IFH511140082-01
IFH511140079-01
NOTICE • Install new seal ring (4) and throttle body.

Do not attempt to remove bolts and Intake Securely tighten the four throttle body bolts to
manifold cover (7). specified torque.
If any repair is required on intake manifold Tightening torque
cover (7), replace it as an intake manifold Throttle body bolt (a): 23 N·m (2.3 kgf-m, 16.5 lbf-
assembly. ft)
(a)
7 4
IFH511140085-01
IFH511140083-01
• Install the MAP sensor (5), then tighten mounting
screws securely.
Assembly
Reassemble in reverse order of disassembly paying
special attention to the following steps.
• Install the throttle cables (1) to throttle drum (2) and
cable bracket (3).
5
• Adjust of throttle control cable.
Refer to “Throttle Control Cable Installation and
Adjustment” (Page 1D-11).
2
IFH511140086-01
• Install the IAC valve (6), then tighten mounting screws

securely.
1
6
3
IFH511140084-02
NOTICE
Air leakage will induce a lean air/fuel mix
which will result in severe engine damage.
Do not reuse gasket/seal ring once removed.

Always use a new one. IFH511140087-01
Intake Manifold Component Inspection 5) Connect the vacuum hose (3) to special tool.
CENFH5111406007
Depression Chamber Special tool
1) Remove the PORT lower side cover. (A): 09917–47011 (Vacuum pump gauge)
Refer to “Lower Side Cover Removal and 6) Check the depression chamber lever (1) is moved to
Installation” in Section 2A (Page 2A-3). fully closed position when vacuum is applied to
2) Check the depression chamber lever (1) is moved by depression chamber with a special tool.
vacuum to fully closed position after engine is If the lever does not smoothly move, replace intake
started. manifold assembly.
(A)
1
2
IEH511140120-06 IFH511140091-01
1. Depression chamber lever 2. Depression chamber
3) Check the depression chamber lever (1) returns by 1

spring to fully opened position when engine is turned
off.
2
IEH511140120-06
1
1. Depression chamber lever 2. Depression chamber
2
7) Install removed parts in original position.
IFH511140088-02 Vacuum Passage

1. Depression chamber lever 2. Depression chamber 1) Disconnect vacuum hose (VSV to vacuum tank) (1)
from VSV.
4) Disconnect the vacuum hose (VSV to depression
chamber) (3) from VSV.
1
3
IFH511140092-01
IFH511140089-01
2) Start engine and run it at idle speed. Throttle Body Removal and Installation
Place a finger over vacuum hose end (1) and engine CENFH5111406008
vacuum is present. NOTICE

If vacuum is not present, clean vacuum passage with The throttle body will lose its original
compressed air, start engine and check again for performance if it is disassembled.
vacuum.
Do not try to disassemble the throttle body.
Check Valve
1) Remove check valve (1).
(Page 1D-8) and “Intake Manifold Disassembly and
Assembly” (Page 1D-13).
Throttle Body Inspection

CENFH5111406009
1 NOTICE
The throttle body will lose its original
performance if it has been disassembled and
reassembled.
• Do not try to disassemble the throttle body.
• Do not try to adjust or remove any of the
IFH511140093-01
throttle body component parts (Throttle
2) Blow air (moderate pressure) through hose fitting on position sensor, throttle valve, throttle
black side “A” of check valve. Air should not pass stop screw, etc.).
through valve from intake manifold (black side “A”) to These components have been factory
green side “B”. adjusted to precise specifications.
3) Blow air (low pressure) through hose fitting on green • Clean throttle body bore by compressed air.
side “B” of check valve. Air should pass through to
• Check that if there is any foreign dust or carbon
black side.
caught at the passage between throttle valve and
If air passes through valve in Step 2 or high pressure
throttle body housing.
is required to cause air to pass in Step 3, replace
If there is, clean the passage inside of throttle body by
check valve.
compressed air thoroughly.
! WARNING • Check that throttle valve moves smoothly.
If vacuum is applied using your mouth, there

is a risk of inhaling harmful fuel vapor.
Be sure to use a hand vacuum pump to apply

vacuum.
4) Install check valve.
NOTE
The check valve is directional. Refer to the
figure for correct installation.
IFH511140094-02
“A”
“C” “D”
“B”
IEH511140048-07
“A”: Black side “C”: To vacuum tank

“B”: Green side “D”: From intake manifold
IFH511140095-02
Cylinder Head Cover Removal and Installation 6) Remove the bolts and low pressure fuel pump (5).
CENFH5111406010 Refer to “Low Pressure Fuel Pump Removal and
Removal Installation” in Section 1G (Page 1G-28).
2) Remove both side covers.
3) Remove the resonator and air intake silencer case
(1). 5
Installation” (Page 1D-2).
1
IFH511140099-01
7) Remove the bolt and harness bracket (6).

8) Remove the bolts and VSV bracket (7).
Disconnect VSV lead wire connector (8) at VSV.
IFH511140096-01 7
4) Disconnect CMP sensor lead wire connectors (2) at
sensor.
IFH511140100-01
9) Remove the hose clamp (9) from resonator bracket

(10) by releasing clamp’s lock.
Remove the bolts and resonator bracket.
2
IFH511140097-01
5) Disconnect ignition coil connectors (3).

Remove the bolts securing the ignition coils.
Remove all ignition coils (4) and spark plugs.
10
9
IFH511140101-01
4
IFH511140098-02
10) Remove the nut and low pressure fuel filter (11) from Installation
filter bracket (12). Remove the bolts and filter Installation is reverse order of removal with special
bracket. attention to the following steps.
• Clean sealing surface on cylinder head and cover.
Remove oil, old sealant and dust from sealing
surface.
12 • After cleaning, apply sealant to cylinder head sealing
surface area as shown in figure.
: Sealant 99000–31140 (SUZUKI Bond
1207B (100 g))
11
IFH511140102-01
11) Disconnect OCV lead wire connector at OCV (13).

Remove the bolts, OCV (Oil Control Valve) and
bracket (14), then discard OCV gasket.
13
IFH511140105-02
14
IFH511140103-01
12) Remove the bolts securing harness bracket (15).
IFH511140106-02
• Install new cylinder head cover gasket (1) to head

cover.
15 NOTICE
A previously used gasket may leak, resulting
in engine damage.

IFH511140104-01
use a new one.
13) Loosen the fourteen bolts securing cylinder head
cover in ascending order of numbers, then remove
the cylinder head cover.
“2” “1”
“12”
“8” “5”
“14”
“10” “9”
“13”
“6” “7” 1
“11”
“3” IEH511140064-06
“4”
IEH511140061-06
• Install cylinder head cover (2) to cylinder head, then OCV (Oil Control Valve) Removal and
tighten cylinder head cover bolts in ascending order of Installation
numbers. CENFH5111406011
Removal
Tightening torque 1) Remove lower side covers.
Cylinder head cover bolt (a): 11 N·m (1.1 kgf-m, Refer to “Lower Side Cover Removal and
8.0 lbf-ft) Installation” in Section 2A (Page 2A-3).
2) Remove the three bolts (1) securing resonator (2),
then remove the resonator.
2
(a)
1
IEH511140065-05
2
2
“13” “14” IFH511140107-02
“3”
“7” 3) Disconnect OCV lead wire connector (3) at OCV.
“10”
“1”
4) Remove the four bolts securing OCV (4), then
“6” remove OCV and resonator bracket (5).
“5”
“2” Discard OCV gasket.
“9” “8”
“4” 3
“12”
“11”
IEH511140066-05
• Install new gasket and OCV, then tighten bolts

securely. 4
• All parts removed have been returned to their original
positions.
5
• Check wire routing. IFH511140108-01
4A (Page 4A-2).
• Check fuel hose routing.
1).
Installation Power Unit Removal and Installation

attention to the following steps. Removal

Before removing power unit;
• Install new gasket (1).
• Relieve fuel pressure.
NOTICE Refer to “Fuel Pressure Relief Procedure” in Section
1G (Page 1G-16).
in engine damage. • Drain engine oil.
• Disconnect battery cables from battery.
Do not reuse the OCV gasket, always replace 1) Remove the lower side covers and oil pan covers.
with new one. Refer to “Lower Side Cover Removal and
NOTE
2) Remove the ring gear cover and intake silencer case
Position the OCV gasket tab “A” as shown. (1).
(Page 1D-2) and “Air Intake Silencer Case Removal
and Installation” (Page 1D-2).
“A” 3) Loosen three bolts and remove fuel hose guard (2).
1
1
IFH511140109-01
• Install OCV (2) and bracket (3), then tighten four bolts, 2
pre-coated with thread lock, to specified torque.
Tightening torque IFH511140111-02
OCV bolt (a): 12 N·m (1.2 kgf-m, 8.5 lbf-ft) 4) Remove the fuel vapor separator (3).
3
(a)
3
IFH511140112-01
IFH511140110-02

original position.
OCV (Oil Control Valve) Inspection

CENFH5111406012
Refer to “OCV (Oil Control Valve) Inspection” in Section
1C (Page 1C-18).
5) Remove the fuel delivery pipe and intake manifold 8) Remove starter motor (8).
assembly (4). Refer to “Starter Motor Removal and Installation” in
Refer to “Intake Manifold Removal and Installation” Section 1I (Page 1I-4).
(Page 1D-8).
IFH511140116-01
IFH511140113-01 9) Remove flywheel (9).

6) Remove all ignition coils and spark plugs. Refer to “Flywheel Removal and Installation” in
Remove the bolts and low pressure fuel pump (5). Section 1K (Page 1K-5).
Refer to “Low Pressure Fuel Pump Removal and
Special tool
(A): 09916–99312 (Flywheel holder)
Remove the cylinder head cover (6).
Refer to “Cylinder Head Cover Removal and
9
(A)
IFH511140117-01
10) Remove battery charge coil (10).

IFH511140114-01
Refer to “Battery Charge Coil Removal and
Installation” in Section 1K (Page 1K-7).
7) Remove the ECM and electric parts holder (7).
Refer to “Electric Parts Holder Removal and
10
IFH511140118-01
IFH511140115-01
11) Remove rectifier/regulator (11). 14) Disconnect O2 sensor lead wire connector.
Refer to “Rectifier / Regulator Removal and Remove the O2 sensor (15).
Special tool
Remove the bolt securing lead wire clamp plate (12).
(B): 09933–39810 (O2 sensor socket)
11
(B)
12 15
IFH511140119-01
IFH511140122-01
12) Disconnect EX. manifold temperature sensor lead
15) Remove screws and CKP sensor (16).
wire connector.
Remove EX. manifold temperature sensor (13).
13
16
IFH511140123-01
IFH511140120-01
16) Loosen screw and disconnect blue lead wire (17)
from oil pressure switch.
13) Disconnect cylinder temperature sensor lead wire
connector.
Remove cylinder temperature sensor (14).
14
17
IFH511140124-01
IFH511140121-01
17) Remove the two bolts securing ring gear under cover 20) Disconnect the water hose (23) from balancer water
(18), then remove the ring gear under cover with jacket cover.
wiring harness.
18
23
IFH511140128-01
IFH511140125-01 21) Remove three bolts, thermostat cover (24) and

18) Disconnect water hose (19) from balancer water thermostat (25).
jacket cover.
24
25
19
IFH511140129-01
IFH511140126-01 22) Disconnect water hose (26) from cylinder block.
19) Disconnect knock sensor lead wire connector (20). Disconnect water hose (27) from cylinder block.
Remove the bolts and sensor protector (21). Remove oil level dipstick.
Remove the knock sensor (22). Remove bolt and engine oil dipstick tube (28).
22 26
21 28
20
27
IFH511140130-01
IFH511140127-02
23) Disconnect water flush hose (29) from cylinder

block.
29
31
IFH511140017-02
IFH511140131-01
24) Remove five power unit mounting bolts (30) from

engine upper side.
31
30
IFH511140018-03
26) Lift up and remove power unit from engine holder.
Installation
IFH511140014-02 Installation is reverse order of removal with special
attention to the following step.
NOTICE
30 Previously used gasket may leak oil and/or
cooling water, resulting in engine damage.

use a new one.
Power unit
• Install dowel pins (1) and gasket (2).
IFH511140015-02
Apply water resistant grease to driveshaft splines.
25) Remove sixteen power unit mounting bolts (31) from : Grease 99000–25350 (SUZUKI Water
engine under side. Resistant Grease EP2 (250 g))
1
31
IFH511140016-02 IFH511140132-02
• Install O-ring (3) to mount seal cover, then apply water • Apply silicone seal to power unit mounting bolts and
resistant grease on O-ring. tighten bolts to specified torque.
• Install engine holder seal (4). : Sealant 93691–80030 (SUZUKI Silicone
NOTE Seal (100 g))
Install seal (4) with lip facing upward. Tightening torque

Power unit mounting bolt (10 mm) (a): 50 N·m (
5.0 kgf-m, 36.0 lbf-ft)
Power unit mounting bolt (8 mm) (b): 23 N·m (2.3
kgf-m, 16.5 lbf-ft)
4
(a)
IEH511140097-06
NOTE
Before installing power unit, apply sealant to IEH511140099-06
the six hatched areas shown in the

illustration.

1207B (100 g)) (a)
IEH511140100-06
(a)
IEH511140101-06
(b)
IEH511140098-04
• Lower the power unit onto engine holder.
NOTE
Rotate crankshaft to aid alignment of
driveshaft and counter shaft splines.
IEH511140102-07
Flywheel
• Install battery charge coil (1).
Refer to “Battery Charge Coil Removal and
(b)
IEH511140103-05
1
Thermostat
• Assemble thermostat (1) and thermostat cover (2) to
cylinder block and secure with bolts. IFH511140135-03
• Install flywheel (2).

Refer to “Flywheel Removal and Installation” in
2 Section 1K (Page 1K-5).
1
Special tool
Tightening torque
Flywheel bolt: 118 N·m (11.8 kgf-m, 85.5 lbf-ft)
IFH511140133-01
CKP sensor
• Install ring gear under cover (1), then tighten bolts
securely.
• Install CKP sensor (2).
Refer to “CKP Sensor Removal and Installation” in
Section 1C (Page 1C-10). (A)
IFH511140137-03
Cylinder head cover

2 Install cylinder head cover (1).
Refer to “Cylinder Head Cover Removal and Installation”
(Page 1D-17).
1
IFH511140134-01
IFH511140136-01
Intake manifold Final assembly check

Install gaskets and intake manifold assembly (1). • Perform the following checks to ensure proper and
Refer to “Intake Manifold Removal and Installation” safe operation of the repaired unit.
(Page 1D-8).
– All parts removed have been returned to their
original positions.
– Fuel and water hose routing match’s service
manual illustration.
Refer to “Fuel Hose Routing” in Section 4B (Page
4B-1) and “Water Hose Routing” in Section 4B
(Page 4B-6).
– Wire routing match’s service manual illustration.
Refer to “Wiring Harness Routing Diagram” in
1
– No fuel leakage is evident when fuel system is
IFH511140138-01 pressurized.
– No water leakage is evident during final test
Fuel delivery pipe running.
Install fuel injectors and fuel delivery pipe (1).
Refer to “Fuel Injector Removal and Installation” in
IFH511140139-01
Fuel vapor separator

• Install fuel vapor separator (1).
IFH511140140-02
Timing Chain, Camshaft Sprocket, Balancer Chain Components

CENFH5111406017
8
9
6 4
13
11
12 10
IEH511140178-04
1. Crankshaft/Drive gear/Balancer drive gear 6. Timing chain guide 11. Balancer chain tensioner
2. Driven gear/Timing sprocket 7. Timing chain 12. Balancer chain guide
3. Driven gear holder 8. IN. camshaft timing sprocket 13. Balancer chain
4. Chain tensioner adjuster 9. EX. camshaft timing sprocket
5. Timing chain tensioner 10. Balancer driven sprocket
Timing Chain, Camshaft Sprocket, Balancer 6) Remove bolt (5), balancer chain tensioner (6),
Chain Removal and Installation washer “a” and spring (7).
CENFH5111406018
Removal
7
1) Remove the power unit.
Refer to “Power Unit Removal and Installation” 5
(Page 1D-20).
2) Remove the oil pump.
Refer to “Oil Pump Removal and Installation” in “a”
Section 1E (Page 1E-4).
6
3) Loosen the bolts securing IN./EX. camshaft timing 6
sprockets to each camshaft.
NOTE IFH511140019-02
• Sprocket bolt is LH thread. 7) Loosen and remove the bolt (8) securing balancer
• Hold camshaft by placing a wrench on the drive sprocket (9) to crankshaft.
hexagon area of the camshaft.
IEH511140183-04
NOTE
IEH511140179-04
To hold the crankshaft, use special tool and
4) Remove the four bolts (1) securing driven gear
flywheel as shown in figure.
holder (2), then remove the driven gear holder.
Special tool
(A)
IEH511140180-04
5) Remove bolts (3) and balancer chain guide (4).

IEH511140184-04
IEH511140181-04
8) Remove the balancer drive sprocket (9) and 11) Remove bolts (13) and chain tensioner adjuster (14).
balancer chain (10).
14 13
9
10
IEH511140188-04
IEH511140185-04 12) Remove bolt (15) and timing chain tensioner (16).
9) Turn the crankshaft in its normal running direction
“A” until the match mark (•) “B” on the crankshaft
drive gear points to 12 o’clock (toward cylinder 15
head).
NOTICE
16
After the timing chain has been removed,
independently turning camshaft or
crankshaft will cause interference between
piston and valve, which cause damage to
these related parts.
IEH511140189-04
Do not rotate the camshaft and/or crankshaft
13) Remove bolt (17), EX. camshaft timing sprocket (18)
with timing chain removed.
and timing chain (19).
Remove oil pump drive gear (20).
17 20
19
“B”
“A”
18
IEH511140186-04
IEH511140190-04
A: Engine normal running direction
B: Match mark (•) on crankshaft drive gear 14) Remove bolt (21) and IN. camshaft timing sprocket
(22).
10) Remove bolts (11) and timing chain guide (12).
21
11
22
12
IEH511140191-04
IEH511140187-04
15) Remove driven gear (23). 2) Check that match mark (•) “C” on the crankshaft
drive gear points to 12 o’clock (towards cylinder
head).
“C”
23
IEH511140192-04
16) Remove drive gear (24).

IEH511140195-04
3) Install the driven gear (2) on the cylinder block so

that match mark (•) “C” aligns with match mark (•)
“D” on the driven gear as shown in illustration.
24
“D”
2
“C”
IEH511140193-04
Installation
Installation is reverse of removal with special attention to
IEH511140196-04
following steps.
4) Fit the dowel pin (3) onto IN. camshaft. Fit IN.
1) Install the drive gear (1) on crankshaft so that dowel camshaft timing sprocket (4) and temporarily tighten
pin hole “A” aligns with match mark (•) “B” on the the sprocket bolt.
drive gear as shown in illustration. Check that match marks (•) “E”, “F” are correctly
aligned as shown in illustration.
“B”
“A”
3
1
4
IEH511140194-04
IEH511140197-04
“F”
“E”
IEH511140198-04
5) Fit the dowel pin (5) onto the EX. camshaft. 8) While aligning another blue plate “I” of timing chain
Install oil pump drive gear (6). with the match mark (•) “J” on the EX. camshaft
timing sprocket (8), fit the chain onto the sprocket.
5 “I”
“J”
6 8
IEH511140199-04
6) Align the blue plate “G” of timing chain (7) with the IEH511140202-04
match mark (•) “D” on the driven gear and fit the 9) Install the EX. camshaft timing sprocket (8) on the
chain onto the driven gear. EX. camshaft, then temporarily tighten the sprocket
bolt.
8
7
“G” “D”
IEH511140200-04
7) As shown in the illustration, fit the timing chain with IEH511140203-04
one blue plate “H” aligned with the match mark (•) 10) Insert the spacer (9) into the chain tensioner (10).
( ) “E” onto the IN. camshaft timing sprocket. Install chain tensioner, then tighten bolt (11)
securely.
Apply engine oil to chain tensioner.
“H”
11
“E”
10
IEH511140201-04
10 11
IEH511140204-04
11) With latch of tensioner adjuster pushed in and 15) Turn the crankshaft two complete rotations in
plunger pushed back into body, insert stopper into direction shown in illustration.
latch and body. As shown in the illustration, check that all match
After inserting stopper, check to make sure that marks are in alignment as stated below when the
plunger will not come out. match mark (•) “C” on the drive gear is pointing to 12
o’clock.
13 15 • The match mark (•) ( ) “E” on the IN. sprocket
12 14
13 aligns with the match mark “F” on the camshaft
housing.
• The match mark (engraved line) “K” on the EX.
sprocket aligns with the mating face “L” between
cylinder head and lower camshaft housing.
IDG211140087-01 “F”
12. Plunger 14. Body “K” “E”
13. Latch 15. Stopper
12) Install timing chain tensioner adjuster, then tighten

bolts (16) to specified torque. “L”
Tightening torque
Tensioner adjuster bolt (a): 11 N·m (1.1 kgf-m,
8.0 lbf-ft)
Apply engine oil to timing chain.
13) Remove the stopper (15) from tensioner adjuster.
“C”
15
IEH511140208-03
16 (a)
16) Check that match mark (•) “C” on the crankshaft
drive gear points to 12 o’clock (towards cylinder
head).
IEH511140206-04
14) Install timing chain guide (17), then tighten bolts

securely.
Apply engine oil to chain guide.
“C”
IEH511140209-03
17
IEH511140207-03
17) Check that match mark (•) “M” on the balancer 20) Align another blue plate “O” of balancer chain with
driven sprocket points to 6 o’clock as shown in the the match mark (•) “P” on the balancer drive sprocket
illustration. (20) and fit the chain on the sprocket.
“O”
20
“P”
“M”
IEH511140210-03 IEH511140213-04
18) Fit the dowel pin (18) on the crankshaft. 21) Install the balancer drive sprocket (20) on the
crankshaft, then temporarily tighten the sprocket bolt
and washer.
Check that match marks “M” and “P” are correctly
aligned as shown in illustration.
18
“O”
“P”
20
IEH511140211-03
19) Align the blue plate “N” of balancer chain (19) with “M”
the match mark (•) “M” on the balancer driven
sprocket and fit the chain on the sprocket. “N”
IEH511140214-04
22) Install balancer chain guide (21), then tighten bolts

(22) securely.
19
“M”
21
22
“N”
IEH511140212-04
IEH511140215-03
23) Assemble tensioner spring (23), washer “a” and

balancer chain tensioner (24).
(A)
23 “a”
24
IEH511140218-03
26) Tighten IN. camshaft timing sprocket bolt to specified

IFH511140020-02 torque.
24) Install chain tensioner (24), then tighten bolt (25)
Tightening torque
securely.
IN. camshaft timing sprocket bolt (c): 60 N·m (
6.0 kgf-m, 43.5 lbf-ft)
NOTICE
Over tightening the sprocket bolt can cause
25
damage to VVT actuator.
Do not over tighten the camshaft timing

sprocket bolt.
24
IEH511140353-03
25) Tighten crankshaft drive gear bolt (26) to specified

torque.
Tightening torque
Crankshaft drive gear bolt (b): 48 N·m (4.8 kgf-
m, 34.5 lbf-ft)
(c)
IEH511140219-05
26 (b)
27) Tighten EX. camshaft timing sprocket bolt to
specified torque.
Tightening torque
EX. camshaft timing sprocket bolt (d): 78 N·m (
7.8 kgf-m, 56.5 lbf-ft)
IEH511140217-04
NOTE
(d)
To hold the crankshaft, use special tool and
flywheel as shown in figure.
Special tool
IEH511140220-06
28) Install driven gear holder (27), then tighten four bolts Timing Chain Tensioner / Chain Guide
securely. Check chain guide shoe for wear or damage.
If excessive wear or other damage is found, replace it.
27
IEH511140221-03
IEH511140224-03
Timing Chain, Camshaft Sprocket, Balancer

Chain Related Parts Inspection Camshaft Timing Sprocket
CENFH5111406019 Check teeth of sprocket for wear or damage.
NOTE If excessive wear or other damage is found, replace it.
If any component is worn excessively,
NOTICE
cracked, defective or damaged in any way, it
must be replaced. The VVT actuator will lose its original
performance if it is disassembled.
Timing Chain / Balancer Chain
• Inspect timing chain and balancer chain for wear or VVT actuator is non-repairable.
damage. Do not try to disassemble and repair the VVT
If excessive wear or other damage is found, replace it. actuator.
If any faulty condition is found, replace the
VVT actuator with a new one.
IEH511140377-03
Tensioner Adjuster
Inspect tensioner adjuster for smooth operation. IEH511140225-03
Replace if faulty. 1. VVT actuator

Check oil delivery passage to tensioner.
I9J011140182-01
1. Latch 2. Tooth surface 3. Oil passage

Driven Gear Holder Balancer Sprocket

• Check driven gear holder. Check teeth of sprocket for wear or damage.
If cracks or other damage is found, replace holder. If excessive wear or other damage is found, replace it.
• Check driven gear bearing.
Replace bearing if pitted, noisy, or rough condition.
• Check oil seal.
If excessive wear or other damage is found, replace
oil seal.
IEH511140229-03
Balancer Chain Tensioner / Chain Guide

• Check tensioner for wear or damage.
IEH511140226-03
• Check chain guide for wear or damage.
NOTE
Install oil seal lip (spring side) facing as
shown in figure.
IEH511140230-03
Oil Pump Drive Gear

Inspect drive gear for wear or other damage.
IEH511140227-03
Drive Gear / Driven Gear / Bearing

• Inspect drive gear and driven gear for wear or other
damage.
• Inspect driven gear bearing for pitting, rough or other
damage.
Replace if necessary.
IEH511140231-03
IEH511140228-03
Camshaft, Tappet and Shim Removal and 5) Remove intake camshaft and exhaust camshaft.
Installation
CENFH5111406020
Removal
Refer to “Power Unit Removal and Installation”
(Page 1D-20).
2) Remove the timing chain.
Refer to “Timing Chain, Camshaft Sprocket,
Balancer Chain Removal and Installation” (Page 1D-
29).
3) Remove two plugs (1) and (2).
IEH511140357-03
6) Remove tappets and tappet shims.
NOTE
2 1
All tappets and tappet shims must be
installed in their original positions.
For ease of assembly, lay out tappets and
record shim thickness for each individual
cylinder/valve position.
IFH511140021-01
4) Remove the bolts securing the camshaft housing (3)

to cylinder head, then remove each camshaft
housing.
NOTE
For ease of assembly, note position of each
individual camshaft housing.
IEH511140234-03
3
3
Installation
1) Apply engine oil around tappets.
2) Install tappets and tappet shims in their original
position.
3
IEH511140355-03
IEH511140235-03
IEH511140356-03
3) Apply engine oil to the surface of each camshaft lobe 4) Install camshaft housing pins as shown in figure.
and journal, then place them onto cylinder head.
NOTE
Before installing camshafts, turn crankshaft
until the match mark “A” on the crankshaft
drive gear points to 12 o’clock (toward
cylinder head).
2
IEH511140239-03
“A” 2. Pin
“A”
1
5) Apply sealant to lower camshaft housing sealing
surface area as shown in figure.
1207B (100 g))
IEH511140236-03 Apply Bond

marked
1. Dowel pin “A”: Match mark (•) on drive gear
line.
IEH511140240-02
6) Install the lower camshaft housing (3).
3
IEH511140237-03
NOTE
When installing the camshafts, align dowel
pin “B” on the IN. camshaft with match mark
“C” on lower camshaft housing and engraved
line “D” on EX. sprocket align with lower
camshaft housing mating face.
IEH511140241-03
3. Lower camshaft housing

“C”
“D”
“B”
IEH511140238-03
“B”: Dowel pin on camshaft

“C”: Match mark on lower camshaft housing
“D”: Engraved line on EX. sprocket
7) Check position of camshaft housing. Install housings 10) Install timing chain and balancer chain.
as indicated by these marks. Refer to “Timing Chain, Camshaft Sprocket,
NOTE 29).
Embossed marks are provided on each 11) Check tappet clearance and adjust as necessary.
camshaft housing indicating position and Refer to “Tappet Clearance Inspection and
direction of installation. Adjustment” in Section 0B (Page 0B-9).
Camshaft, Tappet and Shim Inspection

CENFH5111406021
“E” NOTE
“F” cracked, defective or damaged in any way, it
must be replaced.
“G”
Cam Face
Inspect cam face for scratches and wear.
If any of the above conditions are found, replace
IDG211140103-01 camshaft.
“E”: I: Intake side, E: Exhaust side
“F”: Position from flywheel magneto side Cam Wear
“G”: Pointing to flywheel magneto side Using micrometer, measure cam height.
If measurement exceeds service limit, replace camshaft.
8) Lightly seat all housing bolts.
Special tool
According to numerical order in figure, tighten bolts
: 09900–20202 (Micrometer (25 – 50 mm))
to 1/3 of specified torque, then 2/3 of specified
torque and finally to full specified torque.
Cam height “a”
NOTE Standard Service limit
45.330 – 45.490 mm 45.230 mm
Apply engine oil lightly to housing bolt. IN.
(1.7846 – 1.7909 in) (1.7807 in)
DF200A
44.420 – 44.580 mm 44.320 mm
Tightening torque EX.
(1.7488 – 1.7551 in) (1.7449 in)
Camshaft housing bolt: 12 N·m (1.2 kgf-m, 8.5
lbf-ft)
“21”
“a ”
“19” “10” “2” “6” “14”

“17” “9” “1” “5” “13”
“18” “11” “3” “7” “15”

“20” “12” “4” “8” “16”
“22”
IEH511140242-03
IEH511140244-03
9) Install plugs (4) in lower camshaft housing.
IFH511140022-01
Camshaft Identification Camshaft Journal Wear

Camshaft identification is as follows. Check camshaft journals and camshaft housings for
Identification mark pitting, scratches, wear or damage.
Model If any of the above conditions are found, replace
IN. EX.
DF200A L D camshaft or cylinder head with housing.
NOTE
Camshaft housing and cylinder head must be
replaced as a set.
“A”
“A”
IEH511140245-04
“A”: I.D. mark I9J011140030-01
Camshaft Runout Camshaft Journal Oil Clearance

Support camshaft on a surface plate using a set of V- Check journal oil clearance using Plastigauge as follows.
blocks. 1) Clean housings and camshaft journals.
Measure runout using a dial gauge. 2) Install camshaft to cylinder head.
If measurement exceeds service limit, replace camshaft.
3) Place Plastigauge across the full width of camshaft
Special tool journal (parallel to camshaft).
(A): 09900–20606 (Dial gauge)
Special tool
(B): 09900–20701 (Magnetic stand)
(A): 09900–22301 (Plastigauge (0.025 –
Camshaft runout 0.076 mm))
Service limit: 0.10 mm (0.004 in.) (A): 09900–22302 (Plastigauge (0.051 –
0.125 mm))
(A)
(B) (A)
(A)
IEH511140390-02
IEH511140246-05
4) Install camshaft housings. Tighten housing bolts in 3

steps (1/3 of specification, 2/3 of specification, full
(B)
torque specification) in the indicated order.
Tightening torque
Camshaft housing bolt: 12 N·m (1.2 kgf-m, 8.5
lbf-ft)
NOTE
Do not rotate camshaft while Plastigauge is
installed.
IEH511140248-04
“21”
“19” “10” “2” “6” “14”

“17” “9” “1” “5” “13”
“18” “11” “3” “7” “15”

“20” “12” “4” “8” “16”
“22”
IEH511140247-03
5) Remove camshaft housings.

I9J011140200-02
6) Using scale (1) on Plastigauge envelope, measure
Plastigauge (2) at its widest point. Wear of Tappet and Shim
Camshaft journal oil clearance Check tappet and shim for pitting, scratches, or damage.
Standard: 0.043 – 0.085 mm (0.0017 – 0.0033 in.) If any above conditions are found, replace component.
Service limit: 0.120 mm (0.0047 in.)
2 1
I9J011140076-01
Measure cylinder head bore and tappet outside diameter

IDG211140184-02 to determine cylinder head to tappet clearance.
1. Scale 2. Plastigauge If clearance exceeds service limit, replace tappet or
cylinder head.
If journal oil clearance exceeds the service limit,
Special tool
measure camshaft journal (outside dia.) and
: 09900–20202 (Micrometer (25 – 50 mm))
camshaft housing (inner dia.). Based on
measurements, replace camshaft and/or cylinder Cylinder head bore to tappet clearance
head with camshaft housing. Standard: 0.025 – 0.066 mm (0.0010 – 0.0026 in.)
Camshaft journal outside diameter
Standard: 25.936 – 25.957 mm (1.0211 – 1.0219 Tappet outer diameter
in.) Standard: 33.959 – 33.975 mm (1.3370 – 1.3376 in.)
Camshaft journal (housing) inside diameter Cylinder head tappet bore
Standard: 26.000 – 26.021 mm (1.0236 – 1.0244 Standard: 34.000 – 34.025 mm (1.3386 – 1.3396 in.)
in.)
Special tool
(B): 09900–20202 (Micrometer (25 – 50
mm))
NOTE
Do not forget to remove all bolts shown in
figure.
I9J011140031-01
“3”
“2”
IEH511140250-03
Installation
Installation is in reverse order of removal paying special
NOTICE
I9J011140032-01
A previously used gasket may leak
combustion gas and/or cooling water,
resulting in engine damage.
Cylinder Head Removal and Installation
CENFH5111406022
Removal Do not reuse gasket once removed.
1) Prior to removing cylinder head assembly; Always use a new gasket.
• Remove the power unit.
1) Insert the dowel pins (1) and place a new cylinder
head gasket (2) into position on the cylinder.
(Page 1D-20).
• Remove the timing chain.
Balancer Chain Removal and Installation” (Page 1
1D-29). 1
• Remove the IN. and EX. camshafts.

Refer to “Camshaft, Tappet and Shim Removal
2) Loosen and remove twenty cylinder head bolts in the 2
order indicated in figure.
Remove cylinder head assembly and head gasket.
IEH511140251-03
“4” “5” “8” “9” “7”
“10”
“6”
“13” “17” “19” “15” “11”

“3”
“14” “16” “20” “18” “12”

“2”
“1”
IEH511140249-03
2) Position cylinder head on cylinder.

3) Apply engine oil to cylinder head bolts and tighten
them gradually as follows.
a) Tighten all cylinder head bolts to 50 percent (%)
of specified torque according to sequence in
figure.
Tightening torque
Cylinder head bolt (1st step) [12 mm]: 43
N·m (4.3 kgf-m, 31.0 lbf-ft)
Cylinder head bolt (1st step) [8 mm]: 12 N·m
(1.2 kgf-m, 8.5 lbf-ft)
IEH511140255-03
“17”
4) Install the IN. and EX. camshafts.
“16” “13” “12” “14”
“11” Refer to “Camshaft, Tappet and Shim Removal and
“15” Installation” (Page 1D-38).
5) Install the timing chain and balancer chain.
“4” “6” “10” Refer to “Timing Chain, Camshaft Sprocket,
“8” “2”
“18” Balancer Chain Removal and Installation” (Page 1D-
29).
“7” “5” “1” “3” “9” 6) Install oil pump.
“19”
“20” Cylinder Head Disassembly and Assembly

IEH511140253-03 CENFH5111406023
Disassembly
NOTE 1) Using valve lifter and attachment, remove valve
Do not forget to install all bolts shown in cotters (1) while compressing valve spring.
figure.
Special tool
(A): 09916–19030 (Valve lifter)
(B): 09916–14521 (Valve lifter attachment)
(C): 09916–84511 (Tweezers)
“18”
“19”
IEH511140254-03
(B)
b) Loosen all cylinder head bolts to 0 Nm (0 kgf-m, (A)
0 lbf-ft.) according to reverse sequence in figure.
IEH511140256-03
c) Again tighten all cylinder head bolts to 50
percent (%) of specified torque according to (C)
sequence in figure.
Tightening torque (A)
Cylinder head bolt (3rd step) [12 mm]: 43
(B)
N·m (4.3 kgf-m, 31.0 lbf-ft)
Cylinder head bolt (3rd step) [8 mm]: 12 N·m
(1.2 kgf-m, 8.5 lbf-ft)
d) Finally tighten all cylinder head bolts to specified
torque according to sequence in figure.
Tightening torque
Cylinder head bolt (Final step) [12 mm]: 86
N·m (8.6 kgf-m, 62.0 lbf-ft) 1
Cylinder head bolt (Final step) [8 mm]: 23 I9J011140209-01
N·m (2.3 kgf-m, 16.5 lbf-ft)

2) Remove valve spring retainer (2), valve spring (3) 1) Install valve spring seat (1) to cylinder head.
and valve (4). 2) After applying engine oil to stem seal (2) and spindle
of special tool (A), fit stem seal to spindle.
1 2 3 5 6 4 Then, pushing special tool by hand, install stem seal
to valve guide.
Check to be sure that seal is properly fixed to valve
guide.
1
I9J011140210-01
NOTICE
3) Remove valve stem seal (5) and valve spring seat Removing the stem seal can be damaged,
(6). causing oil to get down past the seal.
NOTE Do not reuse stem seal once removed.

Reassemble each valve and valve spring in Always install new seal.
their original positions.
Special tool
(A): 09917–98221 (Valve guide stem seal
installer attachment)
(B): 09916–57330 (Valve guide installer)
5
6
(B)
(A)
2
I9J011140211-02
Assembly
Reassemble in reverse order of disassembly paying
special attention to the following steps.
I9J011140033-03
3) Apply engine oil to stem seal, valve guide bore and

6 valve stem.
5
4) Install valve (3) to valve guide.
2 NOTE
4
Reassemble each valve and valve spring to
1 their original position.
3
I9J011140212-03
I9J011140034-01
5) Install valve spring (4) and valve retainer (5). Cylinder Head
6) Hold valve spring compressed with special tool and • Remove all carbon from combustion chambers.
install valve cotters (6).
Make sure valve cotters are properly seated in NOTE
groove “A”. • Do not use any sharp edged tool to scrape
NOTE carbon off cylinder head or its
components.
When compressing the valve spring, be
• Be careful not to scuff or nick metal
careful not to damage the tappet hole.
surfaces when decarbonizing.
Special tool
(C): 09916–19030 (Valve lifter)
(D): 09916–14521 (Valve lifter attachment)
(E): 09916–84511 (Tweezers)
I9J011140037-01
• Check cylinder head for cracks in intake and exhaust

(D) (C) ports, combustion chambers, and head surface.
• Check valve seat, if cracks or other damage is found,
IEH511140257-03
replace cylinder head.
(E)
(C)
(D)
6
6
“A”
I9J011140036-02
IEH511140258-03
Cylinder Head Components Inspection and • Check water jackets. If clogged or obstructed, clean
water jackets.
Servicing
CENFH5111406024
NOTE
If cracks, excessive wear or other damage is
found on any component, replace
component.
IEH511140259-03
Cylinder head distortion Valve and Valve Guide

• Using a straightedge and thickness gauge, measure Valve guide to valve stem clearance
cylinder head distortion (gasket surface) at a total of Using a micrometer and bore gauge, take diameter
six locations as shown. readings on valve stems and guides to check guide to
If measurement exceeds service limit, resurface or stem clearance.
replace cylinder head. Be sure to take readings at more than one place along
the length of each stem and guide.
Special tool If measurement exceeds service limit, replace valve and/
(A): 09900–20803 (Thickness gauge) or valve guide.
Cylinder head distortion Refer to “Valve guide replacement” (Page 1D-50).
Service limit: 0.05 mm (0.002 in.) Special tool
(A): 09900–20205 (Micrometer (0 – 25 mm))

Using micrometer, measure valve stem outside
diameter.
Standard (IN.): 5.465 – 5.480 mm (0.2152 – 0.2157 in.)
Standard (EX.): 5.440 – 5.455 mm (0.2142 – 0.2148
in.)
IEH511140260-03
(A)
I9J011140039-02
(A)
Valve guide inside diameter

Using a small bore gauge, measure valve guide inside
IEH511140261-03
diameter.
Manifold seating faces distortion Valve guide inside diameter
Using a straightedge and thickness gauge, check Standard (IN., EX.): 5.500 – 5.512 mm (0.2165 –
cylinder head to manifold seating faces. 0.2170 in.)
If measurement exceeds service limit, resurface or
replace cylinder head.
Special tool
Manifold seating faces distortion
I9J011140040-01
Valve guide to valve stem clearance

Standard (IN.): 0.020 – 0.047 mm (0.0008 – 0.0019 in.)
Standard (EX.): 0.045 – 0.072 mm (0.0018 – 0.0028
in.)
(A)
Service limit (IN.): 0.070 mm (0.0028 in.)
IEH511140262-03 Service limit (EX.): 0.090 mm (0.0035 in.)
Valve stem deflection Valve stem runout

If unable to measure valve guide inside diameter, check Measure valve stem runout.
“Valve stem deflection”. If measurement exceeds service limit, replace valve.
If measurement exceeds service limit, replace valve.
Special tool
If measurement still exceeds service limit with new
(A): 09900–20606 (Dial gauge)
valve, replace valve guide.
Measure valve stem deflection as follows;
(C): 09900–21304 (Steel “V” block set)
1) Install valve into valve guide.
Valve stem runout
2) Position valve head at approx. 5 mm away from
valve seat.
3) Move valve head in the direction “a” – “b”, and
measure deflection.
(A)
Special tool
(A): 09900–20606 (Dial gauge)
: 09900–20701 (Magnetic stand)
Valve stem deflection
(B)
(C)
Service limit (EX.): 0.18 mm (0.007 in.)
I9J011140042-02
Valve head radial runout

Measure valve head radial runout.
To measure runout, rotate valve slowly.
(A)
“b” Special tool
“a” (A): 09900–20606 (Dial gauge)
(B): 09900–21304 (Steel “V” block set)
: 09900–20701 (Magnetic stand)
IEH511140263-03
Valve head radial runout
Valve stem end
Inspect valve stem end face for pitting and wear.
(A)
If pitting or wear is found, valve stem end may be
resurfaced.
Use caution when resurfacing, do not grind away stem
end chamfer.
When chamfer has been worn away, replace valve.
(B)
I9J011140043-03

Measure thickness “a” of valve head.
Special tool
: 09900–20101 (Vernier calipers (150 mm))
I9J011140041-01
Standard (IN.): 1.1 mm (0.04 in.)
Standard (EX.): 1.0 mm (0.04 in.)
Service limit (EX.): 0.7 mm (0.03 in.)
Valve seat servicing

If valve seat contact width is out of specification, reface
valve seat as follows:
Valve seat angle
IN. & EX.: 30°/45°/60°
IN., EX.
“a”
45°
I9J011140044-01
60°
45°
Valve seat contact width 30°
Measure valve seat contact width as follows: IFH511140025-01
1) Remove all carbon from valve and seat. To reface a valve seat, use the following valve seat
2) Coat valve seat evenly with Prussian Blue (or cutting tool.
equivalent). • Intake side
3) Install valve into valve guide. – Valve seat cutter 30° x 45° (Neway 626)
4) Put valve lapper on valve. – Valve seat cutter 60° (Neway 205)
• Exhaust side
Special tool
(A): 09916–10911 (Valve lapper) – Valve seat cutter 30° x 45° (Neway 230)
– Valve seat cutter 60° (Neway 270)
• Solid pilot (Neway, N-150-5.5)
• Handle (Neway, N-505) (09916-54910)
(A) NOTE
Turn cutter clockwise, never
counterclockwise.
1) Remove all carbon from valve and valve seat.

2) Using 45° angle cutter, reface valve seat.
3) Check valve seat contact width “a”.
IEH511140264-01
Refer to “Valve seat contact width” (Page 1D-49).
5) Rotate valve while gently tapping valve contact area Too high (wide)
against seat.
6) Continue until a pattern is on valve seat face with
Prussian Blue.
7) Measure valve seat contact width “a”.
Special tool “a”
Valve seat contact width “a”
Standard (IN., EX.): 1.1 – 1.3 mm (0.04 – 0.05 in.)
I9J011140047-01
If measurement exceeds specification, repair valve
seat.
Refer to “Valve seat servicing” (Page 1D-49). Too low (narrow)
“a”
“a”
I9J011140048-01
IEH511140392-01
• If width “a” is too high (or wide), reface valve seat Valve guide replacement
using 30° angle cutter.
NOTE
• If width “a” is too low (or narrow), reface valve seat
using 60° angle cutter. Be careful not to damage cylinder head when
replacing valve guide.
1) Using valve guide remover, drive valve guide out

from combustion chamber side towards valve spring
side.
NOTE
Do not reuse valve guide once it has been
removed.
Always use a new valve guide (oversize)
when assembling.
Special tool
(A): 09916–44310 (Valve guide remover)
IEH511140266-03
4) Clean up any burrs using 45° angle cutter very

lightly.
(A)
NOTE
Cut seat areas minimally only.
Do not cut more than necessary.
5) Lap valve on seat in two steps, first with coarse grit

lapping compound applied to face and the second
with fine grit compound. I9J011140050-01
6) Recheck valve seat contact width “a”. 2) Ream valve guide hole with ø 10.5 mm reamer to
true hole and remove burrs.
NOTE
NOTICE
Clean and assemble cylinder head and valve
components. Improper handling of the reamer will cause
Fill intake and exhaust ports with solvent to damage to the valve guide hole.
check for leaks between valve seat and valve.
If any leaks occur, inspect valve seat and When refinishing or removing the reamer
face for burrs or other things that could from the valve guide hole, always turn it
prevent valve from sealing. clockwise.
Special tool
(B): 09916–37320 (Valve guide reamer (ø
10.5 mm))
(C): 09916–34542 (Valve guide reamer
handle)
(C) (B)
IEH511140267-03
IEH511140268-03
3) Install valve guide to cylinder head. Valve spring free length

• Heat cylinder head to a temperature of 80 – 100 Check spring strength by measuring free length.
°C (176 – 212 °F). If lower than service limit, replace valve spring.
Apply heat uniformly so that head will not be Special tool
distorted. (A): 09900–20101 (Vernier calipers (150 mm))
• Use special tools to drive new valve guide into
Valve spring free length
hole.
Standard (IN., EX.): 39.75 mm (1.56 in.)
Drive in new valve guide until special tool (valve
Service limit (IN., EX.) 38.20 mm (1.50 in.)
guide installer attachment) contacts cylinder head.
• After installing, check valve guide protrusion “a”.
Special tool
(D): 09916–57330 (Valve guide installer)
(E): 09916–56011 (Valve guide installer
attachment)
Valve guide protrusion “a”
(A)
Standard (IN., EX.): 11.4 – 11.8 mm (0.45 – 0.46 I9J011140054-02
in.)
Measure valve spring preload.
If lower than service limit, replace valve spring.
Special tool
(D) : 09900–20101 (Vernier calipers (150 mm))
“a” (E) Standard (IN., EX.): 147 – 173 N (14.7 – 17.3 kg, 32.4 –
38.1 lbs.) at 31.1 mm (1.22 in.)
Service limit (IN., EX.): 136 N (13.6 kg, 30.0 lbs.) at
31.1 mm (1.22 in.)
I9J011140052-01
4) Ream valve guide bore with ø 5.5 mm reamer.
NOTE
Clean and oil valve guide bore after reaming.
Special tool
(F): 09916–34550 (Valve guide reamer (ø 5.5
mm))
(C): 09916–34542 (Valve guide reamer
handle)
I9J011140055-01
(C)
(F)
IEH511140269-03
Valve spring squareness 4) Remove the seven bolts securing counter-balancer

Use a square and surface plate to check each spring for mechanism assembly (2) to crankcase, then remove
squareness (clearance between end of valve spring and counter-balancer mechanism assembly.
square).
If measurement exceeds service limit, replace valve 2
spring.
Special tool
Valve spring squareness “a”
Service limit (IN., EX.): 2.0 mm (0.08 in.)
“a”
IEH511140271-05
Installation
NOTICE
I9J011140056-02
in engine damage.
Counter-Balancer Mechanism Removal and Do not reuse gasket once removed. Always
Installation use a new one.
CENFH5111406025
Removal
1) Insert the dowel pins (1).
(Page 1D-20).
2) Remove the balancer chain.
29).
3) Remove the bolts securing balancer cover (1) to
crankcase, then remove balancer cover.
1
IEH511140272-05
2) Place counter-balancer mechanism assembly (2)

into position on the crankcase.
1
IEH511140270-05
IEH511140273-05
3) Apply engine oil to balancer housing bolts. 4) Secure STBD balancer shaft in a vise, then remove
Lightly seat all balancer housing bolts at first. bolt (5), washer (6) and driven sprocket (7).
Following sequence in figure, tighten bolts in 3- Account for dowel pin (8).
steps.
Tighten bolts to 1/3 of specified torque, then 2/3 of
specified torque and finally to full specified torque. 7
5
Tightening torque
Balancer mechanism mounting bolt (a): 25 N·m (
2.5 kgf-m, 18.0 lbf-ft)
6 8
“7” “2” “5”
“4” IEH511140277-04
Assembly
“6” “1” (a) “3” 1) Secure STBD balancer shaft in a vise.
Install dowel pin (1), driven sprocket (2) and washer
(3), then tighten bolt (4) to specified torque.
IEH511140378-04 Tightening torque
Balancer driven sprocket (a): 48 N·m (4.8 kgf-m,
Counter-Balancer Mechanism Disassembly and 34.5 lbf-ft)
Assembly
CENFH5111406026
Disassembly
4 (a) 2
1) Remove the three bolts and upper housing (1).
2) Remove the three bolts and lower housing (2).
3 1
IEH511140278-04
1
2
IEH511140379-03
3) Remove STBD balancer shaft assembly (3).

Remove PORT balancer shaft assembly (4).
4
IEH511140380-04
2) Install bearings (5) in base housing (6), upper 4) Install dowel pins (9).
housing (7) and lower housing (8).
Apply molybdenum oil solution to each bearing.
7
8 5
5
5
9
5 IEH511140282-04
6 5) Install PORT balancer shaft assembly (10) in base
IEH511140279-04 housing.
NOTE 6) Install STBD balancer shaft (11) in base housing so
that match mark (•) “B” on STBD balancer gear
• Align bearing tab “A” with notch in each aligns with match mark (•) “B” on PORT balancer
housing. gear as shown in figure.
• Assemble each bearing in its original
position.
“10” “11”
“B” “B”
IEH511140382-03
“A”
5 “B”: Match mark (•)
IEH511140280-04
7) Install upper housing (7) to base housing with arrow
3) Apply molybdenum oil solution to balancer shaft mark on upper housing toward flywheel side.
journals. Install lower housing (8) to base housing.
IEH511140381-04 IEH511140383-04
8) Apply engine oil to housing bolts. Bearing

Lightly seat all housing bolts at first. Check bearings for pitting, scratches, wear or damage.
Following sequence in figure, tighten bolts in 2- If any improper condition is found, replace both upper
steps. and lower halves.
Tighten bolts to 80 percent (%) of specified torque, Always replace both bearing halves, never replace only
then to full specified torque. one half of a bearing set.
Tightening torque
Balancer housing bolt (b): 46 N·m (4.6 kgf-m,
33.3 lbf-ft)
“4” “3”
“2” “1” (b)
IEH511140287-04
“6” “5”
Balancer Shaft Journal
Check balancer shaft journals for pitting, scratches, wear
IEH511140384-04
or damage.
If any of the above condition are found, replace balancer
Counter-Balancer Mechanism Component shaft.
Inspection
CENFH5111406027
NOTE
cracked, defective or damaged in any way, it
must be replaced.
Balancer Gear
Inspect balancer gears. Replace gear if damaged, worn
excessively or other abnormal condition.
IEH511140288-04
Housing
Check base housing, upper housing and lower housing.
If cracks or other damage are found, replace housings
as a set.
NOTE
Base housing, upper housing and lower
housing must be replaced as a set.
IEH511140286-05
IEH511140358-04
Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Components

CENFH5111406028
14
10
12 15 (b)
9 (a)
(d) 16 (c)
5 8
4
6
13
17
7
11
3
2
18
20 (e) 19
1
IFH511140026-01
1. Cylinder block 8. Conrod cap 15. Crankcase (inside) bolt : 58 Nm (5.8 kgf-m, 42.0 lbf-ft)
2. Piston ring set 9. Conrod cap bolt 16. Crankcase (outside) bolt : 37 Nm (3.7 kgf-m, 27.0 lbf-ft)
3. Piston 10. Oil seal 17. Thrust bearing : 11 Nm (1.1 kgf-m, 8.0 lbf-ft)
4. Piston pin 11. Crankshaft 18. Drive gear : 48 Nm (4.8 kgf-m, 34.5 lbf-ft)
5. Piston cooling jet 12. Crankshaft main bearing 19. Washer : Apply engine oil.
6. Conrod 13. Dowel pin 20. Bolt : Apply molybdenum oil solution.
7. Conrod bearing 14. Crankcase : 30 Nm (3.0 kgf-m, 21.5 lbf-ft),

then plus turn in 60 degrees.
Pistons, Piston Rings, Connecting Rods, 2) Remove oil filter (1).

Cylinder and Crankshaft Disassembly and Special tool
Assembly (A): 09915–47341 (Oil filter wrench)
CENFH5111406029
Disassembly
1) Before performing service work in this section:
• Remove power unit.
(Page 1D-20). (A)
• Remove the timing chain and balancer chain.
Balancer Chain Removal and Installation” (Page
1D-29). 1
• Remove cylinder head.
Refer to “Cylinder Head Removal and Installation” IEH511140289-03
(Page 1D-43).
• Remove counter-balancer mechanism.
Refer to “Counter-Balancer Mechanism Removal
3) Remove the three bolts securing oil filter stand (2), NOTE
then remove oil filter stand. For proper assembly, mark cylinder number
on all pistons, conrods, and conrod caps,
using quick drying paint.
2
“2”
“3”
“1”
“4”
IEH511140290-03
4) Remove oil pressure switch (3).
IEH511140293-03
6) Remove all conrod cap bolts (6) and conrod caps

(7).
7 6
IEH511140291-03
5) Remove ten bolts (4).

Remove ten bolts (5).
Remove crankcase from cylinder block.
IEH511140294-03
4 7) Remove crankshaft (8).

Remove oil seal (9) from crankshaft.
5
9
8
IEH511140292-03
IEH511140295-03
8) Remove the bolts and piston cooling jets (10) from 10) Remove two compression rings (top and 2nd) and oil
each cylinder. ring from piston.
Mark cylinder number on conrod using quick dry
paint.
10
IEH511140299-03
9) Mark cylinder number on pistons using quick dry

paint.
Push piston (with conrod) out through the top of IEH511140297-03
cylinder bore. 11) Remove piston pin from piston and conrod using
special tool and arbor press as shown.
NOTE
NOTE
• To prevent damage to piston rings,
decarbon top of cylinder bore wall before • The piston pin is press fit into conrod
removing piston. small end.
• Reassemble each conrod cap to its • Reassemble each piston, piston pin and
original position after removing piston conrod in their original combination and
from bore. position.
Special tool
(A): 09910–39610 (Piston pin remover and
installer)
“1”
“2”
“3”
“4”
13 (A)
12 (A)
IEH511140296-03
11 (A)
IEH511140298-05
11. Base 12. Collar 13. Drive handle

Assembly • Use special tool and arbor press shown in figure.

Assembly is reverse order of disassembly paying special Press fit the piston pin (1) to conrod (with piston) until
attention to the following steps. the line “C” on driver handle is flush with the flat
surface of piston.
NOTICE
Special tool
If any of the parts is reinstalled into a position
(A): 09910–39610 (Piston pin remover and
different from the original position, engine
installer)
problems could occur.
If original components are not replaced, each 6 (A)

piston, piston pin and conrod is to be
assembled and installed in its original order
and position.
1
Piston to conrod 3
• Apply engine oil to piston pin (1), piston pin bore and
conrod (2). 2
Assemble conrod (2) to piston (3) as shown in figure.
NOTE
“96L0” mark on conrod and up mark “A” on 5 (A)
piston dome must face toward flywheel side
“B”.
“B” 4 (A)
“A”
IEH511140305-03
96L0
6 (A)
3 “C”
IFH511140023-01
“A”: Up mark “ ” “B”: Flywheel side 1
1
2
IEH511140306-03
3 1. Piston pin 5. Collar

2. Conrod 6. Driver handle
3. Piston “C”: Line on driver handle
2 4. Base
IEH511140304-03
Piston ring to piston NOTE

1) Install the oil ring. • 1st ring (4) and 2nd ring (3) differ in shape
• Apply engine oil to piston rings. as shown in figure.
• Install spacer (1) first, then side rails (2) to piston. • Also indicated in figure, the 1st and 2nd
ring are marked with the letter “R” which
must face towards top of piston.
2
1 4
4
I9J011140011-01
3 3
NOTE
IEH511140308-03
When installing spacer, do not allow spacer 3) Position piston rings so gaps are staggered at
ends to overlap in groove. approximately 90 degree angles as shown.
“C”
“A”
“F” “G”
“B”
“E” “D”
IEH511140309-03
I9J011140012-01 “C”: Up mark “F”: 2nd ring and oil ring spacer
“D”: 1st ring “G”: Oil ring upper side rail
“A”: Incorrect “B”: Correct
“E”: Oil ring lower side rail
2) Install the piston rings.

• Apply engine oil to piston rings.
• Install 2nd ring (3) and 1st ring (4) to piston.
“R”
“R” 4
3
“R”
IEH511140307-04
Piston to cylinder
1) Install conrod bearing (1) to conrod (2) and conrod
cap (3). “B”
4
NOTICE
If the bearing is reinstalled into a position
If original bearings are not replaced, “A”

assemble each bearing to its original
position. IEH511140311-02
“A”: Up mark ( ) “B”: Flywheel side

NOTICE
If oil is present between the bearing’s outside Piston cooling jet
surface and conrod surface, the bearing • Apply engine oil to O-ring (1).
could heat up to very high temperature,
resulting in seizure. NOTE
It is recommended that O-rings should be
Be sure to thoroughly wipe off any trace of oil replaced with new ones on assembly.
that is present between the bearing’s outside
surface and conrod surface.
2
3
1 3
IEH511140300-03
• Install piston cooling jets (2) in position, then tighten

1 the bolts (3) securely.
2
Tightening torque
IEH511140310-03 Piston cooling jet bolt (a): 11 N·m (1.1 kgf-m, 8.0
2) Apply engine oil to piston and cylinder walls. lbf-ft)
3) Insert piston and conrod assembly (4) into cylinder
bore from cylinder head side using special tool.
NOTE
Position the up mark “A” on piston head to
flywheel side “B”.
Special tool
(A): 09916–77310 (Piston ring compressor)
3 (a)
IEH511140302-04
(A)
IDG211140144-01
Crankshaft to cylinder
Install crankshaft main bearings (1) in cylinder and
crankcase. “A”
Apply molybdenum oil solution to bearings.
NOTICE
“C”
If the bearing is reinstalled into a position
If original bearings are not replaced, “B”

assemble each bearing to its original IEH511140313-04
position.
“A”: Bearing tab “B”: Oil groove “C”: Oil hole
NOTICE
Thrust bearing
If oil is present between the bearing’s outside Apply engine oil to the thrust bearings and install in
surface and crank bearing holder surface, the cylinder block overlapping both sides of the No.4 main
bearing could heat up to very high journal.
temperature, resulting in seizure. Oil grooves “A” on the thrust bearing must face towards
crank webs.
Be sure to thoroughly wipe off any trace of oil
that is present between the bearing’s outside
1
surface and crank bearing holder surface.
NOTE
Assemble main bearing half containing oil
groove/hole to cylinder block.
Assemble the main bearing half without oil
groove to crankcase.
“A”
IEH511140314-01
NOTE
1. Thrust bearing “A”: Oil groove
Align bearing tab “A” with notch in cylinder
and crankcase. Crankshaft drive gear
To assemble the drive gear on crankshaft, align the dot
(•) mark on drive gear with the dowel pin hole on
crankshaft.
1
1
IEH511140312-03
IEH511140315-03
1. Dot (•) mark 2. Dowel pin hole

Crankshaft 3) Install conrod cap.

a) Apply molybdenum oil solution to crank pin and
NOTE
conrod bearing.
Replace the oil seal with new one.
b) Install dowel pins (2) and conrod cap (3) (with
bearing) to conrod with embossed mark “A” on
NOTE
the cap toward flywheel side “B”.
Install upper oil seal with its spring/lipped
side facing inward. NOTE
Reassemble each conrod cap to its original
1) Apply engine oil to upper oil seal lip. position.
Install upper oil seal (1) to crankshaft. Do not mix them in position.
2) Apply molybdenum oil solution to crank pin and
crankshaft main journal and install crankshaft in
cylinder.
NOTE 3
When installing crankshaft to cylinder, be
sure to fit tab of upper oil seal in groove of
cylinder.
2
1
IEH511140318-03
“A”
“B”
IEH511140316-03
IEH511140319-05
3. Conrod cap “A”: Embossed mark “B”: Flywheel side
4) Apply engine oil to conrod bolts.

Tighten conrod cap bolts in three steps as follows.
a) Lightly seat all conrod bolts at first, then tighten
bolts 15 Nm (1.5 kgf-m, 11.0 lbf-ft) of specified
torque.
IEH511140317-03
Tightening torque
Conrod cap bolt (1st step): 15 N·m (1.5 kgf-
m, 11.0 lbf-ft)
b) Tighten bolts 30 Nm (3.0 kgf-m, 21.5 lbf-ft) of 2) Clean mating surface of cylinder and crankcase.
specified torque. Apply suzuki bond to mating surface of crankcase as
shown.
Tightening torque
Conrod cap bolt (2nd step): 30 N·m (3.0 kgf- NOTE
m, 21.5 lbf-ft)
Apply bond to mating surface only.
Do not allow bond to contact surface of
bearing.

1207B (100 g))
IEH511140320-01
c) Finally tighten bolts 60 degrees turn from the

point of step (b) using an angular torque gauge.
Tightening torque
Conrod cap bolt (Final step): 60 degrees
NOTE
Purchase a commercially available angular
torque gauge for this step of tightening bolts.
IEH511140322-03
“A”: Apply bond “–” marked line.
60° 3) Install five dowel pins (2).
IEH511140385-04
d) Pour approx. 2 ml of engine oil to each side

surface of the conrod big end for initial
lubrication.
2
IEH511140323-03
Crankcase to cylinder
1) Install the balancer gallery O-ring (1).
IEH511140321-03
4) Install crankcase to cylinder. Oil filter stand

Apply engine oil to crankcase bolts. • Install seal ring (1) to oil filter stand (2).
Tighten crankcase bolts in three steps following the
• Install oil filter stand to cylinder block and secure with
order indicated below.
bolts (3).
NOTE
Tighten 11 mm (0.433 in.) thread diameter
bolts first (following the order shown in
figure), then tighten 10 mm (0.394 in.) thread 2
diameter bolts.
Tightening torque
Crankcase (inside) bolt (11 mm thread diameter)
[1st step]: 11 N·m (1.1 kgf-m, 8.0 lbf-ft) 2
1 3
[2nd step]: 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
Crankcase (inside) bolt (11 mm thread diameter) IEH511140325-03
[Final step]: 58 N·m (5.8 kgf-m, 42.0 lbf-ft)
Counter balancer mechanism
Tightening torque Refer to “Counter-Balancer Mechanism Removal and
Crankcase (outside) bolt (10 mm thread Installation” (Page 1D-52).
diameter) [1st step]: 10 N·m (1.0 kgf-m, 7.0 lbf-ft)
Crankcase (outside) bolt (10 mm thread Cylinder head
diameter) [2nd step]: 18 N·m (1.8 kgf-m, 13.0 lbf- Refer to “Cylinder Head Removal and Installation” (Page
ft) 1D-43).
Crankcase (outside) bolt (10 mm thread
diameter) [Final step]: 37 N·m (3.7 kgf-m, 27.0 Timing chain / Balancer chain
lbf-ft) Refer to “Timing Chain, Camshaft Sprocket, Balancer
Chain Removal and Installation” (Page 1D-29).
“9” “10” Oil pump

“19” “20”
Refer to “Oil Pump Removal and Installation” in Section
1E (Page 1E-4).
“15” “5” “6” “16”
Power unit
Refer to “Power Unit Removal and Installation” (Page
“11” “1” “2” 1D-20).
“12”
“13” “3” “4” “14”
“17” “18”
“7” “8”
IEH511140324-03
NOTE
After tightening crankcase bolts, check to be
sure that crankshaft rotates smoothly when
turned by hand.
Cylinder, Piston and Piston Ring Inspection and Driven Gear / Bearing
Servicing • Inspect driven gear for wear or other damage.
CENFH5111406030
NOTE
• Inspect driven gear bearing for pitting, rough or other
damage.
found on any component, replace
component.
Cylinder Distortion
Using a straightedge and thickness gauge, measure
cylinder distortion (gasket surface) at a total of six
locations as shown.
If measurement exceeds service limit, resurface or
replace cylinder.
Special tool
Cylinder distortion
Service limit: 0.05 mm (0.002 in.) IEH511140329-03
Piston Cooling Jet

Inspect piston cooling jets.
Refer to “Piston Cooling Jet Inspection” in Section 1E
(Page 1E-9).
Cylinder Bore
Inspect cylinder walls for scratches, roughness, or ridges
which indicate excessive wear.
If cylinder bore is very rough, deeply scratched or ridged,
bore cylinder and use oversize piston.
IEH511140326-03
Cylinder Bore Wear (Difference)
Using telescoping gauge (1), measure cylinder bore in
both axial (vertical line, following crankshaft) and
transverse (horizontal line across crankshaft) directions
at two positions as shown in figure.
NOTE
Purchase a commercially available
(A) telescoping gauge for this measurement.
Check the following:

• Difference between measurements at the two
IEH511140327-03
positions (Taper).
Water Jackets • Difference between axial and transverse
Check water jackets. measurement (Out-of-round).
If clogged or obstruction is found, clean water jacket. If measurement exceeds service limit, bore or replace
cylinder.
Cylinder bore wear (difference)
IEH511140328-03
50 mm
1 (2.0 in.)
IEH511140330-03 IEH511140331-04
3) Calculate the piston/cylinder clearance (Clearance

equals difference between piston diameter and
“a” cylinder bore measurements).
If clearance exceeds service limit, replace piston
and/or cylinder or bore cylinder.
“b”
Piston to cylinder clearance
Standard: 0.045 – 0.065 mm (0.0018 – 0.0026 in.)
I9J011140060-01 Identification of Oversize Piston / Piston Ring

“a”: 50 mm (1.97 in.) “b”: 90 mm (3.54 in.) One oversize piston/piston ring components, 0.50 mm is
available. Oversize piston/piston ring are marked as
Piston to Cylinder Clearance shown, below.
1) Measure the piston diameter at a point 12 mm (0.47
in.) above the piston skirt at a right angle to the Piston
piston pin bore. Oversize I.D. mark
0.50 mm 50
Special tool
(A): 09900–20204 (Micrometer (75 – 100
mm))
Piston skirt diameter
Standard: 96.945 – 96.965 mm (3.8167 – 3.8175
in.)
“A”
“a”
I9J011140062-02
(A) “A”: I.D. mark
I9J011140061-02
“a”: 12 mm (0.47 in.)

1st and 2nd Piston ring
Oversize I.D. mark
2) Measure the cylinder bore at 50 mm (2.0 in.) below 0.50 mm 50
the cylinder head gasket surface at a right angle to
the crankshaft pin.
1st, 2nd ring
NOTE
“B”
Purchase a commercially available
telescoping gauge (1) for this measurement.
Cylinder bore diameter

Standard: 97.000 – 97.020 mm (3.8189 – 3.8197
in.) I9J011140063-03
“B”: I.D. mark

Oil ring Piston Ring

Oversize I.D. mark Piston ring end gap
0.50 mm One red paint Measure piston ring end gap with piston ring in the
lowest position of cylinder bore.
Oil ring spacer If measurement exceeds service limit, replace piston
ring.
Special tool
Piston ring end gap
Standard (1st): 0.20 – 0.30 mm (0.008 – 0.012 in.)
Standard (2nd): 0.30 – 0.45 mm (0.012 – 0.018 in.)
“C” Service limit (1st): 0.70 mm (0.028 in.)
I9J011140064-02
Service limit (2nd): 1.00 mm (0.039 in.)
“C”: I.D. mark
(A)
Piston
Visual inspection 1
Inspect piston for faults, cracks or other damage.
Damaged or faulty piston(s) should be replaced.
Piston ring to groove clearance

Before checking, piston grooves must be clean, dry and 2
free of carbon.
Fit piston ring into piston groove, and measure clearance
I9J011140066-02
between ring and ring groove using thickness gauge.
If measurement exceeds service limit, replace piston 1. Cylinder 2. Piston ring
and/or piston ring.
Piston ring free end gap
Special tool Measure piston ring free end gap using vernier calipers.
(A): 09900–20803 (Thickness gauge) If measurement exceeds service limit, replace piston
Piston ring to groove clearance ring.
Standard (1st): 0.030 – 0.070 mm (0.0012 – 0.0028 in.) Special tool
Standard (2nd): 0.020 – 0.060 mm (0.0008 – 0.0024 (A): 09900–20101 (Vernier calipers (150 mm))
in.)
Service limit (1st): 0.12 mm (0.005 in.) Piston ring free end gap
Service limit (2nd): 0.10 mm (0.004 in.) Standard (1st): Approx. 13.5 mm (0.53 in.)
Standard (2nd): Approx. 13.6 mm (0.54 in.)
Service limit (1st): 10.8 mm (0.43 in.)
Service limit (2nd): 10.9 mm (0.43 in.)
1
(A)
I9J011140065-03
(A)
1. Piston ring
I9J011140067-02
Piston ring groove width

Standard (1st): 1.22 – 1.24 mm (0.048 – 0.049 in.) Piston Pin and Conrod Inspection
CENFH5111406031
Standard (2nd): 1.21 – 1.23 mm (0.048 – 0.048 in.)
Piston Pin
Standard (Oil): 2.51 – 2.53 mm (0.099 – 0.100 in.)
Visual inspection
Piston ring thickness • Check piston pin, conrod small end bore and piston
Standard (1st): 1.17 – 1.19 mm (0.046 – 0.047 in.) pin hole for wear or damage.
Standard (2nd): 1.17 – 1.19 mm (0.046 – 0.047 in.) If badly worn or damaged, replace component.
• Apply engine oil on piston pin so that the piston pin Conrod big end side clearance
can move smoothly in the piston pin hole. Measure conrod big end side clearance with conrod
If improper condition is found, replace the piston pin installed on crank pin as shown.
and/or piston. If measurement exceeds service limit, replace conrod
and/or crankshaft.
Piston pin clearance
Special tool
Measure the following item:
Special tool
Conrod big end side clearance
(A): 09900–20205 (Micrometer (0 – 25 mm))
Standard: 0.300 – 0.450 mm (0.0118 – 0.0177 in.)
(B): 09900–20605 (Dial calipers (10 – 34 mm))
Piston pin outside diameter
Conrod big end width
Standard: 21.995 – 22.000 mm (0.8659 – 0.8661 in.)
Standard: 22.750 – 22.800 mm (0.8957 – 0.8976 in.)
Piston pin hole diameter
Crank pin width
Standard: 22.006 – 22.014 mm (0.8664 – 0.8667 in.)
Standard: 23.100 – 23.200 mm (0.9094 – 0.9134 in.)
Conrod small end bore
Standard: 21.968 – 21.979 mm (0.8649 – 0.8653 in.)
NOTE (A)
The piston pin is press-fit into the conrod
small end bore.
There must be a negative clearance between
the piston pin outside diameter and conrod
small end inner diameter.
IEH511140332-03
Crank Pin and Conrod Bearing Inspection

CENFH5111406032
Crank Pin Diameter
Inspect crank pin for uneven wear or damage.
Measure crank pin for out-of-round “a” – “b” or taper “c” –
“d” with micrometer.
If crank pin is damaged, out-of-round “a” – “b” or taper
(A)
I9J011140068-02
“c” – “d” is out of service limit, replace crankshaft.
Special tool
(A): 09900–20203 (Micrometer (50 – 75 mm))
Crank pin diameter
Standard: 53.982 – 54.000 mm (2.1253 – 2.1260 in.)
Out-of-round and taper
a cd
(B)
(A)
I9J011140069-02 b
(B)
IEH511140333-05
I9J011140070-02
Conrod Bearing Visual Inspection 4) Install conrod cap (with bearing) to conrod with the
Inspect bearing shell for proper contact pattern and embossed mark (4) on cap toward flywheel side.
signs of fusion, pitting, burning or flaking.
Bearing shells found in defective condition must be 4
replaced. “A”
“B”
I9J011140071-01
IEH511140336-05
Conrod Big End Oil Clearance 4. Embossed mark “A”: Flywheel side “B”: Match mark
Check conrod big end oil clearance as follows:
1) Clean surface of conrod (1), conrod cap (2), conrod 5) Apply engine oil to conrod bolts.
bearings and crank pin. Tighten conrod cap bolts in three steps as follows.
2) Install conrod bearing (3) onto conrod and conrod a) Lightly seat all conrod bolts at first, then tighten
cap. bolts 15 Nm (1.5 kgf-m, 11.0 lbf-ft) of specified
torque.
NOTE
Tightening torque
• Reassemble each bearing and conrod cap Conrod cap bolt (1st step): 15 N·m (1.5 kgf-
to their original position. m, 11.0 lbf-ft)
• Do not apply oil to bearing. b) Tighten bolts 30 Nm (3.0 kgf-m, 21.5 lbf-ft) of
specified torque.
Tightening torque
Conrod cap bolt (2nd step) (a): 30 N·m (3.0
kgf-m, 21.5 lbf-ft)
(a)
3 2
IEH511140334-03
3) Place a piece of Plastigauge on crank pin parallel to

crankshaft. Avoid placing Plastigauge over oil hole.
Special tool IEH511140337-03
(A): 09900–22301 (Plastigauge (0.025 –
0.076 mm))
(A)
IEH511140335-03
c) Finally tighten bolts 60 degrees turn from the Crankshaft Inspection

point of step b) using an angular torque gauge. CENFH5111406033
Crankshaft Runout
Tightening torque Using a dial gauge, measure runout at center journal.
Conrod cap bolt (Final step): 60 degrees If measurement exceeds service limit, replace
crankshaft.
NOTE
Special tool
Do not rotate conrod with Plastigauge in
(A): 09900–20607 (Dial gauge)
place.
NOTE Crankshaft runout
Purchase a commercially available angular Service limit: 0.04 mm (0.002 in.)
torque gauge for this step of tightening bolts.
(B) (A)
60°
IEH511140339-03
Crankshaft Thrust Play

IEH511140386-04
1) Measure thrust play with crankshaft, thrust bearing,
journal bearing and crankcase/cylinder block
6) Remove conrod and conrod cap from crank pin.
assembled in a normal manner.
7) Using scale (5) on Plastigauge envelope, measure Tighten crankcase bolts to specified torque.
Plastigauge width at its widest point.
If measurement exceeds service limit, replace Tightening torque
conrod bearing. Crankcase (inside) bolt (11 mm): 58 N·m (5.8
kgf-m, 42.0 lbf-ft)
Conrod big end oil clearance Crankcase (outside) bolt (10 mm): 37 N·m (3.7
Standard: 0.045 – 0.063 mm (0.0018 – 0.0025 in.) kgf-m, 27.0 lbf-ft)
2) Use a dial gauge to read displacement in axial
(thrust) direction of crankshaft.
5 If measurement exceeds service limit, replace
crankshaft thrust bearing.
Crankshaft thrust play
Standard: 0.11 – 0.31 mm (0.004 – 0.012 in.)
Crankshaft thrust bearing thickness
Standard: 2.425 – 2.475 mm (0.0955 – 0.0974 in.)
IEH511140338-03
5. Scale
IEH511140340-03
Out-of-Round and Taper (Uneven Wear) of Journals Crankshaft Journal Oil Clearance
An unevenly worn crankshaft journal shows up as a Check clearance using Plastigauge according to the
difference in diameter at a cross section or along its following procedure.
length (or both).
This difference, if any, is determined by taking NOTE
micrometer readings. Assemble each bearing in its original
If any journal is badly damaged or if measurements position before checking clearance.
exceed service limit, replace crankshaft.
1) Clean surface of bearing holder (crankcase, and
Special tool cylinder), bearing, and main bearing journal.
(A): 09900–20203 (Micrometer (50 – 75 mm))
2) Install main bearing (1) to cylinder and crankcase.
Out-of-round and taper
Service limit: 0.01 mm (0.0004 in.) NOTE
Out-of-round: A – B • Align tab “A” of bearing with notch in

Taper: a – b cylinder and crankcase.
Crankshaft journal outside diameter • Do not apply engine oil to bearing.
Standard: 64.982 – 65.000 mm (2.5583 – 2.5591 in.) • Install main bearing half with oil hole/
groove towards cylinder side.
(A)
1 1
A ab
IEH511140341-03
IEH511140342-03
Crankshaft Main Bearing Inspection
CENFH5111406034
Crankshaft Main Bearing Visual Inspection
Check bearings for pitting, scratches, wear or damage.
If any improper condition is found, replace both upper
and lower halves.
Always replace both bearing halves, never replace only
“A”
one half of a bearing set.
“B”
“C”
IEH511140343-03
“A”: Bearing tab “B”: Oil hole “C”: Oil groove
I9J011140073-01
3) Install crankshaft to cylinder. NOTE

4) Place a piece of Plastigauge across full width of Crankcase must be torqued to specification
bearing (parallel to crankshaft) on journal. in order to assure proper compression of
Do not place Plastigauge over oil hole. Plastigauge and accurate reading of
Special tool clearance.
(A): 09900–22301 (Plastigauge (0.025 –
0.076 mm))
NOTE “19” “9” “10”

“20”
Do not rotate crankshaft while Plastigauge is
installed.
“15” “5” “6” “16”
“11” “1” “2” “12”
“13” “3” “4” “14”
(A)
“17” “18”
“7” “8”
IEH511140345-03
IEH511140344-03
5) Assemble crankcase to cylinder. 7) Remove crankcase from cylinder.

6) Apply engine oil to crankcase bolts. 8) Using scale (2) on Plastigauge envelope, measure
Tighten crankcase bolts in three steps following the Plastigauge width at its widest point.
order indicated below. Crankshaft journal oil clearance
Standard: 0.030 – 0.050 mm (0.0012 – 0.0020 in.)
NOTE
Tighten 11 mm (0.433 in.) thread diameter
bolts first (following the order shown in
figure), then tighten 10 mm (0.394 in.) thread
2
diameter bolts.
Tightening torque
[1st step]: 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
[2nd step]: 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
[Final step]: 58 N·m (5.8 kgf-m, 42.0 lbf-ft)
IEH511140346-03
Tightening torque 2. Scale
diameter) [1st step]: 10 N·m (1.0 kgf-m, 7.0 lbf-ft) 9) If measurement exceeds service limit, replace
Crankcase (outside) bolt (10 mm thread crankshaft main bearing.
diameter) [2nd step]: 18 N·m (1.8 kgf-m, 13.0 lbf-
ft) NOTE
For bearing replacement, see the “Selection
diameter) [Final step]: 37 N·m (3.7 kgf-m, 27.0
of Main Bearings” (Page 1D-74).
lbf-ft)
Selection of Main Bearings

Whenever a bearing requires replacement, select a new “J”
bearing according to following procedure. “I”
1) First, check journal diameter. “H”
As shown in figure, upper (flywheel side) crank web “G”
of No.1 cylinder has five stamped code numerals. “F”
The numerals (1, 2 and 3) represent the journal
diameters shown below.
Numeral stamped Journal diameter
64.994 – 65.000 mm
1
(2.5588 – 2.5591 in.)
64.988 – 64.994 mm
2
(2.5586 – 2.5588 in.)
64.982 – 64.988 mm
3
(2.5583 – 2.5586 in.)
“K”
IEH511140348-04
“A”
“F”: No.1 holder code “I”: No.4 holder code
“G”: No.2 holder code “J”: No.5 holder code
“B”
“H”: No.3 holder code “K”: Flywheel side
“C”
3) There are five main bearings available, each of
“D” differing thickness.
To distinguish them, a color mark is painted at the
position indicated in figure.
“E” Each color represents the following thickness
IEH511140347-03 measured at the center of the bearing.
“A”: No.1 journal code “D”: No.4 journal code Color mark Bearing thickness
“B”: No.2 journal code “E”: No.5 journal code 2.497 – 2.500 mm
“C”: No.3 journal code Black
(0.0983 – 0.0984 in.)
2.499 – 2.503 mm
2) Next, check bearing holder inside diameter without No color mark
(0.0984 – 0.0985 in.)
bearing. 2.502 – 2.506 mm
As shown in figure, the cylinder block PORT side has Yellow
(0.0985 – 0.0987 in.)
five stamped code letters. 2.505 – 2.509 mm
The letters (A, B and C) represent the bearing holder Blue
(0.0986 – 0.0988 in.)
inside diameters shown below. 2.508 – 2.512 mm
Pink
Crank bearing holder inside (0.0987 – 0.0989 in.)
Code
diameter (w/o bearing)
70.0000 – 70.006 mm
A
(2.7559 – 2.7561 in.)
70.006 – 70.012 mm
B
(2.7561 – 2.7564 in.)
70.012 – 70.018 mm
C
(2.7564 – 2.7566 in.)
“L”
IEH511140349-03
“L”: Color mark

4) Select crankshaft main bearing referring to the below Crankshaft Oil Seal Inspection
table. CENFH5111406036
For example, If number stamped on crank web is “1” Inspect condition. If cracked, cut or damaged, replace.
and alphabet stamped on cylinder block is “A”, install
a new bearing painted in “Black” to it’s journal.
Numeral stamped on crank
web (Journal outside diameter)
1 2 3
Code stamped A Black No color Yellow
on cylinder block B No color Yellow Blue
(Bearing holder
C Yellow Blue Pink
inside diameter)
NOTE IEH511140351-03
Measure crankshaft journal oil clearance

again after installing new bearing selected. Oil Filter Stand Seal Ring Inspection
CENFH5111406037
Refer to “Crankshaft Journal Oil Clearance” Inspect seal ring.
(Page 1D-72). Replace seal ring if worn, nicked, cut or other abnormal
condition are noted.
Crankshaft Drive Gear Inspection
CENFH5111406035
Inspect drive gear. Replace gear if damaged, worn or
other abnormal condition are noted.
IEH511140387-03
IEH511140350-03
1E-1 Power Unit Lubrication:
Power Unit Lubrication

Power Head
General Description
Engine Lubrication Description
CENFH5111501001
The engine lubrication system uses a camshaft-driven trochoid oil pump that pressure feeds engine oil to the engine’
moving parts. The chart below shows the lubrication system oil flow.
Engine oil is drawn up by the oil pump through the oil strainer. After passing through the oil filter, engine oil flows to the
main gallery from which various passages distribute oil for lubrication and other engine functions requiring engine oil
pressure to operate.
Oil from the main gallery:

• Lubricates crankshaft journal bearings #1 through #5.
• Lubricates crank pins #1 through #4.
• Sprays through four cylinder lubrication jets to lubricate the cylinder, piston, piston pin and cylinder wall.
• Lubricates counter- balancer shaft journals.
• Passes through cylinder head oil passage to lubricate IN. and EX. camshaft journals and cam faces.
• Supplies pressurized engine oil to operate the VVT system.
Oil flows to the VVT actuator through ECM controlled OCV to advance, retard or retain the intake valve timing.
Power Unit Lubrication: 1E-2
Schematic and Routing Diagram

Engine Oil Lubrication Chart
CENFH5111502001
#1 #1 #1 #1 OIL PRESSURE SWITCH

CAM FACE JOURNAL JOURNAL CAM FACE
#1 CRANK JOURNAL #1 CRANK PIN
E I
#2 #2 X N #2 #2 LUBRICATION JET #1 #1 PISTON
CAM FACE JOURNAL . . JOURNAL CAM FACE
C C M #2 CRANK JOURNAL #2 CRANK PIN

A A A
#3 #3 #3 #3
CAM FACE JOURNAL M M JOURNAL CAM FACE I LUBRICATION JET #2 #2 PISTON
S S N
H H #3 CRANK JOURNAL #3 CRANK PIN
#4 #4 A A #4 #4 G
CAM FACE JOURNAL F F JOURNAL CAM FACE A LUBRICATION JET #3 #3 PISTON
T T L
L #4 CRANK JOURNAL
#5 E
JOURNAL LOWER CAM HOUSING
LUBRICATION JET #4 #4 PISTON
R
Y
#5 CRANK JOURNAL #4 CRANK PIN
LOWER CAM HOUSING VVT OCV MAIN CHAIN TENSIONER
BALANCER LOWER HOUSING
CYLINDER HEAD
UPPER SHAFT LOWER SHAFT
JOURNAL JOURNAL
OIL FILTER
OIL PUMP PRESSURE REGULATOR
OIL STRAINER
OIL PAN
IFH511150002-01

Oil Pressure Check
CENFH5111504001
Refer to “Oil Pressure Check” in Section 0B (Page 0B-24).
Oil Change Reminder System

CENFH5111504002
Refer to “Oil Change Reminder System Description” in Section 1A (Page 1A-14).
Low Oil Pressure Caution System

CENFH5111504003
Refer to “Caution System Description” in Section 1A (Page 1A-6).
Powerhead Lubrication System Diagnosis

CENFH5111504005

Low oil pressure Clogged oil filter. Replace.
Leakage from oil passages. Repair or replace.
Defective oil pump. Replace.
Defective oil pressure regulator. Replace.
Damaged O-ring. Replace.
Combination of above items. Repair or replace.
High oil pressure Using an engine oil of too high viscosity. Replace.
Clogged oil passage. Clean or replace.
Clogged oil pressure regulator. Replace.
Combination of above items. Repair or replace
Oil Pump Removal and Installation Installation
CENFH5111506001 Installation is reverse order of removal with special
Removal
attention to following steps.
• Install oil pump driven gear (1).
Refer to “Power Unit Removal and Installation” in
Section 1D (Page 1D-20).
2) Remove the four bolts securing oil pump (1), then
remove the oil pump.
Note position of washer (2).
1
1
IEH511150005-01
• Install washer (2) and oil pump assembly (3), then

tighten four bolts securely.
Tightening torque
IEH511150002-02 Oil pump bolt (a): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
• Pour approx. 50 ml (1.7 oz.) of engine oil into pump
case for initial lubrication.
2
2
IEH511150003-01
3) Remove the oil pump driven gear (3).

IEH511150006-01
NOTE
For oil pump drive gear removal, refer to
“Timing Chain, Camshaft Sprocket, Balancer
Chain Removal and Installation” in Section
1D (Page 1D-29).
3
(a)
IEH511150007-02
3
IEH511150004-01
Oil Pump Disassembly and Assembly Assembly

CENFH5111506002 Assembly is reverse order of disassembly with special
Disassembly attention to the following steps.
1) Remove the two screws (1) securing oil pump rotor
• Wash, clean and then dry all disassembled parts.
plate (2) to the oil pump case, then remove the oil
pump rotor plate. • Apply thin coat of engine oil to inner and outer rotors,
inside surfaces of oil pump case and plate.
• Assemble pin (1) and inner rotor (2) to oil pump shaft.
2
1
2
IEH511150008-01
2) Take out inner rotor (3) and outer rotor (4).

IEH511150011-01
• Install outer (3) and inner rotor (2) to pump case.
NOTE
3
When installing outer rotor, it must be
original in direction of up and down.
IEH511150009-01 3 2
3) Remove the pin (5) and inner rotor (3).
IFH511150001-01
IEH511150010-01
• Install dowel pins (4) and rotor plate (5), and then Driven Gear
tighten screws (6) securely. Check teeth of gear for wear or damage.
After mounting the rotor plate, make sure that each Replace the gear as necessary.
rotor turns smoothly by hand.
• Pour approx. 50 ml (1.7 oz.) of engine oil into pump
case for initial lubrication.
4 5
4
IEH511150016-01
Radial Clearance
IEH511150013-01
Using thickness gauge, measure radial clearance
between outer rotor and case.
Special tool
6
Radial clearance
Service limit: 0.31 mm (0.0122 in)
If measurement is not within specifications, replace the
oil pump assembly.
(A)
IEH511150014-01
Oil Pump Component Parts Inspection

CENFH5111506003
Oil Pump Assembly
Check outer and inner rotors, rotor plate and oil pump
case for excessive wear or damage.
Replace as necessary.
NOTE IEH511150017-01
If any repair is required on outer rotor, inner

rotor and oil pump case/plate, replace them
as an oil pump assembly.
IEH511150015-01
Side Clearance 3) Loosen screw (3) and disconnect blue lead wire (4)
Using straightedge and thickness gauge, measure side from oil pressure switch.
clearance.
Special tool
Side clearance 4
If measurement is not within specifications, replace the
oil pump assembly.
3
IFH511150008-01
4) Remove oil pressure switch from cylinder block.
Installation
• Before installing oil pressure switch, wrap screw
(A)
threads with sealing tape (1), then tighten switch to
IEH511150018-01 specified torque.
NOTE
Oil Pressure Switch Removal and Installation
CENFH5111506004 Cut off any excess sealing tape from switch
Removal threads before installation.
case (1). Tightening torque
Refer to “Ring Gear Cover Removal and Installation” Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5 lbf-
in Section 1D (Page 1D-2) and “Air Intake Silencer ft)
Case Removal and Installation” in Section 1D (Page
1D-2).
2) Loosen the three bolts and remove the fuel hose 1
guard (2).
1
I9J011150002-01
• Connect the oil pressure switch lead wire (2).

4A (Page 4A-2).
2
(a)
IFH511150003-02
IFH511150009-01
• Start engine and check oil pressure switch for oil 3) Check the continuity between the switch terminal
leakage. and engine body ground.
Reseal switch if oil leakage is found.
Special tool
• Install the air intake silencer case and ring gear cover. : 09900–25008 (Multi circuit tester set)
Installation” in Section 1D (Page 1D-2) and “Ring Tester knob indication
Gear Cover Removal and Installation” in Section 1D Continuity ( )
(Page 1D-2). Oil pressure switch continuity
Engine running: Infinity
Oil Pressure Switch Inspection Engine stopped: Continuity
CENFH5111506005
NOTE
Before checking the oil pressure switch,
make sure the engine oil pressure is within
specification.
1) Loosen the three bolts and remove the fuel hose

guard (1).
I9J011150003-01
If measurement exceeds specification, replace oil

pressure switch.
4) After testing oil pressure switch, reinstall parts
removed earlier.
Oil Strainer Removal and Installation

1 CENFH5111506006
Removal
IFH511150006-01
Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
2) Remove the blue lead wire (2) from oil pressure Mounts Disassembly” in Section 2A (Page 2A-6).
switch (3).
Installation
3 Mounts Assembly” in Section 2A (Page 2A-10).
Oil Strainer Related Parts Inspection

CENFH5111506007
• Inspect oil strainer. Replace strainer if cracked,
damaged or other abnormal conditions.
If clog or obstruction, clean oil strainer.
2 • Check condition of O-rings. Replace O-ring if nicked,
cut, worn or other abnormal condition.
IFH511150007-01
IEH511150022-02
Piston Cooling Jet Removal and Installation

CENFH5111506008
Refer to “Pistons, Piston Rings, Connecting Rods,
Cylinder and Crankshaft Disassembly and Assembly” in
Piston Cooling Jet Inspection

CENFH5111506009
1) Remove the piston cooling jets (1).
Cylinder and Crankshaft Disassembly and
Assembly” in Section 1D (Page 1D-56).
IEH511150023-01
2) Check the piston cooling jets.

If crack or other damage is found, replace the jet.
Clean jets thoroughly to ensure there is no
obstruction.
2 3
IEH511150024-01
1. Piston cooling jet 2. O-ring 3. Bolt
3) Install the piston cooling jets.

Cylinder and Crankshaft Disassembly and
Assembly” in Section 1D (Page 1D-56).
Power Unit Cooling System: 1F-1
Power Unit Cooling System

Power Head
General Description
Water Cooling System Description
CENFH5111601001
The cooling system uses a displacement type flexible vane impeller to supply cooling water to the powerhead
assembly.
To prevent incomplete combustion due to an overcooled engine, and to ensure proper water flow during cold engine
operation, there is a thermostat in the cylinder.
Motor temperature and cooling system efficiency are monitored by cylinder temp. sensor and exhaust manifold temp.
sensor in the cylinder. If temperature higher than normal is detected by a sensor, an advance caution of overheat
condition is provided.
Displacement Type Water Pump Description

CENFH5111601002
In this displacement type water pump, the water pressure is increased by the change in volume between the impeller
and the pump case. As a result, the increased water pressure enables the water pump to circulate the cooling water.
5
6
7
I9J011160003-01
1. Water inlet 3. Key 5. Water pump impeller 7. Driveshaft

2. Water outlet 4. Water pump case 6. Under panel
Water Pressure Valve Description

CENFH5111601003
If cylinder water pressure is high when thermostat is closed, the valve will open to relieve the pressure.
1 2
IEH511160001-02
1. Water pressure valve cover 2. Water pressure valve

1F-2 Power Unit Cooling System:

Cooling Water Circulation Chart
CENFH5111602001
The water cooling system includes the lower unit water pump, lower unit to power unit water supply tube, oil pan water
pressure valve, power unit water passages and thermostat.
This system cools both the power unit and exhaust and is shown in schematic form below.
If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion build-up or
component damage.
ENGINE HOLDER RETURN HOSE Thermostat cover
When open
THERMOSTAT
BALANCER FUEL RETURN

COVER PIPE (Fuel cooler)
CYLINDER BLOCK CYLINDER HEAD
OIL PAN
ENGINE HOLDER BLOCK OIL COOLER
OIL PAN
WATER JACKET COVER OIL PAN PRESSURE VALVE PILOT WATER
HOLE
DRIVESHAFT
HOUSING WATER TUBE
WATER PUMP
PROPELLER EXHAUST OUTLET WATER INTAKE
WATER
IFH511160002-02

Powerhead Cooling System Diagnosis
CENFH5111604001

Overheating powerhead Water inlet screen obstructed. Clean.
Water passage obstructed. Clean or replace.
Pump plate not sealing. Check and repair.
Water pump impeller damage. Replace.
Water pump housing and/or plate worn. Replace.
Water pump housing seal worn. Replace.
Water tube grommet damaged. Replace.
Thermostat damaged/defective. Replace.
Water tube obstructed. Clean.
Water tube defective. Replace.
Water pressure valve damaged/ Replace.
defective.
Overcooling powerhead Thermostat damaged/defective. Replace.
Thermostat Removal and Installation 4) Remove the three bolts (3) securing the thermostat
CENFH5111606001 cover (4), then remove the cover (4) and thermostat
Removal (5).
case.
3
4 5
in Section 1D (Page 1D-2) and “Air Intake Silencer
Case Removal and Installation” in Section 1D (Page
1D-2).
2) Remove the flame arrester (1).
IFH511160005-02
IFH511160003-03
3) Loosen the four bolts and remove the plate (2).
IFH511160004-03
Installation Thermostat Inspection

attention to the following steps. Inspect the thermostat in the following procedures:
1) Remove the thermostat.
• Assemble thermostat (1) and thermostat cover (2) to
Refer to “Thermostat Removal and Installation”
cylinder block and secure with bolts (3).
(Page 1F-3).
Tightening torque 2) Inspect the thermostat.
Thermostat cover bolt (a): 11 N·m (1.1 kgf-m, 8.0 If salt deposits, corrosion, wear or other damage is
lbf-ft) found, clean or replace.
IFH511160006-03
IEH511160007-01
3) Check thermostat opening temperature as follows:

a) Insert a length of thread between thermostat
2
valve/body and suspend thermostat in a
3 (a)
container filled with water.
b) Place thermometer in container and heat water.
Observe water temperature when thermostat
valve opens and releases thread.
Thermostat operating temperature
Standard: 48 – 52 °C (118 – 125 °F)
IFH511160007-03

1
place.
2
3
I9J011160002-01
1. Thermometer 2. Heater 3. Thermostat
If thermostat valve does not open as specified

above, or sticks in any position, replace it.
4) Install the thermostat.
Refer to “Thermostat Removal and Installation”
(Page 1F-3).
Water Pressure Valve Removal and Installation Installation

CENFH5111606003
Removal 1) Install O-ring (1) to water pressure valve cover (2).
1) Remove the lower covers and oil pan covers.
2
2) Remove two bolts, water pressure valve cover (1)
and water pressure valve (2). 1
IDG211160009-01
1
NOTE
Align projections “A” on valve’s seal rubber
with cutaway parts “B” on valve cover when
installing.
IEH511160008-02
“A”
“B”
IEH511160009-02 IDG211160011-01
2) Install water pressure valve (3) and water pressure

valve cover (2) to oil pan and secure with bolts (4).
2 3 2
4
IEH511160010-01
3) Install oil pan covers and lower side covers.

Water Pressure Valve Related Item Inspection

CENFH5111606004
Inspect the water pressure valve in the following
procedures:
1) Remove the water pressure valve.
Refer to “Water Pressure Valve Removal and
Installation” (Page 1F-5).
2) Inspect the water pressure valve.
If salt deposits, corrosion, wear or other damage is
found, clean or replace.
Inspect O-ring. Replace if nicked, cut or torn.
IEH511160011-01
3) Install the water pressure valve.

Refer to “Water Pressure Valve Removal and
Installation” (Page 1F-5).
Water Pump Removal and Installation

CENFH5111606005
Refer to “Water Pump Removal and Installation” in
Water Pump Related Item Inspection

CENFH5111606006
Refer to “Water Pump and Related Item Inspection” in
Water Tube Removal and Installation

CENFH5111606007
Removal
Mounts Disassembly” in Section 2A (Page 2A-6).
Installation
Mounts Assembly” in Section 2A (Page 2A-10).
Water Tube Related Item Inspection

CENFH5111606008
Mounts Related Component Inspection” in Section 2A
(Page 2A-14).
Fuel System: 1G-1
Fuel System
Power Head
Precautions
Precautions on Fuel System Service
CENFH5111700001
! WARNING
Service operation of any type performed on the fuel system involves a risk of fire and injury if proper
precautions are not taken.
Be sure to take the following precautions when working around gasoline or servicing the fuel system.
• Disconnect battery cables except when battery power is required for servicing/inspection.
• Keep the working area well ventilated and away from open flame (such as gas heater) or sparks.
• Do not smoke or allow anyone else to smoke near the working areas.
Post a “NO SMOKING” sign.
• Keep a fully charged CO2 fire extinguisher readily available for use.
• Always use appropriate safety equipment and wear safety glasses when working around a
pressurized fuel system.
• To avoid potential fire hazards, do not allow fuel to spill on hot engine parts or on operating
electrical components.
• Wipe up fuel spills immediately.
• Before loosening or disconnecting the fuel feed line, be sure to relieve the fuel system of fuel
pressure by following the fuel pressure relief procedure.
• When disconnecting a fitting on the fuel line, cover the fitting with a shop cloth to soak up the small
amount of fuel that may flow out from the disconnected fuel line. Put the used cloth in an approved
container.
• Since fuel hose connections vary with the pipe type, connect and clamp each hose using the correct
method for each specific connection.
After connecting a hose, check that there is no twist or kink in the hose.
• When installing hose clamps, position tabs to avoid contact with other parts.
• Be sure hoses do not contact rods, levers or other components with engine either operating or at
rest.
General Description
Electronic Fuel Injection System Description
CENFH5111701001
The fuel injection system used by the DF200A 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 sequential timing) and controls the injector operating signals accordingly.
In regards to fuel injection timing, the fuel injection end timing is set depending on engine rpm. The ECM calculates
the amount of fuel injection based on the engines operating conditions, and determines the fuel injection start timing.
In the injection timing chart below, the injection end timing is set at 100° ATDC on the compression stroke.
1G-2 Fuel System:
Basic sensors
ECM
MAP sensor:
Informs ECM of intake manifold pressure. Fuel injection time duration
CKP sensor: (amount) is determined by
Informs ECM of engine speed and crankshaft angle. a digital map designed in
relation to intake manifold
Compensating sensors pressure and engine speed.
Cylinder temperature sensor:
Informs ECM of cylinder temperature.
Exhaust manifold temperature sensor:
Informs ECM of exhaust manifold temperature.
IAT sensor: Fuel amount compensation
Informs ECM of intake air temperature.
TPS (Throttle position sensor):
Informs ECM of throttle opening angle. Multi-point sequential timing
MAP sensor:
Informs ECM of barometric pressure at time of engine start.
O2 sensor:
Informs ECM of oxygen concentration in exhaust gas. Signal Signal Signal Signal
Battery voltage:
Constantly monitored by the ECM.
Others
CMP sensor:
Informs ECM of camshaft angle. Fuel injector
Shift position sensor:
Informs ECM of shift position (neutral or in-gear).
1 CPU “A”
2 7 A A A A
4
5 6
8
IFH511170001-01
1. Battery charge coil 4. 30 A fuse 7. ECM main relay “A”: Sensor/switch signal input
2. Rectifier/regulator 5. 15 A fuse 8. Fuel injector
3. 60 A fuse 6. Ignition switch 9. ECM
Fuel System: 1G-3
Fuel Injection Timing Chart

CKP sensor
signal
10° 30°
140˚ 220˚ 40˚ 180˚ 100˚ 40˚ 140˚
CMP sensor
CMP sensor
㪫㪛㪚㪫㪛㪚㪫㪛㪚
No.1 cylinder 㪚㫄㪜㫇㪜㫏㪠㫅㪚㫄㪜㫇
㪫㪛㪚㪫㪛㪚
No.3 cylinder 㪠㫅㪚㫄㪜㫇㪜㫏㪠㫅㪚㫄
㪫㪛㪚㪫㪛㪚㪫㪛㪚

No.4 cylinder 㪜㫏㪠㫅㪚㫄㪜㫇㪜㫏㪠㫅
㪫㪛㪚㪫㪛㪚
No.2 cylinder 㪜㫇㪜㫏㪠㫅㪚㫄㪜㫇㪜㫏
Injection time duration Injection end timing: 100° ATDC on compression stroke
No.1 injection
signal
No.3 injection
signal
No.4 injection
signal
No.2 injection
signal
IFH511170011-04
Fuel Injection Control Mode

Before start:
When the ignition switch is turned “ON”, the ECM receives a MAP sensor signal, indicating the static barometric
pressure of the intake manifold. This signal is used to compensate the fuel injection map.
When cranking:
Fuel is injected in each cylinders according to the “Start up mode” map which is based on the cylinder temperature and
intake air temperature (Sequential injection).
After start (Fast-idle function):

The fuel injection amount is controlled so that the engine rpm stays within the fast idle speed map until the cylinder
temperature reaches normal operating temperature.
When idling / trolling:

The fuel injection amount is controlled to maintain a stable engine speed at the specified idle/trolling rpm.
When running (normal operation):

ECM calculates the target air/fuel ratio on basis of signals from O2 sensor, CKP sensor, MAP sensor, etc.
ECM compensates the basic fuel injection amount so as to obtain the calculated air/fuel ratio.
When accelerating:
The fuel injection amount is controlled to increase.
When decelerating:
The fuel injection amount is controlled to decrease.
1G-4 Fuel System:
Fuel Delivery System Component Description

CENFH5111701002
The fuel delivery system is composed of the low pressure fuel line components (fuel tank, filter, pump etc.), fuel vapor
separator, high pressure fuel pump, high pressure fuel filter, fuel pressure regulator (located in the fuel vapor
separator), 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/cm2,
36.3 psi), the valve in the fuel pressure regulator will open and return the excess fuel to the vapor separator chamber.
Pressurized fuel enters into the intake ports through the fuel injector based on the sequential signals supplied from the
ECM.
3 2
9
4 “A”
10
6
7
5
8 11
13
12
14
16
15
IFH511170013-01
1. Fuel tank 6. Float 11. Fuel cooler 16. Intake manifold

2. Primer bulb 7. High pressure fuel pump 12. Fuel delivery pipe “A”: To atmosphere
3. Low pressure fuel filter 8. Fuel pressure regulator 13. Fuel injector
4. Low pressure fuel pump 9. Evaporation hose 14. Air intake silencer case
5. Fuel vapor separator 10. High pressure fuel filter 15. Throttle body
Fuel System: 1G-5
Low Pressure Fuel Pump

The low pressure fuel pump is operated by the plunger contacting the cam.
1
1
2
2
“B” “A”
IEH511170004-02
1. Cam “A”: Fuel in

2. Plunger “B”: Fuel out
Fuel Vapor Separator

The fuel vapor separator incorporates a float 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 atmosphere.
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.
“C”
“A” “B”
1
2
6
3
“D”
“D” 7
“E”
IEH511170005-02
1. Needle valve 4. Float chamber 7. Fuel pressure regulator “C”: Fuel outlet
2. Valve seat 5. Suction filter “A”: Fuel inlet “D”: Fuel return
3. Float 6. High pressure fuel pump “B”: Evaporation gas “E”: Fuel drain
1G-6 Fuel System:
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 balanced.
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/cm2, 36.3 psi).
By-pass fuel is returned to the fuel vapor separator chamber.
VALVE CLOSED VALVE OPENED

(below 250 kPa) (over 250 kPa)
“B”
“A” “A”
IEH511170006-01
“A”: From fuel delivery line “B”: To float chamber (Fuel return)
Fuel Injector
The fuel injector is an electromagnetic valve operated by a signal from the ECM.
When the injection signal is supplied to the fuel injector, the solenoid coil is energized pulling up the plunger.
This opens the injector valve and injects fuel.
Because the fuel pressure is kept constant, the amount of fuel injected is determined by the amount of time (duration)
the valve is open.
3
IEH511170007-01
1. Filter 3. Ball valve

2. Solenoid coil 4. Terminal
Fuel System: 1G-7
High Pressure Fuel Pump Control System Description

CENFH5111701003
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
ECM Signal FP
Ignition switch:
Informs ECM of “START” signal. High pressure
fuel pump
Cylinder temp. sensor:
IFH511170014-01
1 9
CPU
7
2
4
3
“A”
5
FP 8
BATT 6
IFH511170002-03
1. Battery charge coil 5. 15 A fuse 9. ECM

2. Rectifier/regulator 6. Ignition switch “A”: Sensor/switch signal input
3. 60 A fuse 7. ECM main relay
4. 30 A fuse 8. High pressure fuel pump
Duty cycle signal for fuel pump (example: 80% duty)

“ON” time × 100 = duty (%)
1 cycle time
0.8 ms
OFF
ON Time
1 ms (1cycle)
IEH511170010-01
Control Modes
Before start:
For 3 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 voltage.
1G-8 Fuel System:
Air Intake Components Description

CENFH5111701004
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 intake manifold.
Intake manifold pressure, monitored by the MAP sensor, is an indirect measurement 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.
4
9
7 5 “A”
3
6
IFH511170003-01
1. Throttle body 4. Intake manifold 7. IAT sensor “A”: Air flow

2. IAC valve 5. Throttle position sensor 8. Air intake silencer case
3. By-pass air screw 6. MAP sensor 9. VSV
Throttle 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 throttle valve which is connected to the throttle lever linkage.
• The TPS installed on the throttle body informs the ECM of the throttle valve opening angle.
NOTE
Do not try to adjust or remove any of the throttle body component parts (Throttle position sensor,
throttle valve, throttle stop screw, etc.).
These components have been factory adjusted to precise specifications.
IFH511170015-04
1. Throttle body 2. Throttle position sensor

Fuel System: 1G-9
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 passage and provides a means of partially adjusting the total
amount of air necessary for idling/trolling.
1 2
IFH511170006-02
1. Throttle body 2. By-pass air screw
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 the ECM, valve position changes will increase or decrease the air
flow through the IAC passage.
IFH511170007-03
1. IAC valve
1G-10 Fuel System:
Idle Air Control System Description

CENFH5111701005
The ECM controls the position of the IAC valve to regulate a portion of the intake air flow to the intake manifold.
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 and switch shown below monitor the current engine condition and send signals to the ECM.
Based on these signals, the ECM determines the IAC valve setting necessary to achieve the target engine speed 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: Signal

Informs ECM of intake manifold pressure.
Throttle position sensor:

ECM
Informs ECM of throttle opening angle.
Cylinder temp. sensor:

IAC valve
Shift position sensor:
Informs ECM of shift position and change.
IFH511170008-01
4 +12 V
ECM
Gr 1
5 W/B 59 IAC1
1 6 R/Y 47 IAC2
3 O/Bl 50 IAC3
W/Bl 38 IAC4
2
“A”
IFH511170009-04
1. IAC valve 3. Screw shaft 5. Coil “A”: Air flow

2. Valve pintle 4. Rotor 6. Bearing
Fuel System: 1G-11
IAC Valve 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 – 100% duty, according to cylinder temperature, 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. 15% but will vary slightly as idling/trolling conditions change.
When running (Normal operation):

The IAC valve is controlled to operate at 10 – 100% 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 effect” and “Fast-idle function”, the by-pass air screw must be adjusted to provide IAC valve
operation at approx. 15 ± 5% duty at the engine idling/trolling specification.
For the by-pass air screw adjustment procedure, refer to “Idle Speed and Idle Air Control (IAC) Duty
Inspection” in Section 0B (Page 0B-14).
1G-12 Fuel System:

Fuel Pressure Inspection 4) Loosen the clamp and place a large cloth over the
CENFH5111704001 end of fuel feed hose (3).
! WARNING Disconnect high pressure fuel feed hose (3) from
fuel delivery pipe upper union (4).
Gasoline is a flammable material that can
cause fire hazard or burns.
Before starting the following procedure, be

sure to observe “Precautions on Fuel System 3
Service” (Page 1G-1) in order to reduce the
risk or fire and personal injury. 4

guard (1).
IFH511170016-02
1 5) Connect special tools (pressure gauge, pressure

hose and pressure joint) between fuel feed hose and
fuel delivery pipe upper union as shown in figure.
Clamp the hose securely to ensure that no leaks
occur during checking.
! WARNING
IFH511170029-01 cause fire hazard or burns.
2) Relieve fuel pressure in fuel feed line.
Refer to “Fuel Pressure Relief Procedure” (Page 1G- A small amount of fuel may be released when
16). the fuel feed hose is disconnected.
3) Remove ring gear cover and air intake silencer case Place container under the fuel feed hose or
(2). fuel delivery pipe with a shop cloth so that
Refer to “Air Intake Silencer Case Removal and the released fuel is caught in the container or
Installation” in Section 1D (Page 1D-2). absorbed by the cloth.
Place the fuel soaked cloth in an approved
container.
2
Special tool
(A): 09912–58442 (Fuel pressure gauge)
(B): 09912–58432 (Fuel pressure hose)
(C): 09912–58490 (3-way joint & hose)
(A)
(B)
4 6
IFH511170030-01 (C)
IFH511170017-01
4. Delivery pipe upper union 6. High pressure fuel filter

5. Fuel delivery pipe
Fuel System: 1G-13
13) Stop engine and wait 5 minutes.

Check the residual fuel pressure in line.
(C)
(A) Residual fuel pressure
Standard: 200 kPa (2.0 kg/cm2, 28.4 psi.) or more
! WARNING
(B)
The fuel feed line is under high fuel pressure,
make sure to release fuel pressure according
IFH511170031-02
to the fuel pressure relief procedures
6) Reinstall ring gear cover and air intake silencer case. mentioned earlier.
Refer to “Air Intake Silencer Case Removal and Use the following procedures to remove the
Installation” in Section 1D (Page 1D-2). fuel pressure gauge.
7) Ensure the emergency stop switch lock plate is in • Place a container under the joint to catch
place. the fuel.
Shift into neutral position.
• Cover the joint with rag and loosen joint
8) Squeeze fuel primer bulb until you feel resistance. nut slowly to gradually release any
9) Turn ignition switch to “ON” for 3 seconds (to operate residual fuel pressure.
the fuel pump), then turn it “OFF”.
10) Repeat this (“ON” and “OFF”) procedure 3 or 4 times 14) After checking fuel pressure, remove fuel pressure
to pressurize the fuel system and then check the fuel gauge.
pressure.
OFF
ON
7
I9J011170018-01
11) Check for any signs of fuel leakage. IFH511170028-01
12) Measure fuel pressure at cranking or idle speed 7. Joint nut

operation.
Fuel pressure 15) Reconnect fuel line.
Standard: Approx. 255 kPa (2.55 kg/cm2, 36.3 16) With the engine not running and ignition switch “ON”,
psi.) check the fuel system for leaks.
17) Reinstall fuel hose guard, and tighten the bolts
securely.
1G-14 Fuel System:
Fuel System Diagnosis

CENFH5111704004

Engine will not start or Clogging, bending or improper routing of Clean, repair or replace.
hard to start (Fuel does fuel hose.
not reach the fuel delivery Fuel pump failure. Replace.
pipe). Fuel pressure regulator failure. Replace.
Fuel injector(s) failure. Replace.
Wiring connection failure. Repair or replace.
Engine will not start or Shift position sensor failure Replace.
hard to start. Throttle position sensor failure. Replace.
MAP sensor failure. Replace.
ECM failure. Replace.
Cylinder temp. sensor failure. Replace.
IAT sensor failure. Replace.
High pressure fuel pump failure. Replace.
Fuel hose improperly routed. Reroute properly.
IAC system failure. Check idle air control system.
Unstable idling/trolling or Shift position sensor failure Replace.
engine tends to stall. Throttle position sensor failure. Replace.
IAC system failure. Check idle air control system.
IAC passage clogged. Clean.
ECM failure. Replace.
Wire continuity/connection failure. Repair or replace.
Fuel injector(s) clogged. Replace.
Fuel pressure regulator failure. Check fuel pressure. Replace if necessary.
High pressure fuel pump failure. Check fuel pump and its circuit. Replace.
Fuel filter clogged. Clean or replace.
Clogging, bending or improper routing of Clean, reroute, repair or replace.
fuel hose.
Insufficient engine power Air leakage from air intake system. Repair or replace.
in high speed range (Air
intake system failure).
Insufficient engine power Fuel pressure too low. Check fuel pressure. Repair or replace.
in high speed range Throttle position sensor failure. Replace.
(Control circuit or sensor ECM failure. Replace.
failure).
Insufficient engine power Fuel injector(s) clogged. Replace.
in high speed range Throttle position sensor failure. Replace.
(Engine internal parts or ECM failure. Replace.
electrical equipment
failure).
Fuel System: 1G-15
Fuel Injection System Troubleshooting Step 4

CENFH5111704003
Before starting the troubleshooting, make sure that: Check Wire circuit.
• There is no self-diagnostic code indication. • Turn “OFF” ignition switch.
• Emergency stop switch plate is set in place. • Disconnect connector from ECM.
• Measure resistance between each “O/B”, “B/Br”, “R/
Step 1 W”, “Lg” wire terminal of the fuel injector connector
Check fuel injector operating sound. and body ground.
• Check each injector for operating sound at engine
Is resistance infinity?
cranking. ((Page 1G-24))
Do all four injectors make operating sound? Yes Go to step 5.
Yes Fuel injector circuit is in good condition. No “O/B”, “B/Br”, “R/W”, and/or “Lg” wire(s)
are shorted to ground.
No Go to step 2.
Step 5
Step 2 Check Wire circuit.
Check fuel injector resistance. • Connect connector to ECM.
• Turn ignition switch to “OFF”, disconnect connectors • Measure voltage between each “O/B”, “B/Br”, “R/
from fuel injectors. W”, “Lg” wire terminal of fuel injector connector and
• Check for proper connection to fuel injector at each body ground with ignition switch turned “ON”.
terminal.
Is voltage 0 V?
• If good condition, check all fuel injector for
resistance. ((Page 1G-24)) Yes Go to step 6.
Are all injectors in good condition? No “O/B”, “B/Br”, “R/W”, and/or “Lg” wire(s)
are shorted to power supply circuit.
Yes Go to step 3.
No Faulty fuel injector. Step 6

Check fuel injector operating signal.
Step 3 • Connect connectors to each fuel injector and ECM
Check fuel injector power supply. with ignition switch turned “OFF”.
• Measure voltage between each “Gr” wire terminal of • Measure fuel injector operating signal between each
fuel injector connector and engine body ground with “41”, “43”, “46”, “39” terminal of ECM and body
ignition switch turned “ON”. ground. ((Page 1G-25))
Is voltage 10 – 14 V? Is voltage 6 – 10 V or over?
Yes Go to step 4. Yes If check result is satisfactory, substitute a

known-good ECM and recheck.
No • “Gr” wire open or shorted.
• If it is in good condition, check ECM No “O/B”, “B/Br”, “R/W”, and/or “Lg” wire(s)
power source and ground circuit. are open circuit.
1G-16 Fuel System:
Fuel Pressure Relief Procedure 5) Crank the engine 5 – 10 times (3 seconds each time)
CENFH5111706001 to dissipate the fuel pressure in lines.
After making sure that engine is cold, relieve fuel
pressure as follows: 6) Make sure fuel pressure has been relieved by
pinching the high pressure fuel hose (4) between
finger tips (the line should feel soft, without
2) Loosen the three bolts and remove the fuel hose pressure).
guard (1).
IFH511170035-01
IFH511170032-01
7) Upon completion of servicing, connect the ignition
3) Disconnect the high pressure fuel pump lead wire coil primary lead wires and high pressure fuel pump
connector (2) at high pressure fuel pump. lead wire.
2 Fuel Line Removal and Installation

CENFH5111706002
Pay special attention to the following points when
removing or installing fuel hoses.
! WARNING

IFH511170033-01 sure to observe “Precautions on Fuel System
4) Disconnect the ignition coil primary lead wire Service” (Page 1G-1) in order to reduce the
connectors (3) from all of the ignition coils. risk or fire and personal injury.
• The fuel feed line is under high pressure, use special

care when servicing it.
• Spilled gasoline should be wiped off immediately.
• Perform the following checks to ensure proper and
safe operation of the repaired unit.
3
– Check fuel hose routing.
Refer to “Fuel Hose Routing” in Section 4B (Page
4B-1).
– Check for fuel leakage.
Refer to “Fuel Leakage Check Procedure” (Page
IFH511170034-01
1G-17).
Fuel System: 1G-17
Fuel Line Inspection Inspection of Fuel Hose Connections

CENFH5111706003 CENFH5111706005
Visually inspect fuel lines for evidence of fuel leakage, Note that the fuel hose connection varies with each type
cracking, deterioration, or damage. Make sure all clamps of pipe. Be sure to connect and clamp each hose
are secure. Replace parts as needed. correctly by referring to the figure.
• For type “A” (short barbed end) pipe, the hose must
Fuel Leakage Check Procedure completely cover pipe.
CENFH5111706004
Type “A”
After performing any fuel system service, always be sure
there is no fuel leakage by checking as follows. 1
1) Squeeze fuel primer bulb until you feel resistance. 2
2) Shift into “Neutral” position.

3) Ensure emergency stop switch lock plate is in place.
4) Turn ignition switch “ON” for 3 seconds (to operate
fuel pump), then turn it “OFF”. 3
“a”
Repeat this (“ON” and “OFF”) procedure 3 or 4 times
to pressurize the fuel system. I9J011170012-01
5) Once pressurized, check all connections and 1. Clamp (Clip) 3. Joint pipe
components for any signs of leakage. 2. Hose “a”: 3 – 7 mm (0.1 – 0.3 in)
• For type “B” (bent end) pipe, hose must cover the
straight part of pipe by 20 – 30 mm (0.8 – 1.2 in.).
OFF
Type “B”
ON
“b”
I9J011170020-01
“a”
I9J011170013-01
“a”: 3 – 7 mm (0.1 – 0.3 in) “b”: 20 – 30 mm (0.8 – 1.2 in)
• For type “C” pipe, hose must fit up against the flanged
part of pipe.
Type “C”
“a”
I9J011170014-01
“a”: 3 – 7 mm (0.1 – 0.3 in)
• For type “D” pipe, the hose must cover the pipe by 20
– 30 mm (0.8 – 1.2 in.).
Type “D”
“b”
“a”
I9J011170015-01
“a”: 3 – 7 mm (0.1 – 0.3 in) “b”: 20 – 30 mm (0.8 – 1.2 in)

1G-18 Fuel System:
High Pressure Fuel Pump Operating Sound Fuel Vapor Separator Removal and Installation
CENFH5111706007
Inspection Removal
CENFH5111706006
1) Install the emergency stop switch lock plate into
! WARNING
position.
2) Shift into neutral. Gasoline is a flammable material that can
3) Turn ignition switch “ON” and check for fuel pump cause fire hazard or burns.
operating sound.
NOTE sure to observe “Precautions on Fuel System
Fuel pump operating sound is low because Service” (Page 1G-1) in order to reduce the
the pump is inside the fuel vapor separator. If risk or fire and personal injury.
you cannot hear the pump sound clearly, use
a sound scope or long blade screw driver. 1) Relieve fuel pressure in fuel feed line.
Refer to “Fuel Pressure Relief Procedure” (Page 1G-
Fuel pump operating sound 16).
Sounds for approx. 3 seconds only 2) Remove the lower side covers.
(each time the ignition switch is turned to the Refer to “Lower Side Cover Removal and
“ON” position) Installation” in Section 2A (Page 2A-3).
3) Remove the two bolts (1) securing front panel.
IFH511170036-02 1
4) If no pump operating sound is heard: IFH511170037-01
a) Turn ignition switch to the “OFF” position, check 4) Loosen the three bolts and remove the fuel hose
for contact failure in the lead wire connector. guard (2).
b) Check that the drive voltage is outputting from
the ECM and no abnormal conditions exist in the 2
engine main wiring harness.
c) If inspection in steps “a” and “b” are OK, replace
the high pressure fuel pump.
IFH511170038-01
Fuel System: 1G-19
5) Disconnect high pressure fuel pump lead wire Installation

connector (3) at fuel pump. Installation is reverse order of removal with special
6) Disconnect fuel hose (4) from fuel vapor separator. attention to the following steps.
• Install the fuel drain hose (1) through the slit of side
3
cover seal as shown in figure.
IFH511170019-02
7) Remove the three bolts securing fuel vapor

separator. IFH511170040-01

place.
1).
Refer to “Fuel Leakage Check Procedure” (Page 1G-
17).
Fuel Vapor Separator Disassembly and

Assembly
IFH511170039-01 CENFH5111706008
8) Disconnect fuel return hose (5) from fuel vapor Disassembly
separator. 1) Remove the fuel vapor separator.
Installation” (Page 1G-18).
2) Remove five screws (1).
Remove separator cover (2) with high pressure fuel
5
pump from separator case (3).
3
1
IFH511170020-02
9) Disconnect fuel hose (6) from high pressure fuel

filter, then remove evaporation hose (7) from fuel
vapor separator.
2
IEH511170029-01
IFH511170021-02
1G-20 Fuel System:
3) Remove the screw (4) securing float pin (5). 7) Remove suction filter (11).
4) Remove the float (6), float pin (5) and needle valve
(7).
11
4
IEH511170034-01
5 8) Remove high pressure fuel pump (12) and grommet
IEH511170030-01 (13) from separator cover and then disconnect pump
lead wire connector (14).
13 14
7
12
6
IEH511170031-01
IEH511170035-01
5) Remove screw (8) and valve seat (9).
Assembly
Assembly is reverse order of disassembly with special
8 High pressure fuel pump

• Connect pump lead wire connector, then install
grommet (1) and high pressure fuel pump (2).
9 NOTE
Apply fuel to grommet before installing.
IEH511170032-01
6) Remove screw and fuel pressure regulator (10) from

separator case. 2
IEH511170036-01
10
IEH511170033-01
Fuel System: 1G-21
Float / Float pin Setting float height

• Install float (1) and float pin (2), then secure float pin • To correct specification, bend only adjustment tab (1).
with screw (3).
NOTE
When adjusting the tab, do not bend to the
point that it applies pressure to the needle
and seat.
1
1
3
IEH511170037-01
NOTE
After assembling, check for smooth and free
float movement.
IEH511170040-01
Fuel pressure regulator

• Install fuel pressure regulator and tighten screw
securely.
NOTE
Apply fuel to O-ring (1) before installing fuel
pressure regulator.
IEH511170038-01
Checking float height 1
• Measure float height.

Special tool
(A): 09900–20101 (Vernier calipers (150
mm))
Float height “a”
Standard: 48 ± 3 mm (1.89 ± 0.12 in) IEH511170041-01
NOTE
Make sure that the float weight is not applied
to the needle valve.
(A)
“a”
IEH511170039-01
1G-22 Fuel System:
Separator cover/Separator case NOTE

1) Install seal ring (1), then apply SUZUKI Bond evenly Separator cover and case are a set.
to only the outside mating surface of the separator If any repair is required on the cover or case,
case as shown in figure. replace them as a fuel vapor separator
: Sealant 99000–31140 (SUZUKI Bond assembly.
1207B (100 g))
NOTE
• Clean mating surfaces before applying
bond.
• Do not apply bond to seal ring, groove and
inside mating surface.
“A”
IEH511170072-01
Final Assembly Check

• Check to ensure that all removed part are back in
place.
1 Refer to “Fuel Hose Routing” in Section 4B (Page 4B-
1).
IEH511170042-01
“A”: Outside
Refer to “Fuel Leakage Check Procedure” (Page 1G-
17).
2) Install separator case, then tighten screws securely.
NOTE
When installing separator case, align suction
hole “B” with hole “C” of separator case.
“B”
“C”
IEH511170043-02
Fuel System: 1G-23
Inspection of Fuel Vapor Separator Component Fuel Pressure Regulator

Parts Inspect fuel pressure regulator for damage or corrosion.
CENFH5111706009 Check fuel pressure regulator operation.
NOTE
Special tool
(A): 09952–99320 (Hand air pump)
found on any component, replace the
(B): 09940–44121 (Air pressure gauge)
component.
(C): 09940–44130 (Attachment)
Needle Valve / Valve Seat (D): 09912–58490 (3-way joint & hose)
Inspect needle valve and valve seat for groove, other 1) Connect special tools to inlet side of regulator as
damage or dirt. shown in figure.
Replace or clean if necessary.
(B)
(A)
(D)
(C) “A”
IEH511170044-01
Float
Inspect the float for cracks or other damage. IEH511170047-02
2) Pump air into regulator using pump until air is
released through outlet side “A”.
3) Read pressure on gauge when air is released.
Regulator operating pressure:
240 – 270 kPa (2.4 – 2.7 kg/cm2, 34.1 – 38.4 psi)
If out of specification, replace regulator.
IEH511170045-01
Filter
Inspect pump suction filter for clog or other damage.
Replace or clean if necessary.
IEH511170046-01
1G-24 Fuel System:
Fuel Injector Inspection with Injector in Place Individual Fuel Injector Operating Sound
CENFH5111706010
Inspection
1) Using a sound scope or equivalent, check the CENFH5111706011
operating sound of the fuel injector when the engine 1) Disconnect the ignition coil lead wire connectors
is running or cranking. from all of the ignition coils.
Injector operating sound cycle should vary according 2) Disconnect the fuel injector lead wire connector and
to engine speed. connect the test cord.
If no sound or an unusual sound is heard, check
injector circuit (wire or connector) or injector. Special tool
(A): 09930–89260 (Injector test cord (A))
1
(A)
“C l i c k ”
IFH511170041-01
IFH511170043-01
1. Injector body
NOTICE
2) Disconnect the lead wire connector from the fuel
If battery power is applied too long in any of
injector.
the following tests, the coil of the fuel injector
3) Connect a digital tester between the terminals of the may burn.
injector and measure resistance.
If out of specification, replace the fuel injector. Fuel injector test must be completed within
Special tool few seconds to avoid burning of the coil.
3) Connect Gr wire to body ground.
Tester knob indication 4) Momentarily touch the B/Y wire to the starter motor
Resistance (Ω) magnetic switch terminal “B” (connected to battery
Fuel injector resistance positive (+) terminal) and check for injector operating
Standard: 10 – 14 Ω at 20 °C sound.
If out of specification, replace fuel injector.
Fuel injector operating sound
“Click”
B/Y
IFH511170042-01
4) Connect the lead wire connector to the fuel injector

securely. Gr
IFH511170044-02
Fuel System: 1G-25
Fuel Injector Operating Signal Inspection

CENFH5111706012
1
2
(A) (A)
6
37 38 39 40 41 42 43 44 45 46 47 48 49 55 56 57 58 59 60 61 62 63 64 65 66 67
50 51 52 53 54 68 69 70 71 72
1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31
14 15 16 17 18 32 33 34 35 36
5 4
6
39 41 43 46
(White connector) (Black connector)

(A)
IFH511170010-02
1. ECM 3. Wire harness 5. Stevens peak reading voltmeter CD-77

2. Gray test cord connector side 4. Starter motor magnetic switch “B” terminal 6. White connector
Special tool
: Stevens peak reading voltmeter CD-77
NEG 50
1) Disconnect all ignition coil connectors from the ignition coils.
2) Connect the test cord between the ECM and wire harness as shown in figure, then turn ignition switch “ON”.
3) Connect the tester probe (“–”, Black) to the starter motor magnetic switch terminal “B” (connected to battery
positive (+) terminal) as shown in figure.
4) Connect the tester probe (“+”, Red) to each terminal.
Injector Terminal Wire color (Engine harness)
No.1 41 O/B
No.2 43 B/Br
No.3 46 R/W
No.4 39 Lg
5) Crank the engine and measure the voltage.

If out of specification, inspect the related parts as described in “Fuel System Diagnostic Information/Fuel Injection
System Troubleshooting”.
Refer to “Fuel System Diagnosis” (Page 1G-14) and “Fuel Injection System Troubleshooting” (Page 1G-15).
Fuel injector operating signal
Standard: Approx. 6 – 10 V or over
1G-26 Fuel System:
Fuel Injector Removal and Installation 6) Disconnect the four fuel injector connectors (4).
CENFH5111706013
Removal 7) Remove two bolts (6) and fuel delivery pipe (5) (with
fuel injectors).
1) Relieve the fuel pressure in the fuel feed line
according to “Fuel Pressure Relief Procedure”. ! WARNING
16). Gasoline is a flammable material that can
2) Remove the lower side covers. cause fire hazard or burns.
Installation” in Section 2A (Page 2A-3). A small amount of fuel may be released when
the fuel injector is removed from delivery
3) Loosen the three bolts and reomove fuel hose guard pipe.
(1). Place a shop cloth under fuel injector before
removal to absorb any fuel released.
Dispose of fuel soaked cloth in appropriate
container.
1
4
IFH511170045-01
4) Remove the air intake silencer case (2).

IFH511170023-02
5
6
IFH511170047-01
5) Loosen the clamp and place a large cloth over the IFH511170048-02
end of the fuel feed hose (3).
8) Remove each fuel injector (7) from delivery pipe.
Slowly pull the fuel feed hose from the fuel delivery
pipe.
Drain any excess fuel in the hose into a small
container.
IFH511170024-02
IFH511170022-03
Fuel System: 1G-27
Installation 4) Tighten delivery pipe bolts and make sure that

Installation is reverse order of removal with special injectors rotate smoothly.
Tightening torque
! WARNING Fuel delivery pipe bolt (a): 23 N·m (2.3 kgf-m,
16.5 lbf-ft)
reinstalling fuel injector can result in fuel
leakage or damage.
Do not re-use O-ring and cushion once

removed.
Always use new parts.
1) Replace injector O-ring (1) with a new one using

care to avoid nicks or cuts during installation. (a)
1 2
IFH511170050-02
“A” (a)
IEH511170057-01
“A”: Apply fuel to O-ring
2) Replace the cushion (2) with a new one and install to

the cylinder head.
3) Apply a thin coat of fuel to injector O-rings, then
IFH511170051-02
install the injectors into the delivery pipe (3) and
5) Reconnect the fuel feed hose and fuel line securely.
cylinder head.
Make sure that the injectors rotate smoothly.
IFH511170052-01
IFH511170049-01
6) Connect the lead wire connector to the injectors
securely.
7) Make sure the emergency stop switch lock plate is in
place.
Shift into neutral position.
8) Squeeze the fuel primer bulb until you feel
resistance.
Turn ignition switch “ON” for 3 seconds (to operate
fuel pump), then turn it “OFF”. Repeat this (ON and
OFF) procedure 3 or 4 times to pressurize fuel
system.
Check for fuel leaks around fuel injectors.
9) Check to ensure that all removed parts are back in
place.
1G-28 Fuel System:
Low Pressure Fuel Pump Removal and 5) Remove the low pressure fuel pump (4).
Installation Note the position before removing O-ring (6).
CENFH5111706014
NOTICE
Disassembling the low pressure fuel pump
4
can lead to troubles. 6
The low pressure fuel pump is a

nonrepairable component.
Do not attempt to disassemble the low
pressure fuel pump.
It must be replaced as a complete unit if it is
defective.
IFH511170056-01
Removal
1) Remove the lower side covers. Installation
Refer to “Lower Side Cover Removal and Installation is in the reverse order of removal with special
Installation” in Section 2A (Page 2A-3). attention to the following steps.
2) Remove the resonator and air intake silencer case
(1). NOTICE
Refer to “Air Intake Silencer Case Removal and • Before installing the low pressure fuel
Installation” in Section 1D (Page 1D-2). pump, rotate the crankshaft to bring the
No.1 (top cylinder) piston to Top Dead
1 Center on the compression stroke.
• Do not reuse O-ring once removed.
Always use a new O-ring.
• Apply thread lock to the low pressure fuel pump bolts.

• Install the low pressure fuel pump, then tighten bolts
securely.
IFH511170053-01
Tightening torque
3) Disconnect the fuel inlet hose (2) and outlet hose (3) Low pressure fuel pump bolt (a): 10 N·m (1.0 kgf-
from low pressure fuel pump (4). m, 7.0 lbf-ft)
4) Remove two bolts (5) securing fuel pump.
• Connect the fuel inlet and outlet hoses.
4
5
(a)
IFH511170054-01
IFH511170055-01
• Reinstall parts removed earlier.

Fuel System: 1G-29
Low Pressure Fuel Pump Inspection Low Pressure Fuel Pump

CENFH5111706015 Inspect the low pressure fuel pump.
NOTICE If leakage, cracks, damage or other abnormal condition
Disassembling the low pressure fuel pump is found, replace fuel pump assembly.
can lead to troubles.
The low pressure fuel pump is a

nonrepairable component.
Do not attempt to disassemble the low
pressure fuel pump.
It must be replaced as a complete unit if it is
defective.
IEH511170064-02
IEH511170065-02
Low Pressure Fuel Line Components

CENFH5111706016
When disassembling or reassembling fuel line, refer to the construction diagram below.
4
9
9
9 9 5
9 2
6
3
3 3
9
1 7
9
3
8
IFH511170059-01
1. Primer bulb 4. Low pressure fuel filter body 7. O-ring

2. Fuel connector 5. Seal ring 8. Low pressure fuel filter cup/water detection switch
3. Fuel hose 6. Filter element 9. Clip
1G-30 Fuel System:
Low Pressure Fuel Filter / Fuel Hose Inspection High Pressure Fuel Filter Removal and
CENFH5111706017
Fuel Connector
Installation
CENFH5111706018
Inspect fuel connector for leakage, deterioration or other Removal
damage. Replace if necessary.
! WARNING

sure to observe “Precautions on Fuel System
Service” (Page 1G-1) in order to reduce the
risk or fire and personal injury.
1) Relieve the fuel pressure in the fuel feed line.

IEH511170067-01 16).
Fuel Hose
guard (1).
Inspect fuel hose for cuts, cracks, leakage, tears or
deterioration. Replace if necessary.
Fuel Primer Bulb

1
Inspect fuel primer bulb for cracks, leakage,
deterioration or check valve function.
IEH511170068-01
IFH511170058-01
Low Pressure Fuel Filter 3) Remove the two bolts securing high pressure fuel
Inspect low pressure fuel filter (1). filter (2).
Refer to“Low Pressure Fuel Filter Inspection” in Section
4) Remove the hose clip (3).
0B (Page 0B-18).
5) Loosen the clamp and place a large cloth over end of
fuel feed hose (4).
Slowly pull fuel feed hose (4) from high pressure fuel
filter.
3 4
IFH511170057-01
2
IFH511170026-03
Fuel System: 1G-31
6) Loosen the clamp and place a large cloth over end of Water Detection Switch Inspection
fuel hose (5), then disconnect fuel hose (5) from high CENFH5111706019
pressure fuel filter. Inspect the water detection switch using the following
Drain any excess fuel in filter into a small container. procedures.
1) Remove the low pressure fuel filter.
Remove filter cup.
Refer to “Low Pressure Fuel Filter Inspection” in
5
Section 0B (Page 0B-18).
2) Connect the tester probes to the lead wire terminals
as shown.
3) Check if continuity/infinity can be measured by
moving float, checking each position.
If out of specification, replace the switch (fuel filter
case) with a new one.
Special tool
IFH511170060-01
Installation Tester knob indication
Installation is reverse order of removal with special Continuity( )
attention to the following steps. Float position Tester indication
• Check fuel hose routing. Raise the float fully up Continuity
Refer to “Fuel Hose Routing” in Section 4B (Page 4B- Lower the float completely. Infinity
1).
Refer to “Fuel Leakage Check Procedure” (Page 1G- 2
17).
(A)
IDG211170066-02
1. Float 2. Stopper
4) Assemble and re-install the fuel filter.

Refer to “Low Pressure Fuel Filter Inspection” in
Section 0B (Page 0B-18).
1H-1 Ignition System:
Ignition System
Power Head
General Description
Ignition System Description
CENFH5111801001
The ignition system used by DF200A 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 primary
winding based on the signals received from various 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.
1
+12 V IGT1
Ign.1
O 68
+12 V
Ign.2 IGT2
Bl/Y 54
IGT3
3
Gr/Y 66
IGT4
Lg/R 53
+12 V
Ign.3
+12 V
Ign.4
3 GND
IGT +BAT
IFH511180001-02
1. ECM 2. Ignition coil 3. Spark plug

Ignition System: 1H-2
Ignition Control Description

CENFH5111801002
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.
Basic sensors ECM

MAP sensor: Ignition timing is determined by a
Informs ECM of intake manifold pressure. digital map designed in relation to
CKP sensor: intake manifold pressure and
engine speed.
Informs ECM of engine speed and crankshaft angle.
Compensating sensors
Cylinder temperature sensor:
Ignition timing compensation
IAT sensor:
Informs ECM of intake air temperature.
Throttle position sensor:
Informs ECM of throttle opening angle.
Shift position sensor: Signal
Informs ECM of shift position and change.
Knock sensor: Ign. coil
Informs ECM of knoking level.
Others Spark plug
CMP sensor:
Informs ECM of camshaft angle.
Ignition switch:
Informs ECM of “START” signal.
Battery voltage:
Constantly monitored by the ECM.
IFH511180002-04
Ignition Specification
Ignition system Full-transistorized ignition
Advance Electronic microcomputer control
Ignition timing 0° ± 6° BTDC – 26° BTDC
Firing order 1—3—4—2
Ignition Timing Chart

The following chart is an example for ignition at 10° BTDC.

CKP sensor
signal
10° 30°
140˚ 220˚ 40˚ 180˚ 100˚ 40˚ 140˚
CMP sensor
CMP sensor
㪫㪛㪚㪫㪛㪚
No.1 cylinder 㪚㫄㪜㫇㪜㫏㪠㫅㪚㫄㪜㫇
㪫㪛㪚
No.3 cylinder 㪠㫅㪚㫄㪜㫇㪜㫏㪠㫅㪚㫄
㪫㪛㪚
No.4 cylinder 㪜㫏㪠㫅㪚㫄㪜㫇㪜㫏㪠㫅
㪫㪛㪚
No.2 cylinder 㪜㫇㪜㫏㪠㫅㪚㫄㪜㫇㪜㫏
Spark timing
No.1 ignition
signal
No.3 ignition
signal
No.4 ignition
signal
No.2 ignition
signal
IFH511180004-01
Control Mode
• When cranking
The ignition timing is fixed at 5° BTDC until the engine starts.
• When idling/trolling
The ignition timing is controlled within the range of 0° ± 6° BTDC to provide stable engine operation at the specified
idling/trolling speed.
• When running (normal operation)
The ignition timing ranges between 0° BTDC – 26° BTDC, depending on current engine operating conditions.
• Knock control compensation
This compensation is added when knocking is detected so as to recover from knocking state immediately.
Component Location
Ignition System Components Location
CENFH5111803001

Ignition System Symptom Diagnosis
CENFH5111804001

Engine cranks, but will Blown fuse for ignition system. Replace.
not start or weak spark. Loose connection or disconnection of Connect securely.
(No spark) lead wire.
Faulty spark plug(s). Replace.
Faulty ignition coil. Replace.
Faulty CKP sensor. Replace.
Faulty CMP sensor or sensor trigger Replace.
vane of camshaft.
Faulty ECM. Replace.
Spark plug is wet or Incorrect gasoline. Change.
quickly becomes fouled Incorrect spark plug. Replace.
with carbon.
Spark plug quickly Worn piston ring. Replace.
become fouled with oil or Worn piston. Replace.
carbon. Worn cylinder. Replace.
Excessive valve stem to valve guide Replace.
clearance.
Worn valve stem seal. Replace.
Spark plug electrodes Incorrect spark plug. Change.
overheat or burn. Overheated engine. Tune-up.
Loose spark plug. Tighten.
Ignition System Troubleshooting Step 6

CENFH5111804002
Before starting the troubleshooting, make sure that: Measure the battery voltage between input lead
• There is not self-diagnostic code indication. wire at ECM with the ignition switch in “ON”
• Emergency stop switch plate is set in place. position. Is result OK?
Perform the following ignition system tests when the
Yes Go to step 7.
engine is hard to start in order to determine if the cause
is in the ignition or another system. No • Faulty ignition switch.
Step 1 • Faulty ECM main relay.

• Broken wire harness or poor connection
Check the ignition system connector for poor
of related circuit connector.
connections. Is there connection in the ignition
system connectors? Step 7
Yes Go to step 2. Check CKP sensor. Refer to “CKP Sensor
Inspection” in Section 1C (Page 1C-11). Is result
No Poor connection of connectors.
OK?
Step 2 Yes Go to step 8.
Check spark condition.
No • Check air gap between CKP sensor
Yes Go to step 3. and flywheel reluctor bars.
• Adjust CKP sensor air gap.
No No or weak sparks.
• Replace CKP sensor or flywheel.
Step 3
Step 8
Check if the spark plugs are in good condition.
Check CMP sensor. Refer to “CMP Sensor
Yes Go to step 4. Inspection” in Section 1C (Page 1C-12). Is result
OK?
No Replace spark plug with a new one.
Yes Go to step 9.
Step 4
No • Check CMP sensor.
Check ignition coil assembly power supply and
ground circuits for open and short. Are circuits in • Check CMP sensor trigger vane.
good condition? • Replace CMP sensor or Ex. camshaft.
Yes Go to step 5. Step 9
No Repair or replace. Substitute a known-good ignition coil assembly
then repeat step 2. Is check result of step 2
Step 5 satisfactory?
Check ignition coil operating signal. Is result OK? Yes Go to step 10.
Yes Go to step 6. No Substitute a known good ECM, then
No Check ignition coil operating signal wire repeat step 2.
for open, short and poor connection.
Step 10
Check the ignition timing by using timing light
(Approx. 4° BTDC at 1 000 r/min). Is result OK?
Yes System is in good condition.
No Check input signals related to this system.

Spark Plug Removal and Installation 1) Turn the ignition switch OFF.
CENFH5111806001
Refer to “Spark Plug Removal and Installation” in 2) Disconnect the ignition coil connector.
Section 0B (Page 0B-7). 3) Check for continuity between the GND (–) terminal
on the wiring harness side connector and the engine
Spark Plug Inspection body ground.
CENFH5111806002 4) Turn the ignition switch key to the ON position.
Refer to “Spark Plug Inspection and Cleaning” in Section Check for battery voltage by measuring between the
0B (Page 0B-8). BAT (+) terminal and GND terminal on the wiring
harness side connector.
Ignition Coil Removal and Installation 5) Connect the wiring harness connector to the ignition
CENFH5111806003
Removal coil and measure the ignition operating signal.
1) Disconnect the battery cables from the battery. Refer to “Ignition Coil Operating Signal Inspection”
(Page 1H-7).
2) Disconnect the ignition coil connector (1).
• If any failure exists, check for open circuit, short
3) Remove the bolt (2) securing the ignition coil, then circuited battery, short circuited lead and
pull out the ignition coil (3). connector’s contact condition for each circuit.
• If there is no spark even with the wiring harness
2 and spark plug in sound condition, perform the
inspection again using an ignition coil that is
known to be in good condition (new or used from
another cylinder that is operating properly).
3 • If there is still no spark even with the wiring
harness, spark plug and ignition coil in sound
condition, replace the ECM and perform the
inspection again.
1
IFH511180005-02 IGT GND +BAT
Installation
1) Install the ignition coil, then secure the ignition coil
with its mounting bolt.
2) Connect the ignition coil connector.
3) Connect the battery cables to battery.
Ignition Coil Inspection

CENFH5111806004
NOTE
The ignition coil power transistor and high
tension lead are an integral part of the coils
internal circuit. Using resistance
measurements to check for a defect on either
the primary or secondary coil is not possible. I9J011180004-03
Special tool
DCV
Ignition Coil Operating Signal Inspection

CENFH5111806005
Special tool
: Stevens peak reading voltmeter CD-77
SEN 50
1) Disconnect all injector connectors from the fuel injectors.
2) Connect test cords between ECM and wire harness as shown in figure, then turn ignition switch ON.
(A) (A)
4
5
37 38 39 40 41 42 43 44 45 46 47 48 49 55 56 57 58 59 60 61 62 63 64 65 66 67
50 51 52 53 54 68 69 70 71 72
1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31
14 15 16 17 18 32 33 34 35 36
2 3
4 5
55 66
53 54 68
(A)
IFH511180003-02
1. ECM 3. Stevens peak reading voltmeter CD-77 5. Black connector

2. Wire harness 4. White connector
3) Connect the tester probe (“+”, Red) to each terminal.

Ignition coil Terminal Wire color (engine harness)
No.1 68 O
No.2 54 Bl/Y
No.3 66 Gr/Y
No.4 53 Lg/R
4) Connect the tester probe (“–” Black) to No.55 terminal (or to body ground).
5) Crank engine and measure voltage.
If out of specification, inspect the related parts.
Refer to “Ignition System Symptom Diagnosis” (Page 1H-4) and “Ignition System Troubleshooting” (Page 1H-5).
Ignition coil operating signal
Standard: Approx. 5 V
CKP Sensor Inspection

CENFH5111806006
Refer to “CKP Sensor Inspection” in Section 1C (Page 1C-11).
CMP Sensor Inspection

CENFH5111806007
Refer to “CMP Sensor Inspection” in Section 1C (Page 1C-12).
Ignition Switch Inspection

CENFH5111806008
Refer to “Ignition Switch Inspection” in Section 1I (Page 1I-13).
ECM Main Relay Inspection

CENFH5111806009
Refer to “ECM Main Relay Inspection” in Section 1A (Page 1A-50).
1I-1 Starting System:
Starting System
Power Head
General Description
Electric Starter System Description
CENFH5111901001
The starting circuit consists of the battery, starting motor, ignition switch, neutral switch, starter relay, ECM and related
electrical wiring.
These components are connected electrically as shown in the figure below.
In the circuit shown in the figure below, the magnetic switch coils and starter relay coil are magnetized when the
ignition switch is closed (turned to “START”).
The resulting plunger and pinion shift lever movement causes the pinion to engage the engine flywheel gear, the
magnetic switch main contacts to close, and engine cranking to take place.
When the engine starts, the pinion over-running clutch protects the armature from excessive speed until the switch is
opened, at which time the torsion spring causes the pinion to disengage.
9
14 13
15
17 R
G
20 18 W
16
19 1
12
8
11 10
Y/G
7
START
W W Y/G
OFF
ON
Br
Br B GND 3
W W BATT 5
Br Br Br START
Bl/R G
B B
6
IFH511190001-03
1. Battery 6. Emergency stop switch 11. Fuse (30 A) 16. Starter motor
2. Fuse (15 A) 7. Neutral switch (engine side) 12. Fuse (30 A) 17. Plunger
3. Ignition switch 8. Main relay 13. Magnetic switch 18. Shift lever
4. Neutral switch (remote control box side) 9. Starter relay 14. Pull-in coil 19. Pinion & over-running clutch
5. ECM 10. Fuse (60 A) 15. Hold-in coil 20. Ring gear
Starting System: 1I-2
Starter Motor Operation Condition Description Control by Shift Position Sensor

CENFH5111901002 A shift position sensor is installed on the clutch lever
The starter motor relay is controlled by the ECM.
holder and detects the shift position as the clutch lever is
• The starter motor relay will only engage when the interlocked with the SPS shaft.
ignition switch is turned to the “START” position if the This sensor is a variable resistor that changes resistance
all of the following conditions are satisfied. in accordance with the shift position.
– Lock plate is attached to emergency stop switch. The resistance changes (increase / decrease) the
– Neutral switch is in the “ON” position. voltage signal output from the sensor to the ECM. Based
on the sensor voltage, the ECM calculates and detects
– Engine is not already operating.
shift position.
• After returning the ignition key to the “ON” position When attempting to start the engine, the ECM does not
from “START”, the starter motor continues to run for 4 provide an injector operating signal when a shift lever in-
seconds until engine starts. gear position is detected.
NOTE
The continuous operating time of the starter “N”
motor is set at five seconds.
When this time is exceeded, the starter motor “R” “F”
will automatically stop.
2
If the motor stops, wait about ten seconds for
the motor to cool down and try again.
NOTE
If a failure exists in the sub-battery cable or 1
the 15 amp. fuse in its circuit, the starter IFH511190007-03
motor relay circuit will not function.
1. Clutch lever “F”: Forward
2. Shift position sensor “R”: Reverse
Start-In-Gear Protection System Description “N”: Neutral

CENFH5111901003
To avoid accidental movement of the boat at the time of Operation by neutral switch on engine starting
engine starting, the system prohibits starter motor Operation
operation when the shift lever is “IN” gear. Shift High
Fuel Starter
position Ignition pressure
Control by Neutral Switch injection motor
fuel pump
A switch to detect “Neutral” gear position is located on Neutral Yes Yes Yes Yes
the clutch lever holder and operated by the clutch control Forward / No No
lever. Yes No
Reverse (*1:Yes) (*1:Yes)
This ON/OFF type switch is ON in “Neutral” and OFF in
“Forward” or “Reverse”. *1: If it is in neutral judged by the ECM according to the
When attempting to start the engine, the ECM detects shift position sensor signal.
the shift position using the neutral switch.
When the neutral switch is OFF, the ECM does not Operation by shift position sensor on engine
provide a starter motor relay operating signal. starting
Operation
Shift High
“Neutral” Fuel Starter
position Ignition pressure
injection motor
“Reverse” “Forward” fuel pump
Neutral Yes Yes Yes Yes
Forward / No No
Yes Yes
Reverse (*2:Yes) (*2:Yes)
1 *2: If it is in neutral judged by the ECM according to ON

2 signal from the neutral switch.
IFH511190006-01
1. Clutch lever 2. Neutral switch

Component Location
Starting System Components Location
CENFH5111903001

Starter System Troubleshooting
CENFH5111904001
! CAUTION
Failure to take proper precaution when starter system troubleshooting may result in personal injury
and/or damage to electronic components.
If any abnormality is found, immediately disconnect the battery cables from the battery.
NOTE
Before troubleshooting the electric starter system, make sure of the following:
• Battery is fully charged.
• All cables/wires are securely connected.
• Shift is in neutral position.
• Emergency stop switch lock plate is set in place.
• Fuse is not blown.

Motor not running. (No Poor or broken battery connection. Replace.
operating sound of Loose or corroded battery connection. Repair or retighten.
magnetic switch.) Weak or shorted battery. Replace or recharge battery.
Poor ground cable connection. Tighten ground cable.
Defective neutral switch. Neutral switch inspection. Replace.
Fuse blown. Replace.
Defective ignition switch. Ignition switch inspection. Replace.
Open circuit between ignition switch and Repair.
magnetic switch.
Defective emergency stop switch. Replace. Emergency stop switch inspection.
Lead wire disconnected or loose. Retighten.
Poor contacting action of ignition switch Replace. Ignition switch inspection. Magnetic
and magnetic switch. switch inspection.
Defective starter motor control relay. Main relay and starter motor relay inspection.
Poor magnetic switch lead wire Check connector connection.
connector connection.
Open circuit between starter relay and Repair.
magnetic switch.
Defective ECM and its circuit. Inspection of ECM and its circuit.
Open circuit in pull-in coil. Replace magnetic switch. Magnetic switch
inspection.
Brushes are seating poorly or worn. Repair or replace. Brushes inspection.

Motor not running. Weak or shorted battery. Replace or recharge battery.
(Operating sound of Battery voltage too low due to battery Replace battery.
magnetic switch heard.) deterioration.
Loose or corroded battery connection. Repair or retighten.
Burnt main contact point, or poor Replace magnetic switch. Magnetic switch
contacting action of magnetic switch. inspection.
Brushes are seating poorly or worn. Replace or repair. Brushes inspection.
Weakened brush spring. Replace.
Burnt commutator. Replace armature. Commutator inspection.
Shorted or open winding in armature. Replace. Armature inspection.
Excessive friction in engine. Repair.
Starter motor running but Insufficient contact of magnetic switch Replace magnetic switch. Magnetic switch
too slow. (Low torque) main contacts. inspection.
(If battery and wiring are Shorted armature. Replace. Armature inspection.
satisfactory, inspect Dirty or corroded commutator. Repair commutator or replace armature.
starting motor.) Armature inspection.
Worn brushes. Replace brushes.
Weakened brush spring. Replace.
Starter motor running, but Worn pinion tip. Replace over-running clutch.
not cranking engine. Poor sliding of over-running clutch. Repair.
Over-running clutch slipping. Replace over-running clutch.
Worn teeth of ring gear. Replace flywheel.
Starter motor does not Broken contact point of magnetic switch. Replace magnetic switch.
stop running. Short-circuit magnetic switch coil. Replace magnetic switch.
Starter Motor Removal and Installation 2) Remove the nut (1) securing positive (+) battery
CENFH5111906001 cable (2) and main harness (R) lead wire from
Removal
magnetic switch (3) of starter motor.
NOTICE
If the 12 V electrical system is shorted while 3
servicing the starter motor, the engine
electrical circuits could be damaged
seriously.
1
Prior to removing starter motor, disconnect
the battery cable at the battery.
1) Remove ring gear cover. 2

in Section 1D (Page 1D-2). IFH511190008-02
3) Remove two bolts (4), negative (–) battery cable (5), Installation
harness GND lead wire and starter motor band (6). Installation is reverse order of removal with special
• Install starter motor and tighten starter motor
mounting bolts securely.
4
Tightening torque
Starter motor mounting bolt (a): 23 N·m (2.3 kgf-
m, 16.5 lbf-ft)
6
(a)
5
IFH511190009-03
4) Remove two bolts securing starter motor (7).
7
IFH511190012-01
Starter Motor Test

CENFH5111906002
! CAUTION
Sparks resulting from short circuit between
the positive (+) and negative (–) terminals
IFH511190010-01
during connections to the battery could
5) Remove the starter motor, then disconnect the red cause a burn.
lead wire (8) from “S” terminal of starter motor
magnetic switch. Be careful not to short-circuit the positive (+)
and negative (–) cables and connect them
only to the correct terminals.
! CAUTION
If the cable used for the test is not adequately
thick, the cable may become extremely hot
due to large current flowing through it and
you could get burned.
8
Be sure to connect the battery and the

IFH511190011-01
starting motor with a lead wire of the same
size as original equipment.
NOTICE
If battery power is applied too long in any of
the following tests, the coil of the magnetic
switch may burn.
Each test must be completed within 3 – 5

seconds to avoid burning of the coil.
Pull-In / Hold-In Test Plunger and Pinion Return Test

Disconnect the negative lead from the switch/motor
NOTE body.
Before testing, disconnect the brush lead Check that the plunger and pinion return inward.
from terminal “M”. If the plunger and pinion don't return inward, replace the
magnetic switch.
Connect the battery to the magnetic switch as shown in
the figure.
• Check that the plunger and pinion (over-running
clutch) move outward.
If the plunger and pinion don’t move, replace the
magnetic switch.
1
3
4
I9J011190004-01
No-Load Performance Test
NOTE
2 Before performing the following test, secure
the starter motor to the test bench.
I9J011190002-02
1. Terminal “S” 3. Terminal “B” 1) Connect a battery and ammeter to the starter motor
2. Terminal “M” 4. Brush lead as shown.
2) Check that the starter rotates smoothly and steadily
• While connected as above with the plunger out, with the pinion moving out. Check that the ammeter
disconnect the negative lead from terminal “M”. indicates the specified current.
Check that the plunger and pinion remain out. If the
plunger and pinion return inward, replace the Specified current (No-load performance test)
magnetic switch. Within 90 A at 11 V
I9J011190005-01
I9J011190003-01
Starter Motor Components

CENFH5111906003
4 7 2 (a)
3 9
6 8
1 5
10
21 24 24 23 22 28 27
19 20 26 25
12 (b)
11 14 17
15 16 18
13
IEH511190007-01
1. Nut 9. Shift lever 17. Armature 25. Center bracket

2. Bolt 10. Front housing 18. Center cover plate 26. Rubber ring
3. Magnetic switch 11. Screw 19. Internal gear 27. Stopper ring
4. Gasket 12. Through bolt 20. Planetary gear 28. Pinion stopper
5. Spring 13. Rear cover 21. Pinion shaft : 7 Nm (0.7 kgf-m, 5.1 lbf-ft)
6. Plunger 14. Thrust washer 22. Pinion : 5.5 Nm (0.55 kgf-m, 4.0 lbf-ft)
7. Torsion spring 15. Brush holder 23. E-ring : Apply grease.
8. Rubber packing 16. Yoke 24. Washer
Starter Motor Disassembly and Assembly

CENFH5111906004
Disassembly
When overhauling the starting motor, it is recommended
“A”
that the component parts be cleaned thoroughly.
However, the yoke assembly, armature coil, over-
running clutch assembly, magnetic switch assembly and
rubber or plastic parts should not be washed in a “C” “B”
degreasing tank or with a grease dissolving solvent.
These parts should be cleaned with compressed air or
wiped with clean cloth.
NOTE IEH511190008-02
Before disassembling the starting motor, be

sure to put match marks at three locations
(“A”, “B” and “C”) as shown in the figure at
right to avoid any possible component
alignment mistakes.
1) Remove nut (1) from the magnetic switch, then 6) Pull the brush spring (9) up to separate the brush
disconnect the connecting wire (2). from the surface of the commutator, then remove the
2) Remove two bolts (3) securing the magnetic switch. brush holder (10).
3
1
2
9
10
IEH511190009-01 IEH511190013-01
3) Remove the magnetic switch (4). 7) Remove the yoke (11) and armature (12).
11
4
12
IEH511190010-01 IEH511190014-01
4) Remove screws (5), long through bolts (6) and the 8) Remove the center cover plate (13).
rear cover (7). 9) Remove the planetary gears (14) and internal gear
(15).
6
7 14
5
5
6
15
13
IEH511190011-01
5) Remove thrust washer (8) with a screwdriver. IEH511190015-01
10) Remove the center bracket (16) (with shift lever (18),
pinion (19) and pinion shaft (20)) from front housing
(17).
8
18
17
19
IEH511190012-01
20
16
IEH511190016-01
11) Remove the shift lever (18). 14) Remove the pinion shaft (20), washers (24) and
rubber ring (25) from the center bracket.
25
20
18 24
24
IEH511190017-01
12) Push the pinion stopper (21) down, then remove IEH511190020-01
stopper ring (22).

Remove the pinion stopper and pinion (19). Assembly
Assembly is in the reverse order of disassembly with
! WARNING special attention to the following steps.
Reassemble the starter motor, refer to “Starter Motor
Failure to take proper precautions when Components” (Page 1I-7).
removing stopper ring can cause personal
• When installing the armature, use care to avoid
injury.
breaking the brushes.
Wear safety glasses when disassembling and
assembling the stopper ring.
NOTE
Using a screw-driver, pry off the stopper ring.
22
21
21
IDG211190021-01
19
Starter Motor Components Inspection and
Servicing
CENFH5111906005
Armature and Commutator
• Inspect the commutator surface. If surface is gummy
IEH511190018-01 or dirty, clean with # 500 grit emery paper (1).
13) Remove the E-ring (23).
1
23
I9J011190022-01
IEH511190019-01
• Measure the commutator outside diameter. If the • Check for continuity between the commutator (4) and
measurement exceeds the service limit, replace the the armature core (5)/shaft (6).
armature. Replace the armature if continuity is indicated.
Special tool Special tool
(A): 09900–20101 (Vernier calipers (150 (B): 09900–25008 (Multi circuit tester set)
mm))
Commutator outside diameter Continuity ( )
Standard: 29.0 mm (1.14 in.)
Service limit: 28.0 mm (1.10 in.) 4
6
(A)
(B)
(B)
I9J011190023-01 I9J011190025-01
• Check that the mica (insulator) (2) between the 4. Commutator 5. Armature core 6. Shaft
segments (3) is undercut to specified depth “a”.
If the measurement exceeds the service limit, cut to • Check for continuity between adjacent commutator
the specified depth. segments. Replace armature if no continuity is
indicated.
! WARNING
Failure to following proper precautions Continuity ( )
during use of the compressed air may cause
severe personal injury.
Wear safety glasses when using compressed

air.
NOTE
Remove all particles of mica and metal using
compressed air.
I9J011190026-01
Commutator undercut “a”
Standard: 0.5 – 0.8 mm (0.02 – 0.03 in.) Brushes
Service limit: 0.2 mm (0.01 in.) Check the length of each brush (1).
If brushes are worn down to the service limit, they must
3 be replaced.
Special tool
“a” (A): 09900–20101 (Vernier calipers (150 mm))
Brush length
2
I9J011190024-01
2. Mica 3. Segment
Pinion and Over-Running Clutch

• Inspect the pinion for wear, damage or other abnormal
conditions.
Check that the clutch locks up when turned in the
direction of drive and rotates smoothly in reverse
direction. Replace if necessary.
1
IDG211190033-01
Brush Holder
Check brush holder continuity.
Replace the brush holder if the tester doesn't show the
below.
: 09900–25008 (Multi circuit tester set) • Inspect spline teeth for wear or other damage.
Tester knob indication Inspect the pinion for smooth movement. Replace if
Continuity ( ) necessary.
Brush holder continuity

Continuity
Brush holder positive (+) to brush
No
holder negative (–)
Brush holder positive (+) to base
No
plate (ground)
IEH511190023-01
Gear
Inspect planetary gears and internal gear for wear,
damage or other abnormal conditions.
1
IFH511190002-01
1. Base plate
Shift Lever
Inspect the shift lever for wear. Replace if necessary.
IDG211190025-01
IEH511190021-01
Pinion Shaft / Pinion Shaft Bushing Plunger

• Inspect the pinion shaft for wear, damage or other Inspect the plunger for wear or other damage.
abnormal conditions. Replace if necessary. Replace if necessary.
• Inspect the pinion shaft bushing for wear or other
damage.
IEH511190026-01
Magnetic Switch
Push in the plunger and release. The plunger should
IEH511190024-01
return quickly to its original position.
Front Housing
• Inspect the front housing for wear, damage or other
abnormal conditions. Replace if necessary.
• Inspect the bushing for wear or other damage. 1
IEH511190027-01
1. Plunger
Pull-in coil open circuit test

Check for continuity across the magnetic switch terminal
IEH511190025-01
“S” (1) and terminal “M” (2).
If no continuity exists, the coil is open and should be
Armature Shaft Bush replaced.
Inspect the bushing for wear or other damage.
Replace if necessary. Special tool
Continuity ( )
2 (A)
1
IDG211190028-01
I9J011190038-02
1. Terminal “S” 2. Terminal “M” 3. Terminal “B”

Hold-in coil open circuit test Ignition Switch Inspection

Check for continuity across the magnetic switch terminal CENFH5111906010
“S” (1) and coil case (4). Inspect the ignition switch using the following
If no continuity exists, the coil is open and should be procedures:
replaced. 1) Disconnect the ignition switch from remo-con box
wiring harness.
Special tool
2) Check continuity between wiring leads at the key
positions shown in the chart.
Tester knob indication 3) If out of specification, replace the ignition switch.
Continuity ( )
Special tool
4 (A): 09900–25008 (Multi circuit tester set)
Continuity ( )
(A)
3
2 Switch lead wires
Key position
1 B G W Gr Br O
OFF
I9J011190039-01 ON
1. Terminal “S” 3. Terminal “B” START
2. Terminal “M” 4. Coil case
FREE
Contact points test
PUSH
Put the plunger on the under side and then push the
magnetic switch down. : Continuity
IDG211190040-01
At this time, check for continuity between terminal “B”
and terminal “M”.
Continuity indicates proper condition. If no continuity
(OFF) (ON)
exists, replace the magnetic switch and/or plunger.
FREE
Special tool (START)
PUSH
Continuity ( )
(A)
O
Br
B
W
I9J011190040-01
W/R Bl
Gr
G
B G
Bl
Br Br Gr
I9J011190042-02
Starter Motor Relay Inspection 3) Measure the resistance between relay terminals (4)
CENFH5111906011 and (5).
Inspect the starter motor relay using the following If out of specification, replace starter motor relay.
procedures:
1) Disconnect the starter motor relay (1) from the fuse Tester knob indication
box. Resistance (Ω)
Starter motor relay solenoid coil resistance
Standard: 145 – 190 Ω
(A)
I9J011190044-02
IFH511190013-01
2) Check continuity between terminal (2) and (3) each Neutral Switch Removal and Installation
time 12 V power supply is applied to terminal (4) and CENFH5111906012
(5). Removal
Connect the positive (+) lead to terminal (5), and 1) Remove the lower side covers.
negative (–) lead to terminal (4). Refer to “Lower Side Cover Removal and
NOTICE
2) Remove the fuel delivery pipe and intake manifold
If the 12 V power supply wire is connected to assembly.
wrong terminal or touched to each other, the Refer to “Intake Manifold Removal and Installation”
power supply wire, tester may be damaged. in Section 1D (Page 1D-8).
Be careful not to touch 12 V power supply 3) Disconnect the neutral switch lead wire connector
wires to each other or with other terminals. (1) and shift position sensor lead wire connector (2).
Special tool
Continuity ( )
2
Starter motor relay function
Continuity
12 V power applied Yes 1
IFH511190014-04
3 4) Remove E-ring (3) from clutch lever shaft.
2
5
12 V 3
CONT
4
(A)
IDG211190039-01
IFH511190015-01
5) Remove the two bolts (4) securing throttle/clutch Installation

lever holder (5). Installation is reverse order of removal with special
Remove the throttle/clutch lever holder with neutral attention to the following steps.
switch and shift position sensor. • Place the neutral switch (1) in position.
• Apply thread lock to the switch mounting screws.
4 : Thread lock cement 99000–32050 (SUZUKI
• Install the plate (2) and screws, then tighten screws
securely.
• Apply water resistant grease to the switch lever.
: Grease 99000–25350 (SUZUKI Water
5 Resistant Grease EP2 (250 g))
IFH511190016-02
6) Remove the screws and plate (6).
1
2
IFH511190019-03
IFH511190017-03
7) Remove the neutral switch (7).
IFH511190020-04
• Secure lead wire with lead wire clamps, then check

that lead wire routed properly.
IFH511190018-02
IFH511190021-03
• Apply water resistant grease to bush, then install the Neutral Switch Inspection
bush. CENFH5111906013
Check for continuity/infinity of the neutral switch.
• Install the throttle/clutch lever holder with neutral
switch and shift position sensor, then tighten bolts Special tool
securely. (A): 09900–25008 (Multi circuit tester set)
Continuity ( )
Neutral Switch in Remo-Con Box
1) Disconnect the neutral switch lead wire connector
from the ignition switch.
2) Check continuity/infinity between the switch brown
wire leads while operating the remo-con handle.
If out of specification, replace the neutral switch.
Neutral switch function
Shift position Tester indicates
IFH511190022-01
Neutral Continuity
Forward Infinity
Reverse Infinity
(A)
“Reverse” “Forward”
Br
IFH511190023-01
• Install the fuel delivery pipe and intake manifold

assembly. Br
I9J011190045-03
• Check to ensure that all removed parts are back in Neutral Switch on Engine Side
place. 1) Remove lower side covers.
• Check fuel and water hose routing. Refer to “Lower Side Cover Removal and
Refer to “Fuel Hose Routing” in Section 4B (Page 4B- Installation” in Section 2A (Page 2A-3).
1) and “Water Hose Routing” in Section 4B (Page 4B- 2) Remove two bolts (1) securing front panel.
6).
4A (Page 4A-2).
• Check for water leakage.
IFH511190024-01
3) Disconnect the neutral switch lead wire connector 5) If out of specification:

(2). • 1st:
Check the remo-con cable adjustment, readjust if
necessary.
• 2nd:
Check the wire harnesses for open and short
circuits.
If the wire harnesses are in good condition,
replace the neutral switch and recheck.
Refer to “Neutral Switch Removal and Installation”
2
(Page 1I-14).
NOTE
IFH511190025-01 After installing the neutral switch, check for
4) Check continuity/infinity between the Yellow/Green correct function by operating the remo-con
and Brown lead wires while operating the remo-con handle.
handle.
Neutral switch function
Shift position Tester indicates
Neutral Continuity
Forward Infinity
Reverse Infinity
IFH511190026-01
1. Clutch lever 2. Neutral switch
(A)
Y/G
Br
I9J011190047-03
Charging System: 1K-1
Charging System
Power Head
General Description
Charging System Description
CENFH5111B01001
Outline
The battery charging system circuit is illustrated below.
It is composed of the battery charge coil, rectifier/regulator and battery. The three phase AC current generated from
the battery charge coil is converted by the rectifier/regulator into regulated DC current which is used to charge the
battery.
Battery charge coil output
Standard: 12 V 44 A (528 W) at 3 000 r/min
Regulated voltage
Standard: 14.2 – 15.2 V
15 14
2 1
6 9 8
3
11
12
13
7 10
B
“A”
“B”
R
“C”
B
4
IFH5111B0001-02
1. Flywheel (Magneto) 6. 30 A fuse 11. 30 A fuse (Select, STD) “A”: To PTT switch
2. Battery charge coil 7. 10 A fuse 12. No.1 output line “B”: To IAC valve, VSV, OCV
3. Rectifier/regulator 8. 30 A fuse 13. No.2 output line “C”: To PTT relay
4. Battery (Main) 9. 10 A fuse 14. ECM main relay
5. Fuse box 10. 60 A fuse 15. Starter motor relay
1K-2 Charging System:
Isolator Function
The battery charging system is equipped with an isolator function.
When a sub battery is used in addition to the main battery for engine operation, this function allows both the batteries
to be charged at the same time.
To modify the charging circuit and distribute the power to the individual batteries, relocate the 30 amp fuse in [STD]
position to [OPT x] position in the fuse box.
Relocation of the 30 amp fuse to [OPT x] position modifies the charging circuit so the No.2 red output line of the
Rectifier & Regulator can charge the main battery for engine operation and the No.1 red output line can charge the
sub battery.
NOTE
For proper charging circuit operation, the negative terminals of both batteries, main and sub batteries,
must be connected with a cable of the same size as the existing battery cable.
15 14
2 1
6 9 8
3
12
13
7 10 11
“A”
“B”
R
“C”
R
B
4 16
IFH5111B0002-01
1. Flywheel (Magneto) 6. 30 A fuse 11. 30 A fuse (Select, OPT x) 16. Battery (Sub)
2. Battery charge coil 7. 10 A fuse 12. No.1 output line “A”: To PTT switch
3. Rectifier/regulator 8. 30 A fuse 13. No.2 output line “B”: To IAC valve, VSV, OCV
4. Battery (Main) 9. 10 A fuse 14. ECM main relay “C”: To PTT relay
5. Fuse box 10. 60 A fuse 15. Starter motor relay
Battery Requirement Description

CENFH5111B01002
Refer to “Battery Requirement” in Section 0A (Page 0A-5).
Component Location
Charging System Components Location
CENFH5111B03001

Charging System Diagnosis
CENFH5111B04001

Alternator (Battery charge Open or short circuit lead wires. Repair or replace.
coil) does not charge. Open or short circuit battery charge coil. Replace.
Rectifier/Regulator failure. Replace.
Main fuse blown out. Replace.
Poor or broken battery connection. Repair or Replace.
Alternator (Battery charge Rectifier/Regulator failure. Replace.
coil) overcharge. Poorly grounded rectifier/regulator. Repair or Retighten.
Unstable charging Short circuit battery charge coil. Replace.
Loose lead wire connection. Repair or replace.
Rectifier/Regulator failure. Replace.
Poor or broken battery connection. Repair or replace.
Charging System Construction
CENFH5111B06001
1 (a)
10
2
11
5
3
4
12
14
13 6
15
9
7
IFH5111B0003-03
1. Bolt 6. Clamp 11. Fuse case upper cover : 118 Nm (11.8 kgf-m, 85.5 lbf-ft)
2. Flywheel 7. Rectifier/Regulator 12. O-ring : Apply SUZUKI Thread Lock 1342.
3. Dowel pin 8. Bolt 13. Fuse (60 A, 30 A)
4. Battery charge coil 9. Gasket 14. Relay
5. Bolt 10. Wiring harness assembly 15. Fuse
Flywheel Removal and Installation 3) To lock the flywheel (3) when removing attaching
CENFH5111B06002 bolts, use special tool shown in figure.
Removal
Use bolts and threaded holes “A” on top of cylinder
! CAUTION to attach special tool.
Failure to take proper precaution when Special tool

removing flywheel may result in personal (A): 09916–99312 (Flywheel holder)
injury and/or damage to electronic
components.
Prior to removing flywheel, disconnect “A”

1) Remove ring gear cover (1).

in Section 1D (Page 1D-2). 3
IFH5111B0007-03
IFH5111B0005-01
(A)
2) Remove the bolt (2) securing lead wire clamp.
IFH5111B0008-02
4) Remove eight flywheel bolts (4).
2
4
IFH5111B0006-02
IFH5111B0009-02
5) Remove flywheel and dowel pin (5). • Tighten flywheel bolts (3) to specified torque. To lock
flywheel, use special tool as shown in figure.
4 Tightening torque
Flywheel bolt (a): 118 N·m (11.8 kgf-m, 85.5 lbf-ft)
3 Special tool
3 (a)
5
IFH5111B0004-01
Installation
(A)
• Install dowel pin (1).
IFH5111B0010-02
• After installing flywheel and torquing bolts to

specification, check air gap between CKP sensor and
flywheel reluctor bars.
1 Refer to “CKP Sensor Removal and Installation” in
Section 1C (Page 1C-10).
original position.
IEH5111B0020-01
• Install flywheel (2) onto crankshaft making sure to

align dowel pin hole “A” with the pin (1).
NOTE
Before installing the flywheel magneto, wipe
the crankshaft and flywheel clean.
NOTICE
Before tightening flywheel bolts, make sure
the flywheel dowel pin hole and crankshaft
dowel pin align, or severe damage may
result.
2
“A”
1
IEH5111B0008-01
Battery Charge Coil Removal and Installation Installation

CENFH5111B06003 Installation is reverse order of removal with special
Removal attention to the following steps.
! CAUTION • Apply thread lock to the coil securing screws.
Failure to take proper precaution when : Thread lock cement 99000–32050 (SUZUKI
removing electrical parts may result in Thread Lock 1342 (50 g))
personal injury and/or damage to electronic
• Install battery charge coil, then tighten screws
components.
securely.
Prior to removing electrical parts, disconnect • Secure coil lead wire with lead wire clamps (1).
1) Remove flywheel.
Refer to “Flywheel Removal and Installation” (Page
1K-5).
2) Remove four screws securing the battery charge coil
(1).
1
3) Remove the bolt and lead wire clamp (2).
Unfasten the cable tie (3) binding lead wire.
4) Disconnect charge coil lead wire connector (4) from
Rectifier/regulator. IFH5111B0013-02
Remove the battery charge coil (1).
• Check that coil lead wires are routed properly and
away from hot or rotating parts.
For wire routing, refer to “Wiring Harness Routing
Diagram” in Section 4A (Page 4A-2).
• Install flywheel and tighten flywheel bolt to specified
torque.
Refer to “Flywheel Removal and Installation” (Page
1K-5).
2
1
IFH5111B0011-02
IFH5111B0012-02
Battery Charge Coil Inspection Rectifier / Regulator Removal and Installation

CENFH5111B06004 CENFH5111B06005
Measure battery charge coil resistance in the following Removal
procedure.
! CAUTION
1) Disconnect battery charge coil leads from rectifier/
regulator. Failure to take proper precaution when
2) Measure resistance between leads in the removing electrical parts may result in
combinations shown. personal injury and/or damage to electronic
If measurement exceeds specification, replace components.
battery charge coil.
Prior to removing electrical parts, disconnect
Special tool battery cables from battery.
Tester knob indication 1) Disconnect lead wire connectors (1) from rectifier/
Resistance (Ω) regulator (2).
2) Remove the six bolts and rectifier/regulator.
Battery charge coil resistance
Terminal for tester probe connection Resistance
Yellow 1 to Yellow 2
Yellow 2 to Yellow 3 0.14 – 0.30 Ω
Yellow 3 to Yellow 1 2
IFH5111B0014-01
3) Remove the gasket (3).
Y3 Y2 Y1
IEH5111B0013-01 IEH5111B0015-01
Installation
• Install gasket and rectifier/regulator, then tighten bolts
securely.
NOTICE
A previously-used gasket may leak, resulting
in engine damage.
Do not re-use gasket once removed. Always

use a new gasket.
• Connect lead wire connectors. Check that lead wire

routed properly.
4A (Page 4A-2).
Rectifier / Regulator Inspection

CENFH5111B06006
Inspect the rectifier/regulator in the following procedures:
1) Disconnect all lead wires of rectifier/regulator.
2) Measure voltage between terminals in the combinations shown.
If measurement exceeds specification, replace rectifier/regulator.
Special tool
Diode test ( )
Unit: V
Tester probe (+) (Red)
— Black Red 1 Red 2 Yellow 1 Yellow 2 Yellow 3
Black — * * * * *
Tester Red 1 0.6 – 0.9 — * 0.3 – 0.6 0.3 – 0.6 0.3 – 0.6
probe (–) Red 2 0.6 – 0.9 * — 0.3 – 0.6 0.3 – 0.6 0.3 – 0.6
(Black) Yellow 1 0.3 – 0.6 * * — * *
Yellow 2 0.3 – 0.6 * * * — *
Yellow 3 0.3 – 0.6 * * * * —
*: 1.3 V or more (tester’s battery voltage)
NOTE
If the tester reads 1.4 V or below when the tester probes are not connected, replace its battery.
Yellow 1
Yellow 2
Yellow 3
Black
Red2
Red1
IEH5111B0016-01
3) Connect all lead wires of rectifier/regulator.

Main Fuse Inspection

CENFH5111B06007
Inspect the main fuse in the following procedures.
1) Remove the main fuse (1) from fuse box.
IFH5111B0015-02
2) Inspect continuity between both terminal of fuse.

If no continuity is indicated, replace fuse.
Special tool
Continuity ( )
CONT
I9J0111B0023-01
Section 2
Mid Unit
CONTENTS
Precautions .................................................2-1 Precautions...........................................................2B-1

Precaution for Power Trim and Tilt......................2B-1 2
Precautions............................................................. 2-1
Precaution for Mid Unit ......................................... 2-1 General Description .............................................2B-2
Power Trim and Tilt Description ..........................2B-2
Housing and Bracket............................... 2A-1 Principles of Power Trim and Tilt Operation
Precautions...........................................................2A-1 Description ........................................................2B-3
Precaution for Housing and Bracket ................... 2A-1 Schematic and Routing Diagram ........................2B-9
Service Instructions.............................................2A-2 Power Trim and Tilt System Diagram .................2B-9
Lower Side Cover Components .......................... 2A-2 Diagnostic Information and Procedures ..........2B-11
Lower Side Cover Removal and Installation ....... 2A-3 Diagnose PTT System Malfunction...................2B-11
Engine Holder / Oil Pan / Driveshaft Housing Service Instructions ...........................................2B-12
/ Mounts Components ....................................... 2A-4 Checking PTT Fluid Level .................................2B-12
Engine Holder / Oil Pan / Driveshaft Housing Air Bleeding from PTT Unit ...............................2B-12
/ Mounts Disassembly ....................................... 2A-6 Setting Trim Down Position Limit ......................2B-13
Engine Holder / Oil Pan / Driveshaft Housing Power Trim and Tilt Unit Removal and
/ Mounts Assembly.......................................... 2A-10 Installation .......................................................2B-14
Engine Holder / Oil Pan / Driveshaft Housing Power Trim and Tilt Unit Components ..............2B-18
/ Mounts Related Component Inspection ........ 2A-14 Power Trim and Tilt Unit Disassembly ..............2B-19
Clutch Shaft Bearing and Oil Seal Power Trim and Tilt Unit Reassembly...............2B-21
Replacement ................................................... 2A-15 Power Trim and Tilt Unit Components
Mount Oil Seal Cover Oil Seal Replacement .... 2A-17 Cleaning and Inspecting..................................2B-24
Clamp / Swivel / Steering Bracket Power Trim and Tilt Motor Removal and
Components.................................................... 2A-18 Installation .......................................................2B-25
Clamp / Swivel / Steering Brackets Power Trim and Tilt Motor Disassembly and
Disassembly.................................................... 2A-19 Assembly.........................................................2B-26
Clamp / Swivel / Steering Brackets Assembly .. 2A-21 PTT Motor Related Items Inspection.................2B-27
Clamp / Swivel / Steering Brackets Related PTT Motor Relay Inspection..............................2B-29
Components Inspection .................................. 2A-25 PTT Switch Inspection ......................................2B-30
Tilt Limit Switch Inspection................................2B-30
Power Trim and Tilt ................................. 2B-1
2-1 Precautions:
Precautions
Mid Unit
Precautions
Precaution for Mid Unit
CENFH5112000001
Housing and Bracket: 2A-1
Housing and Bracket

Mid Unit
Precautions
Precaution for Housing and Bracket
CENFH5112100001
NOTICE
Do not break or cut bonding wires, as they perform an important function in the prevention of galvanic
corrosion or build up of static charges.
Replace any damaged wire.
NOTE
• When disassembling housing and bracket, inspect mountings and bolts for damage and wear.
• Check the condition of the zinc anodes on lower section of mid unit. Replace if necessary.
2A-2 Housing and Bracket:
Lower Side Cover Components
CENFH5112106001
24
18 17
8
5
20
19
26 22
21
19
25
23 22
25 17
23 19 21 24
13 22 23
25
21 26
9 6
15
17 26 20
24 18
16
14
12
18 20 11
10
3
2
IFH511210013-02
1. Oil pan cover STBD 10. Screw 19. Engine cover hook
2. Oil pan cover PORT 11. Plug 20. Latch
3. Screw 12. Gasket 21. Bolt
4. Bolt 13. Front panel 22. Washer
5. Lower side cover STBD 14. Bolt 23. Washer
6. Lower side cover PORT 15. Washer 24. Pin
7. Side cover seal 16. Cushion 25. Bushing
8. Pin 17. Engine cover hook shaft 26. Screw
9. Grommet 18. Engine cover hook lever : Apply SUZUKI Water Resistant Grease.
Lower Side Cover Removal and Installation

CENFH5112106002
Removal
1) Remove six screws (1) and STBD side cover (2).
IEH511210108-01
2) Remove two screws (3) and PORT side cover (4).
3
4
IEH511210002-04
3) Disconnect PTT switch lead wire connector (5).
IEH511210003-04
4) Remove five screws and STBD/PORT oil pan covers (6) and (7).
IEH511210004-04
Installation
Engine Holder / Oil Pan / Driveshaft Housing / Mounts Components

CENFH5112106003
35
4 5
2
3
7
6
10
8 13
9 14
12
11 15
16 22
17 (a) 20
21
18
30
31
24
26
25
19
28
27
23
29
32
34
33
IFH511210014-02
1. Mount oil seal cover 11. Bolt 21. O-ring 31. Bolt
2. Bolt 12. Upper side mount 22. Bolt 32. O-ring
3. Bolt 13. Spacer 23. Pin 33. Bolt
4. Oil seal 14. Upper mount bolt 24. Engine holder cover 34. Oil strainer
5. Scraper 15. Upper mount 25. Gasket 35. O-ring
6. Pin 16. Washer 26. Bolt : 100 Nm (10 kgf-m, 72.5 lbf-ft)
7. Gasket 17. Nut 27. Water jacket cover : Apply SUZUKI Water Resistant Grease.
8. Upper thrust mount 18. Gasket 28. Gasket : Apply SUZUKI Thread Lock 1342.
9. Upper mount cover 19. Engine holder 29. Bolt
10. Bolt 20. Water return union 30. Water indicator
57
59
56
38
46 37
58
42
41
43
44 39
40
45
48
47
50 (b)
52
49
51
55
54
65 53
60 81
61
82
62
63
64 83
74
66
67 71
76
73 72 75
78
79
69
80
70
68
77 (c) 69
IEH511210110-02
37. Exhaust release pipe 50. Oil drain plug 63. Washer 76. Bolt
38. Bolt 51. Water jacket cover 64. Nut 77. Lower mount bolt
39. Exhaust pipe 52. Gasket 65. Pin 78. Lower side mount
40. O-ring 53. Bolt 66. Bushing (Type: X) 79. Washer
41. Bolt 54. Plug 67. Ring 80. Washer
42. Hose 55. Gasket 68. Bonding wire 81. Bushing
43. Clip 56. Oil level gauge 69. Screw 82. Water tube
44. Gasket 57. Oil level gauge guide 70. Bonding wire 83. Bushing
45. Oil pan 58. O-ring 71. Lower thrust mount : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
46. Seal 59. Bolt 72. Lower mount : 100 Nm (10 kgf-m, 72.5 lbf-ft)
47. Bolt 60. Driveshaft housing 73. Lower mount bracket : Apply SUZUKI Thread Lock 1342.
48. Pin 61. Bolt 74. Lower mount cover : Apply SUZUKI Silicone Seal.
49. Gasket 62. Stud bolt 75. Bolt
Engine Holder / Oil Pan / Driveshaft Housing / 6) Remove bolt and pilot water tube (5).
Mounts Disassembly
CENFH5112106004
1) Remove power unit.
Refer to “Power Unit Removal and Installation” in
2) Remove lower unit.
Refer to “Lower Unit Removal and Installation” in
3) Remove E-ring (1) from clutch lever shaft. 5
IEH511210058-02
1 7) Disconnect water hose (oil pan to 3 way joint) (6)

from oil pan water jacket cover (7).
IFH511210015-01
4) Remove two bolts and throttle lever holder (2).
2
IFH511210018-01
8) Remove water hose (engine holder cover to cylinder

block) (8).
Remove two bolts and vacuum tank (9).
IFH511210016-01
5) Remove pin (3), hose union “A” and side cover seal
(4).
“A”
8
3 IEH511210060-02
IFH511210017-01
9) Operate the PTT motor to extend the PTT rod 12) Remove STBD/PORT upper mount nuts (14) and
upward. washers.
Special tool
: 09945–79310 (PTT cable extension)
10) Remove the screw and bonding wire (10).
Unscrew and remove STBD/PORT lower mount
bolts (11).
Account for washers (12).
14
10
IEH511210063-03
11
IFH511210019-01
10 14
IFH511210005-02
13) Remove driveshaft housing (15) with oil pan (16) and
11 engine holder (17).
12 12
IEH511210062-02
11) Remove eight bolts and mount oil seal cover (13).
17
16
15
IEH511210065-03
13
14) Remove the upper side mounts (18).
Remove three bolts and upper mount cover (19).
IEH511210070-03
18
18
19
IEH511210075-03
15) Remove upper mounts (20), thrust mount (21), 18) Remove three bolts and engine holder (29).
spacer (22) and mount bolts (23).
29
20
21 IEH511210080-03
IEH511210076-03
23 29
20
20
21
22
IEH511210081-03
IEH511210077-04 19) Remove six bolts and water jacket cover (30).
16) Loosen the clamp securing exhaust hose (24), then
remove the exhaust hose from exhaust pipe (25).
Remove the three bolts securing exhaust relief pipe
(26), then remove exhaust relief pipe.
30
26
IEH511210082-03
24
20) Remove three bolts and oil strainer (31).
25
IEH511210078-04
17) Remove two bolts (27) and engine holder cover (28). 31
27 28
IEH511210083-03
IEH511210079-04
21) Remove eight bolts, then remove oil pan (32) from 25) Remove bolts and lower mount covers (39).
driveshaft housing (33).
32
39
33
IEH511210088-04
IEH511210084-04 26) Remove lower mounts (40) and lower thrust mount
22) Remove six bolts and oil pan water jacket cover (34). (41).
40
34 41
IEH511210085-03 IEH511210089-04
23) Remove bolts, water pressure valve cover (35) and 27) Remove the lower side mount (42) from lower mount
water pressure valve (36). (40).
35 42
36
40
IEH511210086-03 IFH511210006-01
24) Remove dowel pins (37).

Remove water tube (38).
37
38
37
IEH511210087-03
Engine Holder / Oil Pan / Driveshaft Housing / Oil Pan to Driveshaft Housing
Mounts Assembly • Install water tube (1) to driveshaft housing (2).
CENFH5112106005
Assembly is reverse order of disassembly with special • Install two dowel pins (3).
attention to the following steps. Apply silicone seal to mating surfaces of driveshaft
housing and oil pan.
Lower Mount / Mount Cover : Sealant 93691–80030 (SUZUKI Silicone
• Assemble the lower mount (2) and lower side mount Seal (100 g))
(3).
1
2
3 3
3
IFH511210008-01
IFH511210007-02
• Install water pressure valve to oil pan.
• Install lower thrust mount (1) with the arrow mark Refer to “Water Pressure Valve Removal and
facing forward. Installation” in Section 1F (Page 1F-5).
• Install lower mounts (2). • Install the oil pan (4) to driveshaft housing (2) by
aligning the water tube with the oil pan water passage.
Tighten the eight bolts securely.
2
1
4
2
IEH511210090-02
• Install lower mount covers (4).

• Tighten mount cover bolts (5), pre-coated with thread IFH511210029-01
lock, to specified torque.
Tightening torque
Lower mount cover bolt (a): 50 N·m (5.0 kgf-m,
36.0 lbf-ft)
5 (a)
4
IEH511210115-02
IFH511210012-01
Engine Holder to Oil Pan

• Apply engine oil to O-rings (1), then install O-rings to
oil strainer (2).
3
• Install oil strainer to engine holder (3), then tighten
bolts securely.
2 6
3
IEH511210098-01
Upper Mount and Mount Cover

1 2
• Assemble these items in the following sequence:
Place upper thrust mount (1) and upper mounts (2) on
IEH511210095-03
upper mount bolts (3).
• Install two dowel pins (4) and gasket (5) to oil pan. • Install spacers (4) to thrust mount.
NOTICE
3
Previously used gasket may leak oil and/or 2
1
cooling water, resulting in engine damage. 2
Do not reuse gasket. Always assemble with a

new gasket.
4
3
4
IEH511210099-02
• Place upper mount assembly into position.
NOTE
• Position the projection “A” on upper
5 mount tube to upper (flywheel) side.
4 • Install upper thrust mount with the lettered
mark “UP” facing upward.
IEH511210096-02
• Install engine holder (3) to oil pan, then securely

tighten it with engine holder bolts (6).
“UP” “A”
IEH511210100-01
IEH511210097-01
• Install the upper mount cover (5) and tighten the

mount cover bolts, pre-coated with thread lock, to
specified torque.
Tightening torque
Upper mount cover bolt (a): 50 N·m (5.0 kgf-m,
36.0 lbf-ft) 2 (a) 1
• Install the upper side mounts (6).
IEH511210067-04
6 6
Lower Mount Bolt
• Place washer (1) between lower mount and lower
mount bracket.
• Install washer (2) and lower mount bolt (3), then
tighten bolt, pre-coated with thread lock, to specified
torque.
5 (a)
IEH511210101-02
Tightening torque
Driveshaft Housing / Oil Pan Lower mount bolt (a): 100 N·m (10.0 kgf-m, 72.5
• Install driveshaft housing with oil pan and engine lbf-ft)
holder to steering bracket.
• Install washer (1) and upper mount nut (2), then
tighten two nuts, pre-coated with thread lock, to
specified torque.
Tightening torque
Upper mount nut (a): 100 N·m (10.0 kgf-m, 72.5 1 3 (a)
lbf-ft) 2
IFH511210020-01
1 1 2 3 (a)
2 (a)
IFH511210021-01
IEH511210066-02
Mount·oil Seal Cover Throttle Lever Holder

• Install dowel pins (1) and gasket (2). • Install throttle lever holder (1) to engine holder, then
tighten bolts securely.
1
1
IEH511210111-01
• Install mount·oil seal cover (3), then tighten eight IFH511210022-01
cover bolts securely. • Install clutch lever shaft arm (2) and E-ring (3).
• Apply Water Resistant Grease to oil seal.
Resistant Grease EP2 (250 g)) 2
3
IFH511210023-01
3 • Install lower unit.

Refer to “Lower Unit Removal and Installation” in
IEH511210112-01
• Install power unit.
Bonding Wire Refer to “Power Unit Removal and Installation” in
• Reattach bonding wire, then tighten screw securely.
IEH511210072-01
Engine Holder / Oil Pan / Driveshaft Housing / • Check condition of oil seal. Replace oil seal if nicked,
Mounts Related Component Inspection cut, worn or other abnormal condition are found.
CENFH5112106006 Refer to “Mount Oil Seal Cover Oil Seal Replacement”
Refer to “Engine Holder / Oil Pan / Driveshaft Housing / (Page 2A-17).
Mounts Disassembly” (Page 2A-6) and “Engine Holder /
Oil Pan / Driveshaft Housing / Mounts Assembly” (Page
2A-10).
NOTE
If any component is found to be excessively
worn, cracked, defective or damaged in any
way, it must be replaced.
Engine Holder
• Inspect the engine holder. Replace if cracked,
damaged, or other abnormal conditions are noted.
IEH511210008-01
• Check water passage. If clogged or obstructed, clean
water passage. Oil Strainer
• Visually check the clutch shaft bearing. Replace if • Inspect the oil strainer. Replace the strainer if
pitted, noisy, rough or other abnormal conditions are cracked, damaged or other abnormal conditions are
found. found.
Refer to “Clutch Shaft Bearing and Oil Seal If clogged or obstructed, clean the oil strainer.
Replacement” (Page 2A-15).
• Check condition of O-ring. Replace O-ring if nicked,
• Check the clutch shaft oil seal. Replace the oil seal if cut, worn or other abnormal condition are found.
nicked, cut, worn or other abnormal conditions are
found.
Refer to “Clutch Shaft Bearing and Oil Seal
Replacement” (Page 2A-15).
IEH511210009-02
Oil Pan / Driveshaft Housing

• Check oil pan, driveshaft housing.
IEH511210007-03
If cracks, defects or other damage is found, replace it.
1. Bearing
Mount Oil Seal Cover

• Inspect the mount oil seal cover. Replace the mount
oil seal cover if cracked, damaged or other abnormal
condition are found.
• Check condition of O-ring. Replace O-ring if nicked,
cut, worn or other abnormal condition are found.
IEH511210010-01
Mounts Clutch Shaft Bearing and Oil Seal Replacement

CENFH5112106007
• Check upper, lower and thrust mounts.
1) Remove the engine holder.
If excessive wear, corrosion or other damage is found,
Refer to “Engine Holder / Oil Pan / Driveshaft
replace mount.
Housing / Mounts Disassembly” (Page 2A-6).
• Inspect mount cover. Replace mount cover if cracked,
damaged or other abnormal conditions are found. 2) Loosen and remove clutch shaft plug (1).
Remove clutch shaft (2).
Remove circlip (3).
1 2
3
IEH511210011-01
Water Tube / Water Tube Grommet IEH511210014-01
• Check water tube. 3) Extract oil seal (4) with oil seal remover.
If a clog or obstruction is found, clean water tube. NOTICE
If cracks, corrosion or other damage is found, replace
water tube. Removing the oil seal can cause damage to
the seal lips, causing oil to leak.
• Check water tube grommet.
If excessive wear or other damage is found, replace Do not reuse oil seal once removed.
grommet. Always use a new oil seal.
Special tool
(A): 09913–50121 (Oil seal remover)
(A)
IEH511210012-02
4
IEH511210013-01
4) Remove bearing (5) with special tool and sliding 6) Apply water resistant grease to outer circumference
hammer. of oil seal (7).
Drive oil seal into engine holder.
NOTICE Apply water resistant grease to the seal lip.
Removing the bearing can cause damage to
the ball retainer. NOTE
If the removed bearing is re-used, problem Install oil seal as shown in the figure.
will occur in shift system.
Do not reuse the bearing once removed. Resistant Grease EP2 (250 g))
Always use a new bearing.
Special tool
(B): 09923–73210 (Bearing remover)
7
(C): 09930–30104 (Sliding hammer)
(B) IEH511210017-01
7) Install circlip (3).

(C) Install clutch shaft (2).
Tighten the clutch shaft plug (1), pre-coated with
thread lock, to specified torque.
IEH511210015-01
Tightening torque
5) Apply engine oil to outer circumference of new
Clutch shaft plug (a): 20 N·m (2.0 kgf-m, 14.5 lbf-
bearing (6).
ft)
Install bearing (6) into engine holder.
: Thread lock cement 99000–32050
(SUZUKI Thread Lock 1342 (50 g))
6
3 1 (a)
IEH511210016-01
IFH511210024-01
8) Reassemble the engine holder.

Housing / Mounts Assembly” (Page 2A-10).
Mount Oil Seal Cover Oil Seal Replacement 4) Reinstall the scraper (2).
CENFH5112106008
1) Remove the mount oil seal cover.
Refer to “Engine Holder / Oil Pan / Driveshaft 2
2) Remove the oil seals (1).
NOTICE
Removing the oil seal can cause damage to
Do not reuse oil seal once removed.

Always use a new oil seal. IFH511210027-01
5) Apply water resistant grease to outer circumference

of oil seals.
1 Drive the two oil seals (one at a time) into the mount
oil seal cover.
Apply water resistant grease to seal lips.
NOTE
Install oil seal with lip (spring side) facing
downward (oil pan side).

Resistant Grease EP2 (250 g))
IFH511210025-01
3) Remove the scraper (2).
IFH511210028-01
6) Install the mount oil seal cover.

IFH511210026-01 Refer to “Engine Holder / Oil Pan / Driveshaft
Housing / Mounts Assembly” (Page 2A-10).
Clamp / Swivel / Steering Bracket Components

CENFH5112106009
9
10
20 24
24
23 11
31
5 (a)
1 19 26
4 22 27
12 32 3
34 23 21
29
30
33
28 2
23 19
25
8 34 22
35
17 11
18 13
10
14
16
15
6
7
IEH511210113-02
1. Clamp bracket STBD 11. Bushing 21. Tilt lock lever PORT 31. Spring
2. Clamp bracket PORT 12. Swivel bracket 22. Bushing 32. Spring
3. Clamp bracket shaft 13. Seal 23. Grease nipple 33. Bonding wire
4. Washer 14. Shim 24. Bushing 34. Screw
5. Nut 15. Circlip 25. Tilt lock lever link 35. Bonding wire
6. Anode 16. Lower mount bracket 26. Bracket : 43 Nm (4.3 kgf-m, 31.0 lbf-ft)
7. Bolt 17. Anode 27. Screw : Apply SUZUKI water resistance grease.
8. Tilt limit switch cam 18. Bolt 28. Nut
9. Steering bracket 19. Washer 29. Washer
10. Washer 20. Tilt lock lever 30. Pin
Clamp / Swivel / Steering Brackets Disassembly 5) Lift steering bracket (6) upward to remove from
CENFH5112106010 swivel bracket.
1) Remove engine holder/oil pan and driveshaft Remove washer (7) and upper bushing (8).
housing.
6) Remove swivel bracket seal (9) and lower bushing
(10).
2) Remove screw and bonding wire (1).
6
1 7
8 10
9
IEH511210024-04
7) Remove two bolts, switch cover (11) and tilt limit

IEH511210021-03
switch.
3) Remove circlip (2). Cut the cable tie (12) securing switch lead wire.
12
2
11
IEH511210022-03 IEH511210025-03
4) Remove lower mount bracket (3), shims (4), and 8) Remove tilt limit switch cam (13).
washer (5) from the steering shaft.
NOTE
Unfasten three stoppers “A” from the tilt limit
3 switch cam to remove it from cam holder.
5
4
13
“A”
IEH511210023-04
IEH511210026-02
9) Remove upper cam holder (14) and lower cam 12) Remove bolts (19) securing PTT unit to the STBD
holder (15) from clamp bracket shaft. and PORT clamp brackets.
NOTE
Use thin flat screw-driver to release the two
hooks to separate the cam holder upper and
lower halves.
19 19
IEH511210030-06
15 14 13) Using flat screw-driver, drive locking edge of lock

washer (20) to clamp bracket side.
IEH511210027-01
10) Connect the special tool to PTT motor and raise the
swivel bracket.
20
Special tool
: 09945–79310 (PTT cable extension)
Remove circlip (16) and push out tilt cylinder upper
rod (17).
IEH511210031-06
14) Remove the two STBD motor mounting bolts (21).

Remove the clamp bracket shaft nut (22) and lock
16 17 washer (20).
20
22
IEH511210028-02
11) Remove bolts and anode (18).
21
IEH511210032-05
18
IEH511210029-04
15) Remove the screw (23) securing bonding wire. Clamp / Swivel / Steering Brackets Assembly
Slide STBD clamp bracket (24) off clamp bracket CENFH5112106011
shaft, then remove PTT unit (25). Assembly is reverse order of disassembly with special
23 Clamp Bracket / Swivel Bracket
NOTE
Before installing clamp bracket to swivel
bracket, apply grease to clamp bracket shaft
and bushings.
24
: Grease 99000–25350 (SUZUKI Water Resistant
Grease EP2 (250 g))
• Insert PORT and STBD bushings (1) into the swivel
IEH511210033-06
bracket (2).
1
1
25
IEH511210104-04
IEH511210035-01
16) Pull PORT clamp bracket (26) outward to remove
• Assemble PORT clamp bracket (3), washer (4), clamp
clamp bracket and bracket shaft (30) from swivel
bracket shaft (5) and swivel bracket (2).
bracket (27).
Remove washer (28) and bushing (29) from each
side of swivel bracket. 3
27 2
26
28
4
IEH511210036-01
29 30
29 28
IEH511210034-06
NOTE • Install washer (6), STBD clamp bracket (7), lock

For proper operation of the tilt limit device, washer (8) and clamp bracket shaft nut (9), then
install the clamp bracket shaft to the port tighten clamp bracket shaft nut to specified torque.
clamp bracket so the red paint mark “A” on Tightening torque
the hex section and the cam holder location Clamp bracket shaft nut (a): 43 N·m (4.3 kgf-m,
hole “B” on the clamp bracket shaft are 31.0 lbf-ft)
positioned as shown in the figure.
• After tightening clamp bracket shaft nut to specified
torque, bend lock washer edge toward nut to secure
nut.
“A”
7 6
9 (a)
“B”
IEH511210037-01
9 8
• Install PTT unit assembly.
IEH511210039-02
Refer to “Power Trim and Tilt Unit Removal and
Installation” in Section 2B (Page 2B-14). • Tighten two PTT unit retaining bolts (10), pre-coated
with thread lock, to specified torque.
Tightening torque
PTT retaining bolt (b): 50 N·m (5.0 kgf-m, 36.0 lbf-
ft)
IEH511210114-01
10 (b)
10 (b)
IEH511210040-03
Tilt Limit Device Steering Bracket

• Install the lower cam holder (1) engaging its locating • Apply water resistant grease to steering bracket shaft.
pin “A” with the clamp bracket shaft hole “B”, then
install the upper cam holder (2).
NOTE
2 Apply water resistant grease to bushings, oil
1
seal lip and pilot shaft portion of steering
bracket.
• Install upper bushing (1) and washer (2) to swivel

bracket.
“B” • Install lower bushing (3) and swivel bracket seal (4) to
“A”
swivel bracket.
IEH511210041-02 NOTE
• Install tilt limit switch cam (3). Install seal (4) with lip (spring side) facing
downward.
• Install steering bracket (5) to swivel bracket.
3
IEH511210042-03
5
• Install tilt limit switch (4), switch holder (5) and switch
cover (6), then secure with bolts.
• Secure switch lead wire with cable tie.
6
1
3
4 5
4
IEH511210043-01
“A”
IEH511210044-02
1. Upper bushing 4. Swivel bracket seal

2. Washer 5. Steering bracket
3. Lower bushing “A”: Seal lip
Lower Mount Bracket Lubrication

• Install washer (1) and shim (2), and then slide the After completing reassembly of the mid unit, apply water
lower mount bracket (3) upward on the splines until it resistant grease through each grease nipple.
contacts the shim. : Grease 99000–25350 (SUZUKI Water Resistant
Grease EP2 (250 g))
1
2
3
IEH511210045-03
• Install circlip (4) to retain lower mount bracket. IEH511210049-04
IEH511210046-03
IEH511210050-03
Bonding Wire
Reattach bonding wire to swivel bracket and tighten
screw securely.
IEH511210051-02
IEH511210047-01
IEH511210048-02
Clamp / Swivel / Steering Brackets Related Clamp Bracket Shaft

Components Inspection Check clamp bracket shaft.
CENFH5112106012 If clamp bracket shaft is bent or twisted, replace shaft.
Refer to “Clamp / Swivel / Steering Brackets
Disassembly” (Page 2A-19) and “Clamp / Swivel /
Steering Brackets Assembly” (Page 2A-21).
NOTE
If any component is found to be excessively
worn, cracked, defective or damaged in any
way, it must be replaced.
Bushings
Check all bushings. If excessive wear or other damage
is found, replace bushing. If bushing fit is loose when
installing, replace bushing. IEH511210053-01
Bracket
Check clamp brackets, steering bracket and swivel
bracket.
If cracks or other damage is found, replace bracket (s).
IEH511210052-01
Oil Seal
Check swivel bracket seal. If excessive wear or other
damage is found, replace seal.
IEH511210054-01
I9J011210118-01
2B-1 Power Trim and Tilt:
Power Trim and Tilt

Mid Unit
Precautions
Precaution for Power Trim and Tilt
CENFH5112200001
! WARNING
Failure to take proper precaution when servicing a PTT unit can cause severe personal injury.
Be sure to take the following precautions when servicing the PTT system:
• During removal or installation of PTT unit, the engine must be firmly secured and its weight fully
supported by the hoist.
• Before checking PTT fluid level, tilt the motor to the full-up position and engage the tilt lock lever.
NOTE
• To prevent system malfunctions, ensure that all components are kept free from dirt or
contamination.
• Reinstall all O-rings, seals, springs etc. with the component(s) to which they belong. This will
prevent possible confusion and will ensure correct reassembly.
Power Trim and Tilt: 2B-2
General Description
Power Trim and Tilt Description
CENFH5112201001
• The power trim and tilt system components are an electric motor, a pump unit, a fluid reservoir and trim/tilt cylinders.
The outboard can be trimmed “UP” or “DOWN” while under way, and can be tilted for beaching, operating in shallow
water or trailering.
Trim and tilt “UP” or “DOWN” is obtained by supplying power to a permanent magnet type motor. This motor will
rotate clockwise for “UP” or counterclockwise for “DOWN”, according to power delivered via the PTT relay, which is
mounted on the electric part holder.
Power Trim and Tilt Hydraulic Diagram
10
1
15
3
17
13
4 18
5
8
2 14
12
7 16
6
19
11
20
IDG211220029-01
1. PTT motor 8. Up relief valve 15. Gear pump

2. Up check valve 9. Free piston 16. Down relief orifice
3. Up shuttle valve 10. Oil reservoir 17. Filter
4. Down shuttle valve 11. Trim rod 18. Tank room orifice
5. Down check valve 12. Manual release valve 19. Impact relief valve
6. Tilt cylinder Upper chamber 13. Pump room orifice 20. Cylinder body
7. Down relief check valve 14. Tilt rod
Principles of Power Trim and Tilt Operation Description

CENFH5112201002
By motor 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. This causes “UP” and “DOWN” movements of the piston rod of the tilt cylinder and the trim rod of
the trim cylinder.
Trim / Tilt Up Circuit

• When the PTT switch is operated “UP” position, the electric motor and gear pump (1) will operation on clockwise
direction.
• Pressurized oil will open “Up” check valve (2) and the oil will flow through “Up” shuttle valve (3) to the “Down” shuttle
valve (4). Following operation of valve (4), “Down” check valve (5) will open mechanically.
• Pressurized oil flows through the “Up” check valve (2) 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 (6) is returned to the pump through “Down” check valve (5).
• 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 (8) begins to open.
4 8
5
2
7
6
IDG211220030-01
Trim / Tilt Down Circuit

• When the PTT switch is operated in the “DOWN” position, the electric motor will rotate in a counterclockwise
direction and turn the gear pump.
• The oil pressure will open the “Down” check valve (1) and oil will be forced through the “Down” shuttle valve (2).
When the oil reaches “Up” shuttle valve (3), the “Up check valve (4) will begin to open mechanically.
• The pressurized oil flows through “Down” check valve (1) and then enters the upper area of the tilt cylinder.
This thereby forces the tilt rod piston downward.
• 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.
• Oil from the lower area of the trim and tilt cylinders now returns to the pump through “Up” check valve (4).
• 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 (5).
• 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 (5).
• To prevent damage from excessive oil pressure when all three rods are fully retraced, this pressure is relieved
through the “Down” relief orifice (5).
3
2
4
IDG211220031-01
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.
• The pressure from a sudden impact will make impact relief valve (1) 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.
• 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.
IDG211220032-01
Manual Release Circuit (Down Mode)

• By opening the manual release valve (1), 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.
• 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 (1) to the reservoir.
IDG211220033-01
Manual Release Circuit (Up Mode)

• With the manual release valve (1) open, the engine can also be raised manually to the fully tilted position.
• Oil from the upper chamber of the tilt cylinder will flow through valve (1) into the lower chamber of the cylinder.
• 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.
IDG211220034-01
Tilt System Pressure Relief

• If engine speed exceeds approx. 1500 r/min when operating in shallow water drive mode, oil pressure will increase
underneath the tilt piston. The relief valve (2) (incorporated in the manual release valve (1)) will then open.
• The oil below the tilt piston will then flow to the reservoir through the relief valve (2).
• As the power of the engine continues to exert downward force on the tilt piston, this will open “Down” check valve
(3), thereby allowing oil from the reservoir to flow into the chamber above the tilt piston.
• 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

• High ambient temperature will, through thermal expansion, induce a build-up of oil pressure inside the PTT unit.
• Expansion of the oil and the resulting high pressure will open the relief valve (2), 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 (4) → free
piston check valve (5) → thermal relief valve (2).
IDG211220035-02

Power Trim and Tilt System Diagram
CENFH5112202001
22 23 26 27
P Lbl P Lbl 4
Lbl
Lbl Lbl
W/R W/R
P P
P
8 7
W/R 9
Lbl
W/R
P
6
OFF
2
ON
W B GND
W BATT
W/R Gr IGN
3
1
B
Lg
R
P
10 B B/W
11
IFH511220001-03
1. Battery 5. ECM 9. Tilt limit switch

2. 15 A fuse 6. PTT switch (side cover) 10. PTT motor relay
3. Ignition switch 7. 10 A fuse 11. PTT motor
4. PTT switch (remote control box) 8. Main fuse 60 A
PTT System Operation

• The PTT relay is controlled by the ECM.
The ON/OFF signal for the PTT UP or DOWN is inputted to the ECM PTT relay drive circuit. The input signal is
sending from ECM terminals No.22 or 23 and the output signal from terminals No.26 or 27, and they control ON/
OFF for PTT relay's UP or Down circuit.
• For the motor trim/tilt UP or DOWN by the PTT relay control circuit in ECM, the battery power must be supplied to
ECM with the sub battery cable connected to the main wiring harness.
Even through any PTT switch is depressed with only the main battery cable connected on these models, the PTT
motor will not be operated.
– When the PTT switch is operated, the following operation takes place:
With the ignition switch is in OFF position, and the PTT switch is operated, the tilt/trim will be operated.
With the above mentioned condition, operating the PTT switch will supply a 12 V power to the ECM.
When this signal is received, the ECM operates the main relay is in ON, allowing the ECM drive signal to
feedback to the ECM and the PTT relay circuit.
Thus the PTT system functions if the PTT switch is operated.
When the PTT switch signal turns from ON to OFF and a predetermined time has elapsed, the ECM drive voltage
will be interrupted automatically.

Diagnose PTT System Malfunction
CENFH5112204001

Motor will not trim/tilt at Blown fuse for PTT system. Inspection and replace.
all (No up, no down). (Main: 60 A, PTT switch: 10 A, ECM: 30
A).
Defective PTT switch. Replace.
Open circuit between main fuse 60 A Repair.
and PTT relay.
Defective main relay. Replace.
Defective PTT relay. Replace.
Defective ECM and/or PTT system Inspection of ECM and its circuit in section 1A.
circuit.
Open circuit between main fuse and Repair.
starter motor magnetic switch.
Defective PTT motor armature. Replace.
Defective PTT motor armature brushes. Replace.
Defective PTT pump. Replace.
Manual release valve leaking. • Ensure that valve is fully closed.
• Inspect manual release valve.
Motor will not trim/tilt up. Defective PTT switch. Replace.
Defective PTT relay. Replace.
Open light blue lead wire circuit. Repair or replace.
Defective ECM. Replace.
Motor will not trim/tilt Defective PTT switch. Replace.
down. Defective PTT relay. Replace.
Open pink lead wire circuit. Repair or replace.
Defective ECM. Replace.
PTT motor operates, but Low PTT fluid level. Added PTT fluid.
no motor trim/tilt Manual release valve leaking. • Ensure that valve is fully closed.
movement. • Inspect manual release valve.
Debris in system. Inspect for debris.
Broken drive joint in PTT pump. Replace.
Broken PTT pump. Replace.
Tilt piston leaking. • Replace PTT unit assembly.
• Inspect tilt/trim rod seal(s).
Motor will not retain Manual release valve leaking. • Ensure that valve is fully closed.
selected trim and tilt • Inspect manual release valve.
setting, creeps Tilt piston leaking. • Replace PTT unit assembly.
downward.
• Inspect tilt/trim rod seal(s).
Debris in system. Inspect for debris.
PTT motor operates at Low PTT fluid level. Added PTT fluid.
higher than normal speed, Manual release valve leaking. • Ensure that valve is fully closed.
or with high pitched • Inspect manual release valve.
“squealing” sound. No Broken drive joint in PTT pump. Replace.
trim/tilt action.
Checking PTT Fluid Level
CENFH5112206001
“A”
1) Raise the engine to a full-tilt up position.
2) Lower the manual tilt lock lever (1).
1
2
IDG211220039-02
“A”: Oil level (when full tilted)
5) Reinstall oil filler plug (2).

IEH511220031-01
3) Remove the oil filler plug (2). Air Bleeding from PTT Unit
CENFH5112206002
1) Check that the manual release valve (1) is tightened
to the specified torque.
2 NOTE
Do not over tighten manual release valve.
Tightening torque
Manual release valve (a): 3.5 N·m (0.35 kgf-m,
2.5 lbf-ft)
Direction of rotation
IEH511220003-02 Counterclockwise: Open
4) If oil can be seen at filler plug level, the reservoir is Clockwise: Close
full.
If fluid level is low, refill with the recommended PTT
fluid.
NOTICE 1 (a)
Mixing of different fluids may cause chemical

reaction and deterioration.
To ensure consistent pump operation, never

mix different types of PTT fluid.
Recommended PTT fluid IEH511220004-02

• 99000-22810 (PTT Fluid (1 Liter))
• Dexron III automatic transmission fluid or
equivalent
2) Operate the PTT switch, raising and lowering the 4) Top mount type:
motor up and down (full tilt position to full trim down Using the throttle only function of the remote control
position) 4 to 5 times. box, move the control handle forward until the
caution buzzer sounds one time.
Side mount type:
Using the throttle only function of the remote control
box, move the warm-up lever upward until the
caution buzzer sounds one time.
“NEUTRAL” “NEUTRAL”
IEH511220032-01
3) Check PTT fluid level, topping off if necessary.

4) Reinstall oil filler plug.
Setting Trim Down Position Limit

CENFH5112206003 I9J011220055-01
Once the ECM has been replaced or the trim sensor
5) Press the “DOWN” side of the PTT switch for three
removed and reinstalled, the resetting of the trim down
seconds and the buzzer will sound two times briefly
position limit should be performed.
indicating the setting has been canceled.
Perform this set-up after the current position setting has
been cancelled, as explained in the following procedure.
1
NOTE
The tilt upper limit should be adjusted by the
tilt limit cam (switch).
DOWN
Canceling The Trim Down Position Limit Setting

1) Turn the ignition key to the “ON” position. I9J011220056-03
Lower the motor until trim position.
1. PTT switch
2) Pull out the emergency stop switch lock plate.
3) Make sure that remote control handle is in “Neutral”. 6) Return the throttle to the fully closed position.
(Check that the neutral switch is in the “ON”
position.) Setting The Trim Down Position Limit
1) Make sure that Ignition key is ON.
2) Press the “DOWN” or “UP” side of the PTT switch so
that the optimum full trim down position for the boat
can be obtained.
3) Pull out the emergency stop switch lock plate.
4) Make sure that remote control handle is in “Neutral”.
(Check that the neutral switch is in the “ON”
position.)
I9J011220054-01
5) Top mount type:

box, move the control handle forward until the
caution buzzer sounds one time verifying the set
mode is active.
Side mount type:
box, move the warm-up lever upward until the
caution buzzer sounds one time verifying the set
mode is active.
6) Press the “DOWN” side of the PTT switch three
times within three seconds. The buzzer will sound IEH511220010-01
one time briefly indicating the setting has been 3) Remove the tilt rod snap ring (2) and push the tilt rod
accepted. upper shaft pin (3) out.
7) Return the throttle to the fully closed position and
install the lock plate on the emergency switch.
Operate the full tilt up and full trim down operations
several times by pressing the PTT switch and check 2
that the setting of the down limit is properly set.
Power Trim and Tilt Unit Removal and 3

Installation 1
CENFH5112206004
Removal
IEH511220011-01
4) Lower the tilt rod to the full down position and
2) Raise the engine to the full tilt up position and lower disconnect the battery cable.
the manual tilt lock lever (1).
! WARNING
servicing a PTT unit can cause severe
personal injury.
During the removal or installation of PTT unit,

the engine must be firmly secured and its
weight fully supported by the hoist. (See
below)
IEH511220012-01
5) Remove the clamp (4) and cut the cable tie (5)
binding PTT motor cable and trim sensor lead.
1
5 4
IEH511220033-01
IEH511220013-02
6) Disconnect the PTT motor cable lead wire connector 9) Remove two STBD motor mounting bolts (11).
(6). Using flat screw-driver, drive locking edge of lock
Remove the PTT motor cable from side cover seal washer (12) to clamp bracket side.
(7). Loosen the clamp bracket shaft nut (13).
NOTE
Complete removal of the clamp bracket shaft
nut is not required.
6 Nut should be loosened as far as the end of
the shaft threads only to facilitate removal of
7 the PTT unit.
12
IFH511220002-01
7) Remove two bolts and anode (8). Remove the screw 13

securing bonding wire (9).
9
11
IFH511220008-02
10) Slide the STBD clamp bracket (14) fully outward to

the right hand side.
Remove the PTT unit (15) from between the clamp
8
brackets.
IFH511220003-03
8) Remove two bolts (10) securing PTT cylinder lower

shaft to STBD/PORT clamp bracket.
14
15
IFH511220009-03
10 10
IFH511220007-03
11) Remove the bonding wire (16) from PTT unit. • Tighten the clamp bracket shaft nut (4) to specified
torque.
Tightening torque
Clamp bracket shaft nut (a): 43 N·m (4.3 kgf-m,
31.0 lbf-ft)
16 • After tightening clamp bracket shaft nut (4) with

specified torque, bend the lock washer (3) edge
toward nut to secure nut.
IFH511220010-02
3
Installation
• Lower tilt rod to full down position. 4 (a)
• Apply water resistant grease to the tilt cylinder lower

shaft (1) and lower shaft bushings (2).
IEH511220021-02
Install the lower shaft (1) and bushings (2) to PTT unit.
3. Washer 4. Nut
Resistant Grease EP2 (250 g)) • Tighten two lower shaft bolts (5), pre-coated with
thread lock, to specified torque.
Tightening torque
2 PTT cylinder lower shaft bolt (b): 50 N·m (5.0 kgf-
m, 36.0 lbf-ft)
2 1
IEH511220019-03
• Place the PTT unit (with lower shaft) in position

between clamp brackets.
5 (b) 5 (b)
IEH511220022-03
IEH511220020-03
• Install anode (6) and bonding wire (7), then tighten • Route the PTT motor cable properly through the side
bolts securely. cover seal and connect the PTT cable connector.
4A (Page 4A-2).
IFH511220004-01
• Apply water resistant grease to tilt rod upper bushings

(8), then install bushings in tilt rod. IEH511220026-02
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.
8
8
IFH511220005-01
IEH511220024-01
• Apply water resistant grease to the tilt rod upper shaft

pin (9), then insert the shaft pin through the swivel
bracket and tilt rod.
Secure the upper shaft with the snap ring (10).
9 10
IEH511220025-01
Power Trim and Tilt Unit Components

CENFH5112206005
1
14
9
2 (a)
8
15
5 (b)
13 4
3 16
23
24 18
7
4
17
10
25
12 19 19
11
26
20
27
21
22
28
30
29 31
IEH511220037-02
1. Tilt rod 10. Free piston 19. Spring 28. Bolt

2. Tilt cylinder head 11. O-ring 20. Brush holder 29. Bolt
3. Trim ram 12. Ring 21. Screw 30. Bolt
4. O-ring 13. Reservoir bolt 22. Oil seal 31. Manual valve
5. Trim cylinder head 14. Field case 23. Drive joint : 210 Nm (21.0 kgf-m, 152.0 lbf-ft)
6. O-ring 15. O-ring 24. Filter : 170 Nm (17.0 kgf-m, 123.0 lbf-ft)
7. PTT manifold 16. Armature 25. O-ring
8. Reservoir 17. Brush set 26. O-ring
9. Cap 18. Breaker assembly 27. Pump assembly
Power Trim and Tilt Unit Disassembly 4) Remove the three screws securing reservoir (1),
CENFH5112206006 then detach the reservoir (1) from cylinder body.
NOTE
Note the position of O-ring (2) and remove it.
Before disassembly, wash the PTT body with
a stiff bristle brush and hot, soapy water to
remove sand or dirt. Dry the PTT body with 1
compressed air.
1) Place the lower section of the PTT unit 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.,
IDG211220059-01
between the vise jaws and PTT components
before tightening vise.
IDG211220062-01
5) Remove the PTT motor assembly (3).

Refer to “Power Trim and Tilt Motor Removal and
IDG211220057-02
Installation” (Page 2B-25).
2) Connect the PTT cable extension to PTT motor Note the position of drive joint (4) and O-ring (5),
cable connector. before removing them.
Special tool
(A): 09945–79310 (PTT cable extension)
5
3
3) Connect the PTT cable extension leads (G, Bl) to
battery and operate PTT motor until tilt rod is at
maximum stroke (full-tilt up position). Unscrew the
filler plug and drain PTT oil into a suitable container.
IDG211220060-01
(A)
6) Remove the manual release valve snap ring (6),
then unscrew the manual release valve (7).
IDG211220058-01
6
IDG211220061-01
7) Remove the three bolts securing the PTT pump 9) Pull the tilt rod/piston assembly (14) out of the tilt
assembly (8), then detach the PTT pump assembly cylinder.
from PTT cylinder body. Remove the free piston (15) from the tilt cylinder.
Note the position of O-rings (9), orifice collar (with
ball valve) (10), orifice collar (with filter and ball
valve) (12) and orifice collar (11), before removing 14
them.
15
IDG211220066-01
10) Unscrew the piston retaining nut from the bottom of

the tilt rod and remove the washer.
Carefully retain and account for four shock valves,
IDG211220063-01 each composed of spring, rod and ball.
10
12
9
9 11
IDG211220064-04
8) Using special tool, unscrew the PTT cylinder head IDG211220067-01

(13). 11) Remove the piston assembly and PTT cylinder head
Special tool from the tilt rod by sliding them down and off the rod
(B): 09944–09820 (PTT cylinder cap tool) end.
(B)
13
IDG211220065-02 IDG211220068-01
12) Using special tool, unscrew the trim cylinder head. Tilt Rod
Special tool • When tightening the piston retaining nut on the tilt rod
(C): 09944–09810 (PTT trim cap tool) piston, apply Thread lock 1342 to the threads.
Tighten the nut to specified torque.
Tightening torque
Piston retaining nut (a): 100 N·m (10.0 kgf-m, 72.5
lbf-ft)
(C)
IDG211220069-02
13) Pull the trim rod/piston assembly out of the trim (a)
cylinder.
IDG211220071-01
Installing Tilt Rod / Piston

• Pour 100 ml (3.4 oz) of PTT fluid into cylinder.
• Insert the free piston into cylinder and push it down to
the bottom of the cylinder.
• Pour PTT fluid into the cylinder until it is topped off.
IDG211220070-01 • Insert the tilt rod/piston into cylinder and thread the tilt
cylinder head by hand until fully seated.
Power Trim and Tilt Unit Reassembly • Tighten the cylinder head to specified torque using
CENFH5112206007
Assembly is reverse order of disassembly with special special tool.
2
NOTE
“A”
• Do not reuse O-rings and seals once
removed.
1
Always use new parts.
• Lubricate all components and O-rings with
PTT fluid before assembly.
• Do not reuse PTT fluid, always refill with
new fluid.
IEH511220038-01
1. Cylinder 2. Free piston “A”: Top OFF

Tightening torque PTT Pump Assembly

Tilt cylinder head (a): 210 N·m (21.0 kgf-m, 152.0 • Install five O-rings and orifice collars to PTT cylinder
lbf-ft) body.
Special tool NOTE
(A): 09944–09820 (PTT cylinder cap tool)
Lubricate O-rings with PTT fluid before
installing.
(A)
• Install PTT pump assembly, then tighten three screws
to specified torque.
Tightening torque
PTT pump case screw (a): 8.5 N·m (0.85 kgf-m,
6.0 lbf-ft)
(a)
O-ring /
Orifice collar
IDG211220073-02
O-ring
Trim Rod
• Pour PTT fluid into the trim cylinder until it is topped O-ring
off.
(a)
• Insert the trim rod/piston assembly into cylinder and
thread the trim cylinder head by hand until fully Orifice collar
seated.
IDG211220075-03
• Tighten the trim cylinder head to specified torque
using special tool.
Manual Release Valve
Tightening torque • Oil and install the manual release valve (1).
Trim cylinder head (a): 170 N·m (17.0 kgf-m, 123.0 Tighten the valve to specified torque.
lbf-ft)
• Install snap ring (2).
Special tool
Tightening torque
(B): 09944–09810 (PTT trim cap tool)
Manual release valve (a): 3.5 N·m (0.35 kgf-m, 2.5
lbf-ft)
(a) “A”
(B) 1 (a)
1 2
IEH511220039-01
“A”: Upper edge IDG211220076-01

PTT Motor 3) Tighten the manual release valve to the specified

• Install the PTT motor. torque.
Refer to “Power Trim and Tilt Motor Removal and Tightening torque
Installation” (Page 2B-25). Manual release valve: 3.5 N·m (0.35 kgf-m, 2.5
lbf-ft)
Reservoir
4) Connect the PTT cable extension to the PTT motor
• Install O-ring (1) and reservoir, then tighten bolts to
cable connector.
specified torque.
Special tool
Tightening torque
(A): 09945–79310 (PTT cable extension)
Reservoir bolt (a): 5 N·m (0.5 kgf-m, 3.5 lbf-ft)
5) Connect the two extension cable lead wires (G to
positive/Bl to negative) to the battery as shown in the
illustration.
1 Operate the PTT motor until the PTT rod is in the
fully trimmed down position (completely retracted).
If the rod does not come down completely, push it in
by hand while operating the motor.
(a)
IDG211220077-01
(A)
PTT Fluid
• Pour recommended PTT fluid into reservoir to
specified level.
Refer to “Checking PTT Fluid Level” (Page 2B-12).
Air Bleeding IDG211220079-01
Before installing the PTT unit on the outboard motor, use 6) Reverse the two extension cable lead wires (Bl to
the following procedure to bleed air from the system. positive/G to negative). Operate the PTT motor until
1) Support the PTT unit in an upright position in a vise. the PTT rod is in the full tilt up position (fully
extended). If the rod does not come up completely,
2) Fill the reservoir with PTT fluid to the specified level,
pull it up by hand while operating the motor.
then install oil filler plug.
“A”
(A)
IDG211220080-01
IEH511220040-01
“A”: Oil level (When full-tilted)

7) Remove the reservoir oil filler plug and fill with PTT
fluid to the specified level.
8) Repeat procedures 5 – 7 until the fluid level in the
PTT unit stabilizes at the specified level.
NOTE
Repeat the air bleeding procedure after the
PTT unit has been installed on the outboard
motor.
Refer to “Air Bleeding from PTT Unit” (Page
2B-12).
Power Trim and Tilt Unit Components Cleaning • Inspect the PTT cap seal and O-ring.
and Inspecting Replace if cuts, nicks, or excessive wear is found.
CENFH5112206008
Thoroughly wash all metal components with cleaning NOTE
solvent and dry them with compressed air. It is recommended that the O-ring always be
Arrange all components on a clean sheet of paper. replaced once the tilt/trim cylinder has been
NOTE disassembled.
• Do not lay PTT components out on a rag, • Inspect the shock valves (spring, rod and ball).
as dirt or lint may be transferred to these Replace if there are any signs of rust or pitting.
items which may cause possible system
operating problems.
• If excessive wear, cracks, defective or
other damage is found on any component,
replace component.
• Inspect tilt rod and trim rod, replace if damaged or

bent is found.
• Inspect the surface of tilt rod and trim rod for scores,
grooves or roughness.
Slight roughness may be removed with fine emery
paper. IDG211220083-01
A badly scored or grooved rod must be replaced. • 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.
IDG211220082-01
IDG211220084-01
• Inspect manual release valve for damage.

Inspect manual release valve O-ring.
Replace if nicked or cut is found.
IDG211220096-01
IDG211220085-02
• Inspect lower rod. 2) Place the lower section of the PTT unit in a vise.
If bending, cracks, corrosion or other damage is Tighten the vise only enough to secure the PTT unit,
found, replace lower rod. DO NOT OVER TIGHTEN.
• Inspect upper shaft for bent, twist or other damage.
NOTE
To prevent damage to the PTT cylinder use
wood blocks, vise jaw protectors, etc.,
between the vise jaws and PTT components
before tightening vise.
IDG211220097-01
• Inspect all bushings for excessive wear or other

damage. Replace if necessary.
If bushing fit is loose when installing, replace bushing.
IDG211220087-02
3) Remove the four screws securing the PTT motor (1)

to the PTT pump assembly.
IDG211220086-01
Power Trim and Tilt Motor Removal and

Installation
CENFH5112206009 IDG211220088-01
Removal 4) Detach the PTT motor from PTT pump assembly.

1) Remove Power Trim and Tilt unit. Note the position of drive joint (2) and O-ring (3) and
Refer to “Power Trim and Tilt Unit Removal and remove them.
Installation” (Page 2B-14).
NOTE 3
Before removing PTT motor, wash the PTT

body with a stiff bristle brush and hot, soapy
water to remove sand or dirt. Dry the PTT
body with compressed air. 2
IDG211220089-01
Installation • Pour recommended PTT fluid into reservoir until

Installation is reverse of removal with special attention to specified level.
following steps. • Perform the air bleeding procedure.
• Ensure that the drive joint (1) is aligned and firmly Refer to “Power Trim and Tilt Unit Reassembly” (Page
inserted into the gear pump assembly. 2B-21).
• Fit O-ring (2) to PTT motor.
Power Trim and Tilt Motor Disassembly and
Assembly
CENFH5112206010
Disassembly
1) For correct assembly, scribe an alignment mark on
the field case and brush holder.
2) Slide cable protector tube upward.
3) Remove the screw securing the motor cable holder
(1), then slide motor cable holder and grommets (2)
out as shown in figure.
IDG211220090-01 2
1
4 1
1 I9J011220034-01
4) Remove the two screws (3) securing the field case to

3
IDG211220091-01 the brush holder.
• Check the level of PTT fluid contained in the PTT
pump assembly. 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
3
are free of dirt or debris.
When attaching the PTT motor to the PTT pump
assembly (3), ensure that the tip of armature shaft (4)
fits firmly into the drive joint (1).
• Tighten the four screws (a) to specified torque.
I9J011220035-01
Tightening torque
PTT motor screws (a): 5 N·m (0.5 kgf-m, 3.6 lbf-ft)
(a)
IDG211220092-02
5) Slide the field case upward and away from the brush • Match up previously scribed alignment marks.
holder. • When assembling field case to brush holder, pull out
on the PTT motor cables as the field case is
NOTE
assembled into position.
When separating field case from brush
• Apply silicone seal to PTT motor cable holder and
holder, push the PTT motor cables into brush
grommets and install cable holder screw.
holder as the field case is removed.
: Sealant 93691–80030 (SUZUKI Silicone
Seal (100 g))
I9J011220036-01
6) Disconnect PTT motor cables from brush holder. I9J011220039-01

Remove armature from field case. Note the position
of the O-ring encircling the brush holder. PTT Motor Related Items Inspection
CENFH5112206011
Armature and Commutator
• Check for continuity between the commutator and the
armature core/shaft. Replace armature if continuity is
indicated.
Special tool
Continuity ( )
I9J011220037-01
Assembly (A)
Assembly is reverse of disassembly with special
• Install O-ring (1).
• Install armature (2) to brush holder first. When
installing the armature, use care to avoid breaking the
brushes.
I9J011220040-01
2
• Check continuity between adjacent commutator
1 segments.
Replace armature if no continuity is indicated.
(A)
I9J011220038-01
I9J011220041-01
• Inspect the commutator surface. Brushes

If surface is gummy or dirty, clean with 400 grit emery • Check the length of each brush.
paper (1). If brushes are worn down to the service limit, they
• Measure commutator outside diameter. must be replaced.
If measurement exceeds service limit, replace
Special tool
armature.
(B): 09900–20101 (Vernier calipers (150
Special tool mm))
(B): 09900–20101 (Vernier calipers (150
Brush length
mm))
Commutator outside diameter Service limit: 5.5 mm (0.22 in.)
Standard: 22.0 mm (0.87 in)
(B)
IDG211220099-01
1 O-ring
(B)
• Inspect the O-ring between the PTT motor and PTT
pump assembly. Replace if cuts, nicks or tears are
found.
I9J011220042-01
• Ensure that the mica (insulator) between commutator

segments are undercut “a” to specified depth.
If undercut is less than service limit, cut to specified
depth.
! WARNING
Failure to following proper precautions
I9J011220045-01
air.
NOTE
Remove all particles of mica and metal using
compressed air.
Commutator undercut
Standard: 1.6 – 1.9 mm (0.06 – 0.07 in.)
“A”
“a”
“B”
I9J011220043-01
“A”: Segment “B”: Mica

PTT Motor Relay Inspection 3) Check continuity between terminal (3) and (5) each
CENFH5112206012 time 12 V power supply is applied to terminal (1) and
1) Remove the PTT motor relay from the electric parts (4).
holder. Connect the positive (+) lead to terminal (1), and
Refer to “Electric Parts Holder Removal and negative (–) lead to terminal (4).
4) Check continuity between terminal (3) and (6) each
2) Check the resistance between each two terminals. time 12 V power supply is applied to terminal (2) and
Special tool (4).
(A): 09900–25008 (Multi circuit tester set) Connect the positive (+) lead to terminal (2), and
negative (–) lead to terminal (4).
Resistance (Ω) 2 5 6
1
PTT relay coil resistance
Between “terminal (1)” and “terminal (4)”: 16 – 24
Ω
Between “terminal (2)” and “terminal (4)”: 16 – 24
Ω
3 4
CONT
(A)
IEH511220042-01
1. Terminal 1 (UP coil) 4. Terminal 4 (GND)

2. Terminal 2 (DN coil) 5. Terminal 5 (For UP)
3. Terminal 3 (Power) 6. Terminal 6 (For DN)
1 2
Special tool
4 Tester knob indication
3
Continuity ( )
PTT relay function

(A)
Continuity
IDG211220027-03 12 V power applied Yes
NOTICE
If the 12 V power supply wire is connected to 5) If inspection in step 2 and/or step 3, 4 fails, replace
wrong terminal or touched to each other, the PTT motor relay.
power supply wire, tester may be damaged. 6) Install the PTT motor relay to the electric parts
holder.
Be careful not to touch 12 V power supply Refer to “Electric Parts Holder Removal and
wires to each other or with other terminals. Installation” in Section 1D (Page 1D-3).
PTT Switch Inspection

CENFH5112206013
Test continuity between the switch lead wires at each of
the three switch positions.
If out of specification, replace PTT switch.
Special tool
Tester knob indication 1
Continuity ( )
Tester probe connection Tester
Red (+) Black (–) indicates
IFH511220006-01
DN side
Terminal (2) Terminal (1) Continuity 2) Test continuity between wires.
depressed
UP side If out of specification, replace switch.
Terminal (3) Terminal (1) Continuity Refer to “Clamp / Swivel / Steering Brackets
depressed
Not Terminal (2) Disassembly” in Section 2A (Page 2A-19) and
Terminal (1) Infinity “Clamp / Swivel / Steering Brackets Assembly” in
depressed Terminal (3)
Special tool
1 (W/R) Tester knob indication
2 (P) Continuity ( )
3 (Lbl)
IEH511220027-01
CONT
1 (Lg)
3 (Lbl)
IEH511220029-03
2 (R)
I9J011220049-03
Tilt Limit Switch Inspection IEH511220041-02

CENFH5112206014
2. Tilt limit switch
1) Disconnect the tilt limit switch lead wire connector
(1).
Refer to “Electric Parts Holder Removal and Push the switch actuator plate.
No continuity
Installation” in Section 1D (Page 1D-3). (Full tilt up position)
Release the switch actuator plate.
Continuity
(Except for full tilt up position)
Section 3
Lower Unit
CONTENTS
Precautions .................................................3-1 Trim Tab Adjustment.........................................3A-23

Precautions............................................................. 3-1 Lower Unit Gears - Shimming and Adjustment ..3A-24
General Precautions ............................................. 3-1
Precaution for Lower Unit ..................................... 3-1
Left Hand Rotation Unit .......................... 3B-1
Diagnostic Information and Procedures ............3B-1
Right Hand Rotation Unit........................ 3A-1 Diagnose Lower Unit Malfunction .......................3B-1 3
Diagnostic Information and Procedures............3A-1 Service Instructions .............................................3B-2
Diagnose Lower Unit Malfunction ....................... 3A-1 Lower Unit Components......................................3B-2
Service Instructions.............................................3A-2 Propeller Removal and Installation .....................3B-5
Lower Unit Components ..................................... 3A-2 Propeller / Propeller Nut / Cotter Pin
Propeller Removal and Installation ..................... 3A-5 Inspection..........................................................3B-5
Propeller / Propeller Nut / Cotter Pin Lower Unit Removal and Installation...................3B-6
Inspection.......................................................... 3A-5 Water Pump Removal and Installation................3B-7
Lower Unit Removal and Installation................... 3A-6 Water Pump and Related Item Inspection ..........3B-9
Water Pump Removal and Installation................ 3A-7 Lower Unit Disassembly......................................3B-9
Water Pump and Related Item Inspection .......... 3A-9 Lower Unit Related Item Inspection ..................3B-13
Lower Unit Disassembly...................................... 3A-9 Propeller Shaft Oil Seal Replacement...............3B-15
Lower Unit Related Item Inspection .................. 3A-12 Driveshaft Oil Seal Replacement ......................3B-16
Propeller Shaft Oil Seal Replacement............... 3A-15 Lower Unit Assembly ........................................3B-17
Driveshaft Oil Seal Replacement ...................... 3A-16 Trim Tab Adjustment.........................................3B-23
Lower Unit Assembly ........................................ 3A-16 Lower Unit Gears - Shimming and Adjustment ..3B-24
3-1 Precautions:
Precautions
Lower Unit
Precautions
General Precautions
CENFH5113000001
Precaution for Lower Unit

CENFH5113000002
! WARNING
Failure to take proper precautions when installing or removing the propeller can result in severe
personal injury.
When installing or removing the propeller:

• Shift into neutral and remove the emergency stop switch lock plate so that the motor cannot be
started accidentally.
• Wear gloves to protect hands, and lock the propeller by placing a block of wood between the
propeller blade tips and the anti-cavitation plate before attempting to remove or install propeller nut.
! WARNING
Failure to take proper precautions when removing or installing the lower unit can result in severe
personal injury.
When installing or removing the lower unit:

• Always disconnect the battery cable, before removing lower unit.
• Remove the emergency stop switch lock plate from the emergency stop switch.
NOTE
• When draining lower unit gear oil, check the following points.
– Water ingress (white, milky appearance)
– Overheating or burning (black appearance, charred smell)
– Metal filings or deposits
• If reassembling with original components and gears, do not omit or add any shims or thrust
washers.
• To simplify reassembly and to prevent confusion, note the positions and quantities of all shims and
thrust washers. Retain these items next to the gears or bearings to which they belong.
Right Hand Rotation Unit: 3A-1
Right Hand Rotation Unit

Lower Unit

Diagnose Lower Unit Malfunction
CENFH5113104001
Trouble Check Chart

Engine stalls when Idling speed set too low. Adjustment.
engaging gear Propeller shaft bearings damaged, Replace.
lacking lubrication or seized.
Engaging gear(s) has no Clutch out of adjustment. Adjustment.
effect on propulsion Driveshaft broken or splines damaged. Replace.
Chipped or worn dog clutches. Replace.
Propeller not secured correctly (fallen Inspection or retighten.
off).
Loss of power. (Assuming Propeller bush slipping. Replace.
engine is OK) Bent or worn propeller. Repair or replace.
Engine shakes the boat Failed propeller bush. Replace.
Bent driveshaft or propeller shaft. Replace.
Damaged propeller. Replace.
Clutch will not engage or Seized shift rod. Inspection.
disengage Clutch shaft and clutch rod have Inspection.
become detached.
Seized/broken remote control cable. Replace.
Problem at control box end. Inspection or replace.
3A-2 Right Hand Rotation Unit:
Lower Unit Components
CENFH5113106001
3 21
2
20
1
19
3
18
8
15
3
4 6
5
16
9 10
11
13 12 14
14 13
17
11
IFH511310002-02
1. Clutch lever 7. Throttle lever holder 13. Washer 19. Bearing

2. Clutch lever bushing 8. Clutch lever holder 14. Pin 20. Circlip
3. Bushing 9. Clutch shaft arm 15. Clutch shaft 21. Plug
4. Spring pin 10. E-ring 16. Clutch rod cover : Apply SUZUKI Water Resistant Grease.
5. Ball 11. Bushing 17. Clutch rod
6. Spring 12. Clutch lever link 18. Oil seal
24
23
25 52 (a)
22
26 50
27
51
28 53
29 54
55
29 30
56
31
57
58
32
36 59
35 37
34
38
34
33
47
49 48
41 39
45
40
44
43 (c) 42 (b)
46
IEH511310110-03
22. Shift rod 33. Nipple 44. Water filter PORT 55. Sealing
23. Bolt 34. Dowel pin 45. Water filter STBD 56. Inner sleeve
24. Clutch rod cover 35. Exhaust seal rubber 46. Screw 57. Water pump impeller
25. Shift rod housing 36. Exhaust seal plate 47. Anode 58. Under panel
26. O-ring 37. Grommet 48. Bolt 59. Gasket
27. Oil seal 38. Pinion bearing 49. Gearcase : 17 Nm (1.7 kgf-m, 12.5 lbf-ft)
28. Washer 39. Trim tab 50. Bushing : 83 Nm (8.3 kgf-m, 60.0 lbf-ft)
29. Pin 40. Bolt 51. Water pump case : 55 Nm (5.5 kgf-m, 40.0 lbf-ft)
30. Magnet 41. Washer 52. Bolt : Apply SUZUKI Water Resistant Grease.
31. Shifter yoke 42. Bolt 53. Dowel pin : Apply SUZUKI Silicone Seal.
32. Horizontal slider 43. Bolt 54. Key
103 (h)
102
101
104
100
99
98
61 (d)
62 97 (g)
105
63
64 (e)
60 65
66
96
67 94
95
93
68 92
91
69
70
71 (f)
72 (i)
86
90
89
73 85 88
84 87
83
80 81 83 82
79
76 77
75 78
73 74
72 (j)
IFH511310003-03
60. Driveshaft 75. Forward gear bearing housing with bearing 90. Shim 105. Circlip
61. Oil seal housing 76. Shim 91. Propeller shaft : 100 Nm (10.0 kgf-m, 72.5 lbf-ft)
62. O-ring 77. Thrust washer 92. O-ring : 100 Nm (10.0 kgf-m, 72.5 lbf-ft)
63. Oil seal 78. Forward bearing 93. Bearing : 145 Nm (14.5 kgf-m, 105.0 lbf-ft)
64. Nut 79. Forward gear 94. Propeller shaft bearing : 23 Nm (2.3 kgf-m, 16.5 lbf-ft)
housing
65. Spacer 80. Detent ball 95. Bearing : 55 Nm (5.5 kgf-m, 40.0 lbf-ft)
66. Driveshaft bearing 81. Connector pin 96. Oil seal : 10 Nm (1.0 kgf-m, 7.0 lbf-ft)
67. Shim 82. Detent spring 97. Bolt : 10 Nm (1.0 kgf-m, 7.0 lbf-ft)
68. Driveshaft collar 83. Detent ball 98. Stopper : Apply SUZUKI Water Resistant Grease.
69. Pinion gear 84. Thrust washer 99. Propeller : Apply SUZUKI Outboard Motor Gear Oil.
70. Washer 85. Clutch dog shifter 100. Propeller bushing set : Apply SUZUKI Thread Lock 1342.
71. Pinion nut 86. Dog pin 101. Spacer
72. Plug 87. Dog spring 102. Washer
73. Gasket 88. Thrust washer 103. Nut
74. Pin 89. Reverse gear 104. Pin
Propeller Removal and Installation Installation

CENFH5113106002
1) Coat the propeller shaft splines liberally with Suzuki
! WARNING water resistant grease.
Failure to take proper precautions when : Grease 99000–25350 (SUZUKI Water
installing or removing the propeller can Resistant Grease EP2 (250 g))
2) Install propeller stopper (1) onto propeller shaft, then
When installing or removing the propeller: slide on the propeller (2).
• Shift into neutral and remove the 3) Fit spacer (3), washer (4) and nut (5), then tighten
emergency stop switch lock plate so that nut to specified torque.
the motor cannot be started accidentally. 4) Push cotter pin (6) through nut and shaft, then bend
• Wear gloves to protect hands, and lock the to secure.
propeller by placing a block of wood Tightening torque
between the propeller blade tips and the Propeller nut (a): 55 N·m (5.5 kgf-m, 40.0 lbf-ft)
anti-cavitation plate before attempting to
remove or install propeller nut. 3
2
Removal
1) Shift to neutral position. 6
5
2) Remove cotter pin (1) from propeller nut and remove 1 4
propeller nut (2).
3) Remove washer (3), spacer (4), propeller (5) and
stopper (6) from the propeller shaft.
I9J011310017-01
(a)
I9J011310001-01
4 I9J011310003-04
5
Propeller / Propeller Nut / Cotter Pin Inspection

1 CENFH5113106003
2 Refer to “Propeller / Propeller Nut and Cotter Pin
6 3 Inspection” in Section 0B (Page 0B-20).
I9J011310002-02
Lower Unit Removal and Installation Installation

CENFH5113106004
Removal 1) Apply water resistant grease to clutch rod splines,
then install clutch rod (1) by aligning clutch rod
! WARNING splines with splines in clutch shaft.

removing or installing the lower unit can Resistant Grease EP2 (250 g))
Always disconnect the battery cable, before

removing lower unit.
1) Remove STBD lower side cover.

Remove bolt and trim tab (1).
IEH511310007-01
2) Ensure that shift rod (2) is at neutral position.

1
NOTE
Before installing lower unit, bring shift to
Neutral position by turning shift rod right or
left.
Fron
t
IFH511310004-01 direc
2 tion
3) Remove seven bolts (2) and separate gearcase (3)
from driveshaft housing.
IEH511310008-01
3) Insert two dowel pins (3).

3 4) Apply water resistant grease to driveshaft and shift
rod splines.
5) Apply a light coating of silicone seal to mating
IFH511310005-01 surfaces of gearcase and driveshaft housing.
4) Remove clutch rod (4) from clutch shaft (if : Sealant 93691–80030 (SUZUKI Silicone
necessary). Seal (100 g))
3
4
IFH511310006-01
IEH511310009-01
6) Set the clutch control lever (4) at neutral position, Water Pump Removal and Installation
then slide the lower unit (5) into place, ensuring that CENFH5113106005
the top of driveshaft engages properly with driven Removal

gear shaft and that water tube locates in water pump 1) Remove the lower unit.
case outlet. Refer to “Lower Unit Removal and Installation” (Page
3A-6).
NOTE 2) Loosen four bolts (1), then remove water pump case
In order for shift rod and clutch rod splines to (2).
be aligned correctly, clutch rod may need to
be turned slightly right or left.
IEH511310012-01
4
3) Remove impeller (3), impeller key (4), pump under
“Neutral” panel (5) and dowel pins (6).
IFH511310007-01
Keep impeller key (4) for reuse and discard the plate
7) Apply silicone seal to seven gearcase bolts (6) and gasket.
tighten them to specified torque.
Seal (100 g)) 3
Tightening torque
Gearcase bolt 10 mm (a): 55 N·m (5.5 kgf-m, 40.0 6
lbf-ft)
5
Gearcase bolt 12 mm (b): 83 N·m (8.3 kgf-m,
4
60.0 lbf-ft)
5 6 (a) 6
IEH511310013-02
4) Remove inner sleeve (7) and rubber sealing (8).
NOTE
6 (b)
To facilitate the removal of inner sleeve from
the pump case, warm up the entire case
using a heater like hair dryer.
IEH511310011-04
8) Shift the clutch control lever to forward and reverse

position from neutral position to check proper gear
engagement.
9) Install the lower side cover.
7 8
IEH511310014-01
Installation
1) Place the dowel pins (1), under panel gasket (2) and
under panel (3) into position.
2) Insert the key (4) in the driveshaft and slide the 8
impeller (5) onto driveshaft, ensuring that key and
keyway are aligned.
1 5
IEH511310017-02
3
4 NOTE
Before installing water pump case assembly,
apply water resistant grease lightly on pump
2 1 case inner sleeve and under panel for initial
lubrication.
IEH511310015-01
3) Place the sealing (7) into groove of the pump case : Grease 99000–25350 (SUZUKI Water
(6). Resistant Grease EP2 (250 g))
NOTE
Do not reuse sealing once removed.
Always use new sealing.
6
IEH511310018-02
7 5) Install the pump case assembly (9) while rotating

driveshaft clockwise to flex the impeller vanes in the
correct direction.
Securely tighten the four pump case bolts (10) to the
IEH511310016-01
specified torque.
4) Install inner sleeve (8) into the pump case, ensuring
that projection of inner sleeve and groove of pump Tightening torque
case are aligned. Water pump case bolt (a): 17 N·m (1.7 kgf-m,
12.5 lbf-ft)
NOTE
Before installing pump inner sleeve, apply
water resistant grease lightly between inner
sleeve and pump case mating surfaces.
9
10 (a)
IEH511310019-01
6) Install the lower unit.

Refer to “Lower Unit Removal and Installation” (Page
3A-6).
Water Pump and Related Item Inspection Lower Unit Disassembly

CENFH5113106006 CENFH5113106007
Inspect the following parts. 1) Remove the lower unit.
• Inspect impeller. Replace if vanes are cut, torn, worn Refer to “Lower Unit Removal and Installation” (Page
or other abnormal condition. 3A-6).
• Inspect pump case. Replace if cracked, distorted or 2) Remove the propeller.
other abnormal conditions are noted. Refer to “Propeller Removal and Installation” (Page
• Inspect pump inner sleeve. Replace if worn, cracked, 3A-5).
distorted, corroded or other abnormal conditions are 3) Remove the water pump and related parts.
noted. Refer to “Water Pump Removal and Installation”
• Inspect under panel. Replace if cracked, distorted, (Page 3A-7).
corroded or other abnormal conditions are noted. 4) Place a drain pan under oil drain plug. Remove oil
drain plug (1) first then air vent plug (2) and allow
NOTE gear oil to drain.
Do not reuse sealing once removed. Inspect oil for water, contaminates or metal.
1
IEH511310108-02
5) Remove two bolts (3) and shift rod guide housing

IEH511310020-01 assembly (4).
IEH511310021-01 IEH511310023-04
6) Remove two bolts (5) securing the propeller shaft

bearing housing to the gearcase.
IEH511310024-03
7) Using special tools, pull out the propeller shaft 9) Use special tool to unscrew driveshaft oil seal
bearing housing. housing (9), then remove oil seal housing from
Remove the propeller shaft and bearing housing driveshaft.
assembly (6).
Special tool
Special tool (D): 09926–29310 (Driveshaft housing
(A): 09930–30104 (Sliding hammer) remover)
(B): 09930–30161 (Propeller shaft remover)
(D)
6
(B)
(A) IEH511310028-03
IEH511310025-03 10) Remove driveshaft bearing spacer (10).

8) Hold the pinion nut securely, then fit special tool to
the driveshaft and loosen the pinion nut (7).
Remove pinion nut (7) and washer (8).
Special tool
(C): 09921–29410 (Driveshaft holder) 10
(C)
IEH511310029-03
11) Slowly lift out driveshaft assembly (11).

Remove the pinion shim (12).
NOTE
IEH511310026-01
The driveshaft pinion gear bearing contains
22 loose roller bearings. Account for all roller
bearings on disassembly.
11
12
7
IEH511310027-03
IEH511310030-03
12) Remove the driveshaft collar (13). 15) Remove the forward gear bearing housing (19).
Account for dowel pin (20).
NOTE
13 The forward gear radial bearing contains 35
loose roller bearing.
Account for all roller bearings on
disassembly.
IEH511310031-03 20
13) Remove the pinion gear (14).
Remove the forward gear (15) and thrust bearing
(16).
16 19
IEH511310034-03
16) To disassemble propeller shaft components, refer to

following:
a) Slide propeller shaft away from reverse gear (21)
and bearing housing assembly (22).
14
15 Account for the reverse gear back-up shim (23)
and reverse gear thrust washer (24).
IEH511310032-03
14) Remove the bearing thrust washer (17) and back-up

21
shim (18).
22
23
24
18 IEH511310035-03
b) Remove horizontal slider (25) and forward gear

17 thrust washer (26).
IEH511310033-03
c) Remove spring (27) from clutch dog shifter (28).
27
26
28
25
IEH511310036-03
d) Use special tool to push the dog pin (29) out of 17) To disassemble shift rod components, refer to
the clutch dog shifter (28). following:
Special tool a) Remove dust seal (35).
(E): 09922–89810 (Shift lock pin b) Slide shift rod (36) out of shift rod guide housing
remover) (37).
c) Draw the oil seal (38) out of shift rod guide
(E)
housing.
29
36
38
28
IEH511310037-03 37
e) Remove clutch dog shifter (28) and connector
35
pin (30) from propeller shaft. IEH511310040-03
d) Separate the shifter yoke (39) from shift rod (36)

by driving out the pin (40).
30 40 39
28
36
29
IEH511310038-03
f) Remove large detent ball (31), detent spring

(32), large detent ball (33) and two small detent IEH511310041-04
balls (34) from connector pin.
Lower Unit Related Item Inspection
CENFH5113106008
! WARNING
Failure to following proper precautions

34 31 air.
32
33
IEH511310039-03 NOTE
• If any component is worn excessively,
cracked, defective or damaged in any way,
it must be replaced.
• Thoroughly wash all metal components
with cleaning solvent and dry with
compressed air.
Gearcase Propeller Shaft Components

• Inspect the gearcase. Replace if cracked, damaged or • Inspect horizontal slider and connector pin.
other abnormal conditions are noted. Replace if worn, damaged or other abnormal
• Visually check the pinion bearing. Replace gearcase if conditions are noted.
pitted, rough or other abnormal conditions are noted. • Inspect clutch dog shifter. Replace if chipped, worn,
damaged or other abnormal conditions are noted.
• Inspect dog pin. Replace if bent, worn or other
abnormal conditions are noted.
• Inspect detent balls. Replace if wear, damage or other
• Inspect propeller shaft/splines. Replace if worn,
twisted, damaged or other abnormal conditions are
noted.
IEH511310042-01
Gears / Bearing
• Inspect forward, reverse and pinion gear teeth and
engaging dogs.
Replace gears if damaged, worn or other abnormal
conditions are noted.
• Inspect propeller shaft forward bearing, forward gear
thrust bearing. IEH511310045-02
Replace bearing if pitted, noisy, rough or other
IEH511310046-01
IEH511310043-01
• Check detent spring by measuring its free length. If
free length is not within specifications, replace detent
Forward Gear Bearing Housing spring.
• Inspect forward gear bearing housing. Detent spring free length “a”
Replace if cracked, damaged or other abnormal Standard: 27.8 mm (1.09 in.)
conditions are noted. Service limit: 25.0 mm (0.98 in.)
• Visually check bearing. Replace if pitted, rough or
other abnormal conditions are noted. “a”
IEH511310047-01
IEH511310044-01
Propeller Shaft Bearing Housing Shift Rod Guide Housing Components

• Inspect housing. Replace if cracked, damaged or • Inspect shift rod guide housing. Replace if cracked,
other abnormal conditions are noted. damaged or other abnormal conditions are noted.
• Inspect reverse gear bearing. Replace bearing if • Inspect shifter yoke. Replace if worn, damaged or
pitted, noisy, rough or other abnormal conditions are other abnormal conditions are noted.
noted. • Inspect shift rod/splines. Replace if worn, twisted,
• Check condition of oil seal and O-ring. damaged or other abnormal conditions are noted.
Replace oil seal and O-ring if nicked, cut, worn or • Inspect O-ring. Replace if nicked, cut, torn, swollen or
other abnormal conditions are noted. other abnormal conditions are noted.
• Inspect oil seal and dust seal. Replace if nicked, cut,
worn or other abnormal conditions are noted.
IEH511310048-01
IEH511310050-01
IEH511310049-01
IEH511310051-01
Driveshaft Oil Seal Housing Propeller Shaft Oil Seal Replacement

CENFH5113106009
• Inspect housing. Replace if cracked, damaged or
1) Remove the propeller shaft bearing housing.
other abnormal conditions are noted.
Refer to “Lower Unit Disassembly” (Page 3A-9).
• Check condition of oil seals. Replace if nicked, cut,
• Inspect O-ring. Replace if worn, nicked, cut or other
IFH511310008-01
2) Extract seals (1) with oil seal remover.
NOTICE
IEH511310052-01
Driveshaft
• Inspect driveshaft/splines. Replace if worn, twisted, Do not reuse the oil seal once removed.
damaged or other abnormal conditions are noted. Always use new one.
• Inspect driveshaft bearing, replace if pitted, noisy,
rough or other abnormal conditions are noted. Special tool
(A)
IEH511310053-01
IFH511310009-01
IEH511310054-01
3) Apply water resistant grease to the inner 3) Apply water resistant grease to inner circumference
circumference of the housing. of driveshaft oil seal housing.
: Grease 99000–25350 (SUZUKI Water : Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g)) Resistant Grease EP2 (250 g))
4) Using an oil seal installer, drive the two oil seals (one 4) Grease the inner lips of oil seal.
at a time) into the propeller shaft bearing housing. With the lips facing away from driveshaft bearing,
The lipped portion of the seal must face towards the place seal in position and drive it into the oil seal
propeller. housing.
Apply water resistant grease to the seal lips.
“A”
“A”
IEH511310059-02
IEH511310057-01 “A”: Direction of water pump case

“A”: Direction of propeller
5) Assemble the driveshaft oil seal housing.
5) Assemble the propeller shaft bearing housing. Refer to “Lower Unit Assembly” (Page 3A-16).
Refer to “Lower Unit Assembly” (Page 3A-16).
Lower Unit Assembly
CENFH5113106011
Driveshaft Oil Seal Replacement
CENFH5113106010 Assembly is in reverse order of disassembly with special
1) Remove the driveshaft oil seal housing. attention to the following steps.
Refer to “Lower Unit Disassembly” (Page 3A-9).
NOTICE
2) Using special tool, remove two oil seals out of the
Failure to correctly adjust the gear position
driveshaft oil seal housing.
will result in lower unit damage.
Special tool Before final assembly of lower unit, be
(A): 09913–50121 (Oil seal remover) absolutely certain that all gear contact, shim
adjustments and tolerances are correct.
NOTICE Refer to “Lower Unit Gears - Shimming and
Removing the oil seal can cause damage to Adjustment” (Page 3A-24).
Do not reuse the oil seal once removed. NOTE
Always use new one.
• Make sure that all parts used in assembly
are clean and lubricated.
• It is recommended that all seals, gaskets
and O-rings be replaced with new on
assembly.
(A) • After assembly, check parts for tightness
and smoothness of operation.
IEH511310058-01
Forward Gear Bearing Housing Driveshaft Collar

• Install dowel pin (1) and forward gear bearing housing • Install driveshaft collar (1).
(2).
NOTE
NOTE The tongue “A” of collar must be located into
Before installing forward gear, check for groove “B” on the gearcase.
correct amount and position of forward gear
radial bearing rollers.
Use oil soluble grease to retain bearing
rollers. “A”
“B”
1
1
IEH511310063-01
Pinion Gear
2
• Place pinion gear in gearcase.
IEH511310060-01
NOTE
Forward Gear
Before installing pinion gear, check for
• Place the forward gear back-up shim (1), thrust correct amount and position of pinion
washer (2), forward gear thrust bearing (3) in position, bearing rollers.
then install forward gear (4). Use oil soluble grease to retain bearing
rollers.
IEH511310061-01
IEH511310064-01
3
IEH511310062-01
Driveshaft • Install driveshaft oil seal housing on gearcase, then

• Install pinion shim (1), then lower the driveshaft tighten oil seal housing to specified torque.
assembly (2) down into the gearcase until the bottom Special tool
of shaft protrudes through center of pinion. (A): 09926–29310 (Driveshaft housing
remover)
Tightening torque
2 Driveshaft oil seal housing: 100 N·m (10.0 kgf-m,
72.5 lbf-ft)
(A)
IEH511310065-02
Driveshaft Oil Seal Housing

• Apply water resistant grease to the driveshaft oil seal.
• Apply water resistant grease to O-ring (1), then install
IEH511310068-01
O-ring into groove on the driveshaft oil seal housing.
: Grease 99000–25350 (SUZUKI Water Pinion Nut
Resistant Grease EP2 (250 g)) • Apply thread lock “1342” to the threads of pinion nut
(2) before threading it onto driveshaft.
NOTE
It is recommended the original pinion nut be
1
used for the purposes of shimming during
repair. A new pinion nut should be used on
final assembly.
• Install washer (1), pinion nut (2), then tighten nut to

• Install driveshaft bearing spacer (2). Tightening torque
Pinion nut (a): 145 N·m (14.5 kgf-m, 105.0 lbf-ft)
Special tool
(A): 09921–29410 (Driveshaft holder)
2
1
2
IEH511310067-02
IEH511310069-01
• Insert two small detent balls (4), large detent ball (5),
detent spring (6) and large detent ball (7) into
connector pin (3).
Then depress detent ball (7) and temporarily insert
stopper pin “C” into dog pin hole of connector pin, as
shown in figure.
(A)
(a)
IEH511310070-01
Propeller Shaft
4
• Slide the clutch dog shifter (1) onto the propeller shaft
(2). 6 7
5
NOTE IEH511310072-01
The marked side with identification grooves NOTE

“A” of the clutch dog shifter must face
towards reverse gear. Temporarily insert a gearcase dowel pin “C”
into the connector pin to prevent the detent
ball from falling out.
1 “B”
“C”
“C”
2
“A”
IEH511310071-01
IEH511310073-02
“A”: I.D. groove “B”: Reverse gear side
• Insert the connector pin (3) (with detent balls) into
propeller shaft (2).
• Align the holes in the clutch dog shifter and connector
pin and then slide the dog pin (8) through both clutch
dog shifter and connector pin. (save the temporarily
installed dowel pin pushed out as the dog pin is
inserted.)
• Install the dog pin retaining spring (9), ensuring that it
fits snugly into the groove on the dog shifter.
IEH511310074-02
Propeller Shaft / Bearing Housing • Using special tools, install the propeller shaft and
• Place the forward thrust washer (5) and reverse thrust housing assembly in the gear case with the mark “UP”
washer (1) on the propeller shaft. of housing toward upside.
• Install back-up shim (3) and reverse gear (2) to Special tool
propeller shaft bearing housing (4). (A): 09922–59410 (Propeller shaft housing
• Slide propeller shaft into reverse gear and propeller installer)
shaft bearing housing. Special tool
(B): 09922–59420 (Housing installer handle)
(A)
4
1 3
2
IEH511310075-01
(B)
• Assemble horizontal slider (6) to connector pin. IEH511310077-01
• Apply water resistant grease to bearing housing O-

ring (7).
6
IEH511310109-02
7 • When the housing is fully seated, tighten both

retaining bolts to the specified torque.
Tightening torque
IEH511310076-02 Bearing housing bolt (a): 23 N·m (2.3 kgf-m, 16.5
NOTE lbf-ft)
Before installing propeller shaft/bearing

housing assembly, move shifter dog to bring
horizontal slider to the neutral position.
(a)
IEH511310078-01
Checking Propeller Shaft Thrust Play • Install pin (7) and washer (6) to shift rod, then slide
Check propeller shaft thrust play. shift rod guide housing onto shift rod.
Refer to “Lower Unit Gears - Shimming and Adjustment” • Install dust seal (8) to shift rod guide housing.
(Page 3A-24).
NOTE
Be sure the horizontal slider (9) is in the
neutral position before installing the shift
unit (shift rod guide housing assembly.).
“A”
10
9
IEH511310079-01
Shift Rod Guide Housing

• Apply water resistant grease to the oil seal.
: Grease 99000–25350 (SUZUKI Water IEH511310082-01
Resistant Grease EP2 (250 g)) 9. Horizontal slider
• Using an oil seal installer, drive the oil seal (1) into the 10. Forward gear bearing housing
“A”: Shift rod center
shift rod guide housing (2).
The lipped portion of oil seal must face towards the
driveshaft housing. • Apply water resistant grease to the shift rod guide
housing O-ring.
NOTE
7 Before installing shift rod guide housing
1 assembly, bring shifter yoke to Neutral
position by turning shift rod right or left.
2 6
8
IEH511310080-01
• Attach shifter yoke (3) to shift rod (4), then insert pin
(5). Front
direction
IEH511310083-01
5 3
4
IEH511310081-01
• Install shift rod guide housing assembly by aligning Leakage Check

shifter yoke (3) with groove in horizontal slider (9), Check for leakage of oil seal and O-ring when applying
then tighten two housing bolts (11) securely. specified pressure inside of the gearcase.
1) Install the test tool into the oil drain 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.
11
NOTICE
Failure to correctly apply the test pressure
will result in oil seal damage.
Do not exceed pressure of 110 kPa (1.1 kg/

IEH511310084-01
cm2, 15.6 psi.).
9 NOTE
Apply low initial pressure of 20 – 40 kPa, (0.2
– 0.4 kg/cm2, 2.8 – 5.7 psi) first, then apply
specified pressure.
Special tool
(A): 09950–69512 (Gearcase oil leakage
tester)
3
(B): 09952–99320 (Hand air pump)
IEH511310085-01
Leakage pressure test
• Turn shift rod from Neutral position to Forward and 100 kPa (1.0 kg/cm2, 14.2 psi.)
Reverse position to check proper gear engagement.
(A)
(B)
IEH511310086-01
4) Once stabilized, pressure should remain steady for

at least 5 min.
If pressure does not fall, sealing performance is
correct.
Water Pump Trim Tab Adjustment

Install the water pump and related parts. CENFH5113106012
Refer to “Lower Unit Removal and Installation” (Page The trim tab counteracts or minimizes propeller torque
3A-6) and “Water Pump Removal and Installation” (Page pull felt through the steering system.
3A-7). If the steering is pulled to the starboard or port side,
adjust the trim tab with following procedure:
Propeller 1) Loosen the trim tab bolt (1).
Install the propeller.
Refer to “Propeller Removal and Installation” (Page 3A-
5).
Lower Unit
Install the Lower Unit.
Refer to “Lower Unit Removal and Installation” (Page 1
3A-6).
IEH511310087-01
2) Changing the trim tab setting.

• To compensate for a veer to starboard, set the
trailing edge of tab (2) to the right (as viewed from
behind).
• To compensate for a veer to port, set the trailing
edge of tab (2) to the left.
IEH511310088-01
3) Tighten the bolt of trim tab.

4) Test drive the boat and repeat the procedure 1) – 3)
to set the trim tab in the best position.
With a properly adjusted trim tab, steering should be
neutral and there should be no tendency for the
steering to be pulled to either port or starboard.
Lower Unit Gears - Shimming and Adjustment

CENFH5113106013
If the lower unit has been rebuilt or has had components replaced, shimming for the correct gear contact and backlash
will have to be checked and/or adjusted to ensure smooth, reliable operation.
Shim/Washer and mounting position
Item Available thickness (mm) Design specification thickness (mm)
0.45, 0.50, 0.55, 0.60, 0.65, 0.70, 0.75,
Pinion gear back-up shim 1.0
0.80, 0.85, 0.90
0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80,
Forward gear back-up shim 1.0
0.85, 0.90, 0.95, 1.0
Forward gear thrust washer 9.5 9.5
Propeller shaft reverse thrust 1.5, 1.7, 1.9, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6,
2.0
washer 2.7, 2.8
Reverse gear back-up shim 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7 1.5
2
4
IEH511310089-02
1. Pinion gear back-up shim 3. Forward gear thrust washer 5. Reverse gear back-up shim
2. Forward gear back-up shim 4. Propeller shaft reverse thrust washer
Forward Gear / Pinion Gear Back-Up Shim Adjusting gear backlash

Adjustment 1) Assemble special tools to driveshaft as shown in
Follow the procedure below to adjust forward gear/pinion figure.
gear.
Special tool
Prior to adjustment (A): 09900–20602 (Dial gauge)
1) Install standard pinion gear back-up shim thickness
(C): 09952–09310 (Backlash indicator tool)
modified according to ± design specification mark on
the gear.
(B) (C)
(A)
“A”
IEH511310090-01
“A”: ± design spec. mark

IEH511310092-01
2) Push forward gear inward and hold it by hand, align

2) Correctly assemble driveshaft oil seal housing,
dial gauge pointer at 90° to the mark on the backlash
driveshaft, forward gear, pinion gear and related
indicator tool and read backlash on dial gauge by
components.
lightly moving driveshaft clockwise and
Refer to “Lower Unit Assembly” (Page 3A-16).
counterclockwise by hand.
Do not install reverse gear at this time.
3) Tighten pinion nut to specified torque. Gear backlash
Approx. 0.3 – 0.5 mm (0.012 – 0.020 in.)
Tightening torque
Pinion nut: 145 N·m (14.5 kgf-m, 105.0 lbf-ft) (C)
(A)
IEH511310093-01
IEH511310091-01
IEH511310094-01
• If the backlash measured is larger than the

specification, add the amount over the
specification to the temporary use forward gear
back-up shim and install this shim.
• If the backlash measured is smaller than the
specification, subtract the amount less than the
specification from the temporary use forward gear
Checking and adjusting tooth contact pattern Optimum tooth contact

(Pinion gear and forward gear) The optimum tooth contact is shown in the figure.
Check tooth contact pattern using the following A shim adjustment may be necessary to obtain this
procedure: contact pattern.
1) To assess tooth contact, apply a light coat of
NOTE
Prussian Blue on the convex surface of the forward
gear. Gear backlash should be checked when
increasing or decreasing shim thickness to
2) Install the propeller shaft and housing assembly
adjust tooth contact.
(minus reverse gear and internal components).
3) Push the propeller shaft inward and hold in position.
Optimum tooth contact
“a”
“b”
Push “A”
“C”
“B”
I9J011310014-02
IEH511310095-01
“A”: Heel “a”: Approx. 1/3 of tooth width
“B”: Convex side “b”: Approx. 1 mm (0.04 in)
4) Using the driveshaft holder tool, rotate the driveshaft
“C”: Toe
5 – 6 times.
Special tool Example [A]
(A): 09921–29410 (Driveshaft holder) Incorrect topside toe contact:
Correction measures:
• Decrease thickness of forward gear shim.
• Slightly decrease pinion gear shim thickness.
(A)
NOTICE
Setting the tooth contact in the top side toe
contact may cause damage and chipping on
forward and pinion gears.
Do not set the tooth contact as such top side
toe contact.
IEH511310096-01
Example of incorrect
5) Carefully pull out propeller shaft and housing to
check tooth contact pattern.
“C”
“A”
“a”
“A”
“B”
“C” IEH511310097-01
“A”: Heel “C”: Toe

“F”
“G”
“D”
“E”
I9J011310013-02
“A”: Concave side “E”: Tooth bottom

“B”: Convex side “F”: Toe
“C”: Heel “G”: Tooth contact pattern
“D”: Tooth top “a”: Tooth width
Example [B] 2) Push the forward gear inward and fix it by hand, then
Incorrect bottom side toe contact: read backlash on dial graduation by lightly moving
Correction measures: driveshaft clockwise and counterclockwise by hand.
• Increase thickness of forward gear shim. Designate this amount of gear backlash as “A”.
• Slightly increase pinion gear shim thickness. NOTE
NOTICE Gear backlash “A” must be known to adjust
reverse gear shim.
Setting the tooth contact in the bottom side
toe contact may cause chipping on pinion Gear backlash “A”
gear. Approx. 0.3 – 0.5 mm (0.012 – 0.020 in)
Do not set the tooth contact as such bottom
side toe contact.
(C)
Example of incorrect
“C” (A)
“A” IEH511310100-01
IEH511310098-01
“A”: Heel “C”: Toe Reverse Gear Back-Up Shim Adjustment

After adjusting the forward gear tooth contact pattern,
Rechecking gear backlash follow the procedure below to adjust the reverse gear.
After obtaining optimum tooth contact, gear backlash 1) Correctly assemble and install reverse gear,
should be measured. propeller shaft, propeller shaft bearing housing and
1) Assemble special tool as shown in figure. related components.
Special tool 2) Screw a slide hammer assembly onto the propeller
(A): 09900–20602 (Dial gauge) shaft and strike it a few gentle outward taps.
(B): 09900–20701 (Magnetic stand) Special tool
(C): 09952–09310 (Backlash indicator tool) (A): 09930–30104 (Sliding hammer)
(B): 09930–30161 (Propeller shaft remover)
(B) (C)
(A)
(B)
(A)
IEH511310099-02
IEH511310101-01
3) Remove two bearing housing retaining bolts, then 7) Read backlash on dial gauge by lightly moving
screw long bolts of special tool to secure the bearing driveshaft clockwise and counterclockwise by hand.
housing. Designate this measurement as backlash (B).
Special tool 8) Compare backlash (B) to backlash (A).
(C): 09951–99310 (Gear holder) Refer to “Rechecking gear backlash” (Page 3A-27).
9) Reverse gear back-up shim adjustment is correct if
(B) is equal to (A).
• If (B) is less than (A), reduce reverse gear back-
up shim thickness.
Checking propeller shaft thrust play

After adjusting all gear positions, measure the propeller
shaft thrust play. If not within the following specification,
a shim adjustment is required.
Propeller shaft thrust play
Approx. 0.2 – 0.4 mm (0.008 – 0.0016 in.)
IEH511310102-01
4) Install the special tool and then attach it to the NOTE

propeller shaft as shown. Use only the propeller shaft reverse thrust
5) Turning bolt (1) counterclockwise to pull reverse washer to adjust thrust play.
gear outward, tighten lightly the bolt after having The forward gear thrust washer must be
stopped. Do not over tighten. maintained at standard thickness (9.5 mm).
Measurement step:
(C) 1) Assemble the gear adjusting gauge to the propeller
shaft.
Special tool
(A): 09951–09530 (Gear adjusting gauge)
(A)
IEH511310103-01
6) Assemble backlash indicator tool and dial gauge as

shown in figure.
Special tool
(D): 09900–20602 (Dial gauge)
(E): 09900–20701 (Magnetic stand) IEH511310105-01
(F): 09952–09310 (Backlash indicator tool)
2) Push propeller shaft inward.
3) Hold the shaft in and set the dial gauge pointer to
(F)
zero.
4) Slowly pull the shaft outward and read the maximum
thrust play on the dial gauge.
• If the measurement is more than the specification,
(D) increase the propeller shaft reverse thrust washer
thickness.
IEH511310104-01 • If the measurement is less than the specification,
reduce the propeller shaft reverse thrust washer
thickness.
Left Hand Rotation Unit: 3B-1
Left Hand Rotation Unit

Lower Unit

Diagnose Lower Unit Malfunction
CENFH5113204001
Trouble Check Chart

Engine stalls when Idling speed set too low. Adjustment.
engaging gear Propeller shaft bearings damaged, Replace.
lacking lubrication or seized.
Engaging gear(s) has no Clutch out of adjustment. Adjustment.
effect on propulsion Driveshaft broken or splines damaged. Replace.
Chipped or worn dog clutches. Replace.
Propeller not secured correctly (fallen Inspection or retighten.
off).
Loss of power (Assuming Propeller bush slipping. Replace.
engine is OK) Bent or worn propeller. Repair or replace.
Engine shakes the boat Failed propeller bush. Replace.
Bent driveshaft or propeller shaft. Replace.
Damaged propeller. Replace.
Clutch will not engage or Seized shift rod. Inspection.
disengage Clutch shaft and clutch rod have Inspection.
become detached.
Seized/broken remote control cable. Replace.
Problem at control box end. Inspection or replace.
3B-2 Left Hand Rotation Unit:
Lower Unit Components
CENFH5113206001
3 21
2
20
1
19
3
18
8
15
3
4 6
5
16
9 10
11
13 12 14
14 13 17
11
IFH511320001-02
1. Clutch lever 7. Throttle lever holder 13. Washer 19. Bearing

2. Clutch lever bushing 8. Clutch lever holder 14. Pin 20. Circlip
3. Bushing 9. Clutch shaft arm 15. Clutch shaft 21. Plug
4. Spring pin 10. E-ring 16. Clutch rod cover : Apply SUZUKI Water Resistant Grease.
5. Ball 11. Bushing 17. Clutch rod
6. Spring 12. Clutch lever link 18. Oil seal
24
23
22
25 52 (a)
26 50
27
51
28 53
29 54
55
29 30
31 56
57
58
32
37 59
36
35 34
38
34
33 47
49 48
41 39
45
44 40
43 (c) 42 (b)
46
IEH511320101-01
22. Shift rod 33. Nipple 44. Water filter PORT 55. Sealing
23. Bolt 34. Dowel pin 45. Water filter STBD 56. Inner sleeve
24. Clutch rod cover 35. Exhaust seal rubber 46. Screw 57. Water pump impeller
25. Shift rod housing 36. Exhaust seal plate 47. Anode 58. Under panel
26. O-ring 37. Grommet 48. Bolt 59. Gasket
27. Oil seal 38. Pinion bearing 49. Gearcase : 17 Nm (1.7 kgf-m, 12.5 lbf-ft)
28. Washer 39. Trim tab 50. Bushing : 83 Nm (8.3 kgf-m, 60.0 lbf-ft)
29. Pin 40. Bolt 51. Water pump case : 55 Nm (5.5 kgf-m, 40.0 lbf-ft)
30. Magnet 41. Washer 52. Bolt : Apply SUZUKI Water Resistant Grease.
31. Shifter yoke 42. Bolt 53. Dowel pin : Apply SUZUKI Silicone Seal.
32. Horizontal slider 43. Bolt 54. Key
108 (h)
107
106 109
105
104
103
61 (d)
62
102 (g)
111
63
64 (e)
60 65
66
101
67 99
100
98
97
68 96
69
70
71 (f)
87 95
72 (i)
86 94
83 93
92
85 90 91
73
84 89
88
81 82
79
80
76 77
78
73 74 75 110
72 (j)
IFH511320002-03
60. Driveshaft 76. Thrust spacer 92. Washer 108. Nut

61. Oil seal housing 77. Reverse gear bearing housing 93. Bearing 109. Pin
62. O-ring 78. Bearing 94. Washer 110. Bearing
63. Oil seal 79. Shim 95. Shim 111. Circlip
64. Nut 80. Reverse gear 96. Propeller shaft : 100 Nm (10.0 kgf-m, 72.5 lbf-ft)
65. Spacer 81. Detent ball 97. O-ring : 100 Nm (10.0 kgf-m, 72.5 lbf-ft)
66. Driveshaft bearing 82. Connector pin 98. Bearing : 145 Nm (14.5 kgf-m, 105.0 lbf-ft)
67. Shim 83. Detent ball 99. Propeller shaft bearing housing : 23 Nm (2.3 kgf-m, 16.5 lbf-ft)
68. Driveshaft collar 84. Detent spring 100. Bearing : 55 Nm (5.5 kgf-m, 40.0 lbf-ft)
69. Pinion gear 85. Clutch dog shifter 101. Oil seal : 10 Nm (1.0 kgf-m, 7.0 lbf-ft)
70. Washer 86. Dog pin 102. Bolt : 10 Nm (1.0 kgf-m, 7.0 lbf-ft)
71. Pinion nut 87. Dog spring 103. Stopper : Apply SUZUKI Water Resistant Grease.
72. Plug 88. Forward gear 104. Propeller : Apply SUZUKI Outboard Motor Gear Oil.
73. Gasket 89. Forward gear bearing 105. Propeller bushing set : Apply SUZUKI Thread Lock 1342.
74. Shift cam housing 90. Thrust washer 106. Spacer
75. Pin 91. Shim 107. Washer
Propeller Removal and Installation Installation

CENFH5113206002
1) Coat the propeller shaft splines liberally with Suzuki
! WARNING water resistant grease.
installing or removing the propeller can Resistant Grease EP2 (250 g))
2) Install propeller stopper (1) onto propeller shaft, then
When installing or removing the propeller: slide on the propeller (2).
• Shift into neutral and remove the 3) Fit spacer (3), washer (4) and nut (5), then tighten
emergency stop switch lock plate so that nut to specified torque.
the motor cannot be started accidentally. 4) Push cotter pin (6) through nut and shaft, then bend
• Wear gloves to protect hands, and lock the to secure.
propeller by placing a block of wood Tightening torque
between the propeller blade tips and the Propeller nut (a): 55 N·m (5.5 kgf-m, 40.0 lbf-ft)
anti-cavitation plate before attempting to
remove or install propeller nut. 3
2
Removal
5
2) Remove cotter pin (1) from propeller nut and remove 1 4
propeller nut (2).
3) Remove washer (3), spacer (4), propeller (5) and
stopper (6) from the propeller shaft.
I9J011310017-01
(a)
I9J011310001-01
4 I9J011310003-04
5
Propeller / Propeller Nut / Cotter Pin Inspection

1 CENFH5113206003
2 Refer to “Propeller / Propeller Nut and Cotter Pin
6 3 Inspection” in Section 0B (Page 0B-20).
I9J011310002-02
Lower Unit Removal and Installation Installation

CENFH5113206004
Removal 1) Apply water resistant grease to clutch rod splines,
then install clutch rod (1) by aligning clutch rod
! WARNING splines with splines in clutch shaft.

removing or installing the lower unit can Resistant Grease EP2 (250 g))
Always disconnect the battery cable, before

removing lower unit.
1) Remove STBD lower side cover.

2) Shift to neutral position. Remove bolt and trim tab 1
(1).
IEH511320007-01
2) Ensure that shift rod (2) is at neutral position.

1
NOTE
Before installing lower unit, bring shift to
Neutral position by turning shift rod right or
left.
Fron
t
IFH511320003-01 direc
2 tion
3) Remove seven bolts (2) and separate gearcase (3)
from driveshaft housing.
IEH511320008-01
3) Insert two dowel pins (3).

3 4) Apply water resistant grease to driveshaft and shift
rod splines.
5) Apply a light coating of silicone seal to mating
IFH511320004-01 surfaces of gearcase and driveshaft housing.
4) Remove clutch rod (4) from clutch shaft (if : Sealant 93691–80030 (SUZUKI Silicone
necessary). Seal (100 g))
3
4
IFH511320005-01
IEH511320009-01
6) Set the clutch control lever (4) at neutral position, Water Pump Removal and Installation
then slide the lower unit (5) into place, ensuring that CENFH5113206005
the top of driveshaft engages properly with driven Removal

gear shaft and that water tube locates in water pump 1) Remove the lower unit.
case outlet. Refer to “Lower Unit Removal and Installation” (Page
3B-6).
NOTE 2) Loosen four bolts (1), then remove water pump case
In order for shift rod and clutch rod splines to (2).
be aligned correctly, clutch rod may need to
be turned slightly right or left.
IEH511320012-01
4
3) Remove impeller (3), impeller key (4), pump under
“Neutral” panel (5) and dowel pins (6).
IFH511320006-01
Keep impeller key (4) for reuse and discard the plate
7) Apply silicone seal to seven gearcase bolts (6) and gasket.
tighten them to specified torque.
Seal (100 g)) 3
Tightening torque
Gearcase bolt (10 mm) (a): 55 N·m (5.5 kgf-m, 6
40.0 lbf-ft)
5
Gearcase bolt (12 mm) (b): 83 N·m (8.3 kgf-m, 4
60.0 lbf-ft)
5 6 (a) 6
IEH511320013-01
4) Remove inner sleeve (7) and rubber sealing (8).
NOTE
6 (b)
To facilitate the removal of inner sleeve from
the pump case, warm up the entire case
using a heater like hair dryer.
IEH511310011-04
8) Shift the clutch control lever to forward and reverse

position from neutral position to check proper gear
engagement.
9) Install the lower side cover.
7 8
IEH511320014-01
Installation
1) Place the dowel pins (1), under panel gasket (2) and
under panel (3) into position.
2) Insert the key (4) in the driveshaft and slide the
impeller (5) onto driveshaft, ensuring that key and
keyway are aligned.
8
1 5
IEH511320017-02
3
4 NOTE
Before installing water pump case assembly,
apply water resistant grease lightly on pump
2 1 case inner sleeve and under panel for initial
lubrication.
IEH511320015-01
3) Place the sealing (7) into groove of the pump case

(6).
NOTE
Do not reuse sealing once removed.
IEH511320018-01
5) Install the pump case assembly (9) while rotating

6
driveshaft clockwise to flex the impeller vanes in the
7 correct direction.
Securely tighten the four pump case bolts (10) to the
specified torque.
IEH511320016-01 Tightening torque
4) Install inner sleeve (8) into the pump case, ensuring Water pump case bolt (a): 17 N·m (1.7 kgf-m,
that projection of inner sleeve and groove of pump 12.5 lbf-ft)
case are aligned.
NOTE
Before installing pump inner sleeve, apply
water resistant grease lightly between inner 9
sleeve and pump case mating surfaces.

Resistant Grease EP2 (250 g)) 10 (a)
IEH511320019-01
6) Install the Lower Unit.

Refer to “Lower Unit Removal and Installation” (Page
3B-6).
Water Pump and Related Item Inspection Lower Unit Disassembly

CENFH5113206006 CENFH5113206007
Inspect the following parts. 1) Remove the lower unit.
• Inspect impeller. Replace if vanes are cut, torn, worn Refer to “Lower Unit Removal and Installation” (Page
or other abnormal conditions. 3B-6).
• Inspect pump case. Replace if cracked, distorted or 2) Remove the propeller.
other abnormal conditions are noted. Refer to “Propeller Removal and Installation” (Page
• Inspect pump inner sleeve. Replace if worn, cracked, 3B-5).
distorted, corroded or other abnormal conditions are 3) Remove the water pump and related parts.
noted. Refer to “Water Pump Removal and Installation”
• Inspect under panel. Replace if cracked, distorted, (Page 3B-7).
corroded or other abnormal conditions are noted. 4) Place a drain pan under oil drain plug. Remove oil
drain plug (1) first then air vent plug (2) and allow
NOTE gear oil to drain.
Do not reuse sealing once removed. Inspect oil for water, contaminates or metal.
1
IEH511310108-02
5) Remove two bolts (3) and shift rod guide housing

IEH511320020-01 assembly (4).
IEH511320021-01 IEH511320023-03
6) Remove two bolts (5) securing the propeller shaft

bearing housing to the gearcase.
IEH511320024-03
7) Using special tools, pull out the propeller shaft 9) Use special tool to unscrew driveshaft oil seal
bearing housing. Remove the propeller shaft and housing (9), then remove oil seal housing from
bearing housing assembly (6). driveshaft.
Special tool Special tool
(A): 09930–30104 (Sliding hammer) (D): 09926–29310 (Driveshaft housing
(B): 09930–30161 (Propeller shaft remover) remover)
(D)
(A)
6 9
(B)
IEH511320099-02 IEH511320027-03
8) Hold the pinion nut securely, then fit special tool to 10) Remove driveshaft bearing spacer (10).
the driveshaft and loosen the pinion nut (7). Remove
pinion nut (7) and washer (8).
Special tool
(C): 09921–29410 (Driveshaft holder)
10
(C)
IEH511320028-03
11) Slowly lift out driveshaft assembly (11).

Remove the pinion shim (12).
NOTE
IEH511320025-01
The driveshaft pinion gear bearing contains
22 loose roller bearings. Account for all roller
bearings on disassembly.
8
11
12
7
IEH511320026-03
IEH511320029-03
12) Remove the driveshaft collar (13). 15) To disassemble propeller shaft components, refer to
following.
a) Slide propeller shaft (19) away from forward gear
(21) and bearing housing assembly (20).
13
19
20
IEH511320030-03
13) Remove the pinion gear (14). 21

Remove the reverse gear (15) (with reverse gear
bearing housing and thrust bearing). IEH511320033-03
b) Remove the forward gear (21), forward gear

thrust bearing (22), forward gear thrust washer
(23), forward gear back-up shim (24).
22
21
14
15
IEH511320031-03
14) Remove the thrust bearing (16), reverse gear

bearing housing (17) and back-up shim (18) from 24
23
reverse gear. IEH511320034-03
c) Remove the propeller shaft thrust washer (25),

propeller shaft thrust bearing (26), bearing
washer (27) and shim (28) from propeller shaft
bearing housing.
16 28
27
26
25
17
18
IEH511320032-03
IEH511320035-03
d) Remove horizontal slider (29). g) Remove large detent ball (34), detent spring
Remove the spring (30) from the clutch dog (35), large detent ball (36) and two small detent
shifter (31). balls (37) from connector pin (33).
33
29
37
30 31 34
35
36
IEH511320036-03 IEH511320039-03
e) Use special tool to push the dog pin (32) out of 16) To disassemble shift rod components, refer to
the clutch dog shifter (31). following.
Special tool a) Remove dust seal (38).
(E): 09922–89810 (Shift lock pin b) Slide shift rod (39) out of shift rod guide housing
remover) (40).
c) Draw the oil seal (41) out of shift rod guide
housing (40).
(E)
32
39
41
31 40
IEH511320037-03
f) Remove the clutch dog shifter (31) and 38

connector pin (33) from propeller shaft. IEH511320040-03
d) Separate the shifter yoke (42) from shift rod (39)

by driving out the pin (43).
43 42
31
33 32
IEH511320038-03
39
IEH511320041-03
Lower Unit Related Item Inspection Gears / Bearing

CENFH5113206008
• Inspect forward, reverse and pinion gear teeth and
! WARNING engaging dogs.
Failure to following proper precautions Replace gears if damaged, worn or other abnormal
during use of the compressed air may cause conditions are noted.
severe personal injury. • Inspect forward gear thrust bearing.
Replace bearing if pitted, noisy, rough or other
Wear safety glasses when using compressed abnormal conditions are noted.
air.
NOTE
• If any component is worn excessively,
cracked, defective or damaged in any way,
it must be replaced.
• Thoroughly wash all metal components
with cleaning solvent and dry with
compressed air.
Gearcase
IEH511320043-01
• Inspect the gearcase. Replace if cracked, damaged or
other abnormal conditions are noted. Reverse Gear Bearing Housing / Bearing
• Visually check the pinion bearing. Replace gearcase if • Inspect the reverse gear bearing housing.
pitted, rough or other abnormal conditions are noted. Replace if cracked, damaged or other abnormal
• Visually check shift cam housing. condition are noted.
Replace gearcase if cracked, damaged or other • Visually check bearing. Replace if pitted, noisy, rough
abnormal conditions are noted. or other abnormal condition are noted.
IEH511320042-01 IEH511320044-01
IEH511320100-01
Propeller Shaft Components Propeller Shaft Bearing Housing

• Inspect horizontal slider and connector pin. • Inspect housing. Replace if cracked, damaged or
Replace if worn, damaged or other abnormal other abnormal conditions are noted.
conditions are noted. • Inspect forward gear bearing and propeller shaft
• Inspect detent balls. Replace if wear, damage or other bearing. Replace bearing if pitted, noisy, rough or
abnormal conditions are noted. other abnormal conditions are noted.
• Inspect clutch dog shifter. Replace if chipped, worn, • Check condition of oil seal and O-ring. Replace oil
damaged or other abnormal conditions are noted. seal and O-ring if nicked, cut, worn or other abnormal
• Inspect dog pin. Replace if bent, worn or other conditions are noted.
• Inspect propeller shaft/splines. Replace if worn,
twisted, damaged or other abnormal conditions are
noted.
IEH511320047-01
IEH511320045-01
IEH511320048-01
IEH511320046-01
• Check detent spring by measuring its free length. If

free length is not within specifications, replace detent
spring.
Detent spring free length “a”
“a”
I9J011310062-01
Shift Rod Guide Housing Components Driveshaft

• Inspect shift rod guide housing. • Inspect driveshaft/splines. Replace if worn, twisted,
Replace if cracked, damaged or other abnormal damaged or other abnormal conditions are noted.
conditions are noted. • Inspect driveshaft bearing, replace if pitted, noisy,
• Inspect shifter yoke. Replace if worn, damaged or rough or other abnormal conditions are noted.
• Inspect shift rod/splines. Replace if worn, twisted,
damaged or other abnormal conditions are noted.
• Inspect O-ring. Replace if nicked, cut, torn, swollen or
• Inspect oil seal and dust seal. Replace if nicked, cut,
IEH511320052-01
IEH511320049-01
IEH511320053-01
Propeller Shaft Oil Seal Replacement

CENFH5113206009
1) Remove the propeller shaft bearing housing.
Refer to “Lower Unit Disassembly” (Page 3B-9).
IEH511320050-01

• Inspect housing. Replace if cracked, damaged or
• Check condition of oil seals. Replace if nicked, cut,
• Inspect O-ring. Replace if worn, nicked, cut or other
IFH511320007-01
IEH511320051-01
2) Extract the seals (1) with oil seal remover. Driveshaft Oil Seal Replacement
CENFH5113206010
NOTICE 1) Remove the driveshaft oil seal housing.
Removing the oil seal can cause damage to Refer to “Lower Unit Disassembly” (Page 3B-9).
the seal lips, causing oil to leak. 2) Using special tool, remove two oil seals out of the
driveshaft oil seal housing.
Do not reuse the oil seal once removed.
Special tool
Always use new one.
Special tool NOTICE
Do not reuse the oil seal once removed.

Always use new one.
(A)
1
(A)
IFH511320008-01
3) Apply water resistant grease to the inner

circumference of the housing.
IEH511320057-01
4) Using an oil seal installer, drive the two oil seals (one
3) Apply water resistant grease to inner circumference
at a time) into the propeller shaft bearing housing.
of driveshaft oil seal housing.
The lipped portion of the seal must face towards the
propeller. Apply water resistant grease to the seal : Grease 99000–25350 (SUZUKI Water
lips. Resistant Grease EP2 (250 g))
4) Grease the inner lips of oil seal.
With the lips facing away from driveshaft bearing,
“A”
place seal in position and drive it into the oil seal
housing.
IEH511320056-01
“A”: Direction of propeller

“A”
5) Assemble the propeller shaft bearing housing.

Refer to “Lower Unit Assembly” (Page 3B-17). IEH511320058-01
“A”: Direction of water pump case
5) Assemble the driveshaft oil seal housing.

Refer to “Lower Unit Assembly” (Page 3B-17).
Lower Unit Assembly Driveshaft Collar

CENFH5113206011
Assembly is in reverse order of disassembly with special • Install driveshaft collar (1).
attention to the following steps. NOTE
NOTICE The tongue “A” of collar must be located into
Failure to correctly adjust the gear position groove “B” on the gearcase.
will result in lower unit damage.
Before final assembly of lower unit, be
absolutely certain that all gear contact, shim
“A”
adjustments and tolerances are correct.
(Refer to “Lower Unit Gears - Shimming and
Adjustment” (Page 3B-24).)
“B”
NOTE
1
• Make sure that all parts used in assembly
are clean and lubricated.
• It is recommended that all seals, gaskets
and O-rings be replaced with new on IEH511320061-01
assembly.
• After assembly, check parts for tightness Pinion Gear
and smoothness of operation. • Place pinion gear (1) in gearcase.
Reverse Gear NOTE

• Assemble the reverse gear (1), back-up shim (2), Before installing pinion gear, check for
reverse gear bearing housing (3) and reverse gear correct amount and position of pinion
thrust bearing (4), then install reverse gear/bearing bearing rollers.
housing assembly. Use oil soluble grease to retain bearing
rollers.
4 1
3
2
1
IEH511320059-01
IEH511320062-01
IEH511320060-01
Driveshaft • Install driveshaft oil seal housing on gearcase, then

• Install pinion shim (1), then lower the driveshaft tighten oil seal housing to specified torque.
assembly (2) down into the gearcase until the bottom Special tool
of shaft protrudes through center of pinion. (A): 09926–29310 (Driveshaft housing
remover)
Tightening torque
2 Driveshaft oil seal housing (a): 100 N·m (10.0 kgf-
m, 72.5 lbf-ft)
(A)
IEH511320063-01

• Apply water resistant grease to the driveshaft oil seal. (a)
• Apply water resistant grease to O-ring (1), then install
IEH511320066-01
O-ring into groove on the driveshaft oil seal housing.
: Grease 99000–25350 (SUZUKI Water Pinion Nut
Resistant Grease EP2 (250 g)) • Apply thread lock 1342 to the threads of pinion nut (1)
before threading it onto driveshaft.
NOTE
It is recommended the original pinion nut be
1
used for the purposes of shimming during
repair. A new pinion nut should be used on
final assembly.
• Install the washer (2) and tighten pinion nut (1) to

• Install driveshaft bearing spacer (2). Special tool
(A): 09921–29410 (Driveshaft holder)
Tightening torque
Pinion nut (a): 145 N·m (14.5 kgf-m, 105.0 lbf-ft)
2
2
1
IEH511320065-01
IEH511320067-01
• Insert two small detent balls (3), large detent ball (4),
detent spring (5) and large detent ball (6) into
connector pin (7). Then depress detent ball (6) and
temporarily insert stopper pin “C” into dog pin hole of
connector pin, as shown in figure.
(A)
7
(a)
IEH511320068-01
3
Propeller Shaft
• Slide the clutch dog shifter (1) onto the propeller shaft 4 5 6
(2).
IEH511320070-01
NOTE
NOTE
The marked side with identification grooves
“A” of the clutch dog shifter must face Temporarily insert a gearcase dowel pin “C”
towards reverse gear. into the connector pin to prevent the detent
ball from falling out.
“B” “C” “C”
1
“A” IEH511320071-02
IEH511320069-03
• Insert the connector pin (7) (with detent balls) into
“A”: I.D. groove “B”: Reverse gear side propeller shaft (2).
• Align the holes in the clutch dog shifter and connector
pin and then slide the dog pin (8) through both clutch
dog shifter and connector pin. (save the temporarily
installed dowel pin “C” pushed out as the dog pin is
inserted.)
• Install the dog pin retaining spring (9), ensuring that it
fits snugly into the groove on the dog shifter.
7
8
IEH511320072-03
Forward Gear / Propeller Shaft / Bearing Housing 4. Slide propeller shaft (11) into forward gear and
Assemble the propeller shaft in the following sequence. propeller shaft bearing housing (6).
1. Apply water resistant grease to O-ring (1), then 5. Assemble horizontal slider (12) to connector pin.
install the O-ring into the groove on the propeller
shaft bearing housing.
11
12
6
1 IEH511320076-01
NOTE
IEH511320073-01
Before installing propeller shaft/bearing
housing assembly, move shifter dog to bring
horizontal slider to the neutral position.
: Gear Oil 99000–22B22 (SUZUKI Outboard
Motor Gear Oil) 6. To hold the correct bearing position, pull propeller
2. Install shim (2), bearing washer (3), propeller shaft shaft backward and then install propeller shaft and
thrust bearing (4), propeller shaft thrust washer (5) housing assembly in the gearcase with the mark
into propeller shaft bearing housing (6). “UP” of housing toward upside.
2
3
4
5
IEH511320074-01
3. Install forward gear back-up shim (7), forward gear

thrust washer (8), forward gear thrust bearing (9) IEH511310109-02
and forward gear (10) to propeller shaft bearing

NOTE
housing.
To make the bearing housing fully seated in
the gearcase, tap the housing gently with
plastic mallet.
9
10
7
8
IEH511320075-01
IEH511320077-01
7. When the housing is fully seated, tighten both • Attach shifter yoke (3) to shift rod (4), then insert pin
retaining bolts to the specified torque. (5).
Tightening torque
Bearing housing bolt (a): 23 N·m (2.3 kgf-m, 16.5
lbf-ft)
5 3
4
IEH511320081-01
• Install pin (7) and washer (6) to shift rod, then slide
(a)
shift rod guide housing onto shift rod.
IEH511320078-01 • Install dust seal (8) to shift rod guide housing.
Checking Propeller Shaft Thrust Play NOTE

Check propeller shaft thrust play. Be sure the horizontal slider (9) is in the
Refer to “Lower Unit Gears - Shimming and Adjustment” neutral position before installing the shift
(Page 3B-24). unit (shift rod guide housing assembly).
10
“A”
IEH511320079-01
IEH511320082-01
Shift Rod Guide Housing 9. Horizontal slider “A”: Shift rod center
10. Shift cam housing
• Apply water resistant grease to oil seal (1).
Using an oil seal installer, drive the oil seal (1) into the
shift rod guide housing (2). The lipped portion of oil
seal must face towards the driveshaft housing.
7
1
2 6
8
IEH511320080-01
• Apply water resistant grease to the shift rod guide Leakage Check
housing O-ring. Check for leakage of oil seal and O-ring when applying
specified pressure inside of the gearcase.
Resistant Grease EP2 (250 g)) 1) Install the test tool into the oil drain hole.
2) Connect the air pump to the tester.
NOTE
3) Rotate driveshaft and propeller shaft clockwise
Before installing shift rod guide housing several times and then apply specified pressure for
assembly, bring shifter yoke to Neutral the test.
position by turning shift rod right or left.
NOTICE
Failure to correctly apply the test pressure
will result in oil seal damage.
Do not exceed pressure of 110 kPa (1.1 kg/

Fro
dire nt cm2, 15.6 psi.).
ctio
n
NOTE
Apply low initial pressure of 20 – 40 kPa (0.2
– 0.4 kg/cm2, 2.8 – 5.7 psi.) first, then apply
specified pressure.
IEH511320083-01 Special tool

• Install shift rod guide housing assembly by aligning (A): 09950–69512 (Gearcase oil leakage
shifter yoke (3) with groove in horizontal slider (9), tester)
then tighten two housing bolts (11) securely. (B): 09952–99320 (Hand air pump)
Leakage pressure test
100 kPa (1.0 kg/cm2, 14.2 psi.)
11
(A)
IEH511320084-02 (B)
IEH511320086-01
3
4) Once stabilized, pressure should remain steady for
at least 5 min.
If pressure does not fall, sealing performance is
correct.
9
IEH511320085-01
• Turn shift rod from Neutral position to Forward and

Reverse position to check proper gear engagement.
Water Pump Trim Tab Adjustment

Install the water pump and related parts. CENFH5113206012
Refer to “Lower Unit Removal and Installation” (Page The trim tab counteracts or minimizes propeller torque
3B-6) and “Water Pump Removal and Installation” (Page pull felt through the steering system.
3B-7). If the steering is pulls to the starboard or port side, adjust
the trim tab with the following procedure.
Propeller 1) Loosen the trim tab bolt (1).
Install the propeller.
Refer to “Propeller Removal and Installation” (Page 3B-
5).
Lower Unit
Install the Lower Unit.
Refer to “Lower Unit Removal and Installation” (Page 1
3B-6).
IEH511310087-01
2) Changing the trim tab setting.

• To compensate for a veer to starboard, set the
trailing edge of tab (2) to the right (as viewed from
behind).
• To compensate for a veer to port, set the trailing
edge of tab (2) to the left.
I9J011310010-03
3) Tighten the bolt of trim tab.

4) Test drive the boat and repeat the procedure 1) – 3)
to set the trim tab in the best position.
With a properly adjusted trim tab, steering should be
neutral and there should be no tendency for the
steering to be pulled to either port or starboard.
Lower Unit Gears - Shimming and Adjustment

CENFH5113206013
If the lower unit has been rebuilt or has had components replaced, shimming for the correct gear contact and backlash
will have to be checked and/or adjusted to ensure smooth, reliable operation.
Shim/Washer and mounting position
Item Available thickness (mm) Design specification thickness (mm)
0.45, 0.50, 0.55, 0.60, 0.65, 0.70,
Pinion gear back up shim 1.0
0.75, 0.80, 0.85, 0.90
0.50, 0.55, 0.60, 0.65, 0.70, 0.75,
Forward gear back up shim 1.0
0.80, 0.85, 0.90, 0.95, 1.00
0.60, 0.70, 0.80, 0.90, 0.95, 1.00,
Propeller shaft thrust shim 1.0
1.05, 1.10, 1.15
0.45, 0.50, 0.55, 0.60, 0.65, 0.70,
Reverse gear back up shim 1.0
0.75, 0.80, 0.85, 0.90
3
4 2
IEH511320088-04
1. Pinion gear back-up shim 3. Propeller shaft thrust shim

2. Forward gear back-up shim 4. Reverse gear back-up shim
Reverse Gear / Pinion Gear Back-Up Shim Adjusting gear backlash

Adjustment 1) Assemble special tools to driveshaft as shown in
Follow the procedure below to adjust reverse gear/pinion figure.
gear.
Special tool
Prior to adjustment (A): 09900–20602 (Dial gauge)
1) Install standard pinion gear back-up shim thickness
(C): 09952–09310 (Backlash indicator tool)
modified according to ± design specification mark on
the gear.
(B)
(C)
(A)
“A”
IDG211320108-01
“A”: ± design spec. mark

IEH511320090-01
2) Correctly assemble driveshaft oil seal housing, 2) Push reverse gear inward and hold it by hand, align
driveshaft, reverse gear, pinion gear and related dial gauge pointer at 90° to the mark on the backlash
components. indicator tool and read backlash on dial gauge by
Refer to “Lower Unit Assembly” (Page 3B-17). lightly moving driveshaft clockwise and
Do not install forward gear at this time. counterclockwise by hand.
Gear backlash
Approx. 0.6 – 0.8 mm (0.024 – 0.031 in.)
(C)
(A)
IEH511320089-01 IDG211320097-03
3) Tighten pinion nut to specified torque. • If the backlash measured is larger than the
Tightening torque specification to the temporary use reverse gear
Pinion nut: 145 N·m (14.5 kgf-m, 105.0 lbf-ft) back-up shim and install this shim.
specification from the temporary use reverse gear
Forward Gear Shim 4) Install forward gear and propeller shaft housing
After adjusting reverse gear backlash, follow the assembly into gearcase, then tighten both bearing
procedure below to adjust forward gear. housing retaining bolts to specified torque.
Adjusting gear backlash

1) Correctly assemble driveshaft oil seal housing,
driveshaft, reverse gear, pinion gear and related
components.
Refer to “Lower Unit Assembly” (Page 3B-17).
2) Tighten pinion nut to specified torque.
Tightening torque
Pinion nut: 145 N·m (14.5 kgf-m, 105.0 lbf-ft)
3) Correctly assemble forward gear, forward gear
bearing, propeller shaft, propeller shaft thrust IEH511320093-01
bearing, propeller shaft bearing housing and related 5) Assemble special tool to driveshaft as shown in
components. figure.
When assemble the forward gear and propeller shaft
Special tool
housing assembly, place the special tool between
(B): 09900–20602 (Dial gauge)
clutch dog shifter and forward gear as shown in the
(C): 09900–20701 (Magnetic stand)
figure.
(D): 09952–09310 (Backlash indicator tool)
NOTE
• Before installing special tool, move shifter (C)
dog to reverse position. (D)
• Use longer spring (free length: 42.3 mm, (B)
1.67 in) in the gear adjust spring set to
adjust the forward gear backlash.
Special tool
(A): 09951–09310 (Gear adjust spring set)
(A)
IEH511320094-01
6) Align dial gauge pointer at 90° to the mark on the

backlash indicator tool and read backlash on dial
gauge by lightly moving driveshaft clockwise and
counterclockwise by hand.
Gear backlash
Approx. 0.3 – 0.5 mm (0.012 – 0.020 in)
IEH511320091-01
(D)
(A)
(B)
IEH511320095-01
• If the backlash measured is larger than the

specification to the temporary use forward gear
IEH511320092-03
specification from the temporary use forward gear
Checking and adjusting tooth contact pattern 3) Using the driveshaft holder tool, rotate the driveshaft
(Pinion gear and forward gear) 5 – 6 times.
Check tooth contact pattern using the following
Special tool
procedure:
(B): 09921–29410 (Driveshaft holder)
1) To assess tooth contact, apply a light coat of
Prussian Blue on the convex surface of forward gear.
NOTE
(B)
• Use shorter spring (free length: 23.8 mm,
0.94 in) in the gear adjust spring set and
install it between forward gear and clutch
dog to check the tooth contact pattern.
• Before installing special tool, move shifter
dog to reverse position.

(A): 09951–09310 (Gear adjust spring set)
4) Carefully pull out the propeller shaft and housing to
check the tooth contact pattern.
(A) “A”
“a”
“B”
“C”
“F”
“G”
“D”
“E”
IEH511320097-02 I9J011310013-02
“A”: Concave side “E”: Tooth bottom

“B”: Convex side “F”: Toe
“C”: Heel “G”: Tooth contact pattern
(A)
“D”: Tooth top “a”: Tooth width

The optimum tooth contact is shown in the figure. A shim
adjustment may be necessary to obtain this contact
pattern.
NOTE
IEH511320092-03
Gear backlash should be checked when
increasing or decreasing shim thickness to
2) Install forward gear and propeller shaft housing
adjust tooth contact.
assembly into gearcase, then tighten both bearing
housing retaining bolts to specified torque.
“a”
“b”
“A”
“C”
“B”
I9J011310014-02
“A”: Heel “a”: Approx. 1/3 of tooth width

IEH511320096-01 “B”: Convex side “b”: Approx. 1 mm (0.04 in)
“C”: Toe
Example [A] Checking propeller shaft thrust play

Incorrect topside toe contact. After adjusting all gear positions, measure the propeller
Correction measures. shaft thrust play. If not within the following specification,
• Decrease thickness of forward gear shim. a shim adjustment is required.
• Slightly decrease pinion gear shim thickness. NOTE
NOTICE Use only the propeller shaft thrust shim to
adjust thrust play.
Setting the tooth contact in the top side toe
contact may cause damage and chipping on Propeller shaft thrust play
forward and pinion gears. Approx. 0.2 – 0.4 mm (0.01 – 0.02 in.)
Do not set the tooth contact as such top side
toe contact. 1) Assemble the gear adjusting gauge to the propeller
shaft.
Example of incorrect Special tool
(A): 09951–09530 (Gear adjusting gauge)
“C”
“A” (A)
I9J011310015-01
Example [B]
Incorrect bottom side toe contact.
Correction measures.
• Increase thickness of forward gear shim.
• Slightly increase pinion gear shim thickness. IDG211320105-01
NOTICE 2) Push propeller shaft inward.

3) Hold the shaft in and set the dial gauge pointer to
Setting the tooth contact in the bottom side
zero.
toe contact may cause chipping on pinion
gear. 4) Slowly pull the shaft outward and read the maximum
Do not set the tooth contact as such bottom thrust play on the dial gauge.
side toe contact. • If the measurement is more than the specification,
increase the propeller shaft thrust shim thickness.
Example of incorrect • If the measurement is less than the specification,
reduce the propeller shaft thrust shim thickness.
“C”
“A”
I9J011310016-01
Section 4
Wire / Hose Routing

CONTENTS
Precautions .................................................4-1 Wiring Harness Routing Diagram........................4A-2

Precautions............................................................. 4-1
Precautions for Wire / Hose Routing..................... 4-1
Fuel / Water Hose Routing ...................... 4B-1
Component Location ............................................. 4-1 Precautions...........................................................4B-1
Electrical Component Location ............................. 4-1 Precautions for Fuel / Water Hose Routing.........4B-1
Schematic and Routing Diagram ........................4B-1
Wire Routing ............................................ 4A-1 Fuel Hose Routing ..............................................4B-1
Schematic and Routing Diagram........................4A-1 Evaporation Hose Routing ..................................4B-5
Wiring Diagram ................................................... 4A-1 Water Hose Routing............................................4B-6
4
4-1 Precautions:
Precautions
Wire / Hose Routing
Precautions
Precautions for Wire / Hose Routing
CENFH5114000001
Component Location
Electrical Component Location
CENFH5114003001
Wire / Hose Routing
DUAL BATTERY CHARGING SYSTEM SINGLE BATTERY CHARGING SYSTEM
Bl
(OPTION) (STD) DIGITAL GAUGE DIAGRAM
BATTERY BATTERY BATTERY OIL PRESSURE SWITCH (OPTION)
NO.2 NO.1 NO.1
CAP
Wiring Diagram
MAP W
R
B/W
P/W
G/W
Bl/B
SENSOR
60A
IAC
VALVE O/Bl
30A
30A
30A
10A
30A
30A
10A
W/B GAUGE
Gr/R CONNECT
P/W
G/W
Bl/B
Gr/R
W/Bl
R/Y
MAIN
MAIN
RELAY
P/W
RELAY
SDS
B
Wire Routing
B/Bl
G/W
Bl/B
CONNECT
Y
O/Y
GAUGE
THROTTLE Br/Y CONNECTOR
R
B/W
10A
POSITION SENSOR
10A
G/W
P/W
Bl/B
MAGNETO
HIGH PRESSURE Bl Gr CKP
B B/R
FUEL PUMP STARTER
RELAY
RELAY
SENSOR
MOTOR
STARTER
STARTER
SDS
INJECTOR
INJECTOR
FUEL PUMP
FUEL PUMP
REGULATOR
OUTPUT No.2
REGULATOR
OUTPUT No.1
REGULATOR
OUTPUT No.1
CONNECTOR
PTT SWITCH
PTT SWITCH
REGULATOR
OUTPUT No.2
ISC. VSV. VVT

ISC. VSV. VVT
M
ECM. IGN COIL

ECM. IGN COIL
CAP
R
R
IAT SENSOR
R
CMP SENSOR #1 CMP SENSOR #2
Y
FUSE CIRCUIT DIAGRAM
O/Y
B/W B/W
FUSE BOX O/G
B
STARTER Y/Bl
B/Bl
R/B
B/Bl B/Bl B/W
MAIN MOTOR Lg/B
B/G
B
RELAY RELAY
IGNITION
Gr
COIL #1 O/B #1
R/B
FUSE Gr/Bl B
10A 30A 30A 10A 60A 30A FUEL INJECTOR
B/W
B/W Gr Gr
Gr W O
B
Lg/Bl W
O2 SENSOR
R
R
R
R
G
W
W
Gr
Gr
P/B
Y/G
R/W
R/W
W/R
P/Y R
Gr/R
W
R
Lg/W B
W
Gr
B/W B
B/Bl
BONDER #1 KNOCK SENSOR
Y/G
CYLINDER TEMP
B
SENSOR
BONDER #2 V/W B
R/G B/W B
B
Gr
B
LIGHTING EX-MANI TEMP
SWITCH B
2200mF 25V
BONDER #3
B/W
Gr
SENSOR IGNITION
Refer to “Wire Color Symbols” in Section 0A (Page 0A-2).
R/G COIL #2
B TROLL MODE NEUTRAL
Y
Y
R/G
SWITCH
B
SWITCH Y Gr
B
Gr B N ON Bl/Y Gr
R/G
B B METER Gr B B/Br #2
UP DN
R
F, R OFF
B
R FUEL INJECTOR
SHIFT R
R/G
B POSITION
Lbl W
SENSOR RECTIFIRE &
R/G
R/G
P
Gr Gr TRIM
B
B B W/Y W/Y W/Y REGULATOR
METER B V B
Gr/R
R/G R/G
JOINT CONNECTOR #1
B B
Bl
Gr Gr
B B TACHOMETER Bl/B Bl/B
G/Y G/Y
Y Y P P
Y
B
WITH LED
Y/G
G/W G/W
Br
Gr/R
10A Gr/G
PTT SWITCH IGNITION VSV
P/Bl
B/W
B/Bl
DN UP NEUTRAL SWITCH COIL #3
Y/G
R
REMOTE CONTROL BOX N ON Gr
F, R OFF Gr R/W #3
Gr/Y
W TUBE B
FUEL INJECTOR
Lbl Lbl
PUSH FREE ST IG OFF Lg W/R
R P
IGNITION GND B
Br/R
SWITCH STOP G Gr/R
BATT W
OCV
SUZUKI
IG Gr
Br Br W/Y W/Y
START Br Br Br B V
Bl/B Bl/B
BZ G/Y G/Y
RESET O Lbl Lbl P P/W
W/R W/R G/W G/W
PUSH TURN P P Lbl Lbl
P P
O O O O/W
BZ Gr Gr W W W W
Bl Bl Br Br Br Br
W/R W/R Y Y/B
G G G Bl/R IGNITION
B G Gr Gr Gr B/Bl
B B Bl Bl/W Bl/W Bl/W
B B B B COIL #4
OVER HEAT & OIL WARNING BUZZER Gr
B
EMERGENCY
#5
Lg/R Gr
B Lg #4
STOP SWITCH W
LOCK PLATE IN RUN R R
FUEL INJECTOR
B
P
R
G
Bl
Br
W
P/Y
LOCK PLATE OFF STOP

R/Y
Lbl
O/B
O/G
P/W
P/B
W/B
R/W
Bl/Y
Y/G
O/Y
Bl/B
R/Bl
Br/R
P/Bl
Bl/W
Gr/G
Lg/W
Gr/Bl
Bl/R
Lg/Bl
R/Bl
V
P
Y
B
B
O
Gr
Gr
Lg
Lbl
#4
Y/B
G/Y
B/R
R/B
B
W/Y
W/Y
V/W
Y/Bl
B/W
G/W
O/W
B/Bl
O/Bl
Br/Y
B/Br
Gr/Y
W/Bl
Lg/R
Lg/B
W
W/Y
B
R
B/W
WATER DETECTION
JOINT SWITCH
B/W Lg
R CONNECTOR
W/R
B P
B
W/Y
Lbl
Lg
R
B/W
Lbl
BATTERY PTT ECM

12V 100AH RELAY
Lbl
W/R
Lbl
Lbl
B B
B
R
UP DN
B
R
W
B/W B/W
TRIM & TILT PTT TILT LIMIT
SENSOR PTT SWITCH MOTOR SWITCH
Wire Routing:
IFH511410001-06
CENFH5114102001
4A-1
4A-2 Wire Routing:
Wiring Harness Routing Diagram

CENFH5114102002
“A” 12
“D”
4 G
3
9 10 (a)
13
11
H
6 15
14
“C”
7 8
“B”
“L”
3 “E”
F 2 3
5
“A”
“D”
I 1
K
17
16
“B”
3
“C”
17
J “B”
“L”
18
“E”
IFH511410002-05
1. Electric parts holder 17. SDS connector

2. Wiring harness 18. Harness bracket
3. Clamp “A”: To IAC valve
4. Fuse box “B”: To ignition coils
5. Joint connector: “C”: To rectifier/regulator
The joint connector is fixed with stopper as shown.
6. Lead wire bonder: “D”: To starter motor
Arrange lead wire bonder as shown.
7. Main harness “E”: To neutral switch.
8. Main harness “F”: The joint connector is fixed with stopper as shown.
9. Washer “G”: Check position of lead wires after installing PTT relay.
10. Nut “H”: PTT relay is fixed with hooks (H) of electric parts holder as shown.
11. Cap: “I”: Set protrusion of PTT relay cushion to square hole of electric parts
Insert two main harness lead wires into cap hole and fit back of their holder.
terminals together. Cover the terminal with cap.
12. SDS connector lead wire “J”: Route the lead wire above the hook.
13. Gauge connector lead wire “K”: Set protrusion of ECM cushion to square hole of electric parts holder.
14. Isolator lead wire connector: “L”: To GND
Set lock part of isolator lead wire connector as shown.
15. PTT relay : 4.5 Nm (0.45 kgf-m, 3.3 lbf-ft)
16. ECM
Wire Routing: 4A-3
21
6 (a)
7 22 (b)
1
8 23
2 3
20 (c)
4
19 (b)
3 5
10
9
12 “A”
11
13
13
14 “B”
18
11
17
12
15 16
IFH511410003-04
1. Starter motor: 15. Tilt limit switch lead wire connector

Install starter motor after assembling the lower damper (2).
2. Starter motor lower damper 16. Trim sensor lead wire connector
3. Starter motor band 17. Main harness GND lead wire
4. Main harness (R) lead wire: 18. Rectifier/regulator
Set main harness (R) lead wire parallel to battery positive (+) cable.
5. Battery positive (+) cable 19. Ex. manifold temp. sensor
6. Nut 20. O2 sensor
7. Cap 21. IAT sensor:
Set the lock part of connector upward.
8. Clamp: 22. Cylinder temp. sensor
Set the cut portion of clamp to the rear side of engine.
9. Main harness GND lead wire: 23. Clamp:
Flat surface of respective cable terminal are put together. Bind the stator harness and O2 sensor harness in the left side of engine
hook.
10. Battery negative (–) cable “A”. Route main harness (R) lead wire between battery negative (–) and
positive (+) cables.
11. Washer “B”. Twist battery cable as shown.
12. Cushion : 8.5 Nm (0.85 kgf-m, 6.2 lbf-ft)
13. Cushion: : 8 Nm (0.8 kgf-m, 5.8 lbf-ft)
Install the cushion to the crankcase bosses.
14. Clamp: : 10 Nm (1.0 kgf-m, 7.2 lbf-ft)
Clamp the main harness, trim sensor lead wire and tilt limit switch
lead wire with the battery cable.
4A-4 Wire Routing:
11 (c) 4 4
6 “C”
5
3 7
“A”
8
2 6
1 8
3 7
“B”
10 (b)
12 (d)
13 (e)
“a”
9 (a)
IFH511410004-04
1. Battery charge coil 12. Flywheel bolt

2. Pin 13. IAC valve
3. Clamp “A”: Taping portion
4. Side cover seal “B”: Outside
5. Speedometer hose (optional parts) “C”: Inside
6. Trim sensor lead wire “a”: 45°
7. PTT cable : 13 Nm (1.3 kgf-m, 9.4 lbf-ft)
8. Tilt limit switch lead wire : 8 Nm (0.8 kgf-m, 5.8 lbf-ft)
9. Oil pressure switch: : 10 Nm (1.0 kgf-m, 7.2 lbf-ft)
Tighten the lead wire 45° as shown. Cover the oil pressure switch with
cap.
10. Cylinder temp. sensor : 118 Nm (11.8 kgf-m, 85.3 lbf-ft)
11. O2 sensor : 1.5 Nm (0.15 kgf-m, 1.1 lbf-ft)
Wire Routing: 4A-5
2 “A”
4 (a)
1
3
7
9 6
5
7
9
6
8
2 “B” 10
11
“C”
IFH511410005-04
1. IAC valve 9. Fuel injector connector

2. Clamp 10. Clamp:
Clamp the knock sensor lead wire at the right side of water return
hose.
3. Throttle position sensor 11. Fuel drain hose
4. Knock sensor “A”: Place the clamp in this range.
5. VSV “B”: Route the knock sensor lead wire behind the fuel hose.
6. Harness “C”: Pass the tilt limit switch and trim sensor lead wires outside of the
fuel drain hose.
7. Fuel injector lead wire: : 22 Nm (2.2 kgf-m, 16.0 lbf-ft)
Make sure not to pinch the fuel injector lead wire between harness and
fuel delivery pipe.
8. Fuel delivery pipe
4A-6 Wire Routing:
1 2 3
5
“A”
9
6
10
8
IFH511410006-03
1. CMP sensor #1 7. Ignition coil #4

2. CMP sensor #2 8. Harness bracket
3. IAT sensor 9. Clamp:
Place the tip of clamp forward of engine.
4. Ignition coil #1 10. OCV
5. Ignition coil #2 “A”: Route harness back of fuel delivery pipe.
6. Ignition coil #3
Wire Routing: 4A-7
2
“C”
“E” 4
5 “D”
“A” “B”
10
7
6
9 8 11
(a)
IFH511410007-02
1. CKP sensor 10. Remote controller harness

2. Evaporation hose 11. Cable holder
3. High pressure fuel pump “A”: Front side
4. Clamp: “B”: Engine side
Clamp the main harness, trim sensor lead wire and tilt limit switch lead
wire with the battery cable.
5. Clamp: “C”: Route the high pressure fuel pump lead wire outside the evaporation
Clamp the main harness and battery cable. hose.
6. Main harness “D”: Put the terminal on the main harness.
7. Battery cable “E”: Place the clamp in this range.
8. Water hose : 5 Nm (0.5 kgf-m, 3.6 lbf-ft)
9. Speedometer hose (optional parts)
4A-8 Wire Routing:
1
3 6
View A
2
(a)
“A”
3
“A”
10
“C”
(a)
“B”
11 8
8
9
7
9
12
IFH511410008-05
1. PTT switch 10. Clamp

2. Band: 11. Tilt limit switch
Bind three cables within 20 mm (0.79 in) from side cover seal hole.
3. Clip: 12. Marking:
Clamp trim sensor lead wire, PTT cable and speedometer hose When lowering the unit to the limit, the marking should be hidden in clamp
(Optional parts). bracket.
4. Band: “A”: Clamp trim sensor lead wire at white taping point. Clamp the lead wire
Bind center of cables. and cable in order of “A” → 2 → 4.
5. Clamp “B”: Clamp tilt limit switch lead wire at yellow taping point.
6. PTT cable clip bracket “C”: Draw lead wires to engine side to avoid slack in this area.
7. Trim sensor : 6 Nm (0.6 kgf-m, 4.3 lbf-ft)
8. Trim sensor bracket : Apply SUZUKI water resistant grease.
9. Trim sensor lever : Apply SUZUKI thread lock 1342.
Fuel / Water Hose Routing: 4B-1
Fuel / Water Hose Routing

Wire / Hose Routing
Precautions
Precautions for Fuel / Water Hose Routing
CENFH5114200001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions on Fuel System Service” in Section 1G
(Page 1G-1).

Fuel Hose Routing
CENFH5114202001
5
4
3
1
IFH511420001-01
1. Fuel hose (fuel connector to low pressure fuel filter) 4. Low pressure fuel pump
2. Low pressure fuel filter / water detection switch 5. O-ring
3. Fuel hose (low pressure fuel filter to low pressure fuel pump) 6. Fuel hose (low pressure fuel pump to 2-way union)
4B-2 Fuel / Water Hose Routing:
15 4 5 10 9
13
3
8
14 7
5
11
2
“a” 12
1
12 16
IFH511420002-08
1. Fuel hose (fuel connector to low pressure fuel filter) 10. 3-way union
2. Low pressure fuel filter/water detection switch 11. Fuel cooler
3. Fuel hose (low pressure fuel pump to 2-way union) 12. Fuel hose (fuel cooler to fuel vapor separator)
4. 2-way union 13. Fuel hose (3-way union to fuel delivery pipe)
5. Fuel hose (2-way union to fuel vapor separator) 14. Fuel delivery pipe
6. Fuel vapor separator 15. Breather hose
7. Fuel hose (fuel vapor separator to high pressure fuel filter) 16. Fuel drain hose
8. High pressure fuel filter “a”: 40 mm (1.57 in.) or more
9. Fuel hose (high pressure fuel filter to 3-way union)
7
6
15
3
“A”
13
14
12 9
1 10
11
IFH511420003-04
1. Fuel hose clamp bracket 9. Fuel hose (2-way union to fuel vapor separator):
Pass the fuel hose (2-way union to fuel vapor separator) so as not to be
squashed between MAP sensor and fuel hose guard.
2. Clamp: 10. Clamp:
The mark position of the fuel hose (3) is installed to the clamp. Place the clamp onto the mark position of fuel hose.
Make sure fuel hose is away from 3-way union hose clip.
3. Fuel hose (fuel connector to low pressure fuel filter) 11. Fuel hose (high pressure fuel filter to 3-way union)
4. Fuel injector 12. 3-way union
5. Fuel injector cushion 13. Fuel hose (3-way union to fuel cooler)
6. Clamp: 14. Fuel hose (3-way union to fuel delivery pipe)
The mark position of the fuel hose (3) is installed to the clamp.
7. Fuel hose (low pressure fuel pump to 2-way union) 15. Clamp
8. 2-way union “A”: Place the clamp (15) in this range.
“b”
“a”
(a) (a)
3 4
3 5
3
“A”
“B”
1
1
(a)
(a)
IFH511420004-03
1. Fuel vapor separator “A”: Unpainted area

2. Fuel hose (fuel vapor separator to high pressure fuel filter) “B”: Insert the fuel hose (fuel vapor separator to high pressure fuel filter) to high
pressure fuel filter union unpainted area.
3. High pressure fuel filter “a”: 35°
4. Fuel cooler “b”: 58°
5. Fuel delivery pipe : 35 Nm (3.5 kgf-m, 25.3 lbf-ft)
2
1
3
IFH511420005-01
1. Fuel hose guard 3. Clamp

2. Fuel hose guard guide 4. Cushion
Evaporation Hose Routing

CENFH5114202002
2
2
1
1 4
“a”
IFH511420006-05
1. Evaporation hose “A”: Assemble the evaporation hose outward the ring gear under cover.
2. Clamp: “B”: Pass the evaporation hose between battery positive (+) and negative (-)
Clamp the evaporation hose not to touch the balancer cover. cables.
3. Clamp: “a”: 8 – 12 mm (0.31 – 0.47 in.)
Install the clamp on marking tape on harness.
4. Hose union
Water Hose Routing

CENFH5114202003
9
1
5
10
5 4
“A”
1
11
11
“B”
2
6 8
IFH511420007-06
1. Water hose (balancer water jacket cover to 3-way union) 8. Water indicator
2. Water hose (3-way union to fuel cooler) 9. Thermostat
3. Water hose (fuel cooler to 3-way union) 10. Thermostat cover
4. 3-way union 11. Water return hose
5. Water hose (3-way union to thermostat cover) “A”: Connect the water return hose to thermostat cover with the painting mark side “A” up.
6. Water hose (engine holder to cylinder block) “B”: Place the clamp between fuel injector #3 and low pressure fuel filter bracket.
7. Water hose (cylinder block to water indicator)
3 1
6
9
“A” 8 10
7
IFH511420008-05
1. Fuel hose guard 7. O-ring

2. Water hose (3-way union to fuel cooler) 8. Water hose (engine holder to cylinder block)
3. Water hose (3-way union to thermostat cover) 9. Water hose (cylinder block to water indicator)
4. Thermostat cover 10. Water indicator
5. Water return hose “A”. Face the clip tip forward.
6. Water return union
4
1
1 3
2
IFH511420009-04
1. Engine holder cover 4. Water hose (cylinder block to water indicator)

2. Gasket 5. Water indicator
3. Water hose (engine holder to cylinder block)
2
IFH511420010-03
1. Water hose (oil pan to 3-way union) 5. Water hose (balancer water jacket cover to 3-way union)
2. 3-way union 6. Water hose (3-way union to fuel cooler):
Route water hose (3-way union to fuel cooler) outside of the drain
union of fuel vapor separator.
3. Water hose (3-way union to balancer water jacket cover) 7. Fuel vapor separator drain union
4. Balancer water jacket cover
2
2
1
4
5
IFH511420011-05
1. Water hose (oil pan to 3-way union): 4. Water flush hose

Route water hose (oil pan to 3-way union) outside of the evaporation hose.
2. Balancer water jacket cover 5. Evaporation hose
3. Gasket
Prepared by
Outboard Motor Engineering Department
October, 2014
Manual No. 99500-96L00-01E
Printed in Japan
428
99500-96L00-01E
99500-96L00-01E
2014
No.55-800 99500-96L00-01E DF200A Service Manual Cover for PS printing (XXmm) 5/1 2014/7/29 DIC619 Pantone 303C Pantone 485 Pantone 294 Black

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99500-96L00-01E

WARNING / CAUTION / NOTICE / NOTE

© COPYRIGHT SUZUKI MOTOR CORPORATION 2014

Precautions ...............................................00-1 Precautions........................................................... 00-1

General Information ................................ 0A-1 Periodic Maintenance Schedule Chart................0B-1

Wire Color Symbols

B (Base Color: Black)

Bl (Base Color: Blue) Bl/B

Warning, Caution and Information Label Locations

1. Label, engine cover 2. Label, mag cover 3. Label S.I.G.P.

Outboard Motor Identification Number Location Fuel and Oil Recommendations

Use only unleaded gasoline. Do not use fuel

IEH511010002-03 Suzuki highly recommends that you use alcohol-free

20003F-XXXXXX Engine Oil

API Classification SAE Viscosity Grade

Break-In Procedures Throttle Recommendation

Break-in period The throttle may be briefly opened beyond

During the last 7 hours of break-in operation,

Propeller Selection Guide Battery Requirement

Dimensions and Weight

Fuel and Oil

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

Cylinder Head / Camshaft

Valve / Valve Guide

Cylinder / Piston / Piston Ring

MAP sensor 1 3–4 0

Cylinder temp. sensor 1–4 0

IAT sensor 2–3 0

CKP sensor 4–2 0

CMP sensor #1 2–4 0

Air intake system 2–2 0

MAP sensor 2 3–2 0

Exhaust manifold temp. sensor 1–5 0

Fuel injector 4–3 0

Throttle position sensor 2–1 0

Shift position sensor 1–2 0

CMP sensor #2 (VVT) 2–6 0

VVT advance 5–1 0

Neutral switch 3–3 0

Oil control valve 6–1 0

Rectifier/Regulator (Over-charging) 1–1 0

Oil pressure switch 5–3 0

Trim sensor 3–7 0

Knock sensor 5–4 0

O2 sensor heater 6–3 0

Tightening Torque Specifications

Thread Tightening torque

I9J011010014-01 10 mm 22 – 35 2.2 – 3.5 16.0 – 25.5

I9J011010015-01 10 mm 34 – 41 3.4 – 4.1 24.5 – 29.5

I9J011010016-01 10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5

Special Tools and Equipment

93691–80030 99000–22B22 99000–25350 99000–31140 99000–32050

09900–20101 09900–20202 09900–20203 09900–20204 09900–20205

09900–20602 09900–20605 09900–20606 09900–20607 09900–20701

09900–20803 09900–21304 09900–22301 09900–22302 09900–25008