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    DT40

    Uploaded by

    Vasilis

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    SUZUKI outsoarD motor DT40C/GE/GER pT40w /Wwik Ta eae FOREWORD This service manual has been prepared primarily for experienced Suzuki mechanics. However, itis believed that apprentices and do-it-yourself mechanics will find it as an extremely useful repair guide. This manual thoroughly covers the most up-to-date information of the DT40C, DT40CE and DT40CER models which are of standard specifications. Since these models are subject to some correction or modifi cation at any time, if found necessary, they will possibly differ in specifications from outboard motors which have been already in service. However, such differences, even if any, have only little or no detri- mental effect on those outboard motors at the time of service provided, To emphasize special information, the words WARNING, CAUTION and NOTE carry special meanings and should be carefully reviewed. WARNING . - The personal safety of the user may be involved. Disregarding this information could result in injury to the owner. = These instructions point out special service procedures or precautions that must be followed to avoid damaging the outboard motor. = Special information to make maintenance easier or important instructions clearer. CAUTION . NOTE. T NOTE: This manual is compiled based on ‘85 (VF) models SUZUKI MOTOR CORPORATION Marine & Power Products Division Copying, quoting or reproducing any part of this Manual is not permitted without explicit approval by SUZUKI MOTOR CORPORATION. @ a ® Motor cover ® Shite lever ® Pilot water hole ® Aoti cavitation plato ® Tilt release lever Tilt tension nut @ Stern brackets Flush plug GD Oil drain plug NOMENCLATURE @) Fuel line coupler ® Speed control grip ® Stop button @ Tie adjusting roa 5 Woter intake ® Gear case {1D Skeg ® Water discharge hole @ Trim tab 28 Fuel gauge ‘The other side ® ® @ @ 3 ww o o ® a e 0 Alirsvent screw Fuel tank Prime bulb Fuel line Remote control lever Remote control box Emergency stop switch Lock-out button Ignition switeh Warm-up lever GROUP INDEX Teal GROUP TITLE EE GENERAL INFORMATION [Eq] ELECTRICAL AND IGNITION [El FUEL system Ey Power UNIT [Ey] HOUSING AND BRACKET [Gy LOWER UNIT EE MOTOR SETTING AND OPTIONAL PARTS [EE TROUBLESHOOTING EE t40w “vr” (85) MODEL ET] pt40c “Vx” (87) MODEL EE pt40c “iL” (90) MODEL EY] _0140¢/40w/40wKk “N” (92) MODEL EE] Dt40T¢ “Rr” (94) MODEL GENERAL INFORMATION CONTENTS MAIN SPECIFICATION BREAKING:IN .... MAINTENANCE, INSPECTION AND SERVICING . SPECIAL TOOL... seeeeeeeeeee APPLICATION CHART OF MATERIALS REQUIRED. . . TIGHTENING TORQUE CHART ........ COOLING SYSTEM ......... SPECIFICATION SERVICE DATA ....... 6 GENERAL INFORMATION MAIN SPECIFICATION Starter system: Maximum horse power: Manual starter 29.4 kW (40PS) a a RE Electric starter TN Brace RN Ny) | © orsocen i / teem Reed valve (SS Tilt position: 5 stages Maximum tilt up angle: 72 degree Cooling system: Displacement type water pup 2.09 (23:11) Clutch type Dog clutch Fig. 1-1 Ignition system: ‘Suzuki “PEI” C.D.1. unit Z) Displacement: ree G30: ® 79 mm (3.11 in) ® 71 mm (2.80 in) © 696 cm? (42.46 cu.in), Exhaust system: Through prop hub exhaust Gear oil: 610 ml (20.6/21.5 US/Imp. oz) BREAKING-IN Breaking.in period is initial 15 hours. This initial 15 hours of operation is the critical period. Adhere to the following treatment referring to the table. In early stagos of broak-in operation, the separate fuel tank (23 liters) should be filled with @ 50 : 1 gasoline-oil mixture and used in combination with the oil from the oil tank. GENERAL INFORMATION 7 ® During initial 5 minutes, operate the engine at trolling speeds. ® During the first 10 hours, operate the engine with a partial throttle (within 1/2 throttle opening). In this period, operate the engi with full throttle for about 1 minute at every 10 minutes. © For the latter 5 hours, operate the engine with ‘a partial throttle (within 3/4 throttle opening). In this period, also operate the engine with full throttle for about 1 minute at every 10 minutes. 50 parts of gasoline to 1 part of SUZUKI CCI oil or BIA certified lubricant or 30 parts of gasoline to 1 part of other out: board motor oil. © Fuel and oil are seperately supplied to the engine. ® tem $10, 20,99 40,50, | Period | (Minutes) (Hours) Breaking-in period Operating La ® remixing gasoline Boil oO ® Fig. 1-2 8 GENERAL INFORMATION MAINTENANCE, INSPECTION AND SERVICING Keeping thie outboard motor in the best operable condition at all times involvee neithor cumbersome measures nor costly expert attention: just carry out simple regular intervals. ordinary services in a systematic manner at This outboard motor user should be advised to go by the following schedule, which is based on the con- cept of systematic care Servicing intervals tions for tightness | tions for tightness "en Tst1Ohrs | Every 50s | Every 100hre Remertt Bolts and nuts | Retighten Retighten. Refer to Service Data. ] Clean and adjust ~ /BBHS 0.8 — 0.9mm Spark plugs i plugga. | _ (0.031 — 0.035in.) Wrehamear | Gheck connec” Gheck connee — *Starting motor brushes _ | _ ition timing | Check brush for | Limit: 8mm | wear (0.354in.) [Check end adjust | ATOO2" — BTDC25° Fuel strainer Check for clean- lines Check for fuel Check for fuel Fuel hoses leakage and hose | [leakage cracking Check for erack | Check for erack Lubrication hose | ond ‘breakage and breakage Water pump Carburetor Check and adjust_| Check and adjust oe Hypoid gear oil, Gear oil (Change Change SAE ESD 616 ml Pistons, cylinder De-carbon | Renew gasket when andhead | 7 _ | de-carboning_ vller eck for damay Grease propeller Propeler _ Check fer damoee | Check foremost | shat | Check for proper | Check for proper | - - Choke operation __| operation | 1 ~ Fuel tank | _ [Check impeller | and casing for Replace if worn, interlock switch | Usually check “OFF” and “ON” | | | wear out Handle Grease | Adjust pre-load | Grease I [Clutchiever Grease __ Io “I Check for tear | Starter rope \ and wear 1 Tit dust pretoad f — | *Neutral start WON” SS - 1 * Only for electric starter type. GENERAL INFORMATION 8 SPECIAL TOOL ‘Snap ring remover Micrometer Dial gauge (closing type) 11,000 mm: 09900-20602 09900-06108 50 ~ 75 mm: 09900-20203 | 1/100 mm: 08900-20606 T-handle box wrench Cylinder gauge set Dial gauge chuck ‘8 mm: 09900-00302.015 10 mm: 09900-00302.017 12 men: 09900.00302.018 114 mm: 09900-00302.019 09900-20508 09900-20701 Impact driver set Thickness gauge 09900.09003 ‘Bit (medium): 09900-09204 Small ne. 75 mm: 09900-21303 (BBIt (large): 09900-09205 09900-20803 Large ..« 100 mm: 09900-21304 Vernier caliper Pocket tester Gear adjusting gauge ot 09951-09510 (09900-20101: Scale 150 mm (09900-20102: Seale 200 mm 10 GENERAL INFORMATION Engine tachometer (Analogue type) 09900.26003 | Electro-tester 09900.28106 SUZUKI converter 09900.28603 Engine tachometer (Digital type) Hydrotester Outboard test wheel 09900-26006 09900-28403 09914-79980 Timing tight Torque wrench Je shaft holder (12V battery-operated) ‘9990071101 eo Ss) 50 ~ 450 kg-om: 100~ 900 kg-em: 09900-21103 09900-27301 500 ~ 2,800 kg-em: 09900-21104 09921-29510 Timing light CCI oil measuring CDI checker (Dry-cell-operated) cylinder ae 09930-76420 09900-21602 09930-99810 GENERAL INFORMATION W | Rotor remover | e © = | Fee, gi=2688 Fer =IeF = | = | Propalle shaft housing installer | CD: Flywheel/propeller shat housing o ooseasoat0 renover plete § ea lore Soe if 0992259420 @: Flywheel remover bolts. douse 20420 ee Shifter lock pin remover Flywheel holder ® ® Attachment 09951-19430 @ Plat 09951-30914 © Shaft 0906189010 Dbort 01107-08408 © wut 08310-12088, | 09922-89810 09930.39520 | Sliding shaft Oil Teakage tester | if cc de | © 09950-69511 | 09930-20102 09821-00004 Propeller shaft housing CD11. test cord Dial calipers remover 09930-30101 09930.09440 09900-20605 12_ GENERAL INFORMATION APPLICATION CHART OF MATERIALS REQUIRED PART NAME PART NO.| NET | __ PART NAME PART NO.| NET SUZUKI SUPER SUZUKI SILICONE SEAL GREASE “A” | 99000-25010 450 ¢ 99000-31120) 50 1 carton 99000-25160 |(12 tubes) 12506 GREASE 1 carton 99000-25170 (12 tubes) 1509 ‘SUZUKI BOND NO. 4 99000-31030 2009 THREAD LOCK SUPER “99330"" 99000:82020| 509 SUZUKI OUTBOARD. MOTOR GEAR OIL 1 carton (24 bes) |400 mt 99000-22540 99000-32050, 509 SEALING COMPOUND 366E a 7 99000-31090) 180 mi {Super oil] '99000-21750/ 0.5L 1.0L (SHELL | SEKIVO) L arrau- ‘sisi! O1L) 4.0L 200L, 99000-21745, 99000 21460 | 99000-21021 ‘99000-21150 99000.21640| 050 99000-21640 100) OSL 10L (SHELL SEKIYU) 1.0L | 99000-21250] wwiPPON om) '99000-21260| 4.0L 99000-21270, 200 GENERAL INFORMATION 13 ENGINE COVER, RECOIL STARTER, MAGNETO, OIL TANK, OIL PUMP 14__ GENERAL INFORMATION CYLINDER, INLET CASE, EXHAUST COVER, SILENCER, CARBURETOR, CRANKSHAFT, IGNITION GENERAL INFORMATION 15 16 GENERAL INFORMATION CLUTCH, STARTER MOTOR, FUEL PUMP, LOWER COVER, HANDLE-GRIP (DT40C) STEERING BRACKET, CLAMP BRACKET, SWIVEL BRACKET Fig. 1-6 GENERAL INFORMATION 17 18 GENERAL INFORMATION DRIVESHAFT HOUSING, WATER PUMP, GEARCASE, EXHAUST TUBE, TRANSMISSION, PROPELLER, GENERAL INFORMATION __ 13 O08 Gea (go J) (the other sie) 610m1 Oe a [Set Fig. 1-9 20 GENERAL INFORMATION REMOTE CONTROL BOX (DT40CER), FUEL TANK Fig, 1-10 GENERAL INFORMATION 21 REMOTE CONTROL BOX (OPTION) Fig. 1-11 22__ GENERAL INFORMATION TIGHTENING TORQUE CHART —— Flywheel nut 200 — 21.0 kam ea Crankcase bolt — 6mm |0.8—1.2kgm [_Bimm [20-26 kom 10mm | 4.6 6.4 kgm — Engine set bolt (6 mm) Upper and lower- | 15 -20ko-m mounting bolt — —— &mm 25-27 kom 10mm 465.4 kgm \— Exhaust tube bolt (6 mm) 11.5 -2.0 kgm L - Pinion nut 12 mm —__ —o 3.0~40 kgm ] Fig, 1-12 Tightening torque for general bolt Types of bolt | By , (Convrint or "marked od ay By Tons {Stainless steel bolt) 10 | | 34-41 | 245-295 = ‘03-08 | 20-48 | - 6 | 08-12 60- 85 8 is-28 | Te0-200 CT marked marked bot wo 40-00 | 20-438 _GENERAL INFORMATION 23 COOLING SYSTEM DESCRIPTION The cooling system employs a perfect cooling system with a displacement type water pump. Water is pumped up and supplied to the cylinder and cylinder head. To prevent incomplete combustion due to an overcooled engine, the cylinder head water passage is provided with a thermostat, by which the water ‘temperature is automatically maintained at a proper level. COOLANT CIRCUIT Main water inlet | | Sub water inlet | Thermostat - 4 + Water pump Cylinder (Exhaust case) Cylinder head Engine nolaer Pilot water _ — + hole Engine holder [-—sl Pilot water hole % Water outlet Water tube i 1 exhaust tube [exhaust tube -——— 4 4 | Woter pump: aL Engine holder it {_Enaine holder Subwater inlet Main water inlet _ |__Water outlet | [exhaust outlet oS i Fig, 1-13 24 GENERAL INFORMATION WATER PUMP Displacement type water pump In this displacement type water pump, the water pressure is increased by the change in volume between the impeller and the pump case. As & result, the increased water pressure enables the water pump to send out the cooling water. a Driveshaft Water pump case SSN THERMOSTAT Description The temperature sensing material contained in the thermostat is wax. The wax is in pellet form, and expands and contracts according as the temperature rises and falls. By expanding, the wax pellet case pushes up the valve to unseat it, thus permitting the coolant to flow through the valve. As the temperature falls, the pellet case contracts to allow the valve to seat, thus preventing the coolant from circulat- ing. In the top part of the thermostat is provided an air breather hole ®. This hole is for letting out the air or yases, if any, Uapped inside the cooling circuit ‘An abnormal coolant temperature rise is often due to the wax pellet case being unable to un- seat the thermostat valve. In such a caso, test the thermostat to determine whether it should be replaced or not. mir Pump case under pane! Impeller Water inlet Water outlet Impelter Key Fig. 1-14 ‘Thermostat temperature 585-615 start toopen °C (°F) (137 — 143) eo" | (Stamped mark) Fig. 1-15 Cooling water passages © When the valve closes The cooling water flows from the cylinder ‘through the [ll -marked passages and collects at the &§)-marked sections. ‘Thermostat Cylinder head — Fig. 1-16 ‘© When the valve opens In the same manner as with the case above, the cooling water that has flowed into the [_]-mark- ed sections will start flowing from the jj -mark ed section as indicated in the illustration through the {Y -marked passages which are now opened. In this way, the cooling water performs circule: tion progressively. ‘Thermostat: ‘Thermostat inspection and servicing The cause of a malfunctioning thermostat is often a foreign matter stuck to the valve seat. GENERAL INFORMATION 25 Inspect the thermostat to make sure it is clean and free of such foreign matters. If necessary, test the removed thermostat for operation by immersing it in a pot filled with water, as shown in Fig. 1-18, Let a piece of string to be pinched by the valve. Then, while holding ‘the other end of the string by hand, suspend the thermostat in a pot in such a way that the ther- mostat floats above the hottam of the pot. Raise the water temperature. If the valve opens (i. e. the thermostat drops to the bottom of the pot) at the temperature specified in the table below, the thermostat is satisfactory. Engine overcooling means that the thermostat valve opens too early on temperature rise. 58.5 —61.8°C (371426) [Thermostat temperature [___ start to open Fig. 1-18 Installation When installing the thermostat on the cylinder head, be sure to assemble it in such a direction that the air breather hole @ faces to arrow- direction. Fig. 1-19 26 GENERAL INFORMATION SPECIFICATION em [Unit Date Dimension & Weight D Overall length DTA0C/CE | DTAOCER | mm 960 675 (in) | @7.80) | 657) }@ overat width | mm 515 380 | od | oa) | (18.20 }@ Overall height Simm 1260 | ean ae, | Umm 1335 | Gnd (5288) J asa 1385 | tind (6453) |@ Weight | DT40C | DT40CE/CER | se | 710 749 (io) | (156.5) (163.1) tks | 720 789 (io) | (158.7) (165.3) | take | 730 780 (io) | 60.9 (1875) ® Transom (Trim position: 3) Sslmm) | 423. (18in, type) | eimm | 520. (18%, type) Lalmm) | 567 (20in. type) Performance J Maximum horsepower Kwves) 294 (40) 1 Recommended operating range tom 4800 ~ 5500 Trotting speed rpm 650 - 700 Power head 1@) Engine type cycle 2 60 numberof eviinder Number 2 a) Bore | @.mm | 790 [Ou aan Stroke | @.nm no Bains (2.80) ‘Total displacement em? 608 * © 2.47 }©9 corrected compression ratio. |: 62 (© Spark plug gap 08-09 (0.031 — 0.036) 16 Choke system Manual | Electric (ora0c) | (DTa0cE/cER) ® intake system Feed valve ® Exhaust system | Cooling system 120 Thermostat temperature start to open. cr) ‘Through prop hub exhaust Displacement type water pump 585-615 (137 — 143) +) GENERAL INFORMATION 27 Item Unit Data starting system Manuel starter (OT40C) | Electric strter (OTAOCE/CER) ® Speed contro! Twist grip (DTAOCICE) | Remote control (OT40CER) ion eystom SUZUKI “PEI” Gasoline {85 — 95 Octane number) }® Mixing ratio Oil injection system (BIA certified oil or SUZUKI "CCI" ol must be used) 6 Fuel tank capacity Ls, | 23 Imp. gal) (6.1/6.1) 2? Gear oll SUZUKI Outboard motor gear oil (hypoid gear oil #90) 8 Gear oil capacity mi (US! 610 | Imp.oz) c20e/a18) Bracket | 22 Tteup angle degree 49~200 8 No, of tilt step adjustable 5 8 Maxinnn Giteup angle degree n Lower Unit Reversing system Gear 8 Transmission Forward--Neutral—Reverse b Reduction system | Bevel ear $B Gear ratio 2.09 (23/11) & Propeller drive system Splines & Propeller (Typed (blade x diameter x pitch) | fin.) | $900 3x11%x 90 st000 2x 11%x 10.0 $1100 3x 11%x 11.0 $1200 3x 11%4x 12.0 S300 3x 11%x 13.0 $1400 3x 11%x 14.0 $1500 3x 11%x 160 $1600 3x 11%/x 16.0 $1700 3x 11%x 17.0 @ Impact protection Spline Urive Hubber Hub 28 GENERAL INFORMATION SERVICE DATA (1) Power head (2) Carburetor vom pw |e a |detlection limit (in) (0.0020) tK-——_______—__. | 2 | Main jot # 180 [Deflection limit | t— mm 50 nay 12 lomconnecting 3 | Main air jo (mm) 13 Pome fin) | (0.20) | | + | Pitot jet # 70 |, |Wear mit on mm 04 ; eylindar haa find (0.008) ® 90 Pilot ar Jer oimm | 2 28 4 [Pistontocylinder | mm | 0.099-0.114 : clearance (in) | (0.0039 — 0.0045) 6 | Arserew urns | soon | 1th 14 5 [Piston pin mm | 19.995 ~ 20.000 — + +—— diameter | Gin |(0.7872-0.7874) 7 | Valve seat # (rm) 18 jg (Pstonpintiole | wn | 19.998 ~20.008 Float level 167 197 diameter (in) | (0.7873 - 0.7876) (0.66 ~0.74) ] 02-04 9 | Idling speed rpm. | 650-700 7 |Piston ring end mm | STD (0.008 — 0.016) L gap tiny 08 (0031) Maximum opening | iq owed | Reed seat mm | 02 clearance timit (in) (0.008) GENERAL INFORMATION 29 (3) Electrical (4) Starting motor (For DT40CE/DT40CER) tm Uni Dat tem | Un Dee °, ATDC 2°/1000 — (2v) "126 (35) ~ ton ti rom i 1 | atery cana 1 |fanition timing ‘ BTDC 25°/5000 Battery capacity | x (Ah) 252 (70) 2. [Condenser here ln ge 0%e | 290-280 2 [Ratna Se | 9 plow | kw | os a [Timinacolt la geze'e) 75-210 1 a5 — am| oe (0.492) rary ol aor enn a [Secondary eo Inge aote) 2300-2100 a Nim! 3 - | [Hmit| 9.354) p [teminscot ln geaere) 020-028 05-08 restos | sto a ‘| | jg commutator | mm {0.020 0.031 element F vay | 20 vndecut tin) 02 ~ —| | Limit (0.008) srersaenoe | I > * - collresitance —@@°20°C) 32-38 sto | 30 Commutator | mm | (1.18) B [some okvpe | wax) | sexs te ameter md |) ay [8 [Soa an | in) 2 Lin mm | 09-10 Late ® [Spark plug gap fin.) (0.035 — 0.039) - |_| 05 Ditrenco sto ° |Fuee | 20 17 | between jmm (0.0020) rmaxlin i,m) [oa Sreommutor |” |timit} gay = [Prionrng nm | 30-50 [sors tind | (0.180.397 “Recommended capacity 30_ GENERAL INFORMATION ELECTRICAL AND IGNITION CONTENTS CONSTRUCTION WIRING DIAGRAM . DISASSEMBLY REASSEMBLY INSPECTION ..... STARTING MOTOR AND RELAY .. . IGNITION SYSTEM . . . 32_ ELECTRICAL AND IGNITION CONSTRUCTION 1. Stator assy 3. Coil, ignition 2. Coil, lighting 4. Sensor, ignition Fig. 2-1 |. Holder, electric parts 6. Cover, junction box . Cover, electric parts holder 7. Holder, CDI control unit CDI unit with ignition coil 9. Fuse case assy Relay assy, starting motor Fig. 2-2 1 2 3. Spark plug 8. Rectifier 4 6. 1. Stopper set, pinion 2. Pinion assy 3. Armature 4, Holder assy, brush Fig. 23 1. Switch assy, em 2. Concent set 2-1, Receptacle assy, lighting 2-2, Plug assy, lamp cord 2-3. Grommet, light cable 3, Solenoid asey, choke Fig. 24 ELECTRICAL AND IGNITION 33 WIRING DIAGRAM [wie coLon 8 Boo. Pink Y-.. Yellow Siv « sc. Roo. Red Bl ° Woe White B Brown iam: 34_ ELECTRICAL AND IGNITION DT40cER ed 4 es) 7 7 -taonomerge Hh tlt | = ooh = To OF Fig. 2-7 DISASSEMBLY DISASSEMBLING THE C.D.I. RECTIFIER Remove the electric parts holder from the en- gine. * Refer to Fig. 4-36 and Fig, 4-41. UNIT AND Remove the blue/red lead wire ® and band ® and remove the C.D.I. unit from the electric parts holder. Remove the white lead wire @ and the screw and remove the rectifier. th: oe =m REASSEMBLY Reassombly is reverse of disassembly, but the following reassembling steps demand attention. Routing of high tension cords 1. Draw out the high tension cords extending ‘out from CDI control holder in arrow direc: tion @ such as to leave no gap between hold: er @ and grommet @ . 2. Hook on the lead wire @ from overheat switch to hook @) Fig. 2-10 Routing of wires within electric parts holder 1. Tighten together the rectifier @ , steering motor relay @ and wire harness lead terminals with common bolt @ . 2. Install the tube extending out from rectifier in the bent shape shown in ®) , ELECTRICAL AND IGNITION 35 Starting motor band fix bolts @ Etveteie pars holder can @) @ Terminal fix boit @® Rectifier @® Starting motor @ Starting motor relay @ Lower demper @® Starting motor band Fig. 2-11 3. Accomble the steering motor @ in the manner shown in Fig. 2-11, When installing steering motor band @) , use care not to forget assem- bling lower danper @ . View A Set the spiral tube @ wound around the wire harness extending out from spiral tube electric parts holder @ on which wire harness is wound such that it comes between the hook @) and re- coil starter @) as shown in Fig. 2-12. ® 2 = ® | @D ® = Fig, 2-12 View B Tighten the fuse cable terminal () together with ® terminal @ of battery cable coming from battery with common nut @ 36_ ELECTRICAL AND IGNITION View C Wiring of Stop ETC lead wire and Oil Warning Always make sure to insert the magneto lead lead wire to Engine Lower Cover wire into the groove (I) provided on back side Install the respective wires in engine lower cover of electric parts holder. as shown in the Fig. 2-16. Install the oil warming lead wire @ to inner side edge of engine lower ®. fel cover @ Fig. 2-14 Wiring around €DI Unit 1. Tighten together the earth terminal of oil warning lamp with that of CDI unit with ter minal fix bolt ( , Make the terminal lead wires horizontal as shown in Fig. 2-15. 2. Set the taped end of oil warning lamp lead wire tube such that it extends out about 30 mm from case as indicated in ® of Fig. 2-15. 3. Wire the oil warning lamp lead wire such that it enters in the slot of CDI unit indicated in ® of Fig. 2-15 and is also properly fitted in the Gu @ Oil warning lead wire @ CDI unit holder notch © of Fig. 2-15. @® Stop ETC lead wire ——-«@ Electric parts holder @ Fig. 2-16 Wire Harness and Battery Cable Clamping When clamping the wire harness and battery cables extending out from the engine lower cov- er by means of clamp @) at front top part of steering bracket @) , make sure to have the clamp installed facing upward. @ CDI unit holder ) Oil warning lamp terminal fix bolt ® assy, @ Wire harness @® Steering bracket @® Magneto ead wire @ CDI unit holder @ Clamp @) Battery cables ® CDI unit @ High tension cord @ CDI unit band Fig, 2.17 Fig. 2-15 ELECTRICAL AND IGNITION 37 INSPECTION ‘The following special tools should be used to check the electrical system. — Hi: High tontion for... Yellow [@| Thickness gauge | ¢ 10804 upper eylinder gi... Blue ®| Pocket tester (09900-26002 Ha High tension for Br | Brown a tower evlinder Gy | Green with Yellow tracer | WoTE: B.» Ba OR; Orange wth Red ace Before using the tester, be sure to make 3 Oranee WIR .. White with Red tracer zero adjustment. —} Ptr pine BIR. . Blue with Red tracer poo. Pink YIG .. Yellow with Green tracer Woe Whi T item How to check | Data 0.8 0.9mm Spark plug gt 19 990 (0.031 —0.035in.) 2300 - 3100 Secondary coil resistance {a1 20°e] Plug cap ~ Plug cap | ae i Fig. 2-19 Tool: @ Scale: Rx 1kQ pan —780 Condenser ‘charge coil [@at 20°C) resistance o-s Fig. 2-20 Tool: ® Scale: Rx 1002 38_ ELECTRICAL AND IGNITION vem How ro check Date 175-210 ‘Timing coil resistance {9 at 20°C) wr | 020-028 Lighting col resistance raped R-Y Fig. 2-22 Tool: @ Seale: Rx 1 Check for continuity on the engine stop switch Check for continuity on the engine start switch line. (Only for manual starter type) tine. (Only for electric starter type) B-auR Engine stop button Resistance (2) w-Br Not dopresed 8 Engine sar button Resitonce (2) Push 2 Not depressed | oo | Push 0 Check for continuity on the neutral start inter- lock switch line, (Only for electric starter type) be-vi0 [-—Guichieer | Revarce a] Wea Q (roman Revese diode Dz > SCR: gate + ground and causing the SCR: to change-over from OFF > ON. The electrical charge in the already charged con. denser Ci flows from C: + SCR: + ground + ignition coil primary and causing high voltage to be induced in ignition coil secondary so as to cause the spark to jump across the spark plug gap. Since this model Is of simultaneous Ignition system, the upper and lower cylinders are ignit- ed at the came time. Due to the operation explained above, ign timing has flat wave characteristics up to 1,000 engine rpm, When speed rises above 1,000 rpm, the output, ot arithmetic circuit built in the IC advances ahead of the output of timing coil, to start angle advance. Up to 2,500 rpm, the advance angle increases in designated ratio corresponding to the rpm. When above this rpm, the angle advance stops and ex: hibits a nearly flat wave characteristic. Advance angle ot magneto itself is 7° but in actuality, through mechanically sliding the magneto stator 20°, a total of 27° (ATOC 2° ~ BTDC 25°) advance angle is realized. 46_ ELECTRICAL AND IGNITION condenser charge col! to Fr a Electronic advanos 1G 4 2 E | — | _ | _ sen; oct il warning Fig. 246 Over-rev. limiter and engine oil level warning device To protect the engine against excessive RPM's, the DT40C/40CE/40CER are equipped with an over-rev limiter and 2 warning device. The warn- ing device slows down the engine speed automa- tically after it has been kept at approximately 5,900 RPM for about 10 seconds. These models are also equipped with an oil level warning device which limits the engine RPM automatically when oil in the reservoir reaches approximately 0.5 lit. (17 02). The oil level warning system does not work if ‘the engine is operated under 3,000 RPM These operation are as follows. Plame | Over-rev. limiter When the engine RPM reaches approximately 5,900 RPM, the over-rev limiter is activated (refer to No. @ in the Fig. 2-47), intermittently interrupting the ignition system to keep its speed at the specified level. A slight engine speed fluctuation will be noted (refer to @)}. A red ‘warning lamp located on the under cover tlushes While the limiter is working (for DT40C/40CE). If engine speed is not reduced after about 10 seconds, the over-rev warning device, which is also incorporated into the CDI unit, is activated automatically. Engine RPM is reduced to ap- proximately 3,000 RPM ( @) ) and the warning lamp is turned on continuously regardless of throttle ps NOTE: When the over-rey, limiter starts wor the over-rev warming device may not be activated if the engine speed is reduced below the specified RPM within 10 seconds. | This will enable you to confirm without the RPM's being limited to 3,000 RPM ELECTRICAL AND IGNITION 47 To release the warning device, and return to normal operation, close the throttle. completely. for one second ( (5) ). CAUTION If the over-rev. warning device activates | frequently while running, something may | be wrong in the system or @ propeller * Lo. change may be necessary. % 1000 RPM ® @ ® © ® C 5 4 Recommended RPM range a 1 4 —_ —________; oe ~ Tire Over 10 seconds 1 second Fig. 2-47 Over-rev, limiter system When the engine speeds up to over 5,900 rpm, the rpm detecting circuit actuates to trigger the SCRz and bring it to ON state, The condenser charge coil + side output then becomes short-circuited by the circuit from condenser charge coil + SCR: ~+ potential divid er circuit > ground so that condenser Ci is not charged and spark fails to ignite, At this time, the condenser charge coil output current flows into SCR2 and through the potential divider circuit causes the warning lamp to light and indi- cate the over-revolution condition. When SCR» turns ON and condenser charge coil output becomes shorted, there will be no input to rpm detecting circuit so that at the next igni- tion timing the sparking takes place without SCR2 being ON. Then at the next ignition tim- ing, there will be input to rom detecting circuit since the SCR2 was not turned ON at the pre- ceding stage. As a result, the SCR: is turned ON and the condenser charge coil is again shorted to prevent the sparking. In this manner, when the speed rises above 5,900 rpm, the ignition turns into intermittent sparking state of misfire-fire- misfire-fire. This condition passes through the spark extinguishing detecting circuit and enters in the rpm detecting circuit, and when about 10 seconds elapse, by means of the signal from this circuit, the intermittent sparking state is forcibly transferred to about 3,000 rpm, However, even if the speed had risen 'to about 5,900 rpm, by returning the throttle and lowering the speed within 9 seconds, the signal will not be given out, Moreover, trigger signal will not be given out to SCR; from rpm detecting circuit so that speed will not drop to 3,000 rpm and the inter- mittent sparking state will be dissolved, In case ‘the speed is dropped from around 5,900 rpm to around 3,000 rpm, by returning the throttle and lowering the speed below this, the trigger signal stops coming out from rpm detecting circuit and jn 1 second the intermittent sparking state will also be stopped. 48 ELECTRICAL AND IGNITION As related above, if running is continued for more than 10 seconds in the speed range exceed- ing 5,900 rpm, the engine speed is forcibly drop- ped to around 3,000 rpm and the driver warned as means of protecting the engine, | CAUTION: tions should be in the 4,800 — 5,500 RPM range. If the engine RPM is not in this recom: | mended range, change proper propeller. It may be necessary for customer to reprop customer's rig to meet customer's boat, |_ toad, and operational requirements. il warning system DT40C/40CE/40CER are equipped with oilwarn- ing devices. When driving with the engine turning at around 3,000 to 5,900 rpm and the remaining amount of oil drops to below 0.5 liter (17/18 US/IMP oz), oil level switch turns ON @) and timer circuit starts to actuate. In about 10 seconds, signal is transmitted to rpm detecting circuit, From this circuit, trigger signal is sent to SCR2 which turns ON and drops (2) the engine speed to constant 3,000 rpm. In the DT40C/ A0CE at this time, the warning lamp located at engine lower cover front turns ON to warn the driver that the oil is low. This action is similar to that of over-rev. limiter. In DT40CER, the buzzer sounds off. When the oil is replenished at this state, the oil level switch turns OFF. The timer circuit then stops actuating and no signal is send to rpm detecting circuit. As @ result, gate signal is not sent to SCR: so that SCR does not turn ON. ‘About one second elapses from the time the oil level switch turns OFF to when the contro! on 3,000 rpm is removed. Engine speed '3,000 rpm 3000, \ | oi repeishmene 1 about tOilavet switch OFF) eon Fig. 2-48 5 1 lamp is viewed in dark place, the lamp may appear to be lighted dimly but this does not indicate abnormal condition. When ‘there is oil shortage, the lamp will be light- ed brightly. | Overheat switch (Only for DT40CER) If the engine has overheated accidentally during navigation, the warning buzzer in the remote controller starts sounding (97° — 105°C). At this time, somewhere is abnormal. Immediately close the throttle all the way, set the shift lever to the “N” position and then carry out the check given below. © Check whether or not something clogs on the water intake hole. If such is the caso, eliminate it, © Check whether or not water is delivered from the water discharge hole. If it is not, cooling water circuit or pump is abnormal. NoT! InDT40C/40CE, the warning lamp lights up when the engine overspeeds or when the fuel oil decreases to the preset low level. In the DTAQCER, an additional warning provision is used: in the event of engine ‘over-heating, the buzzer in the remote con- troller sounds off. | Thus, the conditions for which the user is alerted by visual or auditory warning are three in number, as follows (pT40c/40ce) * Condition of low fuel oil level ‘Suppose this condition occurs when, dur- ing normal cruising, the engine is held anywhere between 3,000 and 5,900 rpm by proper throttle control: then the engine will go down all by itself to 3,000 | rpm end stay there, At the same time, | the warning lamp lights up. Suppose again the engine is running at a level below 3,000 rpm while this condi tion of low fuel oil level exists in the tank (with the user being unaware of it): as the user tries to pick up engine speed, the ongino comes to but stays at 3,000 rpm without responding to the throttle lever and, at the same time, the warning amp lights up. © Condition of overspeeding (causing the over-rev limiter to work) When the user is cruising at full throttle, the engine might start running rough. In such a case, the engine will start slowing | down all by itself after 10 seconds of | rough running, and will settle at 3,000 pm. At the same time the warning lamp will fight up. | (DT40cER) | © What are stated above for DT40C/40CE | __ with respect to the conditions of low fuel oil level and overspeeding hold good for DT40CER. Additionally, however, the ‘warning buzzer in the remote controller | will sound off. ‘* Condition of engine overheating The buzzer in the remote controller will sound off when this condition occurs (97° — 105°C). The buzzer will keep on sounding even if the user stopped the engine: the continued buzzer sounding is indicative of overheated condition of tho engine, ELECTRICAL AND IGNITION 49 IGNITION TIMING ADJUSTMENT Static adjustment Toadjust ignition timing withoutstarting engine, proceed as follows: 1. Max. advance side 1) Shift the clutch to forward, 2) Fully open the throttle grip (or remote control lever). 3) Keep this condition to align the mark @ on ‘the magneto stator @ and the cylinder-to- crankcase fitting surface © with each other. 4) Keep this condition to loosen the screws @ on the throttle cam @, turn the throttle cam @® toward the direction indicated by the arrow mark © until contacting the crankcase- side stopper ©, and fix the cam by tightening the screws @ at this position. 5) Still keep this condition to loosen the screw (® on the carburetor, open the carburetor link toward the direction indicated by the arrow mark () fully until hitting against the opponent, move the rotor ) toward the direction indicated by the arrow mark W so as to contact the throttle cam @), and tighten the screw {9 at this condition. 2, Max, rotard side 1) Place the shift lever (or remote control lever) in the Forward 1st notch. 2) Align the mark ‘Bon the magneto stator and the cylinder-to-crankcase fitting surface © with each other. Turn the adjust bolt ©) so that the adjust bolt cap @ contacts the crankease-side stopper (D). and fix it by the nut @. 3) Move the throttle limiter (D toward the direc- tion W until hitting against the undercover- side stopper ©), and check to see whether the carburetor can be fully opened at this condi tion. 4)If the carburetor can not be fully opened, adjust the rod © for proper length and fix it by the nut ®. The rod @ should have a standard length of 108 mm (4.25 in.). 5) Adjust the throttle cable so that the stator can be fully opened and closed. (OT40C/ 40CE} 50__ELECTRICAL AND IGNITION Ignition Timing Standard 26° + 1° BTDC/ 5000 rpm. 2 = 1 ATDC/ 1000 rpm Maximum advance timing Maximum retard timing Fig. 249 [Dynamic adjustment] ] adjustment, start the engine up for about 5 minutes. * Before starting this adjustment, be sure to remove the throttle rod i) Full advanced ignition timing adjustment 1) Shift the clutch to forward. 2)To check the full-advanced ignition timing, keep engine running at 1000 rpm and move the throttle limiter @ to the full-advanced position ®. WARNING: This procedure is required to check the ignition timing while running the engine at 5,000 rpm bur It is dangerous and therefore, as a substitute method, here we di safe procedure in which advanced by hand with the engine running at less than 1,000 rpm. Fig. 2-50 3)While keeping the throttle limiter @ in this position, check that the timing plate points to 18.5° BTDC, using a timing light. NOTE: | © When this method, asa substitue is used, | the ignition timing should be sot at 18.6° | BTDC at 1,000 rpm, but in actual oper- ation, the ignition timing will be 18° BTDC at 5,000 rpm, showing a time lag of 0.5". ELECTRICAL AND IGNITION 51 ‘© The actual ignition timing is 25° BTDC, | | this being the result of 7° advance by the ‘magneto and 18° advance caused by slid- ing the stator. ‘Arrow mark on recoil starter side Fig. 2-51 4) If ignition timing is off 18.5° BTDC, loosen two serews (D and by moving the thrattle cam @ to right and left as shown to adjust. After adjusting, tighten screws (1) securely. Fig. 252 52_ ELECTRICAL AND IGNITION 5) After adjustment, install the throttle rod to the original position @). Fig. 2-53 Full retarded ignition adjustment 1)Shift the clutch to Neutral and keep the engine revolution speed at 1000 rpm. 2) Ignition timing is indicated by the timing arrow (D) attached on the side of the recoil starter pointing at any of the lines engraved on the outer surface of the flywheel. 3) Using @ timing fight, make sure the timing arrow remains within a range of 2° + 1° ATDC @ at 1000 rpm. If not, the ignition timing must be readjusted. 4)To retard the ignition timing, loosen the lock nut @) and tum the adjust screw @ counterclockwise, To advance it, turn the adjust screw @ clockwise. 5) After the timing has been adjusted properly, tighten the lock nut @). CHECKING OF CDI UNIT 1) Check using Pocket Tester CDI unit test chart I — ead of tester Toren [aac [84 [aie | pik whites! 5 on | \_| on | oFF JorF | on aL SY 5 aw ort [ore [om 3 Tore | om =| Ble! on on | on |S | oFF | ow 4+ —)— ive | oN | ON | ON | oFF | \ | ON — i f—- i Pink | ON | ON [oN [ofr [ore | © ON: Meter reading should be 100k2 or less. © OFF: Meter reading should be more than 100k © CON: Meter needle swings once and return immediately. - a NOTE: | 1. Set the meter in R x 100 range. | 2. After checking of CON, allow a little ‘time before next checking. 2) Check using CDI checker Part No: 09930-99810 1, Before using the checker be sure to select pro- per voltage range on voltage selector. (100V, 117V, 220V and 240V) If the selector socket is not set at proper voltage range, remove fuse and pull out vol- tage selector and reinsert into unit so that proper voltage scale is visible in cutaway. 2. Connect CDI unit to test lead to checker. 3. Connect AC cord to power outlet. ELECTRICAL AND IGNITION 53 4, Push “TEST” button. ‘© Both the power light and CDI indicator light should come on. This indicates that ‘the CDI unit is functioning correctly. ‘If power light is ON and CDI indicator light is OFF, the CDI unit is NOT functioning correctly and should be replaced. If both lights OFF check the following. = Fuso .......... If blown replace, —AC Source Check plug. ® Power tight @ Fuse (2amp.) @ AC source @ Test lead connector @ Test button CDI indicator light 54 ELECTRICAL AND IGNITION FUEL SYSTEM CONTENTS CARBURETOR . 56 REED VALVES . . 60 FUEL PUMP AND FUEL FILTER ot FUEL TANK - 62 SQUEEZE PUMP 63 FUEL CONNECTOR PLUG 56 FUEL SYSTEM CARBURETOR CONSTRUCTION Carburetor assy Jet, pilot Spring, air screw Screw, pilot ais Nozzle Fig. 3-1 6. Flost 7. Valve assy, needle 8, Jet, main 9. Knob, choke SPECIFICATIONS unit mm we SSC BO * nant #10 * Min ie or » Pott #70 + Pilot air jet Oo20 Qos + Bye $07 * bya? eos * By as3 eos «Vest ots » Pato oro Arsoentamopen | T= He » Samend mak la «Flat el | oer OPERATION Low spood The gasoline flows into the chamber through a gap between the valve seat and the needle valve ‘® . Under this setting, the fuel level is deter mined by the needle vaive @), float (8) and valve seat ©. The gasoline which has entered into the chamber will flow through the main jet (Band tube and reaches the pilot jet (© where the metering of the fuel takes place. Moreover, at this point, the metered gasoline will be mixed with the air flow that has been also metered by the pilot air jet © . Finally, the thus-produced mixture is inject- ed into the cylinder through the pilot outlet ©. FUEL SYSTEM _57 High speed The gasoline that has entered into the chamber is metered by the main jet @. Then, at the inside of the nozzle ©, the metered gasoline will be mixed with the air flow which has been also metered by the main air jet ®. Finally, the thus-produced mixture is injected into the cyl inder through the main bore. be Gosotine B® gain Fig. 32

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