DF115B 140B 99500-99l10-01e

TOP
99500-99L10-01E
99500-99L10-01E
BOTTOM
No. 2599 99500-99L10-01E DF115B/BZ_DF140B/BZ S/M Cover14 (16 mm) 5/0 2022/1/13 DIC502 Pantone 186 Pantone 3590 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 DF115B/BZ, DF140B/BZ 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 November, 2021.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2021

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
Power Trim and Tilt ................................................ 2B-1
Lower Unit................................................................... 3-i
Precautions .............................................................. 3-1
Right Hand Rotation Unit ....................................... 3A-1
Left Hand Rotation Unit.......................................... 3B-1
Wire / Hose Routing ................................................... 4-i
Precautions .............................................................. 4-1
Wire Routing .......................................................... 4A-1
Fuel / Water Hose Routing..................................... 4B-1
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
CENNP3130000001
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 Scheduled Maintenance ......................................0B-1

General Description .............................................0A-1 Periodic Maintenance Schedule Chart................0B-1
Symbols .............................................................. 0A-1 Lubrication Point .................................................0B-2
Abbreviations ...................................................... 0A-1 Service Instructions .............................................0B-3
Wire Color Symbols ............................................ 0A-2 Engine Oil Level Check.......................................0B-3
Warning, Caution and Information Label Engine Oil Change and Engine Oil Filter
Locations........................................................... 0A-3 Replacement .....................................................0B-3
Outboard Motor Identification Number Gear Oil Change .................................................0B-5
Location ............................................................ 0A-4 Spark Plug Removal and Installation ..................0B-5
Fuel and Oil Recommendations.......................... 0A-4 Spark Plug Inspection and Cleaning ...................0B-6
Break-In Procedures ........................................... 0A-5 Tappet Clearance Inspection and Adjustment ....0B-7
Propeller Selection Guide ................................... 0A-5 Idle Speed and Idle Air Control (IAC) Duty
Battery Requirement ........................................... 0A-6 Inspection........................................................0B-12
Powerhead Direction of Rotation Description ..... 0A-6 Breather Line and Fuel Line Inspection ............0B-14
Specifications.......................................................0A-7 Low Pressure Fuel Filter Inspection..................0B-15
Specifications ...................................................... 0A-7 Water Pump and Water Pump Impeller
Service Data ....................................................... 0A-9 Inspection........................................................0B-16
Tightening Torque Specifications...................... 0A-14 Propeller / Propeller Nut and Cotter Pin
Inspection........................................................0B-16
Special Tools and Equipment ...........................0A-15
Anode Inspection ..............................................0B-17
Recommended Service Material ....................... 0A-15
Bonding Wire Inspection ...................................0B-18
Special Tool ...................................................... 0A-16
Battery Inspection .............................................0B-18
Maintenance and Tune-Up...................... 0B-1 Thermostat Inspection.......................................0B-19
Bolts and Nuts Inspection .................................0B-19
Precautions...........................................................0B-1
Oil Pressure Check ...........................................0B-20
Precautions for Maintenance .............................. 0B-1
Cylinder Compression Pressure Check ............0B-21
General Description .............................................0B-1
Recommended Oil and Lubricants...................... 0B-1
0A-1 General Information:
General Information
General Information
General Description
Symbols
CENNP3130101001
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 SUZUKI MOLY PASTE in a ratio of 1 : 1)
Apply SUZUKI Outboard Motor Gear Oil.
Apply SUZUKI Super Grease A.
Apply SUZUKI Moly Paste.
Apply SUZUKI Water Resistant Grease.
Apply SUZUKI Bond 1207B.
Apply SUZUKI Silicone Seal.
Apply SUZUKI Thread Lock 1342H.
Apply SUZUKI Thread Lock Super 1333B.
Use special tool.
Do not reuse.
Note on reassembly.
Use peak voltmeter Stevens CD-77.
Abbreviations G:
CENNP3130101002 GND: Ground
Abbreviations used in this service manual are as follows:
I:
A:
IAC: Idle Air Control
ATDC: After Top Dead Center
IAT: Intake Air Temperature
AC: Alternating Current
IG: Ignition
B:
Ign.: Ignition
BCM: Boat Control Module
IGT: Ignition Timing
BTDC: Before Top Dead Center
IN (In.): Intake
C:
L:
CKP Sensor: Crankshaft Position sensor
LPS: Lever Position Sensor
CMP Sensor: Camshaft Position sensor
M:
D:
MAP: Manifold Absolute Pressure
DBW: Drive By Wire
P:
DC: Direct Current
PORT: Port
DOHC: Double Over Head Camshaft
PTT: Power Trim and Tilt
E:
S:
ECM: Engine Control Module
SPC System: Suzuki Precision Control System
ETV: Electric Throttle Valve
SPS: Shift Position Sensor
ESA: Electric Shift Actuator
STBD: Starboard
EX (Ex.): Exhaust
SIGP: Start-In-Gear Protection
F:
T:
FP: Fuel Pump
TPS: Throttle Position Sensor
General Information: 0A-2
NOTE
On Keyless start system model,
The key operation described in this manual is
as follows:
• “Turn the main switch ON position”
represents that the keyless start system is
turned ON by switch knob operation.
• Conversely, “Turn the main switch OFF
position” represents that the keyless start
system is turned OFF by switch knob
operation.
Wire Color Symbols

CENNP3130101003
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)
Bl (Blue Color) Bl/B

Black (Stripe Color)
I9J011010001-02
Warning, Caution and Information Label Locations

CENNP3130101004
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.
INP313010001-02
1. Label, engine cover 2. Label S.I.G.P.

Outboard Motor Identification Number Location Fuel and Oil Recommendations

CENNP3130101005 CENNP3130101006
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
1 motor and fuel system.
Use only unleaded gasoline. Do not use fuel

having lower than the recommended octane,
or fuel that may be stale or contaminated by
IMP311010004-01 dirt/water etc.
1. Identification number plate
Suzuki highly recommends that you use alcohol-free
Example unleaded gasoline with a minimum pump octane rating
of 87 (R/2+M/2 method) or 91 (Research method).
1 However, blends of unleaded gasoline and alcohol with
equivalent octane content may be used.
DF115B Allowable maximum blend of a single additive
10% Ethanol
11506F–XXXXXX
Engine Oil
NOTICE
Use of a poor quality engine oil can adversely
2 3 affect engine performance and life.
INP313010002-01
1. Model 3. Serial number Suzuki recommends that you use Suzuki

2. Pre-fix Marine 4-Cycle Engine Oil or its equivalent.
Engine Serial Number Location Oil quality is a major contributor to your engine’s
A second engine serial number plate is pressed into a performance and life. Always select good quality engine
boss on the cylinder block. oil.
Suzuki recommends the use of SAE 10W-40 or 10W-30
SUZUKI MARINE 4-CYCLE ENGINE OIL (ECSTAR).
1 If SUZUKI MARINE 4-CYCLE ENGINE OIL is not
available, select a NMMA certified FC-W oil or good
XXXXXX quality 4-cycle motor oil from the following chart
according to the average temperatures in your area.
API Classification SAE Viscosity Grade

SG
SH
10W–40
SJ
SL
SM
10W–30
SN
IMP311010005-01 SP
˚C –20 –10 0 10 20 30 40
TEMP.
1. Serial number plate ˚F –4 14 32 50 68 86 104
INP313010003-01
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 NOTICE

CENNP3130101007
NOTICE Running continuously at full throttle for more
than 5 minutes at a time during the last 7
Failure to follow the break-in procedures hours of break-in operation may cause
described below can result in severe engine severe engine damage such as seizure.
damage.
During the last 7 hours of break-in operation,
Be sure to follow the engine break-in do not operate at wide open throttle for more
procedures described below. than 5 minutes at a time.
The first 10 hours are critically important to ensure
correct running of either a brand new motor or a motor Propeller Selection Guide
that has been reconditioned or rebuilt. How the motor is CENNP3130101008
operated during this time will have direct bearing on its An outboard motor is designed to develop its rated
life span and long-term durability. power within a specified engine speed range. In the case
of models DF115B/DF115BZ/DF140B/DF140BZ,
Break-in period maximum rated power is delivered as follows.
10 hours
Warm-Up Recommendation Recommended full throttle speed range
DF115B/DF115BZ 5000 – 6000 r/min
NOTICE DF140B/DF140BZ 5700 – 6300 r/min
Running at high speed without sufficient
warm-up may cause severe engine damage NOTICE
such as piston seizure. Installing a propeller with either too much or
too little pitch will cause incorrect maximum
Always allow sufficient idling time (5 engine speed, which may result in severe
minutes) for the engine to warm-up before damage to the motor.
running at high speed.
Select a propeller that will allow the engine to
Allow sufficient idling time (more than 5 minutes) for the reach the recommended operating range at
engine to warm up after cold engine starting. full throttle with the maximum boat load.
Throttle Recommendation If the standard propeller fails to meet the above

requirement, use another pitch propeller to hold the
NOTE engine speed within the range specified above.
Avoid maintaining a constant engine speed
for an extended period at any time during the Propeller size chart
engine break-in period by varying the throttle Right-hand rotation propeller
position occasionally. Blade × Dia. (in) × Pitch (in)
3 × 13 and 1/2 × 15
First 2 hours 3 × 14 × 17
For the first 15 minutes, operate the engine in-gear at 3 × 14 × 19
idling speed. During the remaining 1 hour and 45 3 × 14 × 21
minutes, operate the engine in-gear at less than 1/2 3 × 14 × 23
(half) throttle (3000 r/min). 3 × 13 and 7/8 × 15
3 × 13 and 7/8 × 17
NOTE
3 × 13 and 7/8 × 19
The throttle may be briefly opened beyond 3 × 13 and 7/8 × 21
the recommended setting to plane the boat, 3 × 13 and 7/8 × 23
but must be reduced to the recommended 3 × 13 and 7/8 × 25
setting immediately after planning.
Left-hand rotation propeller
Next 1 hour Blade × Dia. (in) × Pitch (in)
Operate the engine in-gear at less than 3/4 (three - 3 × 13 and 7/8 × 17
quarter) throttle (4000 r/min). 3 × 13 and 7/8 × 19
3 × 13 and 7/8 × 21
Last 7 hours 3 × 13 and 7/8 × 23
Operate the engine in-gear at a desired engine speed.
However, do not operate continuously at full throttle for
more than 5 minutes.
Battery Requirement Powerhead Direction of Rotation Description

CENNP3130101009 CENNP3130101010
Suzuki recommends a 12 V cranking type lead acid This outboard motor is designed with a L.H. (left hand)
battery for the DF115B/DF115BZ/DF140B/DF140BZ. rotation powerhead utilizing an offset crankshaft. This
Minimum battery requirement for starting the engine is design has the advantage of reducing the size of the
provided below. motor and keeping the overall motor’s weight closer to
The battery must satisfy one of the specifications the boat transom and therefore closer to the boat C/G
described below. (Center of Gravity).
Rotation of the driveshaft is accomplished through a
NOTE crankshaft drive gear and a driveshaft driven gear.
• The specifications listed below are the These gears are located beneath the powerhead in the
minimum battery rating requirements for same oil bath location as the camshaft chain.
starting the engine. As the rotational direction of the driven gear will be
opposite of the drive gear, a left hand rotation
• Additional electrical loads from the boat
powerhead design was adopted to retain a conventional,
will require larger capacity batteries.
standard rotation (right hand) propeller shaft output.
• Dual-purpose (Cranking/Deep Cycle)
batteries can be used if they meet the
minimum specifications listed below
(MCA, CCA, or RC).
• Do not use a Deep Cycle battery for the
main cranking battery.
• The use of Maintenance-Free, sealed, or
Gel-Cell batteries is not recommended
because they may not be compatible with
Suzuki’s charging system.
• When connecting batteries in parallel, they
must be of the same type, capacity,
manufacturer, and of similar age. When
replacement is necessary, they should be
replaced as a set.
• It is recommended that the battery be
installed in an enclosed case.
• When connecting batteries, hexagon nuts
must be used to secure battery leads to
battery terminals.
Battery specification
650 Marine Cranking Amps (MCA)/ABYC, or 512 Cold
Cranking Amps (CCA)/SAE or 160 Reserve Capacity
(RC) Minutes/SAE or 12 V 100 AH
Specifications
Specifications
CENNP3130107001
NOTE
These specifications are subject to change without notice.
Model Pre-Fix
Data
Item Unit
DF115B/DF115BZ DF140B/DF140BZ
PRE-FIX 11506F/11506Z 14005F/14005Z
Dimensions and Weight

Data
Item Unit
Overall length (front to back) mm (in) 828 (32.6)
Overall width (side to side) mm (in) 520 (20.5)
L mm (in) 1624 (63.9)
Overall height
X mm (in) 1751 (68.9)
L kg (lbs) 188 (414.5) 186 (410.1)
Weight (without engine oil)
X kg (lbs) 192 (423.3) 190 (418.9)
mm (inch
L 534 (20)
type)
Transom height
mm (inch
X 661 (25)
type)
Performance
Data
Item Unit
Maximum output kW (PS) 84.6 (115) 103 (140)
Recommended operating
r/min 5000 – 6000 5700 – 6300
range
Idle speed r/min 700 ± 50 (in-gear: Approx. 700)
Powerhead
Data
Item Unit
Engine type 4-stroke DOHC
Number of cylinders 4
Bore mm (in) 86 (3.39)
Stroke mm (in) 88 (3.46)
Total displacement cm3 (cu. in) 2045 (124.8)
Compression ratio 10.6 : 1
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
Suzuki highly recommends the use of alcohol-free unleaded gasoline
with a minimum pump octane rating of 87 (R/2+M/2 method) or 91
Fuel
(Research method). However, blends of unleaded gasoline and
alcohol with equivalent octane content may be used.
• API classification: SG, SH, SJ, SL, SM, SN, SP or NMMA certified
FC-W oil.
Engine oil
• Viscosity rating: SAE 10W-40 or 10W-30,
NMMA FC-W 10W-40 or 10W-30
5.5 (5.8/4.8): Oil change only
Engine oil amounts L (US/Imp. qt) 5.7 (6.0/5.0): Oil filter change
6.2 (6.6/5.5): Engine overhaul
SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear oil, API
Gear oil
classification GL-5.
Gearcase oil capacity ml (US/Imp. oz) 1050 (35.5/37.0)
Bracket
Data
Item Unit
Trim angle
(When transom board angle ° 22.4 (–6 to 16.4) 21.5 (–6 to 15.5)
14°)
Number of trim position PTT system
Maximum tilt angle ° 75 (–6 to 69)
Lower Unit
Data
Item Unit
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
Propeller shaft rotation (When shift into DF115B/140B: Clockwise
forward) DF115BZ/140BZ: Counterclockwise
Reduction System
Data
Item Unit
1st reduction gear ratio
29 : 36 (1.24)
(Crankshaft drive gear: Driven gear)
2nd reduction gear ratio (Lower unit gear) 12 : 25 (2.08)
Total reduction gear ratio 2.59 (36/29 x 25/12)
Service Data
CENNP3130107002
NOTE
These service data are subject to change without notice.
Powerhead
Data
Item Unit
kPa
**Cylinder compression pressure 1200 – 1800 (12.2 – 18.3, 174 – 261)
(kgf/cm2, psi.)
**Cylinder compression pressure max. kPa
100 (1.0, 14)
difference between cylinders (kgf/cm2, psi.)
kPa 390 – 470 (4.0 – 4.8, 57 – 68) at 3000 r/min
**Engine oil pressure
(kgf/cm2, psi.) (at normal operating temp.)
Thermostat operating temperature °C (°F) 58 – 62 (136 – 144)
**Figures shown are guidelines only, not absolute service limits.
Cylinder Head / Camshaft

Data
Item Unit
Cylinder head distortion Limit mm (in) 0.05 (0.002)
Manifold seating faces distortion Limit mm (in) 0.10 (0.004)
std. mm (in) 39.510 – 39.670 (1.5555 – 1.5618)
IN
Limit mm (in) 39.410 (1.5516)
Cam height
std. mm (in) 39.420 – 39.580 (1.5520 – 1.5583)
EX
Limit mm (in) 39.320 (1.5480)
Top, std. mm (in) 0.020 – 0.062 (0.0008 – 0.0024)
2nd,
Camshaft journal oil 3rd, Limit mm (in) 0.120 (0.0047)
clearance 4th
std. mm (in) 0.045 – 0.087 (0.0018 – 0.0034)
5th
Limit mm (in) 0.120 (0.0047)
Top, std. mm (in) 23.000 – 23.021 (0.9055 – 0.9063)
2nd,
Camshaft journal (housing) 3rd, Limit mm (in) —
inside diameter 4th
std. mm (in) 26.000 – 26.021 (1.0236 – 1.0244)
5th
Limit mm (in) —
Top, std. mm (in) 22.959 – 22.980 (0.9039 – 0.9047)
2nd,
Camshaft journal outside 3rd, Limit mm (in) —
diameter 4th
std. mm (in) 25.934 – 25.955 (1.0210 – 1.0219)
5th
Limit mm (in) —
std. mm (in) —
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) 30.959 – 30.975 (1.2189 – 1.2195)
Cylinder head tappet bore std. mm (in) 31.000 – 31.025 (1.2205 – 1.2215)
Valve / Valve Guide

Data
Item Unit
IN mm (in) 33 (1.3)
Valve diameter
EX mm (in) 28 (1.1)
Tappet clearance IN std. mm (in) 0.23 – 0.27 (0.009 – 0.011)
(Cold engine condition) EX std. mm (in) 0.33 – 0.37 (0.013 – 0.015)
IN ° 15, 45, 60
Valve seat angle
EX ° 15, 45
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) 6.000 – 6.012 (0.2362 – 0.2367)
EX
IN,
Valve guide protrusion std. mm (in) 13.3 – 13.7 (0.52 – 0.54)
EX
IN std. mm (in) 5.965 – 5.980 (0.2348 – 0.2354)
Valve stem outside diameter
EX std. mm (in) 5.940 – 5.955 (0.2339 – 0.2344)
IN Limit mm (in) 0.14 (0.0055)
Valve stem deflection
EX Limit mm (in) 0.18 (0.0071)
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) 1.0 (0.04)
IN
Limit mm (in) 0.7 (0.03)
Valve head thickness
std. mm (in) 1.2 (0.05)
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) 42.73 (1.682)
Valve spring free length
Limit mm (in) 41.02 (1.615)
std. N (kgf, lbf) 164 – 190 (16.7 – 19.4, 36.8 – 42.7) at 32.6 mm (1.28 in)
Valve spring preload
Limit N (kgf, lbf) 151 (15.1, 33.3) at 32.6 mm (1.28 in)
Valve spring squareness Limit mm (in) 2.0 (0.08)
Cylinder / Piston / Piston Ring

Data
Item Unit
Cylinder distortion Limit mm (in) 0.05 (0.002)
std. mm (in) 0.020 – 0.040 (0.0008 – 0.0016)
Piston to cylinder clearance
Limit mm (in) 0.100 (0.0039)
Cylinder bore std. mm (in) 86.000 – 86.020 (3.3858 – 3.3866)
Cylinder measuring position mm (in) 50 (1.97) from cylinder top surface
Piston skirt diameter std. mm (in) 85.970 – 85.990 (3.3846 – 3.3854)
Piston measuring position mm (in) 8.5 (0.33) from piston skirt end
Cylinder bore wear Limit mm (in) 0.100 (0.0039)
std. mm (in) 0.20 – 0.35 (0.008 – 0.014)
1st
Limit mm (in) 0.70 (0.028)
Piston ring end gap
std. mm (in) 0.35 – 0.50 (0.014 – 0.020)
2nd
Limit mm (in) 1.00 (0.039)
std. mm (in) Approx. 11.6 (0.46)
1st
Limit mm (in) 9.3 (0.37)
Piston ring free end gap
std. mm (in) Approx. 11.5 (0.45)
2nd
Limit mm (in) 9.2 (0.36)
std. mm (in) 0.030 – 0.070 (0.0012 – 0.0028)
1st
Piston ring to groove Limit mm (in) 0.120 (0.0047)
clearance std. mm (in) 0.020 – 0.060 (0.0008 – 0.0024)
2nd
Limit mm (in) 0.100 (0.0039)
1st std. mm (in) 1.22 – 1.24 (0.048 – 0.049)
Piston ring groove width 2nd std. mm (in) 1.51 – 1.53 (0.059 – 0.060)
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) 1.47 – 1.49 (0.058 – 0.059)
std. mm (in) 0.006 – 0.017 (0.0002 – 0.0007)
Pin clearance in piston pin hole
Limit mm (in) 0.040 (0.0016)
std. mm (in) 20.997 – 21.000 (0.8267 – 0.8268)
Piston pin outside diameter
Limit mm (in) 20.980 (0.8260)
std. mm (in) 21.006 – 21.014 (0.8270 – 0.8273)
Piston pin hole diameter
Limit mm (in) 21.040 (0.8283)
std. mm (in) 0.003 – 0.016 (0.0001 – 0.0006)
Pin clearance in conrod small end
Limit mm (in) 0.05 (0.002)
Crankshaft / Conrod
Data
Item Unit
Conrod small end bore std. mm (in) 21.003 – 21.013 (0.8269 – 0.8273)
std. mm (in) 0.032 – 0.050 (0.0013 – 0.0020)
Conrod big end oil clearance
Limit mm (in) 0.080 (0.0031)
Conrod big end inside diameter std. mm (in) 47.000 – 47.018 (1.8504 – 1.8511)
Crank pin outside diameter std. mm (in) 43.982 – 44.000 (1.7316 – 1.7323)
Crank pin outside diameter
Limit mm (in) 0.010 (0.0004)
difference (Out-of-round and taper)
Conrod bearing thickness std. mm (in) 1.481 – 1.496 (0.0583 – 0.0589)
std. mm (in) 0.100 – 0.250 (0.0039 – 0.0098)
Conrod big end side clearance
Limit mm (in) 0.350 (0.0138)
Conrod big end width std. mm (in) 21.950 – 22.000 (0.8642 – 0.8661)
Crank pin width std. mm (in) 22.100 – 22.200 (0.8700 – 0.8740)
Crankshaft center journal runout Limit mm (in) 0.04 (0.002)
std. mm (in) 0.020 – 0.040 (0.0008 – 0.0016)
Crankshaft journal oil clearance
Limit mm (in) 0.065 (0.0026)
Crankcase bearing holder inside
std. mm (in) 62.000 – 62.018 (2.4409 – 2.4417)
diameter
Crankshaft journal outside diameter std. mm (in) 57.994 – 58.012 (2.2832 – 2.2839)
Crankshaft journal outside diameter
Limit mm (in) 0.010 (0.0004)
difference (Out-of-round and taper)
Crankshaft bearing thickness std. mm (in) 1.991 – 2.006 (0.0783 – 0.0790)
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
• 0 ± 5 BTDC (at 700 r/min) • 0 ± 5 BTDC (at 700 r/min)
Ignition timing °
• 14 BTDC (at 5500 r/min) • 15 BTDC (at 6000 r/min)
Over revolution limiter r/min 6100 6400
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 0.15 – 0.25
Battery charge coil output (12 V) W 480 (at 6000 r/min)
Type — NGK LKR6E
Standard spark plug
Gap mm (in) 0.8 – 0.9 (0.031 – 0.035)
Main fuse: 60
Load fuse: 60
Starter motor: 30
Fuse amp. rating A
PTT switch/IAC: 15
Ign. coil/Injector/ECM: 30
Fuel pump: 15
Recommended battery capacity (12 V) Ah (kC) 100 (360) or larger
Fuel injector resistance Ω at 20 °C 11.5 – 12.5
IAT sensor/Cylinder temp. sensor/Ex.
mani. temp. sensor (Thermistor kΩ at 25 °C 1.8 – 2.3
characteristic)
O2 sensor heater Ω at 20 °C 5.5 – 8.5
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
Max. continuous time of use Sec. 30
Motor output kW 1.4
std. mm (in) 12.3 (0.48)
Brush length
Limit mm (in) 7.0 (0.28)
std. mm (in) 0.5 (0.02)
Commutator undercut
Limit mm (in) 0.2 (0.01)
std. mm (in) 29.4 (1.16)
Commutator outside diameter
Limit mm (in) 28.4 (1.12)
PTT Motor
Data
Item Unit
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)
Tightening Torque Specifications

CENNP3130107003
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 8.1
8 mm 25 2.5 18
Cylinder head bolt
10 mm 70 7.1 52
8 mm 25 2.5 18
Crankcase bolt
10 mm 52 5.3 38
Conrod cap bolt 9 mm 17 Nm (1.7 kgf-m, 13 lbf-ft), then plus turn in 60°.
Camshaft housing bolt 6 mm 11 1.1 8.1
IN. timing sprocket bolt 10 mm 78 8.0 58
Oil pump drive sprocket bolt 10 mm 78 8.0 58
Timing chain tensioner adjuster bolt/nut 6 mm 10 1.0 7.4
Intake manifold bolt/nut 8 mm 23 2.3 17
Throttle body bolt 8 mm 23 2.3 17
Oil pressure switch — 13 1.3 9.6
Fuel delivery pipe nut 8 mm 23 2.3 17
Low pressure fuel pump bolt 6 mm 10 1.0 7.4
Thermostat cover bolt 6 mm 10 1.0 7.4
Flywheel bolt 16 mm 245 25 181
8 mm 23 2.3 17
Starter motor mounting bolt
10 mm 50 5.1 37
Engine oil filter — 14 1.4 10
Engine oil drain plug — 13 1.3 9.6
8 mm 23 2.3 17
Power unit mounting bolt
10 mm 50 5.1 37
Driveshaft housing bolt 10 mm 50 5.1 37
Mount case cover bolt 8 mm 23 2.3 17
Upper mount nut 12 mm 80 8.2 59
Upper mount plate nut 12 mm 80 8.2 59
Upper mount cover bolt 10 mm 50 5.1 37
Lower mount bolt 12 mm 60 6.2 45
Clamp bracket shaft nut — 43 4.4 32
Water pump case bolt 8 mm 17 1.7 13
Gearcase bolt 10 mm 54 5.6 41
Propeller shaft bearing housing bolt 8 mm 23 2.3 17
Pinion nut 14 mm 120 12 89
Propeller nut 18 mm 55 5.6 41
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 2.0 – 4.0 0.20 – 0.41 1.5 – 3.0
6 mm 4.0 – 7.0 0.41 – 0.71 3.0 – 5.2
8 mm 10 – 16 1.0 – 1.6 7.4 – 12
I9J011010014-01
10 mm 22 – 35 2.2 – 3.6 16 – 26
(Conventional or “4” marked bolt)
5 mm 2.0 – 4.0 0.20 – 0.41 1.5 – 3.0
6 mm 6.0 – 10 0.61 – 1.0 4.4 – 7.4
8 mm 15 – 20 1.5 – 2.0 11 – 15
I9J011010015-01
10 mm 34 – 41 3.5 – 4.2 25 – 30
(Stainless steel bolt)
5 mm 3.0 – 6.0 0.31 – 0.61 2.2 – 4.4
6 mm 8.0 – 12 0.82 – 1.2 5.9 – 8.9
8 mm 18 – 28 1.8 – 2.9 13 – 21
I9J011010016-01
10 mm 40 – 60 4.1 – 6.1 30 – 44
(“7” marked bolt)
Special Tools and Equipment

Recommended Service Material
CENNP3130108003
93691–80030 99000–25350 99000–31140 99000–32020 99000–32160

SUZUKI Silicone Seal SUZUKI Water SUZUKI Bond 1207B SUZUKI Thread Lock SUZUKI Thread Lock
(100 g) Resistant Grease EP2 (100 g) Super 1333B (50 g) 1342H (50g)
(250 g)
Special Tool
CENNP3130108004
01500–0840A 09900–20101 09900–20202 09900–20203 09900–20204

Bolt Vernier calipers (150 Micrometer (25 – 50 Micrometer (50 – 75 Micrometer (75 – 100
mm) mm) mm) mm)
09900–20605 09900–20607 09900–20701 09900–20803 09900–21304

Dial calipers (10 – 34 Dial gauge Magnetic stand Thickness gauge Steel “V” block set
mm)
09900–22303 09900–25007 09900–25011 09912–58432 09912–58442

Plastigauge (0.025 – Peak volt adapter Circuit tester set Fuel pressure hose Fuel pressure gauge
0.076 mm)
09912–58490 09912–66310 09913–50121 09915–47341 09915–64512

3-way joint & hose Micrometer (0 - 25 Oil seal remover Oil filter wrench Compression gauge
mm)
09915–64530 09915–64550 09915–77311 09915–78211 09916–10912

Compression gauge Compression gauge Oil pressure gauge Oil pressure gauge Valve lapper
hose hose attachment adapter
09916–14910 09916–19030 09916–34542 09916–37810 09916–38210

Valve lifter attachment Valve lifter Valve guide reamer Valve guide reamer (ø Valve guide reamer (ø
handle 6 mm) 11 mm)
09916–46020 09916–49040 09916–57350 09916–68010 09916–77310

Valve guide remover Tappet holder Valve guide installer Tappet holder spacer Piston ring
handle compressor
09916–84511 09917–47020 09917–49610 09917–87810 09917–98221

Tweezers Vacuum pump gauge Vacuum pump adapter Valve guide installer Valve guide stem seal
attachment installer attachment
09919–16010 09921–29410 09922–59410 09922–59420 09923–73210

Deep socket wrench Driveshaft holder Propeller shaft Housing installer Bearing remover
(10 mm) housing installer handle
09930–30104 09930–30161 09930–39220 09930–49220 09930–76311

Sliding hammer Propeller shaft Flywheel remover Flywheel holder Timing light
remover
09930–88730 09930–89260 09930–89290 09930–89350 09933–39810

36-pin test cord set Injector test cord (A) 18 pin & 34 pin test H.T cord adapter O2 sensor socket
cord
09941–64511 09944–09810 09944–09820 09945–69010 09945–79310

Bearing remover PTT trim cap tool PTT cylinder cap tool PTT rod holder PTT cable extension
09950–69512 09951–09020 09951–09530 09951–19220 09951–38710

Gearcase oil leakage Gear adjust spring set Gear adjusting gauge Attachment Plate
tester
09951–59910 09951–99310 09952–99320

Shaft (removal and Gear holder Hand air pump
installation)
0B-1 Maintenance and Tune-Up:
Maintenance and Tune-Up

General Information
Precautions
Precautions for Maintenance
CENNP3130200001
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
CENNP3130201001
Refer to “Fuel and Oil Recommendations” in Section 0A (Page 0A-4).
Scheduled Maintenance
Periodic Maintenance Schedule Chart
CENNP3130205001
NOTE
I = Inspect and clean, adjust, lubricate or replace, if necessary
T = Tighten
R = Replace
Interval
Every 100 hrs. Every 200 hrs. Every 300 hrs.
Item to be serviced Initial 20 hrs.
or every 12 or every 12 or every 36
or 1 month
months months 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
I I
Low pressure fuel filter
Replace every 400 hours or every 2 years.
Idle speed I I
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
CENNP3130205002
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))
1 3
5
8
INP313020001-01
1. Throttle and shift linkage 4. Grease nipple, tilt lock lever 7. Trim ram pad (DF140B/DF140BZ)
2. Grease nipple, clutch lever 5. Grease nipple, steering bracket 8. Propeller shaft
: Before applying grease, lock the motor in
the fully tilted up position.
3. Grease nipple, swivel bracket 6. Grease nipple, steering bracket (DF115B/
DF115BZ transom “L”)
: Before applying grease, lock the motor in
the fully tilted up position.
Service Instructions
Engine Oil Level Check Engine Oil Change and Engine Oil Filter
CENNP3130206001
Replacement
Inspect oil level CENNP3130206002
Before every use Change engine oil

Initially after 20 hours (1 month) and every 100 hours
1) Place outboard motor upright on a level surface.
(12 months)
2) Remove motor cover.
3) Remove oil level dipstick (1) and wipe it clean. Replace engine oil filter
(12 months)
NOTE
• Engine oil should be changed while engine
is warm.
• When replacing engine oil filter, change
engine oil at the same time.
Engine Oil Change

1 1) Place outboard motor upright on a level surface.
IMP311020003-01
2) Remove oil filler cap.
4) Reinsert dipstick fully into dipstick tube, then remove
it to check oil level.
5) Oil level should be between full level Max. mark
(Hole) and low level Min. mark (Hole).
If level is low, add recommended oil to full level Max.
mark.
• API classification: SG, SH, SJ, SL, SM, SN, SP or
NMMA certified FC-W oil.
• Viscosity rating: SAE 10W-40 or 10W-30, NMMA
FC-W 10W-40 or 10W-30.
INP313020003-02
“A”
“B”
IMP311020001-02
“A”: Upper limit “B”: Lower limit
INP313020002-02
3) Place a container under engine oil drain plug. 7) Reset oil change reminder system’s operation time
4) Remove engine oil drain plug (1) and gasket (2) to to zero (cancellation).
drain engine oil.
NOTE
Refer to “Oil Change Reminder System
Description” in Section 1A (Page 1A-15).
2 8) Start engine and allow it to run for several minutes at

1 idle speed.
Check oil drain plug for oil leakage.
Turn off engine and wait for approx. two minutes,
then recheck engine oil level.
IMP311020005-01 Engine Oil Filter Replacement

5) Install new gasket and oil drain plug. 1) Drain engine oil in the same manner of engine oil
Tighten engine oil drain plug to specified torque. change procedure.
NOTICE 2) Place a shop cloth under the oil filter adapter case
before removal to absorb any oil released.
A previously-used gasket may leak, resulting
in engine damage. 3) Using an oil filter wrench to loosen the oil filter, then
remove the filter and O-ring.
To avoid water entry into oil pan or oil Special tool
leakage into the environment do not reuse : 09915–47341 (Oil filter wrench)
gasket once removed.
Always use a new one. NOTE
Before fitting a new oil filter, be sure to oil the
Tightening torque O-ring.
Engine oil drain plug (a): 13 N·m (1.3 kgf-m, 9.6
lbf-ft)
(a)
I9J011020004-01
IMP311020006-02
6) Pour recommended engine oil into oil filler opening,

then install oil filler cap.
• API classification: SG, SH, SJ, SL, SM, SN, SP or
NMMA certified FC-W oil.
• Viscosity rating: SAE 10W-40 or 10W-30, NMMA
FC-W 10W-40 or 10W-30.
Engine oil amounts
Oil change only: 5.5 L (5.8/4.8 US/Imp.qt)
Oil filter change: 5.7 L (6.0/5.0 US/Imp.qt)
Engine overhaul: 6.2 L (6.6/5.5 US/Imp.qt)
4) Screw the new filter on by hand until filter O-ring

contacts the mounting surface.
5) Tighten the filter 3/4 turn from the point of contact
with mounting surface using an oil filter wrench.
Tightening torque
Engine oil filter: 14 N·m (1.4 kgf-m, 10 lbf-ft)
6) Pour the recommended engine oil into the oil filler
opening, then install oil filler cap. Check the oil level
in the same manner of engine oil change procedure. IDG211020008-02
7) Reset oil change reminder system’s operation time 5) Install oil level plug before removing oil filler tube
to zero (cancellation). from drain hole.
NOTE 6) Install oil drain plug.
Refer to “Oil Change Reminder System NOTICE

Description” in Section 1A (Page 1A-15). An used gasket may leak and allow water to
enter the gearcase causing severe damage.
8) Start engine and allow it to run for several minutes at
idle speed.
Do not reuse gaskets once removed.
Check oil filter for oil leakage.
Always use a new gasket.
Turn off engine and wait for approx. two minutes,
then recheck engine oil level.
NOTE
Gear Oil Change To avoid a possible low gear oil level,

CENNP3130206003 recheck gear oil level 10 minutes after doing
Change gear oil procedure in step 6. If oil level is low, add
Initially after 20 hours (1 month) and every 100 hours additional gear oil until level is correct.
(12 months)
1) Place outboard motor upright on a level surface. Spark Plug Removal and Installation
CENNP3130206004
2) Place a container under the lower unit.
Inspect spark plug
3) Remove lower gear oil drain plug (1) first, then Every 100 hours (12 months)
remove gear oil level plug (2) and drain gear oil.
Standard spark plug
NGK LKR6E
2
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
1 equipment and accessories.
IDG211020007-03
Only resistor (R) type spark plugs must be
4) Fill with recommended gear oil through oil drain hole
used with this engine.
until oil just starts to flow out from oil level hole.
Recommended gear oil Removal
• Suzuki Outboard Motor Gear Oil or API
! WARNING
classification GL5, Viscosity rating SAE # 90
Hypoid gear oil. The hot engine can burn you.
Gear oil amount
Wait until the engine is cool enough to touch.
1050 ml (35.5/37.0 US/Imp. oz)
1) Remove fuel hose guard.
Refer to “Fuel Hose Guard Removal and Installation”
in Section 1D (Page 1D-2).
2) Remove ignition coils.
Refer to “Ignition Coil Removal and Installation” in
Section 1H (Page 1H-7).
3) Remove the spark plugs (1).
IDG211020060-01
Spark Plug Gap

Measure spark plug gap with a thickness gauge. Adjust
INP313020004-01 to within specified range if gap is out of specification.
Special tool
Installation : 09900–20803 (Thickness gauge)
Installation is in the reverse order of removal with special
attention to the following point. Spark plug gap “a” (Standard)
• Tighten the spark plug to the specified torque. 0.8 – 0.9 mm (0.031 – 0.035 in)
Tightening torque
Spark plug: 28 N·m (2.9 kgf-m, 21 lbf-ft)
Spark Plug Inspection and Cleaning

CENNP3130206005
NOTICE
Non-resistor types of spark plugs will
interfere with the function of the electronic “a”
ignition, causing misfiring, or causing
problems with other electronic boat
I9J011020007-01
equipment and accessories.
Condition of Electrodes
Only resistor (R) type spark plugs must be
Inspect electrode for a worn or burnt condition.
used with this engine.
If it is extremely worn or burnt, replace spark plug.
Also, be sure to replace spark plug if it has a broken
Inspect spark plug
insulator, damaged thread, etc.
Every 100 hours (12 months)
Standard spark plug NOTICE
NGK LKR6E Use of improper spark plugs can cause
Carbon Deposits severe engine damage.
Inspect for carbon deposits on spark plug base. If the reach is too short, carbon will be
If carbon is present, remove it with a spark plug cleaning deposited on the threaded portion of the plug
machine or by carefully using a pointed tool. hole resulting in possible engine damage.
Confirm the thread size and reach when

replacing the plug.
IHM811020049-03
Tappet Clearance Inspection and Adjustment Tappet clearance (Cold engine condition)
CENNP3130206006 IN.: 0.23 – 0.27 mm (0.009 – 0.011 in)
Inspect tappet clearance EX.: 0.33 – 0.37 mm (0.013 – 0.015 in)
Inspection
Too small a tappet clearance may reduce engine power,
“a”
too large a tappet clearance increases valve noise and
hastens valve and seat wear.
When the tappets are set to the specified clearance, the
engine will run without excessive noise from the valve
mechanism and will deliver full power. In this engine, the
tappet clearance is increased or decreased by replacing
the shim disc, made of a special wear resistant material, (A)
fitted to the top of the tappet. Using the proper tools I9J011020008-01
provides for easy removal and installation of the shim
“a”: 90°
disc.
Tappet clearance adjustment should be checked and
6) If out of specification, adjust tappet clearance by
adjusted:
changing shim.
• During scheduled periodic inspection.
• When valve mechanism is serviced. Adjustment
• When camshafts are disturbed by removing them for Tappet clearances are adjusted by replacing tappet
inspection. shim.
1) Remove spark plugs. 1) With cam nose vertical to valve, turn tappet cut-away
Refer to “Spark Plug Removal and Installation” towards center of cylinder head as shown in figure.
(Page 0B-5).
2) Remove ring gear cover.
Refer to “Ring Gear Cover Removal and Installation”
3) Remove cylinder head cover.
Refer to “Cylinder Head Cover Removal and
Installation” in Section 1D (Page 1D-3).
NOTE
“B”
1 “A”
This is a left hand (LH) rotation powerhead. I9J011020009-01
1. Shim “B”: Spark plug hole

4) Rotate crankshaft counterclockwise to bring cam
“A”: Cut section of the tappet
nose vertical to shim surface.
5) Measure tappet clearances by inserting thickness 2) Rotate crankshaft to open (lift up) valve and then
gauge between cam and shim surface. remove camshaft housing bolts where shim is to be
NOTICE replaced.
3) Assemble the special tools “A” and “B”, then install
Turning of the engine in clockwise can cause
special tools with camshaft housing bolts as shown
water pump impeller damage.
in figure.
Rotate the crankshaft in the normal running Special tool
direction only (counterclockwise) to prevent (A): 09916–49040 (Tappet holder)
water pump impeller damage. (B): 09916–68010 (Tappet holder spacer)
NOTE
• Rotate crankshaft and measure clearance
for each tappet respectively by bringing
cam nose vertical to shim surface.
• All tappet clearances can be measured
during two crankshaft rotations.
Special tool
(A): 09900–20803 (Thickness gauge)
NOTE
2
When installing shim, identification mark on
the shim should face down (towards tappet).
5) After removing shim, measure thickness of original

(A) shim and determine correct thickness of shim for
proper tappet clearance as calculated by following
formula.
Special tool
(B)
(C): 09912–66310 (Micrometer (0 - 25 mm))
IDG211020012-02
2. Camshaft housing bolt
(C)
2
IDG211020056-01
Tappet clearance specifications

IN. side: A = B + (C – 0.25 mm)
(A)
EX. side: A = B + (C – 0.35 mm)
(B)
A: Correct thickness of shim for proper tappet
clearance (mm)
IDG211020055-01
B: Thickness of original shim (mm)
2. Camshaft housing bolt C: Original tappet clearance (mm)
! WARNING “C”
Failure to take proper precautions when

installing or removing the tappet shim can
250 “a”
result in severe personal injury.
When installing or removing the tappet shim:

I9J011020013-01
• Never put in the hand between camshaft
and tappet. “C”: I.D No. “a”: 2.50 mm
• Use a magnet to remove and install shim.

Shim size chart
Thickness Thickness
4) Rotate top of cam 90 degree clockwise and remove I.D. No. I.D. No.
(mm) (mm)
shim from cut-away at tappet.
218 2.18 260 2.60
(Two tappets can be adjusted at the same time)
220 2.20 263 2.63
223 2.23 265 2.65
4 225 2.25 268 2.68
228 2.28 270 2.70
230 2.30 273 2.73
233 2.33 275 2.75
235 2.35 278 2.78
238 2.38 280 2.80
3
240 2.40 283 2.83
243 2.43 285 2.85
245 2.45 288 2.88
248 2.48 290 2.90
IDG211020043-01
250 2.50 293 2.93
3. Shim 4. Magnet 253 2.53 295 2.95
255 2.55 298 2.98
258 2.58 300 3.00
6) Install shim with the identification number facing

down (towards tappet).
7) Rotate crankshaft to open (lift up) valve.
8) Remove special tools and tighten camshaft housing
bolts (a) to specified torque.
Tightening torque
Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
8.1 lbf-ft)
5 (A)
(B)
(a)
6
IDG211020044-02
5. Tappet 6. Camshaft
9) Recheck tappet clearance.
NOTE
After completing tappet clearance
adjustment and securing camshaft housing
bolts, inspect tappet clearance again.
10) After checking and adjusting all valves, reinstall parts

removed earlier.
Installation is in the reverse order of removal.
11) Final assembly check
• All parts removed have been returned to their
original positions.
• Check wire and hose routing.
Refer to “Wiring Harness Routing Diagram” in
Section 4A (Page 4A-4), “Fuel Hose Routing” in
Section 4B (Page 4B-1) and “Water Hose
Routing” in Section 4B (Page 4B-5).
• 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
0.63 – 0.67 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300 1. Measure tappet clearance “Engine cold”.
2. Measure present shim size.
0.68 – 0.72 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
3. Match clearance in vertical column with
0.73 – 0.77 268 270 273 275 278 280 283 285 288 290 293 295 298 300 present shim size in horizontal column.
0.78 – 0.82 273 275 278 280 283 285 288 290 293 295 298 300
[ EXAMPLE ]
0.83 – 0.87 278 280 283 285 288 290 293 295 298 300
Tappet clearance is — 0.35 mm
Maintenance and Tune-Up:
0.88 – 0.92 283 285 288 290 293 295 298 300 Present shim size — 2.40 mm
Shim size to be used — 2.50 mm
IMP311020024-01
0B-10
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 – 0.04 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268
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
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
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
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
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
0.30 – 0.32 218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295
0.33 – 0.37 SPECIFIED CLEARANCE / NO ADJUSTMENT REQUIRED

0.38 – 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 – 0.44 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.45 – 0.49 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.50 – 0.54 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
Tappet shim selection chart (EX. side)
0.55 – 0.59 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.60 – 0.64 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300 1. Measure tappet clearance “Engine cold”.
2. Measure present shim size.
0.65 – 0.69 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
3. Match clearance in vertical column with
0.70 – 0.74 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300 present shim size in horizontal column.
0.75 – 0.79 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
[ EXAMPLE ]
0.80 – 0.84 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300 Tappet clearance is — 0.40 mm
0.85 – 0.89 270 273 275 278 280 283 285 288 290 293 295 298 300 Present shim size — 2.40 mm
Shim size to be used — 2.48 mm
0.90 – 0.94 275 278 280 283 285 288 290 293 295 298 300
IHN111020009-02
Idle Speed and Idle Air Control (IAC) Duty

Inspection
CENNP3130206007
Inspect idle speed and IAC duty

(12 months)
NOTE
Before checking idle speed/IAC duty, make
sure of the following.
I9J011020033-01
• Engine must be warmed up.
• Check idle speed after engine speed has SDS tool is used
stabilized. To perform the idle speed and IAC duty inspection, use
• Check throttle link mechanism and throttle personal computer and the SDS tool.
valve for smooth operation. 1) Connect the SDS tool to engine.
• Lead wires and hoses of electronic fuel Refer to the step 1 on the SDS operation manual.
injection and engine control systems are 2) Start the engine and allow to warm up.
connected securely. 3) Check the engine speed and IAC duty by using
• Ignition timing is within specification. “Service data/Engine data” mode in the SDS.
• Tappet clearance is checked according to Idle speed in neutral gear (IAC duty)
maintenance schedule. Standard: 650 – 750 r/min (Duty: Approx. 10%)
• No abnormal air drawn in from air intake
system. NOTE
After all items are confirmed, check idle During the period of idling or trolling, the IAC
speed and IAC duty. duty is approx. 10%, however it varies by the
load, the climate, water condition etc. to keep
There are two methods available for performing the idle the engine speed at preset value.
speed / IAC duty inspection and adjustment;
1) Using a personal computer and the SDS (Suzuki 4) If engine idle speed/IAC duty is out of the
Diagnostic System) software. specification, the following adjustment must be
Suzuki recommends using this method as it is performed.
possible to monitor the inspection data. a) Turn the by-pass air screw in an appropriate
direction to bring it to the standard specification.
NOTE
Idling/trolling speed is controlled by the IAC
1 system.
Do not attempt to adjust the throttle valve
opening by turning the throttle stop screw.
INP313020007-01 1
1. SDS service connector
2) Adjust engine speed by the IAC duty fixed mode.

In IAC duty fixed mode, engine speed can be
adjusted while monitoring engine speed by
tachometer.
INP313020008-02
1. By-pass air screw

b) Shift into forward, check in-gear idle speed. 4) During IAC duty fixed mode, adjust engine speed to
650 – 750 r/min. by turning by-pass air screw.
NOTE Turning air screw counterclockwise:
• The IAC duty at the trolling speed will be Engine speed will increase.
increased more than that at idle speed due Turning air screw clockwise:
to the load. Engine speed will decrease.
• Trolling speed (in-gear idle speed) is the
same as engine idle speed.
• Idling/trolling speed of 650 – 750 r/min. is
controlled by the IAC system. 1
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-9).
INP313020008-02
Adjust engine speed by the IAC duty fixed mode
1. By-pass air screw
Checking and adjustment of idle speed / IAC duty by IAC
duty fixed mode are as follows;
5) When finished adjusting the idle speed, opening the
1) Start engine and allow to warm up. throttle will automatically cancel the IAC fixed mode.
2) Shift into Neutral and close the throttle fully (this will
cause a full close throttle signal to be input to the NOTE
ECM). The fixed mode of IAC can also be canceled
3) To set the IAC valve duty to constant 8.8%, turn the manually by shifting to Forward or Reverse
ignition switch from ON to START 5 times within 10 or raising the engine speed (changes the TPS
seconds. full close throttle signal to OFF).
At this time, the caution buzzer will sound to notify
that IAC duty is in fixed mode. 6) Return the throttle to full close and check engine
speed.
NOTE It should now be stable at 650 – 750 r/min.
During IAC duty fixed mode, the “Check NOTE
Engine” lamp will flash.
Idling/trolling speed is controlled by IAC (idle
NOTE air control) system.
If engine speed does not return to
• The ignition switch operation to set the specification, IAC passage may be clogged
IAC valve into the fixed mode should be or IAC system may not be operating
performed with the engine running at idle. correctly. See “Idle Air Control System
• During IAC duty fixed mode, the caution Description” in Section 1G (Page 1G-9).
buzzer will sound in a repeating pattern of
0.5 second on with an interval of 3 seconds NOTE
off. Trolling speed (in-gear idle speed) is same as
• IAC duty fixed mode will continue for 5 idle speed.
minutes after which it will automatically
cancel.
Breather Line and Fuel Line Inspection

CENNP3130206008
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

INP313020009-01
Low Pressure Fuel Filter Inspection NOTICE

CENNP3130206009
Improperly loosening the filter cup can cause
Inspect low pressure fuel filter switch lead wires damage.
• Be careful not to twist the switch lead wire
(12 months)
when removing the filter cup.
Replace low pressure fuel filter • Disconnect the lead wire connector before
Every 400 hours or 2 years removing the filter cup.
• If water accumulation or sediment is found, clean the
low pressure fuel filter.
• If leakage, cracks or other damage is found, replace
the low pressure fuel filter.
“a”
2
IMP311020026-02
1 4) Place a rag under the filter before removal to catch

any spilled fuel.
5) Separate the fuel filter cup (3) from the fuel filter
INP313020005-01
body (4) by turning the fuel filter cup
counterclockwise.
1. Low pressure fuel filter
4
! WARNING
Gasoline is extremely flammable and toxic.
It can cause a fire and can be hazardous to
people and pets.
Always take the following precautions when 3

servicing the fuel filter
IMP311020027-02
• Stop the motor before cleaning the low
6) Drain fuel and water in the fuel filter cup into a
pressure fuel filter.
suitable container.
• Be careful not to spill fuel. If you do, wipe it
7) Pull out the filter element (5).
up immediately.
8) Inspect the filter element (5), O-ring (6) and seal ring
• Do not smoke, and keep away from open
(7) for damage.
flames and sparks.
If they are damaged, replace them.
1) Turn the engine off and allow it to cool. 4
Make sure that the ignition switch is in the OFF
position.
2) Remove fuel hose guard. 7
6
Refer to “Fuel Hose Guard Removal and Installation” 5
3) Push the connector lock tab “A”, then disconnect the 3
switch lead wire connector (2).
IMP311020002-03
9) Wash the filter element (5) with clean solvent and dry
it.
10) Assemble the seal ring (7) and filter element (5) in
their original positions.
11) Verify that the O-ring (6) is in place in the top of the
filter cup (3) and screw the filter cup back into place.
12) Connect the switch lead wire connector (2). Propeller / Propeller Nut and Cotter Pin
13) Restart the engine and check that there are no leaks Inspection
CENNP3130206011
around the fuel filter.
Inspect propeller/propeller nut and cotter pin
Water Pump and Water Pump Impeller Initially after 20 hours (1 month) and every 100 hours
Inspection (12 months).
CENNP3130206010
1) Inspect propeller for bent, chipped or broken blades.
Inspect water pump/pump impeller Replace propeller if damage noticeably affects
Every 200 hours (12 months) operation.
Replace water pump impeller 2) Remove the propeller.
Every 300 hours (36 months) Refer to “Propeller Removal and Installation” in
Section 3A (Page 3A-5).
3) Inspect propeller splines. Replace propeller if splines
are worn, damaged or twisted.
4) Inspect propeller bush for slippage.
Replace if necessary.
IDG211020032-01
IDG211020016-01
IDG211020033-01
1) Remove the lower unit and water pump case.

Refer to “Water Pump Removal and Installation” in
Section 3A (Page 3A-7). IDG211020017-01
2) Inspect water pump case, inner sleeve and under 5) Install the propeller and related parts.
panel. Replace if wear, cracks, distortion or corrosion Refer to “Propeller Removal and Installation” in
is found. Section 3A (Page 3A-5).
3) Inspect water pump impeller. 6) Make sure that propeller nut is torqued to
Replace if vanes are cut, torn or worn. specification and cotter pin is installed securely.
SUZUKI recommends that replacing the water pump
impeller every 300 hours (36 months). Tightening torque
Propeller nut: 55 N·m (5.6 kgf-m, 41 lbf-ft)
4) Assemble the water pump related items.
Refer to “Water Pump Removal and Installation” in
5) Install the lower unit assembly.
Refer to “Lower Unit Removal and Installation” in
Anode Inspection NOTE

CENNP3130206012
The anode cover (1) may be separated from
Inspect anodes (External) the power unit body by inserting and turning
Initially after 20 hours (1 month) and every 100 hours a 10 mm bolt (2) to function as a screw jack.
(12 months)
Inspect anodes (Internal powerhead)
Every 100 hours (12 months) 2
If 2/3 of zinc anode has corroded away, replace anode.
The anode should be periodically cleaned with a wire 1 1
brush to ensure maximum effectiveness.
NOTICE
If anodes are not properly maintained,
underwater aluminum surfaces (such as the
lower unit) will suffer galvanic corrosion
damage.
IMP311020016-01
• Periodically inspect anodes to make sure
they have not become detached.
• Do not paint anodes, as this will render
them ineffective.
• Periodically clean anodes with a wire
brush to remove any coating which might
decrease their protective ability.
IMP311020017-01
NOTE
The anode (3) securing bolt should be
covered with suzuki silicone seal.
: Sealant 93691–80030 (SUZUKI Silicone Seal

IDG211020034-01 (100 g))
I9J011020023-01
IDG211020035-01
Bonding Wire Inspection • Batteries should always be kept out of

CENNP3130206013 reach of children.
Inspect bonding wires • When checking or servicing battery,
Every 100 hours (12 months) disconnect the negative (black) cable.
If breakage or other damage is found on bonding wire, Be careful not to cause a short circuit by
replace the wire. allowing metal objects to contact the
If rust, corrosion or other damage is found on terminal, battery posts and motor at the same time.
clean with cleaning solvent or replace the wire. • Wear approved eye protection.
Connecting Battery
! WARNING
Battery posts, terminals, and related
accessories contain lead and lead
compounds that may be hazardous.
Wash hands after handling.

INP313020006-01
NOTICE
Failure at the battery connection will cause
incorrect operation of the engine control
system.
Be sure to take the following precautions:

• Ensure battery cable connections are
clean and secure.
• Be sure to use hexagon nuts to secure
battery cables to the battery terminals to
IDG211020022-01 avoid loss of electrical power.
Do not use wing nuts to secure the battery
Battery Inspection cables.
CENNP3130206014
• Check the nuts periodically for proper
Inspect battery tightness.
• Do not disconnect battery leads from the
(12 months)
battery while the engine is running.
! WARNING
handling the battery may cause severe injury.
Be sure to take the following precautions

when handling the battery:
• Never expose the battery to open flames or
electric sparks as batteries generate gas
which is flammable and explosive.
• Do not place the battery near the fuel tank.
• Battery acid is poisonous and corrosive.
Avoid contact with eyes, skin, clothing,
and painted surfaces.
If you come in contact with battery acid,
flush immediately with large amounts of
water and seek immediate medical
attention.
How to connect Battery solution level should be between UPPER level

1) Connect positive (+) terminal first. and LOWER level.
If level is low, add distilled water only.
2) Connect negative (–) terminal second.
3) Upon completion of connection, lightly apply grease
to battery terminals.
4) Install the terminal cap on the positive battery
terminal to prevent an accidental short circuit of
battery terminals.
1
I9J011020031-01
3
2 Battery Solution Specific Gravity Check
Measure the specific gravity of battery solution using a
hydrometer.
Battery solution specific gravity (Temperature)
1.28 (20 °C)
IFH511020002-01
1. Red lead 3. Black lead

2. Sub battery cable
How to disconnect
1) Disconnect negative (–) terminal first.
2) Disconnect positive (+) terminal second.
I9J011020032-01
1
3 Thermostat Inspection
CENNP3130206015
2
Inspect thermostat
Inspect thermostat every 100 hours (12 months).
Refer to “Thermostat Inspection” in Section 1F (Page
1F-4).
IFH511020002-01
1. Red lead 3. Black lead

2. Sub battery cable
Bolts and Nuts Inspection
CENNP3130206016
Battery Solution Level Check Inspect bolts and nuts

NOTICE (12 months)
If you add diluted sulphuric acid to the Check that all bolts and nuts listed below are tightened
battery after it has been initially serviced, you to their specified torque.
will damage the battery. Refer to “Tightening Torque Specifications” in Section 0A
(Page 0A-14).
Never add diluted sulphuric acid to the • Cylinder head cover bolts
battery after it has been initially serviced.
Follow the battery manufacturer’s • Intake manifold bolts and nuts
instructions for specific maintenance • Flywheel bolt
procedures. • Power unit mounting bolts
• Clamp bracket shaft nut
• Lower mount bolts and nuts
• Gearcase bolts
• Propeller nut
Oil Pressure Check NOTE

CENNP3130206017
! CAUTION • Before installing adapter, wrap threads
with sealing tape (1), then tighten adapter.
Engine oil can be hot enough to burn you.
• Cut off any excess sealing tape from
threads before installation.
Do not remove the oil pressure gauge
adapter when the engine is hot. Wait until
engine cools.
1
Check the engine oil pressure periodically.
1) Check the engine oil level.
2) Remove STBD side cover.
Refer to “Side Cover Removal and Installation” in
Section 2A (Page 2A-3). IMP311020019-01
3) Remove the plug (1) for oil pressure service port.
(B) (A)
IMP311020020-01
IMP311020018-01
4) Install oil pressure gauge adaptor into oil pressure 5) Start engine and allow to warm up.
service port. 6) After warming up, shift into forward gear and
increase engine speed to 3000 r/min, then compare
Special tool
pressure indicated on gauge to specifications.
(A): 09915–77311 (Oil pressure gauge)
(B): 09915–78211 (Oil pressure gauge NOTE
adapter)
The figure shown below is a guideline only,
not an absolute service limit.
Oil pressure
390 – 470 kPa (4.0 – 4.8 kgf/cm2, 57 – 68 psi.)
If oil pressure is lower or higher than specification,
the following causes may be considered.
Low oil pressure
• Clogged oil filter
• 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
• Clogged oil passage
• Clogged oil pressure regulator
• Combination of above items
7) Tighten the oil pressure service port plug to the
specified torque.
Tightening torque 6) Move and hold throttle lever in full open position.
Oil pressure service port plug: 13 N·m (1.3 kgf- 7) While cranking engine with starter motor, note
m, 9.6 lbf-ft) maximum compression pressure reading on gauge
for each cylinder.
NOTE
• Before installing oil pressure service port NOTE
plug, wrap threads with sealing tape (1), Figures shown are guidelines only, not
then tighten plug. absolute service limits.
• Cut off any excess sealing tape from
threads before installation. Cylinder compression pressure
Standard: 1200 – 1800 kPa (12.2 – 18.4 kgf/cm2,
174 – 261 psi.)
1
Cylinder compression pressure max. difference
between cylinders
100 kPa (1.0 kgf/cm2, 15 psi.)
Low compression pressure can indicate one or more
of following:
• Excessively worn cylinder wall
IMP311020021-01
• Worn piston or piston rings
• Stuck piston rings
Cylinder Compression Pressure Check
CENNP3130206018 • Poor seating of valves
The compression pressure reading of cylinder is good
• Ruptured or otherwise damaged cylinder head
indicator of its internal condition.
gasket
The decision to overhaul the power unit is often based
on the results of a compression test. 8) Reinstall parts removed earlier (Spark plugs, etc.).
Periodic maintenance records kept at your dealership
should include compression readings for each
maintenance service.
1) Start engine and allow to warm up, then shut engine
off.
2) Disconnect all fuel injector connectors at fuel
injector.
3) Remove all spark plugs.
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)
(A)
(B) (C)
IEH511020049-01
5) Disconnect remote control throttle cable from throttle

lever.
Section 1
Power Head
CONTENTS
Precautions .................................................1-1 Self-Diagnostic Code “4 – 1” Model

Precautions............................................................. 1-1 Discrimination (ECM and Wiring Harness
Precautions for Powerhead................................... 1-1 Mismatch)........................................................1A-37
Self-Diagnostic Code “5 – 4” Knock Sensor......1A-38
Engine Control......................................... 1A-1 Self-Diagnostic Code “3 – 6” O2 Sensor...........1A-39
Precautions...........................................................1A-1 Self-Diagnostic Code “6 – 3” O2 Sensor
Precautions on Engine Control Diagnosis........... 1A-1 Heater .............................................................1A-40
Self-Diagnostic Code “9 – 4” Keyless System
General Description .............................................1A-2
Authentication Error ........................................1A-41
Engine Control System Description .................... 1A-2
Control Module for System Control ..................... 1A-3
Communication Error ......................................1A-41
Caution System Description................................ 1A-6
Self-Diagnostic System Description .................... 1A-9
Failure .............................................................1A-41
Fail-Safe System Description............................ 1A-14
Troubleshooting Without Self-Diagnostic
Oil Change Reminder System Description........ 1A-15
Code................................................................1A-41
Water in Fuel Alert System Description ............ 1A-15
Troll Mode System Description ......................... 1A-16 Service Instructions ...........................................1A-42
Keyless Start System Description ..................... 1A-17 How to Use the 36-pin Test Cord Set ...............1A-42
Inspection of the ECM and Its Circuit................1A-43
Component Location .........................................1A-19
Inspection of the Keyless Control Unit and Its
Engine Control System Components / Engine
Circuit ..............................................................1A-47
Electrical Device Location ............................... 1A-19
Keyless Control Unit Circuit Voltage Table .......1A-48
Diagnostic Information and Procedures..........1A-19
ECM Main Relay Inspection..............................1A-49
ECM Power and Ground Circuit Check............. 1A-19
ECM Removal and Installation..........................1A-49
Troubleshooting with Self-Diagnostic Code ...... 1A-22
Keyless fob Battery Replacement .....................1A-49
Self-Diagnostic Code “3 – 4” MAP Sensor........ 1A-22
ECM Power Relay Inspection ...........................1A-50
Self-Diagnostic Code “1 – 4” Cylinder Temp.
Registering The First and Second Keyless fob
Sensor............................................................. 1A-23
ID Codes .........................................................1A-51
Self-Diagnostic Code “2 – 3” IAT Sensor .......... 1A-24
Unpairing an ECM from the Keyless Start
Self-Diagnostic Code “1 – 5” Ex. Manifold
System ............................................................1A-52
Temp. Sensor ................................................. 1A-25
Self-Diagnostic Code “3 – 7” Trim Sensor ........ 1A-26 Engine Electrical Devices ....................... 1C-1
Self-Diagnostic Code “2 – 1” TPS (Throttle
Precautions...........................................................1C-1
Position Sensor).............................................. 1A-27
Precaution for Engine Electrical Device ..............1C-1
Self-Diagnostic Code “1 – 2” SPS (Shift
Position Sensor).............................................. 1A-28 General Description .............................................1C-1
Self-Diagnostic Code “1 – 1” Rectifier / Sensor and Switch Description ...........................1C-1
Regulator (Over Charging).............................. 1A-29 ECM Power Source Line.....................................1C-7
Self-Diagnostic Code “4 – 3” Fuel Injector ........ 1A-30 Component Location ...........................................1C-9
Self-Diagnostic Code “4 – 2” CKP Sensor ........ 1A-31 Location of Sensor and Switch............................1C-9
Self-Diagnostic Code “2 – 4” CMP Sensor........ 1A-32 Service Instructions .............................................1C-9
Self-Diagnostic Code “2 – 2” Air Intake Resistance Check ...............................................1C-9
System ............................................................ 1A-33 Cylinder Temp. Sensor Removal and
Self-Diagnostic Code “3 – 2” MAP Sensor 2..... 1A-34 Installation .......................................................1C-10
Self-Diagnostic Code “3 – 3” Neutral Switch..... 1A-36 Cylinder Temp. Sensor Inspection ....................1C-10
Self-Diagnostic Code “5 – 3” Oil Pressure Ex. Manifold Temp. Sensor Removal and
Switch ............................................................. 1A-37 Installation .......................................................1C-11
1-ii Table of Contents
Ex. Manifold Temp. Sensor Inspection .............1C-11 Cylinder Head Disassembly and Assembly ......1D-24
CKP Sensor Removal and Installation ..............1C-12 Cylinder Head Components Inspection and
CKP Sensor Inspection .....................................1C-12 Servicing .........................................................1D-27
IAT Sensor Removal and Installation................1C-12 Pistons, Piston Rings, Connecting Rods,
IAT Sensor Inspection.......................................1C-12 Cylinder and Crankshaft Components ............1D-33
CMP Sensor Removal and Installation .............1C-13 Pistons, Piston Rings, Connecting Rods,
CMP Sensor Inspection ....................................1C-13 Cylinder and Crankshaft Disassembly and
MAP Sensor Removal and Installation..............1C-14 Assembly.........................................................1D-34
MAP Sensor Output Voltage Inspection............1C-15 Cylinder, Piston and Piston Ring Inspection
O2 Sensor Removal and Installation.................1C-16 and Servicing ..................................................1D-40
O2 Sensor Output Voltage Inspection...............1C-16 Piston Pin and Conrod Inspection .....................1D-44
O2 Sensor Heater Inspection............................1C-17 Crank Pin and Conrod Bearing Inspection ........1D-45
Knock Sensor Removal and Installation ...........1C-18 Crankshaft Inspection .......................................1D-47
Knock Sensor Inspection ..................................1C-18 Crankshaft Main Bearing Inspection .................1D-48
IAC Valve Removal and Installation..................1C-19 Crankshaft Drive Gear Inspection .....................1D-50
IAC Valve Inspection.........................................1C-19
Shift Position Sensor Removal and Power Unit Lubrication ........................... 1E-1
Installation .......................................................1C-20 General Description .............................................1E-1
Shift Position Sensor Power Source and Engine Lubrication Description ...........................1E-1
Output Voltage Inspection...............................1C-21 Schematic and Routing Diagram ........................1E-1
Shift Position Sensor Mounting Position Engine Oil Lubrication Chart ...............................1E-1
Adjustment ......................................................1C-22 Diagnostic Information and Procedures ............1E-2
Neutral Switch Removal and Installation...........1C-22 Oil Pressure Check .............................................1E-2
Wire harness Removal and Installation.............1C-23 Oil Change Reminder System.............................1E-2
TPS Inspection..................................................1C-26 Low Oil Pressure Caution System ......................1E-2
Trim Sensor Removal and Installation ..............1C-27 Powerhead Lubrication System Diagnosis..........1E-2
Trim Sensor Inspection .....................................1C-28
Service Instructions .............................................1E-3
Emergency Stop Switch Inspection...................1C-28
Oil Pump Removal and Installation .....................1E-3
Inspection Oil Pump Component Parts ...............1E-4
Power Unit Mechanical ........................... 1D-1
Oil Pressure Switch Removal and Installation ....1E-4
General Description .............................................1D-1 Oil Pressure Switch Inspection ...........................1E-5
Power Unit Construction Description ..................1D-1 Oil Strainer Removal and Installation ..................1E-6
Diagnostic Information and Procedures............1D-1 Oil Strainer Related Parts Inspection ..................1E-6
Cylinder Compression Check..............................1D-1
Oil Pressure Check .............................................1D-1 Power Unit Cooling System.....................1F-1
Service Instructions.............................................1D-2 General Description ............................................. 1F-1
Tappet Clearance Inspection ..............................1D-2 Water Cooling System Description ..................... 1F-1
Fuel Hose Guard Removal and Installation ........1D-2 Displacement Type Water Pump Description ..... 1F-1
Ring Gear Cover Removal and Installation.........1D-2 Water Pressure Valve Description ...................... 1F-1
Cylinder Head Cover Removal and Schematic and Routing Diagram ........................ 1F-2
Installation .........................................................1D-3 Cooling Water Circulation Chart.......................... 1F-2
Air Intake Silencer Removal and Installation.......1D-5
Diagnostic Information and Procedures ............ 1F-3
Electric Parts Holder Removal and Installation ....1D-5
Powerhead Cooling System Diagnosis ............... 1F-3
Intake Manifold and Throttle Body
Service Instructions ............................................. 1F-3
Components......................................................1D-6
Thermostat Removal and Installation.................. 1F-3
Intake Manifold Removal and Installation ...........1D-7
Thermostat Inspection......................................... 1F-4
Throttle Body Removal and Installation ..............1D-8
Water Pressure Valve Removal and
Throttle Body Inspection .....................................1D-9
Installation ......................................................... 1F-4
Power Unit Removal and Installation ..................1D-9
Water Pressure Valve Related Item
Timing Chain, Chain Tensioner and Camshaft
Inspection.......................................................... 1F-5
Sprockets Components...................................1D-13
Water Pump Removal and Installation ................ 1F-5
Water Pump Related Item Inspection ................. 1F-5
Sprockets Removal and Installation................1D-14
Water Tube Removal and Installation ................. 1F-5
Water Tube Related Item Inspection................... 1F-5
Sprockets Inspection.......................................1D-17
Camshaft, Tappet and Shim Removal and Fuel System ............................................. 1G-1
Installation .......................................................1D-18
Camshaft, Tappet and Shim Inspection ............1D-20 Precautions.......................................................... 1G-1
Cylinder Head Assembly Components .............1D-22 Precautions on Fuel System Service ................. 1G-1
Cylinder Head Removal and Installation ...........1D-23 General Description ............................................ 1G-1
Table of Contents 1-iii
Electronic Fuel Injection System Description ......1G-1 Ignition Timing Inspection ...................................1H-6
Fuel Delivery System Components Ignition Coil Removal and Installation .................1H-7
Description ........................................................1G-4 Ignition Coil Inspection ........................................1H-7
High Pressure Fuel Pump Control System Ignition Coil Operating Signal Inspection ............1H-8
Description ........................................................1G-7 CKP Sensor Inspection .......................................1H-9
Air Intake Components Description.....................1G-8 CMP Sensor Inspection ......................................1H-9
Idle Air Control System Description ....................1G-9 Ignition Switch Inspection....................................1H-9
Water in Fuel Alert System Description ............1G-10 ECM Main Relay Inspection................................1H-9
Diagnostic Information and Procedures..........1G-10
Fuel Pressure Inspection ..................................1G-10 Starting System .........................................1I-1
Fuel System Diagnosis .....................................1G-12 General Description .............................................. 1I-1
Fuel Injection System Troubleshooting .............1G-13 Electric Starter System Description...................... 1I-1
Service Instructions...........................................1G-14 Starter Motor Operation Condition
Fuel Pressure Relief Procedure ........................1G-14 Description ......................................................... 1I-3
Fuel Line Removal and Installation ...................1G-14 Start-In-Gear Protection System Description ....... 1I-4
Fuel Line Inspection ..........................................1G-14 Component Location ............................................ 1I-4
Fuel Leakage Check Procedure .......................1G-14 Starting System Components Location................ 1I-4
Inspection of Fuel Hose Connections ...............1G-15 Diagnostic Information and Procedures ............. 1I-5
High Pressure Fuel Pump Operating Sound Starter System Troubleshooting........................... 1I-5
Inspection........................................................1G-15 Service Instructions .............................................. 1I-7
Fuel Vapor Separator Removal and Starter Motor Removal and Installation................ 1I-7
Installation .......................................................1G-16 Starter Motor Test ................................................ 1I-8
Fuel Vapor Separator Disassembly and Starter Motor Components................................... 1I-9
Assembly ........................................................1G-17 Starter Motor Disassembly and Assembly ......... 1I-10
Inspection of Fuel Vapor Separator Starter Motor Components Inspection and
Component Parts ............................................1G-20 Servicing .......................................................... 1I-14
Fuel Injector Inspection with Injector in Place ...1G-21 Ignition Switch Inspection................................... 1I-17
Individual Fuel Injector Operating Sound Starter Motor Relay Inspection........................... 1I-18
Inspection........................................................1G-22 Neutral Switch Removal and Installation............ 1I-19
Fuel Injector Operating Signal Inspection .........1G-23 Neutral Switch Inspection................................... 1I-19
Fuel Injector Removal and Installation ..............1G-24
Low Pressure Fuel Pump Removal and Charging System ..................................... 1K-1
Installation .......................................................1G-26 General Description .............................................1K-1
Low Pressure Fuel Pump Inspection ................1G-27 Charging System Description..............................1K-1
Water Detection Switch Inspection ...................1G-27 Battery Requirement Description ........................1K-1
Component Location ...........................................1K-2
Ignition System........................................ 1H-1 Charging System Components Location.............1K-2
General Description .............................................1H-1 Diagnostic Information and Procedures ............1K-2
Ignition System Description ................................1H-1 Charging System Diagnosis................................1K-2
Ignition Control Description .................................1H-2
Service Instructions .............................................1K-3
Component Location ...........................................1H-4 Charging System Construction ...........................1K-3
Ignition System Components Location ...............1H-4 Flywheel Removal and Installation......................1K-4
Diagnostic Information and Procedures............1H-4 Battery Charge Coil Removal and Installation ....1K-5
Ignition System Symptom Diagnosis...................1H-4 Battery Charge Coil Inspection ...........................1K-6
Ignition System Troubleshooting.........................1H-5 Rectifier / Regulator Removal and Installation ....1K-6
Service Instructions.............................................1H-6 Rectifier / Regulator Inspection ...........................1K-7
Spark Plug Removal and Installation ..................1H-6 Main Fuse Inspection ..........................................1K-8
Spark Plug Inspection .........................................1H-6
1-1 Precautions:
Precautions
Power Head
Precautions
Precautions for Powerhead
CENNP3131000001
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
CENNP3131100001
! 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-14).
– 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
CENNP3131101001
The DF115B/DF115BZ/DF140B/DF140BZ 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 Ignition system Ignition coil
MAP sensor Idle air control system IAC valve
IAT sensor Fuel pump system High pressure fuel pump
Cylinder temp. sensor
Exhaust manifold temp. sensor
Water detection switch Caution system Caution Buzzer

TPS Water in fuel alert system
Neutral switch Self diagnostic system

Multi function gauge
Shift position sensor Fail safe system
Knock sensor
Operating hour indication system
Oil changing reminder system
Oil pressure switch
Emergency stop switch Starer motor relay,

Start-in-gear protection system (Starter motor)
Ignition switch
Starter motor relay control system
PTT switch PTT relay control system PTT motor relay
Trim sensor
Trim gauge
O2 sensor
Troll mode switch
INP313110001-02
Control Module for System Control

CENNP3131101002
Engine Control Module (ECM)
The ECM sends signals to control the actuators based on the information inputs from each sensor/switch and BCM
(Boat Control Module). 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.
Fuel pump control • Controls high pressure fuel pump drive.
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.
PTT 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.
ECM Input / Output Circuit Diagram (Normal Key Start Model)
MAIN RELAY
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 BUZZER RESET BUZZER RESET

SW SW
19
PTT SW
PTT UP SW
23
PTT DN SW
22
PTT
M 27 RELAY UP
PTT PTT
RELAY RELAY DN
26 O2 SENSOR
CKP HEATER
SENSOR 60
4
CMP
SENSOR
69
IAC1
59 M
IAC2
47
SENSOR IAC3
50
PWR (5V)
7 IAC4
MAP 38
SENSOR
6
SHIFT POSITION SENSOR IGN COIL #1

8 68
THROTTLE POSITION SENSOR

5 IGN COIL #2
54
TRIM SENSOR
28
IGN COIL #3
66
O2 SENSOR
3
IGN COIL #4
IAT SENSOR 53
14 PWR GND
55
67
CYL TEMP SENSOR PWR GND
15
BUZZER
IPS 57
EX-MANI TEMP OVER HEAT
SENSOR LED
17 63
CHECK ENGINE
SENSOR GND LED
31 62
OIL PRESSURE
WATER
LED
DETECTION 64
SWITCH
21
TRIM GAUGE
IPS 58
OIL PRESSURE
SW
11 OVER REV LED
65
TROLL MODE TACHO METER

SW 1
2
COMMUNICATION LINE A 34
SDS TOOL
COMMUNICATION LINE B 35
CAN (H) 13
from keyless
KNOCK SENSOR
56 control unit
CAN (L) 25
EMERGENCY
ECM GND
STOP SW 61
9
INP313110002-03
ECM Input / Output Circuit Diagram (Keyless Start Model)
MAIN RELAY
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
PTT SW
PTT UP SW
23
PTT DN SW
22
PTT
M 27 RELAY UP
PTT PTT
RELAY
26 RELAY DN O2 SENSOR
CKP HEATER
SENSOR 60
4
CMP
SENSOR
69
IAC1
59 M
IAC2
47
SENSOR IAC3
50
PWR (5V)
7 IAC4
MAP 38
SENSOR
6
SHIFT POSITION SENSOR IGN COIL #1

8 68
THROTTLE POSITION SENSOR

5 IGN COIL #2
54
TRIM SENSOR
28
IGN COIL #3
66
O2 SENSOR
3
IGN COIL #4
IAT SENSOR 53
14 PWR GND
55
67
CYL TEMP SENSOR PWR GND
15
BUZZER
IPS 57
EX-MANI TEMP OVER HEAT
SENSOR LED
17 63
CHECK ENGINE
ECM SENSOR GND LED
MAIN SW PWR RELAY 31 62
KEYLESS START SW
7 OIL PRESSURE
WATER
BATTERY ECM PWR RELAY LED
DETECTION 64
PWR 17
16 POWER SWITCH
21
GND TRIM GAUGE
14 BUZZER IPS 58
4 Bz
OIL PRESSURE
SW
ECM PWR INPUT 11 OVER REV LED
9 65
KEYLESS CONTROL UNIT
SELECT SW
TROLL MODE TACHO METER
1 SW 1
2
EMERGENCY SW
2
COMMUNICATION LINE A 34
CAN (H) 13 SDS TOOL
To ECM COMMUNICATION LINE B 35
CAN (L) 25
CAN (H) 13
from keyless
KNOCK SENSOR
56 control unit
CAN (L) 25
EMERGENCY
ECM GND
STOP SW 61
9
INP313110015-02
Model Identification by the ECM and Wiring Harness

The ECM receives an input voltage signal from No.32 ECM terminal in a predetermined time after the engine is
started.
The ECM then determines if the input voltage is consistent with the model’s programming data.
If the voltage signal is consistent with the model data, the ECM performs normally.
If the voltage signal is not consistent with the model data, the ECM limits engine speed to 3000 rpm while operating
the remote control lever, and a 4-1 diagnostic code is triggered.
NOTE
• The ECM is different between two models (DF115B/DF115BZ and DF140B/DF140BZ).
• The model identification is carried out between model group DF115B/DF115BZ and DF140B/
DF140BZ.
• The wiring harness is different between DF115B/DF115BZ and DF140B/DF140BZ.
The wiring harness and resistor of No.32 ECM terminal exist only in DF140B/DF140BZ.
Resistor
32 ECM
Wiring
harness
DF140B/DF140BZ
INP313110003-01
There are two kinds of wire harness on this model line-up.

One is exclusive parts of DF115B/DF115BZ.
Other is exclusive parts of DF140B/DF140BZ.
Caution System Description

CENNP3131101005
The following 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
• KEYLESS FOB CAUTION *1
• KEYLESS FOB LOW BATTERY VOLTAGE CAUTION *1
• KEYLESS FOB CONTROL UNIT LOW BATTERY VOLTAGE CAUTION *1
(*1: Keyless start model only)
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” Yes Yes
Overheat Yes “C” Yes Yes
Low battery voltage Yes “D” Yes No
Keyless FOB *1 Yes “D” No No
Keyless FOB low battery
Yes “D” No No
voltage *1
Keyless control unit low battery
Yes “D” No No
voltage *1
(*1: Keyless start model only)
Lamp Check / Buzzer Check Low Oil Pressure Caution System

Normal key start model: Condition:
When the ignition key is turned to the “ON” position: Immediate activation of system when the oil pressure
• Four Caution lamps turns on for two seconds. switch is turned “ON” due to an engine oil pressure drop
• Caution buzzer sounds for two seconds. below 100 kPa (1.0 kgf/cm2, 14 psi).
Keyless start model: Action:

When the keyless start system is turned “ON”. • When this system activates, the red OIL lamp will light
• Four Caution lamps turn on and caution buzzer and the caution buzzer sounds.
sounds for first two seconds. • If this caution system operates at higher than 1000
• After indicating the total motor operating hours for the r/min, the engine speed will be reduced to
next three seconds, four caution lamps turn on again approximately 1000 r/min.
until the engine is started. • The engine automatically stops 3 minutes after the
• Four cation lamps continue turning on while the caution system is activated.
engine is stopped with the keyless start system ON. NOTE
• Four caution lamps become OFF after engine starting. If the engine is automatically stopped due to
NOTE the caution system, the engine can be started
again. However, the caution system will
If the caution system is activated, only the repeatedly activate until the cause is
corresponding lamp will light. eliminated.
Over-Revolution Caution System Reset:

Condition: Stop engine and check engine oil level. Refill engine oil
The ECM controlled over revolution limiter will engage at to the correct level if below the low oil mark.
the engine speeds shown below. Once engaged it will If the engine oil level is correct, the following causes may
initiate an intermittent fuel injection signal to reduce be considered:
engine speed.
• Improper oil viscosity.
Over revolution limiter • Malfunctioning oil pressure switch.
DF115B/DF115BZ: 6100 r/min.
• Clogged oil strainer or oil filter.
DF140B/DF140BZ: 6400 r/min.
• Worn oil pump relief valve.
Action: • Oil leakage from the oil passage.
• When the engine speed detected by ECM exceeds • Excessive wear/damage of oil pump.
the preset maximum engine speed more than ten
seconds, the engine speed will be limited to NOTE
approximately 3000 r/min. The low oil pressure caution system is reset
• If the engine speed is reduced to the over revolution when the oil pressure is restored to over 100
system maximum preset value or lower within ten kPa with approx. 1000 r/min or less engine
seconds, the over revolution caution will be speed operation.
automatically canceled. However, the engine must be stopped and
checked immediately once the system is
Reset: activated.
Close throttle to reduce engine speed below approx.
3000 r/min for one second.
Overheat Caution System Reset:

Condition 1 (Maximum temperature) Close throttle completely and then shift into neutral.
Immediate activation of system when: System reset will occur when cylinder temperature drops
• Cylinder temperature reaches 100 °C (212 °F) below the limits shown below. However, the system may
be activated again unless the cause for overheat (such
• Exhaust manifold temperature reaches 90 °C (194 °F)
as insufficient water) is removed.
Condition 2 (Temp. rise vs Time)
Immediate activation of system when: Caution cause Reset temperature
Condition 1 Approx. 78 °C
• The average temperature difference during three
(Maximum temperature) (172 °F)
consecutive 10 second measurement periods of the
Condition 2 Approx. 76 °C
cylinder temperature sensor at engine speeds of 500
(Temperature rise vs Time) (169 °F)
r/min or higher exceeds the limits as shown below.
Temperature range Temperature difference Low Battery Voltage Caution System
80 – 89 °C Condition 1:
Approx. 3 °C (37 °F)
(176 – 192 °F) System is activated when the battery voltage decreases
90 °C – (194 °F –) Approx. 0.6 °C (33 °F) to less than 9 V for 30 seconds.
Condition 2:
• The average temperature difference during three System is activated if the battery voltage is less than 2 V
consecutive 10 second measurement periods of the for more than 2 seconds with the ignition switch is turned
exhaust manifold temperature sensor at engine “ON” and the engine not running.
speeds of 500 r/min or higher exceeds the limits as
shown below. Action:
Temperature range Temperature difference When this system activates, the red CHECK ENGINE
65 – 74 °C lamp will light and the caution buzzer sounds.
Approx. 11 °C (52 °F)
(149 – 165 °F)
75 °C – (167 °F –) Approx. 1.4 °C (35 °F) Reset:
Condition 1:
Action: This caution system is automatically reset when battery
When this system activates,the red TEMP lamp will light voltage increases to more than 9 V. Refrain from using
and the caution buzzer sounds. electrical equipment requiring high amperage such as
If this caution system operates at higher than 2000 r/min, hydraulic trim tabs, hydraulic jack plate, etc. after this
the engine speed will be reduced to approximately 2000 caution is activated.
r/min. Condition 2:
The engine automatically stops 3 minutes after the For the caution system to engage under this condition
caution system is activated. possibilities such as a deteriorated battery, poor battery
cable connection, battery switch in the OFF position, etc,
NOTE
must be inspected.
If the engine is automatically stopped due to To cancel the caution system activation for these
the caution system, the engine can be started conditions, check all power source related items and
again. eliminate the problem.
However, the caution system will repeatedly
activate until the cause is eliminated. Keyless fob Caution System
NOTE
This caution system is applicable only to
keyless start models.
Condition:
This system operates when an identification error of
keyless fob occurs.
Action:
When this system activates, “CHECK ENGINE” lamp will
flash according to the self-diagnostic code “9-2”.
Reset:
Inspect the keyless fob and keyless control unit, and
repair or replace the component that has caused the
failure.
NOTE NOTE
If this system activates, check following: If this system activates, check following:
• The keyless fob is within the • The battery is in sound condition.
communication range of the keyless • Contact failure of the battery terminal.
control unit.
• The keyless fob is in communication
mode. Self-Diagnostic System Description
CENNP3131101006
• There is not any object that interferes with Normal key start model:
the radio wave between the keyless fob The self-diagnostic system alerts the operator when an
and the keyless control unit. abnormality occurs in a signal from a sensor, or switch,
• The keyless fob battery has sufficient etc.
capacity. When the system is activated, the “CHECK ENGINE”
lamp flashes (lights intermittently) according to each
• The keyless fob is the one that has been code pattern, along with a buzzer sound.
authenticated by the keyless start system When the engine is running, the buzzer sounds a series
of the engine. of short (0.2 sec.) beeps. When the engine is not
running, the buzzer sounds according to each code
Keyless fob Low Battery Voltage Caution System pattern, but not simultaneously with the flashing lamp.
The buzzer sound can be temporally canceled by
NOTE pushing the ignition key in.
keyless start models. Keyless start model:
The self-diagnostic system alerts the operator when an
Condition: abnormality occurs in a signal from a sensor, or switch,
This system operates when the battery voltage of the etc.
keyless fob drops to a point which could impair keyless When the system is activated, the “CHECK ENGINE”
fob performance. lamp flashes (lights intermittently) according to each
code pattern, along with a buzzer sound.
Action:
When this system activates, “CHECK ENGINE” lamp will NOTE
flash according to the self-diagnostic code “9-1”. The buzzer sound will be stopped 60 seconds
after activating the diagnostic system.
Reset:
Inspect the keyless fob battery and replace it. NOTE
NOTE When diagnosis code of “9-1”, “9-2”, “9-3”,
“9-4”, “9-5” or “9-6” appears, buzzer will not
If this system activates, replace the battery of
sound.
keyless fob.
In this case, only flash “CHECK ENGINE”
lamp according to each code pattern.
Keyless Control Unit Low Battery Voltage Caution
System
Monitor-Tachometer
NOTE
keyless start models.
Condition:
This system operates when the battery voltage of the
keyless control unit drops to a point which could impair
keyless control unit performance.
Action:
When this system activates, “CHECK ENGINE” lamp will “A”
flash according to the self-diagnostic code “9-3”. I9J011110005-01
“A”: “CHECK ENGINE” lamp

Reset:
Inspect the power source of system, and replace or
recharge the battery.
Self-Diagnostic Code
Backup Restart
Priority Failed item Code Lamp flashing pattern
present ability
1
1 MAP sensor 1 3–4 0

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

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

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

YES NO
MCODE00D42-0-01
1
5 CMP sensor 2–4 0

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

YES YES
MCODE00D22-0-01
MAP sensor 2 (Pressure detect 1
7 3–2 NO YES
passage) 0
MCODE00D32-0-01
1
8 Exhaust manifold temp. sensor 1–5 0

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

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

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

YES NO
MCODE00D12-0-01
1
12 Neutral switch 3–3 0

YES NO
MCODE00D33-0-01
1
13 Rectifier/regulator (Over-charging) 1–1 0

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

NO YES
MCODE00D53-0-01
Model discrimination 1
15 4–1 YES YES

(ECM and Wiring Harness mismatch) 0
MCODE00D41-0-01
1
16 Trim sensor 3–7 0

YES YES
MCODE00D37-0-01
1
17 Knock sensor 5–4 0

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

YES YES
MCODE00D63-0-01
1
20 Keyless fob battery low *1 9–1 0

NO YES
MCODE00D91-0-01
Backup Restart
Priority Failed item Code Lamp flashing pattern
present ability
1
21 Keyless fob authentication error *1 9–2 0

NO YES
MCODE00D92-0-01
1
22 Keyless control unit battery low *1 9–3 0

NO YES
MCODE00D93-0-01
1
23 Keyless system authentication error *1 9–4 0

NO YES
MCODE00D94-0-01
1
24 Keyless system communication error *1 9–5 0

NO NO
MCODE00D95-0-01
1
25 Keyless system failure *1 9–6 0

NO NO
MCODE00D96-0-01
*1: Keyless start model only
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 the failed item, the self-diagnostic indication appears until the ECM receives the
proper signal with the engine running.
• Cancellation of the self-diagnostic indication is automatically performed when the failure is
corrected and a normal signal is received by the ECM for a period of 20 – 30 seconds.
• 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.
NOTE
To cancel the diagnostic display for oil pressure switch failure, perform the following procedure after it
is corrected:
1. Turn the ignition switch to ON. The diagnostic code for oil pressure switch failure will continue to
be displayed until a normal signal sequence is received by the ECM.
2. Turn the ignition switch to OFF once and turn ON again.
At the second turning ON, cancel of the oil pressure switch failure code is completed.
NOTE
The rectifier/regulator self-diagnostic indication may not display (be canceled) by turning the ignition
switch “ON” because the ECM detects only battery voltage, not charging output.
Under this condition the buzzer will not sound and diagnostic code not appear.
However, if the rectifier/regulator have failed, the self diagnostic indication will again appear 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 “0.14 – 4.73 V” signal (With engine running)
• No signal
Cylinder temp. sensor • Receiving an out of range “–46 to +170 °C (–50.8 – +338.0 °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
• No signal
Exhaust manifold temp. sensor • Receiving an out of range “–46 to +170 °C (–50.8 – +338.0 °F) (0.10 – 4.6 V)”
signal
Trim sensor • Receiving an out of range “0.2 – 4.8 V” signal.
• Receiving an out of range “0.35 – 4.8 V” TPS main sensor signal.
Throttle position sensor • The addition of two output voltages of the main sensor and sub sensor makes
outside the specified range.
Shift position sensor • Receiving an out of range “0.2 – 4.8 V” signal.
Rectifier/Regulator • Receiving 16 V or higher signal
(Over-charging)
Fuel injector • No operation signal from the ECM
• During the rotation of the predetermined crankshaft angle, the normal CKP sensor
CKP sensor
signal pattern is not received by the ECM.
• During four crankshaft rotations, the normal CMP sensor signal pattern is not
CMP sensor
received by the ECM.
• During the ECM’s receiving input of the complete close signal from the throttle
Air intake system position sensor, the engine operates at an abnormally high speed.
(Criterion: 2300 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
pressure exceeds 50 kPa.
• While the shift sensor outputs the forward or reverse signal, the ECM receives
Neutral switch
input of the neutral signal from the neutral switch.
• While the engine is stopped and the ignition switch is “ON”, the ECM receives an
Oil pressure switch
“OFF” signal from the oil pressure switch.
Model discrimination (ECM and • There is discrepancy of signal voltage between the model ID voltage of ECM and
Wiring Harness mismatch) input voltage from ECM terminal No.32.
• 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 heater
O2 sensor heater
circuit)
• Keyless fob battery voltage decreased.
Keyless fob battery low
• For detail, refer to “Keyless fob Low Battery Voltage Caution System” (Page 1A-9).
• Authentication error between Keyless fob and keyless unit occurred.
Keyless fob authentication
• Communication error between Keyless fob and keyless unit occurred.
error
• For detail, refer to “Keyless fob Caution System” (Page 1A-8).
• Keyless control unit power source voltage decreased.
Keyless control unit battery low • For detail, refer to “Keyless Control Unit Low Battery Voltage Caution System”
(Page 1A-9).
Keyless system authentication • ECM detected that its ID code does not correspond with the ID code registered in
error the keyless control unit.
Failed item Condition

• The ECM cannot receive CAN communication information from keyless control
Keyless system
unit.
communication error
(Faulty wire harness of keyless start system.)
Keyless system failure • There is an irregularity on the internal circuit of the keyless control unit.
NOTE
Failed item “MAP sensor 2” condition will be caused by clogged pressure detect passage (1) in intake
manifold assembly.
INP313110004-02
Fail-Safe System Description

CENNP3131101007
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
MAP sensor 1 • 40 – 101.3 kPa (The control takes place in accordance with the engine speed.)
Cylinder temp. sensor 60 °C (140 °F)
IAT sensor 45 °C (113 °F)
Exhaust manifold temp. sensor 60 °C (140 °F)
Trim sensor • The control is continued with fixed sensor output as 3.3 V.
• The throttle opening is fixed to default with the throttle motor relay turned off.
Throttle position sensor ECM controls the engine speed at the maximum of 2000 r/min by operating the
remote control lever.
• ECM detects the shift position as neutral even under in-gear condition and controls
the engine speed to idling.
Shift position sensor • If the “Throttle only” button is pressed with the remote control lever in neutral, the
engine speed can be controlled at the maximum of 2000 r/min by operating the
lever.
CKP sensor • The ECM prohibits ignition and fuel injection.
CMP sensor • The ECM prohibits ignition and fuel injection.
Air intake system • The control is executed with the maximum engine speed as 2000 r/min.
Neutral switch • Shift position judgment is performed only by the shift position sensor.
• The ECM controls engine speed at the maximum 3000 r/min while operating the
Model discrimination (ECM and
remote control lever.
Wiring Harness mismatch)
(The engine rpm is controlled by making the fuel injection signal intermittent.)
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.
Oil Change Reminder System Description Cancellation Procedure

CENNP3131101008
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.
Indication of System Activation
Buzzer
I9J011110008-02
I9J011110007-02
Oil lamp
NOTE
• Cancellation of the system is possible
whether or not the engine oil has been
replaced.
Once the system has been activated,
SUZUKI strongly recommends that the
I9J011110009-02
engine oil be replaced before canceling the
system.
Action • If the engine oil has been replaced with the
system not activated, it is still necessary to
Starting operation
perform the cancellation procedure to
(*1) (*4) reset the Oil Change Reminder System.
Indication Cancellation
(*2) (*4) Water in Fuel Alert System Description
CENNP3131101009
Indication Cancellation This engine is equipped with an integral fuel filter/water
(*3) (*4) separator and associated alert system.
The alert system will activate if water separated from the
Indication Cancellation fuel exceeds a specific volume.
(*3) (*4) If this system activates, the red REV-LIMIT lamp will
flash and a buzzer will begin a series of triple beeps
Indication Cancellation
when the engine is in neutral only.
Repeat If this system activates, stop the engine, and check the
I9J011110010-03 fuel filter/water separator for water.
*1: Lapse of initial 20 hour’s operation For inspection and cleaning of the fuel filter, refer to the
*2: Lapse of 80 hour’s operation “Low Pressure Fuel Filter Inspection” in Section 0B
*3: Lapse of 100 hour’s operation (Page 0B-15) and “Water Detection Switch Inspection” in
*4: When performing cancellation before system activation Section 1G (Page 1G-27).
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:

• When pressing the “UP” switch, one short beep
1 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
• When pressing the “DN” switch at the
Troll Mode System Description
CENNP3131101011 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. • When pressing the “UP” switch at the
The “Troll Mode System” is activated by pressing the troll upper limit of trolling speed, the engine
mode switch, when the motor is running at in-gear idle speed will not change and three long (0.8
speed. By using this system, you can set and maintain a sec.) beeps will sound.
desired engine speed with the control switch in a range
• Shift operation and throttle control remain
from in-gear idle speed (Approx. 700 r/min) to 1200
operational, even in troll mode.
r/min.
5V Canceling The Troll Mode:

1 The troll mode can be canceled by shifting the remote
control lever to the neutral position, or by increasing the
engine speed to 3000 r/min or more. In both cases, two
2 short (0.1 sec.) beeps sound when canceling the troll
TROLL SW
mode.
2
IDG211110031-01
1. ECM 2. Troll mode switch
During Troll mode, ECM will control the engine speed as

follows:
ECM calculates the target engine speed with the input
signal from the switch, then controls the IAC valve and
the trolling speed is made to become to the target speed.
Setting The Troll Mode:

1) Shift into forward or reverse gear and make sure that
the throttle is fully closed (in-gear idle speed).
2) Press the “UP” or “DN” position of the troll mode
switch, until you hear one beep.
The REV/TRL (or REV) lamp on the monitor gauge
will light indicating that the motor has been set to the
troll mode. The REV/TRL (or REV) lamp will
continue to light while the motor is in the troll mode.
Keyless Start System Description

CENNP3131101012
The keyless start system uses a coded keyless fob to transmit an access code to the engine’s starting system.
The engine can be started without operating a mechanical key when the keyless fob is located within a 1 m (39.3 in)
radius of the keyless control unit.
The keyless start system consists of a keyless fob, keyless control unit, ECM, power relay, main switch, and related
wiring.
Radio communication is performed between the keyless fob and the keyless control unit.
The keyless control unit and ECM are connected by a CAN communication bus to exchange information through CAN
communication.
The system operates by means of radio communication by cross-checking the ID code of the keyless fob, keyless
control unit and ECM.
When the ID codes between the keyless fob, keyless control unit and ECM match, the power relay turns ON to supply
voltage to the engine control system, enabling the engine to be started.
Keyless control unit ECM

Keyless fob
Keyless fob ID code
System ID code System ID code
Unit ID code Unit ID code
Keyless fob ID code Receiving

/ transmitting
circuit
Battery Main switch (Included +12V
antenna)
Power relay
INP313110005-01
Function of component parts

Main key The main knob key is used for pairing the keyless fobs and powering the system.
Emergency key The emergency key is used to create a pass code and to enter the pass code to start
the engine(s) when all keyless fobs have been lost or misplaced.
Keyless fob Transmits ID code signal to keyless control unit.
Keyless control unit Transmits its ID code to ECM.
ECM • Check keyless control unit ID code.
• Transmit its ID code to keyless control unit.
Shifting to keyless start system ON Shifting from keyless start system ON to OFF
With the keyless fob within the 1 m (39.3 in) radius, turn When the keyless fob and the keyless control unit are
and release the main switch knob from “Neutral” to ON/ within the communication range, the keyless start
OFF position: system turns OFF after 30 seconds if the main switch
1) First: The ID code of the keyless fob and the ID code knob is turned from neutral to ON/OFF and release
registered in the keyless control unit are cross- knob.
checked. It takes about one minutes for the ECM internal circuit to
When both ID codes match, communication for turn OFF.
cross-checking the keyless fob comparison is When the keyless fob is outside the communication
terminated. range of the keyless control unit, the keyless start
system is locked.
2) Second: The system ID codes are cross-checked for
comparison between the keyless control unit and
Emergency start
ECM.
As a backup in case the keyless fob is not available, the
The functions of ECM are enabled by matching the
system can be put into engine start standby mode by
system ID codes.
entering a passcode using the emergency mechanical
3) Third: Registered unit ID codes are cross-checked key.
between the keyless control unit and the ECM.
When both unit ID codes match, the power relay Immobilizer system
turns ON and the ECM enters engine start standby The engine can be started only when the keyless fob ID
mode. code corresponds with the registered code in keyless
When the cross-check is complete, the engine is control unit.
enabled to start (cranking, ignition, and injection). If
not, the system power is turned OFF.
Component Location
Engine Control System Components / Engine Electrical Device Location
CENNP3131103001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-4).
Diagnostic Information and Procedures

ECM Power and Ground Circuit Check
CENNP3131104001
Wiring Diagram
Normal key start model

2
7
R
4 3
5
6
W
W
Gr 36
W
9 B/Bl 12
ECM
8
P/B 24
1
BATT W
IG Gr Gr
GND B B
INP313110006-02
1. Battery 4. 60 A fuse 7. Starter motor

2. Battery cable 5. 30 A fuse 8. 15 A fuse
3. 60 A fuse 6. ECM main relay 9. Sub-battery cable
Keyless start model

2
7
R
4 3
5
6
W
Gr 36
W
9 B/Bl 12
ECM
8
P/B 24
IG Gr Gr
BATT W W
PWR R/W R/W Gr
START O
Br
G
B “B”
B
12 B
Gr
“A” B
G
10 W
P/W
P/W
P/W
11 W
W
R/W
INP313110007-02
1. Battery 5. 30 A fuse 9. Sub-battery cable “A”: To ECM

2. Battery cable 6. ECM main relay 10. Keyless control unit “B”: From keyless control unit
3. 60 A fuse 7. Starter motor 11. ECM power relay
4. 60 A fuse 8. 15 A fuse 12. Emergency stop switch
Circuit Description When this power signal is received by keyless

The ECM is battery dependent and must be provided control unit, it turns the ECM power relay on,
with its own dedicated 12 V power supply. The electrical then battery voltage is supplied through R/W
circuits which provide this supply are: lead line to No.12 terminal of ECM.
1)
NOTE
a) Normal key start model:
Ensure battery cable connections are clean
The sub battery cable to the white lead wire in
and secure.
the remote control extension harness to the
Failure at the battery connection will cause
ignition switch.
incorrect operation of the ECM and starter
When the ignition switch is turned ON, battery
motor cranking system.
power passes from the white lead wire, through
the ignition switch contacts to the gray output 2) The engine wiring harness to the main relay. When
lead wire to the No.12 terminal of ECM. the ECM main relay is energized by turning the
b) Keyless start model: ignition switch ON, a circuit is formed which supplies
The sub-battery cable to the white lead wire in battery voltage to the No.36 terminal of ECM.
the remote control extension harness to the main
switch.
When the main switch is turned ON, battery
power passes from the white lead wire, through
the main switch contacts to the gray output lead
wire to the keyless control unit.
Troubleshooting 4) Measure the voltage between the No.12 terminal

and body ground.
Step 1
Is the voltage 12 V (Battery Voltage)?
Is operation of the main relay heard when the
ignition switch is turned “ON”? Yes Go to step 5.
Yes Go to step 4. No Normal key start model:

• Check the ignition switch.
No Go to step 2.
Refer to “Ignition Switch Inspection” in
Step 2 Section 1I (Page 1I-17).
Are the main fuses (60 A and 60 A, for ignition and • Gr, B/Bl wire open circuit or poor
ECM) and sub battery cable fuse (15 A) in good connection.
condition? Keyless start model:
Yes Go to step 3. • Check the main switch.
Refer to “Ignition Switch Inspection” in
No Replace. Section 1I (Page 1I-17).
Step 3 • Gr, (R/W), B/Bl wire open circuit or poor
connection.
1) Disconnect the ECM connector at the ECM with
the ignition switch “OFF”. • Faulty ECM power relay.
2) Measure the voltage between the No.24 terminal
Step 5
of the ECM connector and body ground.
1) Turn the ignition switch “OFF”.
2) Connect the test cord set between the ECM and
Yes Go to step 4. the main wire harness.
Refer to “How to Use the 36-pin Test Cord Set”
No • Check the ECM main relay. (Page 1A-42).
Refer to “ECM Main Relay Inspection” 3) Turn the ignition switch “ON”.
(Page 1A-49). 4) Measure the voltage between the No.24 terminal
• Poor ECM main relay connection. and body ground.
• P/B wire open, shorted or poor Is the voltage approx. 0.8 V?
connection.
Yes Go to step 6.
Step 4
No • P/B wire open, shorted or poor
1) Turn the ignition switch “OFF”. connection.
2) Connect the test cord set between the ECM and
• If the wiring and connection is OK,
the main wire harness.
intermittent trouble or a faulty ECM may
Refer to “How to Use the 36-pin Test Cord Set”
be the cause.
(Page 1A-42).
3) Turn the ignition switch “ON”. Step 6
1) Turn the ignition switch “ON”.
2) Measure the voltage between the No.36 terminal
and body ground.
Yes ECM power and ground circuit are in good

condition.
No • Gr wire open, shorted or poor

connection.
• Faulty ECM main relay.
Troubleshooting with Self-Diagnostic Code

CENNP3131104002
! 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

CENNP3131104003
Wiring Diagram
ECM
5V
1
C
W
P
B/W U
5V
IEH511110028-01
1. MAP sensor
Troubleshooting Step 2
Step 1 1) Check the MAP sensor output voltage change.
Refer to “MAP Sensor Output Voltage Inspection”
1) With the ignition switch “OFF”, disconnect the
in Section 1C (Page 1C-15).
MAP sensor connector.
2) With the ignition switch “ON”, check the voltage at Is it in good condition?
the “R” wire terminal of the MAP sensor
Yes • Substitute a good ECM and recheck.
connector.
No • Faulty MAP sensor.
• “R” wire shorted to “W” wire, “B/W” wire
open, poor “B/W” wire connection, poor
B/W “W” wire connection, “W” wire open or
W poor MAP sensor connection.
R be the cause.
IMP311110015-03
Is the voltage approx. 4 – 5 V?
Yes Go to step 2.
No • “R” wire open, “R” wire shorted to

ground or a poor wire connection.
substitute a known-good ECM and
recheck.
Self-Diagnostic Code “1 – 4” Cylinder Temp. Sensor

CENNP3131104004
Wiring Diagram
ECM
5V
C
B Lg/W
1 P
B B/W
U
IFH511110005-01
1. Cylinder temp. sensor
Step 1 1) Check the cylinder temp. sensor.
Refer to “Cylinder Temp. Sensor Inspection” in
Section 1C (Page 1C-10).
cylinder temp. sensor lead wire connector.
the “Lg/W” wire terminal of the cylinder temp.
Yes Poor cylinder temp. sensor connection,
sensor connector.
be the cause.
No Faulty cylinder temp. sensor.

B/W
Lg/W
IMP311110016-03
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.
Self-Diagnostic Code “2 – 3” IAT Sensor

CENNP3131104005
Wiring Diagram
ECM
5V
C
Lg/B
1 P
B/W
U
I9J011110024-03
1. IAT sensor
Step 1 1) Check the IAT sensor.
Refer to “IAT Sensor Inspection” in Section 1C
1) With the ignition switch “OFF”, disconnect the IAT
(Page 1C-12).
sensor connector.
the “Lg/B” wire terminal of the IAT sensor
Yes Poor IAT sensor connection, intermittent
connector.
trouble or a faulty ECM may be cause.
No Faulty IAT sensor.

Lg/B
B/W
IMP311110017-02
Yes Go to step 2.
No • “Lg/B” wire shorted to “B/W” wire or

ground circuit.
Self-Diagnostic Code “1 – 5” Ex. Manifold Temp. Sensor

CENNP3131104006
Wiring Diagram
ECM
5V
C
1 B V/W
P
B B/W
U
I9J011110030-02
1. Ex. manifold temp. sensor
Troubleshooting
Step 2
Step 1 1) Check the Ex. manifold temp. sensor.
Refer to “Ex. Manifold Temp. Sensor Inspection”
1) With the ignition switch “OFF”, disconnect the Ex.
manifold temp. sensor lead wire connector.
the “V/W” wire terminal of the Ex. manifold temp.
Yes Poor Ex. manifold temp. sensor
sensor connector.
connection, intermittent trouble or a faulty
ECM may be the cause.
No Faulty Ex. manifold temp. sensor.

B/W
V/W
IMP311110019-03
Yes Go to step 2.
No • “V/W” wire shorted to “B/W” wire or

ground circuit.
Self-Diagnostic Code “3 – 7” Trim Sensor

CENNP3131104007
Wiring Diagram
ECM
1
5V
B R
C
Y W/Y P
U
Bl B/W
IMP311110035-01
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.
W/Y
B/W
R
IMP311110020-01
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-28).
Is it in good condition?
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.
Self-Diagnostic Code “2 – 1” TPS (Throttle Position Sensor)

CENNP3131104008
Wiring Diagram
1 ECM
5V
Br/Y
C
P
B/W U
I9J011110059-01
1. TPS
Troubleshooting
Step 1
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.
B/W
Br/Y
IDG211110013-01
Yes Go to step 2.
No • “R/Bl” 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-26).
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” or “P/W”
wire connection, “Br/Y” or “P/W” wire open or poor TPS connection.
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.
Self-Diagnostic Code “1 – 2” SPS (Shift Position Sensor)

CENNP3131104009
Wiring Diagram
1 ECM
5V
B R/W
C
Y P/Bl P
Bl Br/B
U
IMP311110036-01
1. SPS
Troubleshooting
Step 1
1) Remove 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/W” wire terminal of the SPS lead wire connector.
P/Bl
Br/B
R/W
IMP311110022-03
Yes Go to step 2.
No • “R/W” wire open, “R/W” wire shorted to ground circuit or poor connection.
Step 2
1) Check the SPS output voltage change.
Refer to “Shift Position Sensor Power Source and Output Voltage Inspection” in Section 1C (Page 1C-21).
Yes Poor shift position sensor connection, intermittent trouble or a faulty ECM may be the cause.
No • Faulty SPS.
• “R/W” or “Bl” wire shorted to “P/Bl” or “Y” wire, “Br/B” or “B” wire open, poor “Br/B” or “B” wire
connection, poor “P/Bl” or “Y” wire connection, “P/Bl” or “Y” wire open or poor SPS connection.
Self-Diagnostic Code “1 – 1” Rectifier / Regulator (Over Charging)

CENNP3131104010
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-7).
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

CENNP3131104011
Wiring Diagram
IMP311110007-02
1. Fuel injector
Troubleshooting
Step 3
Step 1 1) With the ignition switch “OFF”, disconnect the
connectors from the fuel injectors.
1) Using a sound scope, check that each injector has
an operating sound when the engine is cranking. 2) Check the voltage at “Gr” wire terminal with the
ignition switch “ON”.
Do all injectors make an operating sound?
Yes Fuel injector and its circuit are in good

condition.
No Go to step 2.
Step 2 Gr
1) Check the fuel injector, the wiring connection and
the wire harness of the fuel injector not making the
operating sound. I9J011110023-02
Is the voltage 12 V (battery voltage)?

Are all of the above OK?
Yes Substitute a known-good ECM and Yes Go to step 4.

recheck. No Power circuit open.
No • Faulty injector or its circuit.
Step 4
• Go to step 3. 1) Disconnect the ECM connectors with the ignition
switch “OFF”, and check all of the injectors for
resistance.
Refer to “Resistance Check” in Section 1C (Page
1C-9).
Is the resistance 11.5 – 12.5 Ω for each injector?
Yes Substitute a known-good ECM and

recheck.
No Faulty injector or its circuit.

Self-Diagnostic Code “4 – 2” CKP Sensor

CENNP3131104012
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-12).
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-9).
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

CENNP3131104013
Wiring Diagram
ECM
1 2
Gr
Y/Bl
C
P
B/W U
IFH513110021-01
1. CMP sensor 2. + 12 V (From main relay)
Step 1 Was terminal “Y/Bl” voltage in step 2 within
specification?
Is the CMP sensor installed properly and the wire
harness connected securely? Yes Go to step 4.
Yes Go to step 2. No “Y/Bl” wire open or shorted to ground/
power supply circuit. If the wiring and
No Correct.
connection is OK, substitute a known-
Step 2 good ECM and recheck.
1) With the ignition switch “OFF”, disconnect the Step 4
connector from the CMP sensor.
Was terminal “Gr” voltage in step 2 within
2) Check for proper connection to the CMP sensor at
specification?
“Gr” and “Y/Bl” wire terminals.
3) If OK, turn the ignition switch “ON” and check the Yes Go to step 5.
voltage at the “Gr” and “Y/Bl” wire terminals of the
CMP sensor connector. No “Gr” wire open circuit. If the wiring and
connection is OK, substitute a known-
B/W
Y/Bl Step 5
Check the CMP sensor and sensor trigger vane.
Refer to “CMP Sensor Inspection” in Section 1C (Page
1C-13).
Gr
IMP311110023-01 Is check result satisfactory?
CMP sensor voltage Yes Substitute a known-good ECM and
Terminal “Gr”: 10 – 14 V recheck.
Terminal “Y/Bl”: 4 – 5 V
No Replace CMP sensor.
Is the voltage satisfactory?
Yes Go to step 5.
No Go to step 3.
Self-Diagnostic Code “2 – 2” Air Intake System

CENNP3131104014
Wiring Diagram
1 ECM
5V
Br/Y
C
P
B/W U
I9J011110059-01
1. MAP sensor
Troubleshooting
Step 2
Step 1 1) Check the TPS output voltage change.
Refer to “TPS Inspection” in Section 1C (Page 1C-
26).
TPS connector.
the “R” wire terminal of TPS connector.
Yes Go to step 3.
No • Faulty TPS.
• “R” wire shorted to “Br/Y”” wire, “B/W”
R wire open, poor “B/W” wire connection,
poor “Br/Y” or “P/W” wire connection,
“Br/Y” wire open or poor TPS
connection.
B/W • If the wiring and connection is OK,
Br/Y
IDG211110013-01 intermittent trouble or a faulty ECM may
be the cause.
Yes Go to step 2. Step 3

1) Check the MAP sensor, IAC system and intake
No • “R” wire open, “R” wire shorted to manifold (system) for air leakage.
ground circuit or poor wire connection.
Is the result OK?
substitute a known-good ECM and Yes Intermittent trouble or faulty ECM.
recheck. Substitute a known-good ECM and
recheck.
No Faulty air intake system.

Self-Diagnostic Code “3 – 2” MAP Sensor 2

CENNP3131104015
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
1) With the ignition switch “OFF”, disconnect the MAP sensor connector.
2) With the ignition switch “ON”, check the voltage at the “R” wire terminal of the MAP sensor connector.
B/W
W
R
IMP311110015-03
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-15).
Yes Go to step 3.
No Faulty MAP sensor.

Step 3
1) With the ignition switch “OFF”, disconnect the electronic throttle body connector.
2) With the ignition switch “ON”, check the voltage at the “R/Bl” wire terminal of the electronic throttle body
connector.
B/W
Br/Y
IDG211110013-01
Yes Go to step 4.
Step 4
1) Check the TPS output voltage change.
Refer to “TPS Inspection” in Section 1C (Page 1C-26).
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.
Self-Diagnostic Code “3 – 3” Neutral Switch

CENNP3131104016
Wiring Diagram
ECM
C
Br Br
P
Y/G Y/G
U
12 V (From ignition switch)

INP313110008-01
1. Neutral switch
Troubleshooting
Step 1
1) Remove the 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 “Y/G” wire terminal of the neutral switch connector.
Y/G
Br
IFH513110024-02
Yes Go to step 2.
No • “Y/G” wire shorted to “Br” wire or ground circuit.

Step 2
1) Check the neutral switch.
Refer to “Neutral Switch Inspection” in Section 1I (Page 1I-19).
Yes • Poor neutral switch connection, intermittent trouble or a faulty ECM.

• Neutral switch arm damage.
No Faulty neutral switch.

Self-Diagnostic Code “5 – 3” Oil Pressure Switch

CENNP3131104017
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.
I9J011110064-01
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-5).
Yes Poor oil pressure switch wire connection, intermittent trouble or a faulty ECM may be the cause.
No Faulty oil pressure switch.
Self-Diagnostic Code “4 – 1” Model Discrimination (ECM and Wiring Harness Mismatch)

CENNP3131104018
Troubleshooting
Step 1
1) Check the ECM and wire harness combinations match.
Is the result OK?
Yes Substitute a known-good ECM and recheck.
No Replace with the correct ECM and wire harness combination.

Self-Diagnostic Code “5 – 4” Knock Sensor

CENNP3131104027
Wiring Diagram
ECM
1
C
R P/Y P
U
IMP311110032-01
1. Knock sensor
Troubleshooting
Step 1
1) With the ignition switch “OFF”, disconnect the knock sensor connector.
2) With the ignition switch “ON”, check the voltage between P/Y wire terminal of the knock sensor connector and
body ground.
P/Y
INP313110009-01
Is the voltage 4 – 5 V?
Yes Go to Step 2.
No • P/Y wire open, P/Y wire shorted to ground circuit or poor sensor connection.
• If the wire and connection are OK, substitute a known-good ECM and recheck.
Step 2
1) Inspect knock sensor.
Refer to “Knock Sensor Inspection” in Section 1C (Page 1C-18).
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

CENNP3131104028
Wiring Diagram
OX 12 V
GND
1 ECM
Gr
W
Gr B/W
C
B Gr/Bl P
W
U
Lg/Bl
+B
OXH
IMP311110006-01
1. O2 sensor
Troubleshooting Are they in good condition?
Step 1 Yes Go to step 2.

1) With the ignition switch “OFF”, disconnect the O2 No Gr/Bl wire shorted, or Gr/Bl or B/W wire
sensor connector. open.
2) Check continuity between Gr/Bl terminal of O2
sensor connector and ground, also between Gr/Bl Step 2
and B/W terminals of O2 sensor connector. 1) Check the O2 sensor output voltage.
Make sure there are not continuity. Refer to “O2 Sensor Output Voltage Inspection” in
Gr/Bl ? Is each voltage OK?
Yes Poor O2 sensor connection, intermittent

trouble or a faulty ECM may be the cause.
B/W
No Faulty O2 sensor.
IFH511110017-01
3) Disconnect ECM connectors.

Refer to “ECM Removal and Installation” (Page
1A-49).
4) Check continuity between Gr/Bl terminal of O2
sensor connector (harness side) and No.3
terminal of ECM black connector (harness side),
also between B/W terminal and No.31 terminal.
Make sure there are continuity.
Gr/Bl
B/W
1 2 3 4 5 6 7 8 9 10 11 12 37 38 39 40 41 42 43 44 45 46 47 48
13 14 15 16 17 18 19 20 21 22 23 24 49 50 51 52 53 54 55 56 57 58 59 60
25 26 27 28 29 30 31 32 33 34 35 36 61 62 63 64 65 66 67 68 69 70 71 72
INP313110010-02
Self-Diagnostic Code “6 – 3” O2 Sensor Heater

CENNP3131104029
Wiring Diagram
OX 12 V
GND
1 ECM
Gr
W
Gr B/W
C
B Gr/Bl P
W
U
Lg/Bl
+B
OXH
IMP311110006-01
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.
W W
IFH511110024-01
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-17).
Is the voltage OK?
Yes • Gr or Lg/Bl wire open or shorted to ground, or poor No.85 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.
Self-Diagnostic Code “9 – 4” Keyless System Authentication Error

CENNP3131104030
This condition:
ECM detected that its ID code does not correspond with the ID code registered in the keyless control unit.
Correction:
Change the ECM to correspond with their ID codes.
Self-Diagnostic Code “9 – 5” Keyless System Communication Error

CENNP3131104031
This condition:
The ECM cannot receive CAN communication information from keyless control unit.
Correction:
• Check communication such as open circuit on communication wire, poor or loose connections.
• Check the CAN communication line output voltage.
Refer to “Inspection of the Keyless Control Unit and Its Circuit” (Page 1A-47).
Self-Diagnostic Code “9 – 6” Keyless System Failure

CENNP3131104032
This condition:
There is an irregularity on the internal circuit of the keyless control unit.
Correction:
Replace the keyless control unit and ECM.
Troubleshooting Without Self-Diagnostic Code

CENNP3131104033
Before troubleshooting, make sure that there is not a self-diagnostic code indication.
Condition Possible cause Correction / Reference Item

Engine cranked, but not Faulty spark plug Replace.
start (or stops shortly Faulty injector or its circuit Check the injector and its circuit.
after starting) Faulty ignition coil or its circuit Check the ignition coil and its circuit.
Faulty high pressure fuel pump Check the high pressure fuel pump.
Faulty low pressure fuel pump Replace.
Faulty ECM. Replace.
Faulty wire continuity / connection Correct or Replace.
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 spark plug. Replace.
Faulty ignition coil or its circuit. Check the ignition coil and its circuit.
Faulty wire continuity / connection Correct or replace.
How to Use the 36-pin Test Cord Set
CENNP3131106001
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
6 (A) 7
(A)
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 5
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
8
INP313110011-01
1. ECM 3. Gray connector side 5. Black connector 7. Black connector

2. Black connector side 4. White connector 6. White connector 8. Wire harness
Inspection of the ECM and Its Circuit

CENNP3131106002
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
: 09900–25011 (Circuit tester set)
Tester knob indication
DC voltage ( )
1) Turn ignition switch OFF.
2) Connect the test cord between ECM and wire harness as shown in figure.
3) Turn ignition switch ON.
4) Connect the tester probe (“–”, Black) to body ground, and measure voltage according to the “ECM Circuit Voltage
Table” (Page 1A-44).
ECM
2 1
(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)
3
I9J011110037-03
1. Black connector side 3. Wire harness

2. Gray connector side
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
I9J011110017-02
“A”: Black connector side “B”: Gray connector side
NOTE
For Keyless start system model;
“Ignition switch ON” represents that the keyless start system is turned ON.
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.
0.7 V or more While engine idling after warmed up.
3 Gr/Bl O2 sensor
0.2 V or less Engine stopped (ignition switch “ON”).
4 R/B CKP sensor — —
Approx. 3.8 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 0.14 – 4.73 V Ignition switch ON.
7 R Power source for sensor Approx. 5 V Ignition switch ON.
Approx. 3.8 V Shift into Forward.
8 P/Bl Shift position sensor Approx. 2.5 V Shift into Neutral.
Approx. 1.2 V 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.
10 G Starter relay control
Ignition switch “ON”, Normal (Shift into
Approx. 0 V
Forward 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 W/G CAN (H) Approx. 2.5 V or 3.6 V Ignition switch “ON”.
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.
Wire
color
Ignition switch “ON”, PTT switch “DN”
Approx. 12 V
depressed.
22 P PTT switch “DOWN”
Ignition switch “ON”, PTT switch not
Approx. 0 V
depressed.
Ignition switch “ON”, PTT switch “UP”
Approx. 12 V
depressed.
23 Lbl PTT switch “UP”
Ignition switch “ON”, PTT switch not
Approx. 0 V
depressed.
Approx. 12 V Ignition switch OFF.
24 P/B Ground for ECM main relay
Approx. 0.8 V Ignition switch ON.
25 B/Lg CAN (L) Approx. 2.5 V or 1.4 V Ignition switch “ON”.
Approx. 0 V PTT switch “DN” free.
26 P PTT relay “DOWN”
Approx. 12 V PTT switch “DN” push.
Approx. 0 V PTT switch “UP” free.
27 Lg PTT relay “UP”
Approx. 12 V PTT switch “UP” push.
28 W/Y Trim sensor Approx. 0.3 – 4.5 V Ignition switch “ON”.
29 — — — —
30 — — — —
31 B/W Ground for sensors — —
Approx. 2.6 V Ignition switch ON.
32 Br Start switch
Approx. 12 V Ignition switch START position.
Approx. 12 V Ignition switch “ON”, shift into neutral.
33 Y/G Neutral switch While engine running, shift into forward or
Approx. 0 V
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 #4 Approx. 12 V or 0 V Ignition switch ON.
39 Lg/Y 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 — — — —
45 — — — —
46 R/W No.3 fuel injector (-) Approx. 12 V Ignition switch “ON”.
47 R/Y IAC valve #2 Approx. 12 V or 0 V Ignition switch ON.
48 — — — —
49 — — — —
50 O/Bl IAC valve #3 Approx. 12 V or 0 V Ignition switch ON.
51 — — — —
52 — — — —
53 Lg/R No.4 Ignition coil Approx. 0 V Ignition switch “ON”.
54 Bl No.2 ignition coil Approx. 0 V Ignition switch “ON”.
55 B Ground for power — —
Approx. 2.5 V Ignition switch “ON”.
56 P/Y Knock sensor
Approx. 2.5 V While engine running at idling speed.
57 Bl/W Buzzer — —
58 W/Y Trim gauge — —
59 W/B IAC valve #1 Approx. 12 V or 0 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 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 — —
Wire
color
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 Approx. 0.3 V or 5 V Ignition switch “ON”.
70 — — — —
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.
Stop switch plate in, shift into neutral. Ignition
Approx. 12 V
switch “ON”. Engine stopped.
Inspection of the Keyless Control Unit and Its Circuit

CENNP3131106004
NOTICE
If you connect a voltmeter or ohmmeter directly to keyless control unit terminals by removing keyless
control unit connector, you can damage the control unit.
Never connect a voltmeter or an ohmmeter directly to any terminal of keyless control unit by
disconnecting control unit connector.
Special tool
(A): 09930–89290 (18 pin & 34 pin test cord)
DC voltage ( )
NOTE
In this inspection, the 34 pin test cord in the test cord set is not required.
1) Turn the main switch “OFF”.

2) Connect the 18-pin test cord between the keyless control unit and wire harness as shown in figure.
3) Turn the main switch “ON”.
4) Connect the tester probe (“–”, Black) to No.14 terminal (or to body ground), and measure the voltage according to
the “Keyless Control Unit Circuit Voltage Table” (Page 1A-48).
(A)
3
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
IFH513110050-02
1. Keyless control unit 2. White connector 3. Black connector

Keyless Control Unit Circuit Voltage Table

CENNP3131106005
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
“A”
1
IFH513110031-06
1. Keyless control unit “A”: 18-pin connector
Wire
color
Approx. 0 V When system is “OFF”.
1 Y Select switch
Approx. 4.7 V When system is “ON”.
When system is “ON”, emergency stop switch
Approx. 4.5 V
Mode switch plate in.
2 G
(Emergency stop switch) When system is “ON”, emergency stop switch
Approx. 0 V
plate out.
3 B/Lg CAN (L) Approx. 2.5 V or 1.4 V When system is “ON”.
4 Bl Buzzer Approx. 12 V When system is “ON” or “OFF”.
5 — — — —
6 — — — —
7 Gr Main switch Approx. 12 V When main switch knob is “ON/OFF” position.
8 — — — —
Approx. 11.3 V When system is “OFF”.
9 P/B ECM power input
10 — — — —
11 — — — —
12 W/G CAN (H) Approx. 2.5 V or 3.6 V When system is “ON”.
13 — — — —
14 B Ground — —
15 — — — —
16 W Battery power Approx. 12 V When system is “ON” or “OFF”.
Approx. 11.3 V When system is “OFF”.
17 P/B ECM power relay
18 — — — —
ECM Main Relay Inspection 4) Measure the resistance between relay terminals (4)
CENNP3131106007 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
1
(A)
INP313110012-01
I9J011110039-01
1. ECM main relay
ECM Removal and Installation

3) Check continuity between terminal (2) and (3) each CENNP3131106008
time 12 V power supply is applied to terminal (4) and Refer to “Wire harness Removal and Installation” in
(5). Section 1C (Page 1C-23).
Connect the positive (+) lead to terminal (5), and
negative (–) lead to terminal (4). Keyless fob Battery Replacement
CENNP3131106010
NOTICE 1) Insert a flat-blade screwdriver in the slot of the
If the 12 V power supply wire is connected to keyless fob, and then pry off the lower case (1).
wrong terminal or touched to each other, the Note the position of O-ring (2).
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): 09900–25011 (Circuit tester set)
Tester knob indication 1
Continuity ( )
ECM main relay function IFH513110051-01
Continuity
12 V power applied Yes
2
12 V power not applied No
2 3
5
1
IFH513110052-02
12 V
2) Remove the battery (3) using a flat-blade
CONT screwdriver as shown in the figure.
4
(A)
I9J011110038-02
ECM Power Relay Inspection

CENNP3131106011
3 Inspect the ECM power relay using the following
procedures:
1) Turn the keyless start system “OFF”.
2) Disconnect the ECM power relay (1) from the
keyless wiring.
INP313110013-02
3) Replace the battery (3) so its (+) terminal faces the

lower case side as shown in the figure.
1
Lithium disc battery type:
CR2025 or equivalent.
IGG211110009-02
3) Check continuity between terminal (2) and (3) each

time 12 V power supply is applied to terminal (4) and
(5).
negative (–) lead to terminal (4).
NOTICE
IFH513110054-01 • If the 12 V power supply wire is connected
4) Confirm that the O-ring (2) is into place on the lower to wrong terminal or touched to each
case. other, the power supply wire, tester may be
Reinstall the lower case (1), and then fit lower case damaged.
securely.
2
• Diodes are used inside the power relay.
Failure to correctly supply the battery
voltage will result in power relay damage.
Be careful not to short-circuit the positive

(+) and negative (–) cable, and connect
1
them only to the correct terminal.
IFH513110055-01
Special tool
NOTE : 09900–25011 (Circuit tester set)
Dispose of the used battery properly Tester knob indication
according to applicable rules or regulations. Continuity ( )
Do not dispose of lithium batteries with
ordinary household trash. ECM power relay function
Continuity
12 V power not applied No
If out of specification, replace ECM power relay.

3) How to register the first keyless fob ID code

Make sure the first keyless fob is placed less than
CONT 0.3 m (12 in.) from the keyless control unit.
The second keyless fob must be separated more
3 than 1 m (3.2 feet) from the keyless control unit, or
lock the second keyless fob function by operating its
4
lock button.
4) Turn the main switch knob from “Neutral” to “ON &
OFF”, then release the knob.
2
The red LED on the keyless fob lights up; within 10
seconds, briefly press the keyless fob button.
5
Neutral “ON & OFF”
IFH513110057-04
PUSH
START
STOP
Main switch knob

IMP311110031-01
5 3 2 4
IFH513110058-02
Red LED
Registering The First and Second Keyless fob Lock button
ID Codes
CENNP3131106012
ID codes of individual keyless fobs must be registered to
enable the keyless start system.
To register the ID code of the first and second keyless
IFH513110060-02
fob, do the following:
1) Complete the system wiring. NOTE
2) Connect the battery cable and sub battery cable to If the buzzer emits five (5) short sounds when
the battery. the main switch knob is turned from
“Neutral” to “ON & OFF” position, the
NOTE keyless fob function may be locked.
When the system wiring is completed using Press the lock button on the keyless fob for
the keyless control unit with the following more than one second to unlock the keyless
part number, two keyless fob ID codes must fob function. Then perform step 4 again.
be registered.
The system cannot be operated until two ID 5) When the initial registration is successful, the buzzer
codes are registered. emits one (1) short sound, followed by one (1) long
Part number: 37171-96L02 or 37171-96L12 sound, and the keyless fob’s red LED turns off.
NOTE
• If the ID code registration is not
successfully completed, the buzzer emits
five (5) short sounds.
• If the registration is not successful, wait
for about one minute, then perform step 4
again.
6) How to register the second keyless fob ID code Unpairing an ECM from the Keyless Start
Make sure the second keyless fob is placed less System
than 0.3 m (12 in.) from the keyless control unit. CENNP3131106013
The first keyless fob must be separated more than 1 When the outboard motor is resold, removed and started
m (3.2 feet) from the keyless control unit, or lock the in a test tank, or if it is necessary to use the ECM on
first keyless fob function by operating its lock button. another engine, the ECM must be unpaired with the
keyless control unit by erasing the ID code in the ECM.
7) Using the same procedure that was used for
Do the following to erase the ID code:
registering the first keyless fob, register the second
keyless fob ID code by operating the main switch NOTE
knob and the second keyless fob.
The keyless fob ID code registered in the
8) To confirm the keyless fob registration was keyless control unit cannot be erased from
successful: the keyless control unit.
a) Turn the main switch knob from “Neutral” to “ON
& OFF” and release it. 1) Make sure the keyless fob and the keyless control
b) The buzzer emits two (2) short beeps and the unit are within communication range.
four caution lamps light continuously in the 2) Turn the main switch knob from “Neutral” to “ON &
monitor-tachometer. OFF” position, then release the knob.
The keyless control unit and the ECM are paired Confirm that the keyless start system has been
when the procedure above is complete. turned ON.
NOTE Neutral “ON & OFF”

• Once an ECM has been connected and
paired to a keyless start control unit, the
PUSH
START
STOP
ECM/outboard cannot be started with a

normal key switch.
To unpair an ECM from an keyless control
unit, see page “Unpairing an ECM from the
Keyless Start System” (Page 1A-52).
• For multiple engine applications, the Main switch knob
IMP311110031-01
instance setting must be completed before
this first key-on action. 3) Connect the black lead wire and the yellow lead wire
in the keyless control harness.
Black
Yellow
IGG211110010-01
B
Y Y
B B
Y: Yellow, B: Black
IFH513110064-01
4) The buzzer starts sounding in the following patterns:

Four (4) long sounds, followed by:
• Two (2) short sounds emitted four (4) times
• Three (3) short sounds emitted four (4) times
• Four (4) short sounds emitted four (4) times
Buzzer sounding pattern

ON
OFF
4 times
4 times
4 times
IFH513110065-01
Immediately remove the lock plate from the

emergency stop switch, then reinstall it.
If the unpairing is unsuccessful, the buzzer will
continuously emit short beeps until the black lead
wires are reconnected.
IFH513110066-01
5) Disconnect the black wire lead from the yellow wire

lead, and then reconnect the two (2) black wire
leads.
6) The buzzer sounds when unpairing is completed
successfully.
Four caution lamps in the monitor-tachometer
become OFF.
7) Remove the battery cable from the battery.
NOTE
After unpairing an ECM from the keyless start
system, do not turn the main switch knob to
“ON & OFF” position.
If the switch is turned, the ID code cross-
check will be performed again between the
keyless control unit and ECM.
1C-1 Engine Electrical Devices:
Engine Electrical Devices

Power Head
Precautions
Precaution for Engine Electrical Device
CENNP3131300001
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
CENNP3131301001
CKP Sensor • CMP sensor 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 ECM main relay.
degrees apart, except at two positions where they are
30 degrees apart.
During one crankshaft rotation, 32 signals are input to
the ECM.
1
• Failure symptom:
Without the CKP sensor signal input, the ECM does
not output the ignition and fuel injection signals.
INP313130002-01
1. CMP sensor
1 • The CMP sensor is a GMR (Giant Magnet Resistive)

semiconductor type sensor.
2
The GMR semiconductor has the property of varying
the electrical resistance depending on the intensity of
IMP311130014-02
the magnetic force applied.
When the line of magnetic force from the magnet to
1. CKP sensor 2. Reluctor bar
the GMR semiconductor is increased or decreased,
the electrical resistance of the GMR semiconductor
will change. The changes in resistance as the
magnets pass create the sensors waveform.
When a trigger vane on the camshaft reluctor aligns
with the sensors internal magnet, the electrical
resistance of the GMR will decrease.
When a trigger vane moves away from the sensor, the
electrical resistance of the GMR will increase.
When the GMR semiconductor voltage becomes
higher than the standard value, the sensors signal will
be lower. And when the voltage becomes lower than
the standard value, the sensors signal will be higher.
Engine Electrical Devices: 1C-2
• The six camshaft trigger vanes provide six high • Failure symptom:
voltage signals from the CMP sensor to the ECM Without the CMP sensor signal input, the ECM does
during one camshaft rotation (two rotations of not output the ignition and fuel injection signals.
crankshaft).
2
3
“A”
“B”
6 5
IEH511130109-02
1. Camshaft 5. CMP sensor

2. Trigger vane 6. Signal
3. Magnet resistive semiconductor “A”: High voltage
4. Magnet “B”: Low voltage
ECM cylinder identification

Cylinders are identified by a calculation combined from two signals; one from the CKP sensor and one from the CMP
sensor.
32 signals / crankshaft 1 rotation

CKP sensor
signal
10° 30°
140° 220° 40° 40°

180° 100° 140°
CMP sensor
signal
CMP sensor - 6 signals / 720° (crankshaft 2 rotation)
TDC TDC TDC
No.1 cylinder Cm. Ep. Ex. In. Cm. Ep.
TDC TDC
No.3 cylinder In. Cm. Ep. Ex. In. Cm.
TDC TDC TDC
No.4 cylinder Ex. In. Cm. Ep. Ex. In.
TDC TDC
No.2 cylinder Ep. Ex. In. Cm. Ep. Ex.
Cm.: Compression, Ep.: Explosion, Ex.: Exhaust, In.: Intake

IMP311130085-01
Cylinder Temperature Sensor Exhaust Manifold Temperature Sensor

The cylinder temperature sensor is installed on the The exhaust manifold temperature sensor is installed on
cylinder (top side) and used to detect the cylinder the exhaust manifold water jacket cover (rectifier/
temperature. regulator) and used to detect exhaust manifold
This is a thermistor type sensor (resistance of which temperature.
changes depending on temperature) and inputs a signal This sensor is the same type as the cylinder temperature
to the ECM as a voltage value. This signal is used to sensor, and inputs a signal to the ECM as a voltage
compensate the fuel injection time duration, ignition value.
timing, etc. This signal is also used to detect engine over-heat.
This sensor is also used to detect engine over-heat as
the ECM detects both the temperature and temperature
change gradient (temperature rise vs time).
INP313130003-01
1. EX. manifold temp. sensor
IMP311130016-01 IAT (Intake Air Temperature) Sensor

1. Cylinder temp. sensor The IAT sensor is installed on the air intake silencer 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
value.
This signal is used to compensate the fuel injection time
duration.
2
1
INP313130032-02
1. IAT sensor 2. Air intake silencer

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 holder and
used to detect the intake manifold pressure. 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:
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”
in Section 1I (Page 1I-4).
IMP311130019-01
1. MAP sensor
1
TPS (Throttle Position Sensor)
The TPS is installed on the throttle body and detects the INP313130034-01
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 clutch holder and detects the
The varying resistance value is converted to voltage and shift position with the clutch lever operation interlocked.
input to the ECM. This sensor is a variable resistor that changes resistance
Based on the TPS voltage, the ECM calculates the idle (ohms) in accordance with the shift position.
and throttle opening positions to determine the control The varying resistance value is converted to voltage and
modes of the various controls systems (Idle air control, input to the ECM.
fuel injection control system, etc.). Based on the SPS voltage and remote control lever
position sensor signal, the ECM calculates and
determines the change of shift position and executes the
1 following controls.
• When the shift is in neutral, fuel injection is controlled
to prevent engine speed from exceeding 3000 r/min.
INP313130033-01
1
1. TPS
INP313130035-01
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 and the tilt up limit.
the ignition timing to prevent knocking. The trim sensor signal also displays the trim position
onto gauge screen through the ECM.
NOTE
When the ECM has been replaced, the trim
sensor removed/reinstalled, or the mid unit
1 overhauled, resetting of both the tilt up limit
and trim down limit must be performed.
INP313130004-01
1. Knock sensor
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.
IMP311130058-01
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
injectors, ignition coils, CMP sensor and high pressure
fuel pump.
With the ignition switch in the “OFF” position, and the UP
or DOWN button of the PTT switch located in side cover
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.
1
1
INP313130005-01
1. O2 sensor
INP313130006-01
1. ECM main relay

Cranking Switch Signal Emergency Stop Switch

The ECM detects the engine being started by the ignition When the cord from the plate of the switch is secured to
switch ON. When the ignition switch is turned to ON the operator, the plate will be pulled off if the operator is
position, a voltage (12 V) signal is input to the ECM. suddenly thrown overboard.
Pushing the start button, the ECM in turn controls the The circuit of emergency stop switch will be closed when
actuators for ignition, fuel injection, etc. to the starting the plate is removed.
mode. Then the ECM does not provide fuel injector operating
Normal key start model signal, ignition signal, fuel pump operating signal and
starter motor relay operating signal.
2 3 Failure symptoms:
+12V 1 A switch short circuit will not allow the motor to start.
OFF
IG
ST
ECM 1
I9J011130004-03
1. Ignition switch 3. Starter motor relay

2. Neutral switch
IEH511130110-01
1. Emergency stop switch

Keyless start model
+12 V
1
OFF 4
“A”
ON
2 3 5
IGG211130001-01
1. Main switch 4. Neutral switch

2. Keyless control unit 5. ECM
3. ECM power relay “A”: To starter motor relay
ECM Power Source Line

CENNP3131301002
Normal key start model:
The sub battery cable to the white lead wire in the remote control extension harness to the ignition switch.
When the ignition switch is turned ON, battery power passes from the white lead wire, through the ignition switch
contacts to the gray output lead wire to the No.12 terminal of ECM.
NOTE
Ensure battery cable connection are clean and secure.
Failure at the battery connection will cause incorrect operation of ECM.

2
7
R
4 3
5
6
W
Gr 36
W
9 B/Bl 12
ECM
8
R/B 24
1
BATT W
IG Gr Gr
GND B B
INP313130007-02
1. Battery 6. ECM main relay

2. Battery cable 7. Starter motor
3. 60 A fuse 8. 15 A fuse
4. 60 A fuse 9. Sub-battery cable
5. 30 A fuse
Keyless start model:

The sub-battery cable to the white lead wire in the remote control extension harness to the main switch.
When the main switch is turned ON, battery power passes from the white lead wire, through the main switch contacts
to the gray output lead wire to the keyless control unit.
When this power signal is received by keyless control unit, it turns the ECM power relay on, then battery voltage is
supplied through R/W lead line to No.12 terminal of ECM.
Keyless start model
2
7
R
4 3
5
6
W
W
Gr 36
W
9 B/Bl 12
ECM
8
R/B 24
IG Gr Gr
BATT W W
PWR R/W R/W Gr
START O
Br
G
B “B”
B
12 B
Gr
“A” B
G
10 W
P/W
P/W
P/W
11 W
W
R/W
INP313130008-02
1. Battery 8. 15 A fuse
2. Battery cable 9. Sub-battery cable
3. 60 A fuse 10. Keyless control unit
4. 60 A fuse 11. ECM power relay
5. 30 A fuse 12. Emergency stop switch
6. ECM main relay “A”: To ECM
7. Starter motor “B”: From keyless control unit
Component Location
Location of Sensor and Switch
CENNP3131303001
Resistance Check
CENNP3131306001
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-9).
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
I9J011130006-04
1. Wire harness 3. 36-pin connector (Gray)

2. 36-pin connector (Black)
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)
11.5 – 12.5 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)
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)
Cylinder Temp. Sensor Removal and Cylinder Temp. Sensor Inspection

CENNP3131306003
Installation
CENNP3131306002 1) Remove the cylinder temperature sensor.
Removal Refer to “Cylinder Temp. Sensor Removal and
1) Remove ring gear cover. Installation” (Page 1C-10).
Refer to “Ring Gear Cover Removal and Installation” 2) Immerse temperature sensing part of cylinder temp.
in Section 1D (Page 1D-2). sensor in water.
2) Unfasten cable tie (1). 3) Measure resistance between sensor terminals while
Disconnect lead wire connector (2). heating water gradually.
3) Remove water outlet pipe (3). 4) If measured resistance does not change in the
proportion indicated, replace sensor.
Cylinder temp. sensor specification
2 Water
3
temperature: 0 (32) 25 (77) 50 (122) 75 (167)
°C (°F)
1 Resistance 0.73 – 0.33 –
5.3 – 6.6 1.8 – 2.3
(kΩ) 0.96 0.45
INP313130009-01
4) Loosen and remove cylinder temp. sensor (4).
4
2
I9J011130051-01
1. Thermometer 2. Heater
5) Reinstall the cylinder temp. sensor.

Refer to “Cylinder Temp. Sensor Removal and
IMP311130023-01 Installation” (Page 1C-10).
Installation
attention to the following points.
• Clean mating surface of sensor and installation
position.
• Tighten sensor to the specified torque.
Tightening torque
Cylinder temp. sensor: 8.0 N·m (0.82 kgf-m, 5.9
lbf-ft)
• Check wire routing.
Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-4).
• Check for water leakage.
Ex. Manifold Temp. Sensor Removal and Ex. Manifold Temp. Sensor Inspection
CENNP3131306005
Installation
CENNP3131306004 1) Remove the Ex. manifold temp. sensor.
Removal Refer to “Ex. Manifold Temp. Sensor Removal and
1) Unfasten cable clamp. Installation” (Page 1C-11).
Disconnect Ex. manifold temp. sensor lead wire 2) Immerse temperature sensing part of Ex. manifold
connector (1). temp. sensor in water.
2) Remove Ex. manifold temp. sensor (2). 3) Measure resistance between sensor terminals while
heating water gradually.
4) If measured resistance does not change in the
proportion indicated, replace sensor.
Ex. manifold temp. sensor specification
1 Water
temperature: 0 (32) 25 (77) 50 (122) 75 (167)
2
°C (°F)
Resistance 0.73 – 0.33 –
5.3 – 6.6 1.8 – 2.3
(kΩ) 0.96 0.45
INP313130036-01
1
Installation
• Clean mating surface of sensor and installation
position.
• Tighten sensor to the specified torque.
Tightening torque
Ex. manifold temp. sensor: 8.0 N·m (0.82 kgf-m, 2
I9J011130051-01
5.9 lbf-ft)
1. Thermometer 2. Heater
• Check wiring harness routing.
Refer to “Wiring Harness Routing Diagram” in Section 5) Reinstall the Ex. manifold temp. sensor.
4A (Page 4A-4). Refer to “Ex. Manifold Temp. Sensor Removal and
Installation” (Page 1C-11).
CKP Sensor Removal and Installation IAT Sensor Removal and Installation
CENNP3131306006 CENNP3131306008
Removal Removal
1) Remove ring gear cover. Disconnect sensor lead wire connector and remove IAT
Refer to “Ring Gear Cover Removal and Installation” sensor (1) from air intake silencer.
2) Unfasten the clamp and disconnect CKP sensor lead
wire connector (1).
3) Remove two screws and CKP sensor (2).
1
INP313130038-02
1
Installation
INP313130037-01
IAT Sensor Inspection
CENNP3131306009
Installation 1) Remove the IAT sensor.
Installation is in the reverse order of removal with special Refer to “IAT Sensor Removal and Installation”
attention to the following points. (Page 1C-12).
• Apply thread lock to the sensor mounting screws. 2) Immerse temperature sensing part of IAT sensor in
: Thread lock cement 99000–32160 water.
(SUZUKI Thread Lock 1342H (50g)) 3) Measure resistance between sensor terminals while
heating water gradually.
• Install CKP sensor with air gap between sensor and
reluctor bar on flywheel, then tighten sensor mounting 4) If measured resistance does not change in the
screws securely. proportion indicated, replace sensor.
CKP sensor air gap “a” IAT sensor specification

0.75 mm (0.030 in) Water
temperature: 0 (32) 25 (77) 50 (122) 75 (167)
°C (°F)
Resistance 0.73 – 0.33 –
5.3 – 6.6 1.8 – 2.3
(kΩ) 0.96 0.45
1
2
“a”
1
IMP311130026-02
1. CKP sensor 2. Reluctor bar
• Check to ensure that all removed parts are back in

original position. 2
I9J011130007-03
• Check wire routing. 1. Thermometer 2. Heater
4A (Page 4A-4). 5) Reinstall the IAT sensor.
Refer to “IAT Sensor Removal and Installation”
CKP Sensor Inspection (Page 1C-12).
CENNP3131306007
Inspect the CKP sensor.
Refer to “Resistance Check” (Page 1C-9).
CMP Sensor Removal and Installation CMP Sensor Inspection

CENNP3131306010 CENNP3131306011
Removal 1) Turn ignition switch OFF.
1) Remove fuel hose guard. 2) Remove CMP sensor.
3) Connect the test cords.
Refer to “How to Use the 36-pin Test Cord Set” in
2) Disconnect CMP sensor connector. Section 1A (Page 1A-42).
3) Remove CMP sensor (1).
Special tool
1
1 (A)
3 (A)
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
INP313130010-01
Installation 2
Installation is in the reverse order of removal. INP313130011-01
1. ECM 3. Black connector

2. Wire harness 4. Black connector
4) Connect the tester probe (“+”, Red) to No.69

terminal.
Connect the tester probe (“–”, Black) to No.31
terminal.
Special tool
DC voltage ( )
36-pin test cord (Black connector)

3
69
INP313130012-01
36-pin test cord (Black connector) MAP Sensor Removal and Installation
CENNP3131306012
4 Removal
1) Disconnect MAP sensor connector (1).
31 2) Remove bolts and MAP sensor (2) from intake
manifold.
INP313130013-01
1

6) Measure the voltage when the tip of a steel
2
screwdriver is brought near and then pulled away
from the sensor tip.
When screwdriver is brought near
Approx. 5.0 V IMP311130029-01
When screwdriver is pulled away Installation

Approx. 0.3 V Installation is in the reverse order of removal with special
attention to the following point.
• Apply engine oil to O-ring.
5
4
IMP311130077-01
IMP311130001-01
4. Screw driver 5. CMP sensor
7) If the voltage does not change in the above test,

check wire harnesses for open and short.
If wire harnesses are in good condition, replace CMP
sensor and recheck.
8) Reinstall the CMP sensor.
MAP Sensor Output Voltage Inspection 5) Connect the tester probe (“+”, Red) to No.6 terminal.
CENNP3131306013 Connect the tester probe (“–”, Black) to No.31
1) Turn ignition switch OFF. terminal.
2) Connect the test cords. 36-pin test cord (White connector)
3
Special tool
6
(A)
(A)
INP313130015-01
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
4
31
2
INP313130014-02
1. ECM 3. White connector

3) Remove the MAP sensor.

4) Install MAP sensor into special tool. INP313130016-02
Connect vacuum pump gauge (with hose) to MAP 6) Turn ignition switch ON.
sensor (special tool) as shown in the figure. 7) While applying negative pressure (vacuum) to MAP
Special tool sensor, measure “6” terminal voltage.
(C): 09917–49610 (Vacuum pump adapter) MAP sensor output voltage change
(D): 09917–47020 (Vacuum pump gauge)
Negative pressure: 0 40 80
kPa (kgf/cm2, psi) (0, 0) (0.4, 5.8) (0.8, 12)
(D) “6” terminal voltage (V) 4.10 2.48 0.86
(At 101.3 kPa, 1.0 kgf/cm2, 14.7 psi barometric

pressure.)
(C)
Special tool
PRESSURE DC voltage ( )
VACUUM 8) If out of specification, Check wire harnesses for open
IMP311130076-05
and short. If wire harnesses are in good condition,
replace MAP sensor and recheck.
9) Reinstall MAP sensor.
Refer to “MAP Sensor Removal and Installation”
(Page 1C-14).
O2 Sensor Removal and Installation O2 Sensor Output Voltage Inspection

CENNP3131306014 CENNP3131306015
Removal 1) Turn ignition switch “OFF”.
1) Unfasten cable tie (1) binding lead wire and 2) Connect the test cords.
disconnect O2 sensor lead wire connector. Refer to “How to Use the 36-pin Test Cord Set” in
2) Using special tool, remove O2 sensor (2). Section 1A (Page 1A-42).
Special tool Special tool
(A): 09933–39810 (O2 sensor socket) (A): 09930–88730 (36-pin test cord set)
1
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
2
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
INP313130017-01
2
INP313130014-02
(A) 1. ECM 3. White connector

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

2
Connect the tester probe (“–”, Black) to No.31
terminal.
Special tool
DC voltage ( )
IMP311130031-01
36-pin test cord (White connector)

Installation
Installation is in the reverse order of removal with special 3
• Tighten the O2 sensor to the specified torque. 3
Tightening torque
O2 sensor: 10 N·m (1.0 kgf-m, 7.4 lbf-ft)
NOTE
• Always keep the O2 sensor away from any
grease and oil. INP313130018-01
• Examine O2 sensor gasket for damage.

Always replace O2 sensor assembly if 36-pin test cord (Black connector)
sealing performance is suspect. 4
31
INP313130016-02
4) Turn ignition switch ON. 4) If measurement exceeds specification, replace O2

5) Measure the O2 sensor output voltage. sensor.
5) Connect O2 sensor lead wire connector to wire
O2 sensor output voltage
harness.
0.2 V or less
6) Start engine and allow to warm up. Refer to “How to Use the 36-pin Test Cord Set” in
7) After warming up, measure the O2 sensor output Section 1A (Page 1A-42).
voltage while holding the engine speed at idling.
Special tool
NOTE (A): 09930–88730 (36-pin test cord set)
The O2 sensor outputs 0 volt to 1.0 volt
3
according to the oxygen concentration in
exhaust gas. (A)
5 (A)
O2 sensor output voltage at idling

0.7 V or more 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
6
8) If the voltage does not change in the above test,
check wiring harness for open and short. 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
If wiring harness is in good condition, replace O2
sensor and recheck.
O2 Sensor Heater Inspection 4

INP313130019-01
CENNP3131306016
1) Turn ignition switch OFF. 3. ECM 5. Black connector
2) Disconnect O2 sensor lead wire connector.
3) Measure resistance between sensor terminals (1) 7) Connect the tester probe (“+”, Red) to No.60
and (2). terminal.
O2 Sensor heater resistance at 20 °C (68 °F) Connect the tester probe (“–”, Black) to No.31
5.5 – 8.5 Ω terminal.
Special tool
1 2 : 09900–25011 (Circuit tester set)
DC voltage ( )

5
IFH511130011-02
1. Heater (+) 2. Heater (–) 60
INP313130020-01

6
31
(a)
INP313130021-01
INP313130022-01
8) Turn ignition switch “ON” and measure the O2
sensor heater voltage.
Knock Sensor Inspection
O2 sensor heater voltage CENNP3131306018
Approx. 12 V (Battery voltage) 1) Turn ignition switch OFF.
9) Start engine and allow to warm up. 2) Connect the test cords.
10) After warming up, measure the O2 sensor heater
voltage while holding the engine speed at idling.
Special tool
O2 sensor heater voltage at idling
Approx. 0 – 0.3 V
11) If inspection in step 9 and/or step 11 out of 1
specification, check wiring harness for open and
(A)
short. 3 (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
50 51 52 53 54
55 56 57 58 59 60 61 62 63 64 65 66 67
68 69 70 71 72
4
Knock Sensor Removal and Installation
CENNP3131306017 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
Removal 14 15 16 17 18 32 33 34 35 36
1) Remove intake manifold.

Refer to “Intake Manifold Removal and Installation”
in Section 1D (Page 1D-7). 2
INP313130011-01
2) Unfasten cable clamps.
Disconnect the sensor lead wire connector (1).
Remove the knock sensor (2).
3) Connect the tester probe (“+”, Red) to No.56
1 terminal.
1 Connect the tester probe (“–”, Black) to No.31
terminal.
Special tool
2 DC Voltage ( )
INP313130039-01
Installation
• Tighten knock sensor to the specified torque.
Tightening torque
Knock sensor (a): 22 N·m (2.2 kgf-m, 16 lbf-ft)
36-pin test cord (Black connector) Tighten IAC valve mounting screws to the specified
torque.
3
Tightening torque
IAC valve mounting screw: 1.5 N·m (0.15 kgf-m, 1.1
56
lbf-ft)
IAC Valve Inspection

CENNP3131306037
1) Remove the ring gear cover.
INP313130023-01 in Section 1D (Page 1D-2).
2) Disconnect connector from IAC valve.
36-pin test cord (Black connector) 3) Check each coil of IAC valve for resistance.
4 IAC valve resistance
Terminals Resistance
31 Between “1” and “2”
Between “3” and “2”
25 – 34 Ω
If out of specification, replace IAC valve.
INP313130016-02
4) Check for sensor output voltage.

2 3
Sensor output voltage 1
Ignition switch ON Approx. 2.5 V

Engine running at idle speed Approx. 2.5 V 4
6
5) If out of specification, check wire harnesses for open 5
replace knock sensor and recheck.
IAC Valve Removal and Installation INP313130041-01
CENNP3131306036 4) Remove IAC valve.

Removal
5) Connect the connector to IAC valve.
6) When the ignition switch is turned “ON” and “OFF”,
check that the valve moves to open and returns to
closed.
2) Disconnect IAC valve lead wire connector.
3) Remove IAC valve (1).
I9J011130018-01
7) If the valve does not moves, check the wiring

harness for continuity (between ECM and IAC valve
INP313130040-01 and connector contact condition.
8) Reinstall IAC valve.
Installation Refer to “IAC Valve Removal and Installation” (Page
Installation is in the reverse order of removal with special 1C-19).
Shift Position Sensor Removal and Installation Installation

CENNP3131306020 Installation is in the reverse order of removal with special
Removal
• Apply water resistant grease to O-ring.
Disconnect battery cables from battery.
2) Remove side covers and front panel. : Grease 99000–25350 (SUZUKI Water
Refer to “Side Cover Removal and Installation” in Resistant Grease EP2 (250 g))
3) Unfasten cable clamp (1).
Disconnect shift position sensor lead wire connector
(3poles) (2).
IMP311130004-02
• Install shift position sensor (1) to shift lever holder (2),

then align the tip of clutch lever “A” and groove of the
shift position sensor “B” as shown in the figure.
2
1
INP313130042-01
4) Cut cable tie (3). 1

Remove shift position sensor(4). “A”
“B”
NOTE
Prior to removal, mark the sensor’s original
position with a paint or scribe for accurate
reinstallation. 2
INP313130024-01
• Apply thread lock to bolt, then tighten bolt to the

4
specified torque.
Tightening torque
Shift position sensor mounting bolt (a): 5.0 N·m (
0.51 kgf-m, 3.7 lbf-ft)
INP313130043-01
: Thread lock cement 99000–32160
(SUZUKI Thread Lock 1342H (50g))
(a)
IMP311130006-05
Shift Position Sensor Power Source and Output 4) Turn ignition switch ON.
Voltage Inspection Check for shift position sensor power source voltage.
CENNP3131306021
1) Turn ignition switch OFF. Shift position sensor power source voltage
Approx. 5 V
Refer to “How to Use the 36-pin Test Cord Set” in 5) Connect tester probe (“+”, Red) to No.8 terminal.
Section 1A (Page 1A-42). Connect tester probe (“–”, Black) to No.31 terminal.
Special tool
(A): 09930–88730 (36-pin test cord set) 3
1
8
(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 INP313130026-01
14 15 16 17 18 32 33 34 35 36
2 4
INP313130014-02

31
3) Connect tester probe (“+”, Red) to No.7 terminal.

Connect tester probe (“–”, Black) to No.31 terminal.
Special tool
INP313130016-02
Tester knob indication 6) Check for shift position sensor output voltage while
DC voltage ( ) operating clutch lever.
36-pin test cord (White connector) Shift position sensor output voltage
Shift position Output voltage
3 Forward Approx. 3.8 V
Neutral 2.5 V
Reverse Approx. 1.2 V
7
Neutral
Reverse Forward
INP313130025-01
5

4
31 INP313130044-01
5. Clutch lever
If out of specification:
• 1st check sensor mount position, readjust if
necessary.
INP313130016-02 Refer to “Shift Position Sensor Mounting Position
Adjustment” (Page 1C-22).
• 2nd check wire harnesses for open and short. Neutral Switch Removal and Installation
If wire harnesses are in good condition, replace CENNP3131306023
shift position sensor and recheck. Removal

Refer to “Shift Position Sensor Removal and 1) Turn ignition switch OFF.
Installation” (Page 1C-20). Disconnect battery cables from battery.
2) Remove side covers and front panel.
Shift Position Sensor Mounting Position Refer to “Side Cover Removal and Installation” in
Adjustment Section 2A (Page 2A-3).
CENNP3131306022
3) Unfasten cable clamp (1).
If sensor output voltage is out of specification, the
Disconnect neutral switch lead wire connector
following adjustment procedure must be performed.
(2poles) (2).
2
2) Loosen the screw (1) securing shift position sensor.
Adjust the location of shift position sensor and
perform the sensor output voltage check so that
each of the output voltage comes to the
specification.
Refer to “Shift Position Sensor Power Source and
Output Voltage Inspection” (Page 1C-21).
1
INP313130046-01
1 4) Cut cable tie (3) and (4).

Remove two screws (5), then remove neutral switch
bracket (6) and neutral switch (7).
6 5
INP313130045-01
3) When the specified sensor output voltage has been

obtained, tighten the sensor mounting screw.
Refer to “Shift Position Sensor Removal and 4
Installation” (Page 1C-20). 7
4) Recheck the sensor output voltage and readjust the INP313130047-01

sensor position as necessary.
NOTE
If the specified sensor output voltage cannot
be obtained even though attempting the
adjustment of shift position sensor location
several times, check for wear and damage of
the component parts of shift link mechanism.
5) Reinstall parts removed earlier.

Check to ensure that all removed parts are back in
place.
Installation Wire harness Removal and Installation

Installation is in the reverse order of removal with special CENNP3131306024
attention to the following points. Removal

• Install neutral switch arm (1), spring (2) and neutral 1) Turn ignition switch OFF.
switch (3) as shown in the figure. Disconnect battery cables from battery.
Apply water resistant grease to neutral switch arm. 2) Remove side covers and front panel.
: Grease 99000–25350 (SUZUKI Water Section 2A (Page 2A-3).
Resistant Grease EP2 (250 g))
1
4) Remove nut, then remove lead wire (1) and (2).
Disconnect lead wire connector (3).
3
2
IMP311130067-01
• Apply thread lock to neutral switch mounting screws. 2

Tighten neutral switch mounting screws securely. 1
(SUZUKI Thread Lock 1342H (50g)) INP313130049-01
5) Unfasten cable clamp.

Loosen screw and disconnect lead wire from oil
pressure switch (4).
INP313130048-01
INP313130050-01
6) Unfasten cable tie. 9) Remove air intake silencer.

Disconnect lead wire connector (5), (6), (7) and (8). Refer to “Air Intake Silencer Removal and
Disconnect lead wire connector (15) and (16).
5 4
7
15
6
8
INP313130051-01
16
7) Unfasten cable tie (9), then disconnect lead wire

connector (10).
Disconnect lead wire connector (11), (12) and (13). INP313130054-01
11) Disconnect lead wire connector (17), (18), (19) and

11 (20).
10
19
9 20
12
18
17
10
13
INP313130052-01
8) Remove eight bolt (14) securing harness bracket.

INP313130055-01
12) Remove throttle body bracket (21).
14
21
INP313130053-01
INP313130056-02
14
INP313130027-02
13) Remove two cable clamps (22) and connector (23) 17) Remove bolt and harness GND lead wire (29).
from throttle body bracket.
29
22
23
INP313130061-01
INP313130057-01 18) Remove battery cable from electric parts holder (30).
14) Unfasten cable clamp. Remove electric parts holder.
Disconnect lead wire connector (24) and (25).
NOTE
To remove electric parts holder, slide it as
24 shown in the figure.
30
25
INP313130058-01
15) Remove bolt (26) securing main harness GND lead

wire and negative (–) battery cable.
Remove nut (27) securing positive (+) battery cable
and main harness (R) lead wire. INP313130062-01
19) Disconnect PTT motor relay connectors and remove

PTT motor relay (31).
27 Remove cable clamp (32) from electric parts holder
by releasing clamp’s lock.
26
INP313130059-01
16) Disconnect Red lead wire connector (28) from

terminal “S” of starter magnetic switch.
28
INP313130060-01
20) Remove fuse box (33), connectors and joint Refer to “Wiring Harness Routing Diagram” in Section
connector from electric parts holder. 4A (Page 4A-4).
TPS Inspection
CENNP3131306029
31
Special tool
1
INP313130063-01
(A)
(A)
32 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
33
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
INP313130014-02

INP313130064-01
21) Remove ECM (34).
4) Connect tester probe (“–”, Black) to No.31 terminal
34 (or to body ground).
3
INP313130065-01
Installation
attention to the following points. INP313130029-01
• Set electric parts holder to starter motor band as

shown in the figure. 36-pin test cord (Black connector)
4
31
INP313130016-02
5) Turn the ignition switch ON.

INP313130066-01


Slowly move the throttle lever to open, and check if
voltage changes linearly within specification, 1 4
according to throttle valve opening angle.
Sensor output voltage
6
FCT position: Approx. 0.7 V
5 2
WOT position: Approx. 3.8 V 3
Special tool
DC voltage ( ) INP313130067-01
NOTICE Installation
The throttle body will lose its original Installation is in the reverse order of removal with special
performance if it has been disassembled and attention to the following points.
reassembled. • Assemble trim sensor as shown in the figure.
: Grease 99000–25350 (SUZUKI Water
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.
7) If out of specification, check wire harnesses for open

replace the throttle body and recheck.
Trim Sensor Removal and Installation

CENNP3131306033
Removal
2) Remove side covers and front panel. IMP311130073-02
Refer to “Side Cover Removal and Installation” in • Bind the white taping point “A” on the trim sensor lead
Section 2A (Page 2A-3). wire to swivel bracket with cable tie.
3) Remove PTT motor cable and trim sensor lead wire
from side cover seal.
Unfasten cable clamp (1) binding trim sensor lead
wire.
“A”
Cut cable tie (2) and (3).
Disconnect trim sensor lead wire connector (4).
4) Remove trim sensor (5).
IMP311130074-01
• Set Trim Down Position Limit and Tilt Up Limit

Position.
Refer to “Setting Trim Down Position Limit” in Section
2B (Page 2B-18) and “Setting Tilt Up Limit Position” in
Section 2B (Page 2B-19).
IMP311220016-02 Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-4).
Trim Sensor Inspection Emergency Stop Switch Inspection

CENNP3131306034 CENNP3131306035
Inspect trim sensor in the following procedures: 1) Disconnect the emergency stop switch lead wire.
1) Turn ignition switch OFF. 2) Check the continuity/infinity between the wiring leads
2) Connect the test cords. under the condition shown below.
Special tool
Special tool
Continuity ( )
1 Tester probe connection Tester
Red (+) Black (–) indicates
(A) Lock plate
(A) Infinity
installed
Black Black
Lock plate
Continuity
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 removed
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
(A)
2
INP313130030-01

B
2. Wire harness

Connect tester probe (“–”, Black) to No.31 terminal. B
Special tool
: 09900–25011 (Circuit tester set) IDG211130064-01

DC voltage ( )

3 (A)
28 31 B
B
IDG211130065-01
3) If out of specification, replace the emergency stop

INP313130031-01
switch.
Operate the PTT switch, and check if voltage
changes linearly within specification, according to
trim/tilt position.
Sensor output voltage
Trim/Tilt position Output voltage
Full trim down Approx. 2.0 V
Full tilt up Approx. 4.2 V
6) If out of specification, check wire harnesses for open

replace trim sensor and recheck.
1D-1 Power Unit Mechanical:
Power Unit Mechanical

Power Head
General Description
Power Unit Construction Description
CENNP3131401001
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 the figure.
No.1
No.2
No.3
No.4
IMP311140002-01

Cylinder Compression Check
CENNP3131404001
Refer to “Cylinder Compression Pressure Check” in Section 0B (Page 0B-21).
Oil Pressure Check

CENNP3131404002
Refer to “Oil Pressure Check” in Section 0B (Page 0B-20).
Power Unit Mechanical: 1D-2
Tappet Clearance Inspection Ring Gear Cover Removal and Installation
CENNP3131406001 CENNP3131406003
Refer to “Tappet Clearance Inspection and Adjustment” Removal
in Section 0B (Page 0B-7). 1) Turn ignition switch OFF.
Fuel Hose Guard Removal and Installation 2) Remove nut (1), then remove ring gear cover (2).
CENNP3131406002
Removal
1) Remove fuel hose guard (1).
2
INP313140001-01
Installation
INP313140011-01
Installation
Installation is in the reverse order of removal with special • Install spacer, nut and washer as shown in the figure.
• Install two cushions (1).
IMP311140078-01
INP313140012-01
• Install four cushions (2).
2 2
INP313140013-01
Cylinder Head Cover Removal and Installation

CENNP3131406004
Removal
1) Remove side covers.
9
(Page 1D-2).
3) Loosen clamp, then disconnect breather hose (1).
INP313140017-01
1 7) Remove CMP sensor.

Refer to “CMP Sensor Removal and Installation” in
8) Remove six harness bracket bolts (10).
Remove two hose bracket bolts (11).
9) Disconnect lead wire connector (12).
10) Remove four ignition coils.
Refer to “Ignition Coil Removal and Installation” in
Section 1H (Page 1H-7).
INP313140014-01

10
Loosen screw and disconnect lead wire from oil
pressure switch (2).
2
10
10
11 12
INP313140018-02
11) Remove low pressure fuel filter (13).

Remove low pressure fuel pump (14).
INP313140015-01
5) Unfasten cable tie.

Disconnect lead wire connector (3), (4), (5) and (6),
then remove lead wire (7) from connector holder (8).
14 13
8
3
5
INP313140002-01
12) Remove fifteen bolts securing cylinder head cover in

4 ascending order of numbers, then remove cylinder
6 head cover.
7
INP313140016-01
6) Unfasten three cable tie.

Disconnect four fuel injector connectors (9).
“5” “4”
“13”
“11” “8”
“14”
“15”
“12” “9” “10” 1

“7” “6”
“2”
“3” “1”
IMP311140020-03 IMP311140113-02
13) Remove gaskets (15) from cylinder head cover. • Install new gaskets (2) to cylinder head cover.
NOTICE
15 A previously used gasket may leak, resulting
in engine damage.
Do not reuse gasket once removed. Always

use a new one.
INP313140003-01
Installation
• Clean sealing surface on cylinder head and cover.
• Remove oil, old sealant, and dust from sealing
surfaces.
IMP311140023-02
• After cleaning, apply sealant to cylinder head sealing
• Install cylinder head cover to cylinder head, then
surface area as shown in the figure.
tighten cylinder head cover bolts in ascending order of
: Sealant 99000–31140 (SUZUKI Bond numbers.
1207B (100 g))
NOTE
Use care when installing cylinder head cover.
Be certain cylinder head cover gaskets
remain in their correct position.
Tightening torque
Cylinder head cover bolt (a): 11 N·m (1.1 kgf-m,
8.1 lbf-ft)
“11” “12”
“3”
INP313140019-01
“5” “8”
• Apply sealant to cylinder head cover as shown in the “1” “2”

figure.
Install breather plate (1) to cylinder head cover, apply “4” “7” “6”
thread lock to screws, then tighten screws securely. “9” “10”
: Sealant 99000–31140 (SUZUKI Bond

1207B (100 g)) “14”
“13” “15”
: Thread lock cement 99000–32160 IMP311140024-03
• Install low pressure fuel pump. Air Intake Silencer Removal and Installation
Refer to “Low Pressure Fuel Pump Removal and CENNP3131406005
Installation” in Section 1G (Page 1G-26). Removal

• Perform the following final assembly checks to ensure 1) Remove side covers and front panel.
proper and safe operation. Refer to “Side Cover Removal and Installation” in
– All parts removed have been returned to their
original positions. 2) Disconnect IAT sensor connector (1).
Remove two bolts (2).
– Check wire hose routing.
Section 4A (Page 4A-4). 1
– Check hose routing.
Refer to “Fuel Hose Routing” in Section 4B (Page
4B-1) and “Water Hose Routing” in Section 4B 2
(Page 4B-5).
– No oil leakage is evident during final test running.
INP313140020-01
INP313140021-01
3) Disconnect breather hose (3) and remove air intake

silencer (4).
3
4
INP313140022-01
Installation
Electric Parts Holder Removal and Installation

CENNP3131406006
Refer to “Wire harness Removal and Installation” in
Intake Manifold and Throttle Body Components

CENNP3131406007
7
(c)
(a)
(b)
2
10 9
(a)
11
(a)
6
(a)
3
INP313140023-01
1. Intake manifold 6. Gasket 11. Throttle body bracket

2. Gasket 7. IAC valve : 23 Nm (2.3 kgf-m, 17 lbf-ft)
3. Throttle body 8. IAC valve filter : 5.0 Nm (0.51 kgf-m, 3.7 lbf-ft)
4. Gasket 9. MAP sensor : 1.5 Nm (0.15 kgf-m, 1.1 lbf-ft)
5. Plate 10. O-ring : Apply engine oil.
Intake Manifold Removal and Installation 7) Remove fuel delivery pipe and fuel injectors.
CENNP3131406008 Refer to “Fuel Injector Removal and Installation” in
Removal Section 1G (Page 1G-24).
1) Relieve fuel pressure. 8) Remove air intake silencer.
Refer to “Fuel Pressure Relief Procedure” in Section Refer to “Air Intake Silencer Removal and
1G (Page 1G-14). Installation” (Page 1D-5).
2) Turn ignition switch OFF. Remove ring gear cover.
Disconnect battery cables from battery. Refer to “Ring Gear Cover Removal and Installation”
3) Remove side covers and front panel. (Page 1D-2).
Refer to “Side Cover Removal and Installation” in Remove MAP sensor.
Section 2A (Page 2A-3). Refer to “MAP Sensor Removal and Installation” in
4) Remove fuel hose guard. Section 1C (Page 1C-14).
Refer to “Fuel Hose Guard Removal and Installation” Remove throttle body.
(Page 1D-2). Refer to “Throttle Body Removal and Installation”
(Page 1D-8).
5) Disconnect fuel outlet hose (1) from low pressure
fuel pump. 9) Remove breather hose (8) and fuel hose (9) from
intake manifold.
8
1
9
IMP311140079-01
INP313140024-01
6) Loosen clamp and place a large cloth over end of
fuel feed hose (2). 10) Remove six bolts and two nuts in ascending order of
Slowly pull fuel feed hose from fuel delivery pipe. numbers.
Drain any excess fuel in hose into a small container. Remove intake manifold (10).
! WARNING
“5” “2”
Gasoline is a flammable material that can 10
cause fire hazard or burns.
“7”
A small amount of fuel may be released when

“8”
the fuel feed hose is disconnected.
Place container under the fuel feed hose or
“6”
fuel delivery pipe upper union with a shop
cloth so that the released fuel is caught in the “4”
“3” “1”
container or absorbed by the cloth.
Place the fuel soaked cloth in an approved INP313140025-01
container.
Installation
• Install new gaskets (1) into groove of intake manifold.
2
INP313140004-01
1
2
IMP311140085-01 INP313140027-01
• Install intake manifold, then tighten bolts and nuts to 5) Remove bolts (3) and (4), then remove throttle body
the specified torque according to sequence in the bracket (5) and throttle body (6).
figure.
Tightening torque
Intake manifold bolt & nut (a): 23 N·m (2.3 kgf-m, 4 3
17 lbf-ft)
6
5
“4” “7”
3
“2” (a)
“1” 4
INP313140028-01
“3” 6) Remove plate (7) and gasket (8).

“6” “8”
“5”
INP313140026-01
7
• Perform the following final assembly checks to ensure
proper and safe operation.
– All parts removed have been returned to their
original positions.
– Wire and hose routing matches service manual
illustration.
Section 4A (Page 4A-4) and “Fuel Hose Routing” in
INP313140030-02
– No fuel leakage is evident during final test running.
Throttle Body Removal and Installation 8

CENNP3131406009
Removal
3) Remove air intake silencer. INP313140029-01
Refer to “Air Intake Silencer Removal and
Installation” (Page 1D-5). Installation
4) Remove flame arrester (1). Installation is in the reverse order of removal with special
Disconnect connector (2). attention to the following points.
NOTICE Power Unit Removal and Installation

CENNP3131406011
Air leakage will induce a lean air/fuel mix Removal
which will result in severe engine damage.
Do not reuse gasket once removed.
Always use a new gasket. 2) Remove side covers and front panel.
• Install new gasket (1) and (2). Section 2A (Page 2A-3).
3) Remove side cover seal (1).
Unfasten cable clamp.
Disconnect trim sensor lead wire connector and PTT
motor cable connector.
INP313140031-01
• Install throttle body to intake manifold. Lightly seat all

1
bolts at first, then tighten bolts to the specified torque
according to sequence in the figure.
IMP311140092-01
Tightening torque
Throttle body bolt (a): 23 N·m (2.3 kgf-m, 17 lbf-ft)
“6” “1”
(a) “3”
(a)
“2” “5” INP313140033-01

“4”
INP313140032-01
4) Remove two bolts securing harness bracket (2).
Remove clamp (3) from side cover stand.
Throttle Body Inspection 5) Remove bolt and water return hose pipe (4) from
CENNP3131406010 engine holder.
NOTICE
The throttle body will lose its original 3
performance if it has been disassembled and
reassembled. 4
• Do not try to disassemble the throttle body.

• Do not try to adjust or remove any of the
throttle body component parts (Throttle
position sensor, throttle valve, throttle 2
stop screw, etc.). 2
These components have been factory
adjusted to precise specifications. INP313140005-01
6) Disconnect water hose (5) and (6) from engine

• Clean throttle body bore by compressed air. holder.
• Check that throttle lever and throttle valve moves Remove fuel drain hose (7) and evaporation hose (8)
smoothly. from clamps and engine holder.
• Replace throttle body if necessary.
h) Remove cylinder temp. sensor.

Refer to “Cylinder Temp. Sensor Removal and
Installation” in Section 1C (Page 1C-10).
7
i) Remove Ex. manifold temp. sensor.
Refer to “Ex. Manifold Temp. Sensor Removal
and Installation” in Section 1C (Page 1C-11).
j) Remove starter motor.
8 Refer to “Starter Motor Removal and Installation”
6 in Section 1I (Page 1I-7).
5 k) Remove flywheel.
Refer to “Flywheel Removal and Installation” in
IMP311140095-01
Section 1K (Page 1K-4).
7) Remove E-ring (9), cotter pin (10) and washer (11), l) Remove battery charge coil.
then remove clutch shaft arm (12). Refer to “Battery Charge Coil Removal and
Installation” in Section 1K (Page 1K-5).
m) Remove rectifier / regulator.
12
Refer to “Rectifier / Regulator Removal and
Installation” in Section 1K (Page 1K-6).
n) Remove clutch holder (13) and clutch lever
9
11 holder (14).
10
13
INP313140006-01

(Page 1D-2).
9) Remove cylinder head cover.
Refer to “Cylinder Head Cover Removal and
Installation” (Page 1D-3).
INP313140007-01
10) For power unit disassembling;
a) Remove intake manifold.
Refer to “Intake Manifold Removal and 14
Installation” (Page 1D-7).
b) Remove fuel vapor separator.
Refer to “Fuel Vapor Separator Removal and
Installation” in Section 1G (Page 1G-16).
c) Remove wire harness.
Refer to “Wire harness Removal and Installation”
d) Remove knock sensor.
Refer to “Knock Sensor Removal and INP313140008-01
Installation” in Section 1C (Page 1C-18). o) Remove oil filter adapter case (15).
e) Remove oil pressure switch.
Refer to “Oil Pressure Switch Removal and
Installation” in Section 1E (Page 1E-4).
f) Remove CKP sensor.
Refer to “CKP Sensor Removal and Installation”
g) Remove O2 sensor. 15
Refer to “O2 Sensor Removal and Installation” in
INP313140009-01
11) Remove eight bolts securing power unit. 14) Remove three dowel pins (16) and gasket (17).
17
16
IMP311140102-01 INP313140010-01
Installation
NOTICE
Previously used gasket may leak oil and/or
cooling water, resulting in engine damage.
Do not reuse gasket. Always replace with

new part.
IMP311140103-01 • Install three dowel pins (1) and gasket (2).
12) Remove eight bolts securing power unit. Apply water resistant grease to driveshaft splines.
2 1
IMP311140104-01
IMP311140107-01
NOTE
Before installing power unit, apply sealant to
the two hatched areas shown in the
illustration at below.

1207B (100 g))
IMP311140105-01
13) Lift up and remove power unit from engine holder.

• Apply sealant to power unit mounting bolts.

Tighten eight bolts to the specified torque.
: Sealant 93691–80030 (SUZUKI Silicone
Seal (100 g))
Tightening torque
Power unit mounting bolt (b): 23 N·m (2.3 kgf-m,
17 lbf-ft)
IDG211140063-01
• Lower power unit onto engine holder. (b)
NOTE
Rotate crankshaft to aid alignment of
driveshaft and counter shaft splines. IMP311140110-01
• Apply sealant to power unit mounting bolts.

Tighten eight bolts to the specified torque according to
sequence in the figure.
Seal (100 g))
Tightening torque
Power unit mounting bolt (a): 50 N·m (5.1 kgf-m,
37 lbf-ft)
(b)
IMP311140111-01
Perform the following final assembly checks to

ensure proper and safe operation.
(a) • All parts removed have been returned to their original
positions.
• Fuel and water hose routing matches service manual
illustration.
“4” “3” “2” “1”
Refer to “Fuel Hose Routing” in Section 4B (Page 4B-
IMP311140108-02 1) and “Water Hose Routing” in Section 4B (Page 4B-
5).
• Wire routing matches service manual illustration.
4A (Page 4A-4).
• No fuel leakage is evident when fuel system is
pressurized.
(a) Refer to “Fuel Leakage Check Procedure” in Section
1G (Page 1G-14).
• No water leakage is evident during final test running.
“5” “6” “7” “8”
IMP311140109-02
Timing Chain, Chain Tensioner and Camshaft Sprockets Components

CENNP3131406012
8
9
7
5
4
3
6
1
IMP311140005-02
1. Crankshaft/Drive gear 4. Timing chain guide 7. Oil pump drive sprocket

2. Driven gear/Timing sprocket 5. Timing chain tensioner 8. Exhaust camshaft and timing sprocket
3. Timing chain 6. Timing chain tensioner adjuster 9. Intake camshaft and timing sprocket
Timing Chain, Chain Tensioner and Camshaft 4) Remove bolts (3) and timing chain guide (4).
Sprockets Removal and Installation
CENNP3131406013
Removal
3
1) Remove the power unit.
Refer to “Power Unit Removal and Installation”
(Page 1D-9).
2) Turn the crankshaft in its normal running direction
4
“A” until the matching mark “B” (key) on the
crankshaft drive gear points to 12 o’clock position
(toward cylinder head). 3
NOTICE
IDG211140077-01
After the timing chain has been removed, 5) Remove bolt, nut and chain tensioner adjuster (5).
independently turning camshaft or Remove bolt (6) and chain tensioner (7).
crankshaft will cause interference between
piston and valve, which cause damage to
these related parts. 6
Do not rotate the camshaft and/or crankshaft

with timing chain removed.
7
IMP311140063-02
6) Remove timing chain (8), exhaust camshaft timing

“B”
sprocket (9) and pin (10).
Remove bolt (11), intake camshaft timing sprocket
(12) and pin.
NOTE
“A”
Hold camshaft by placing a wrench on the
IDG211140075-01 hexagon area of camshaft.
“A”: Crankshaft normal running direction
“B”: Matching mark (key)
8
3) Remove bolt (1) and oil pump drive sprocket (2).
NOTE
hexagon area of camshaft.
11
9 10 12
1 IDG211140079-01
IDG211140076-01
7) Remove driven gear (13). 4) Tighten the bolt (6) to the specified torque.
NOTE
13 Tightening torque
IN. timing sprocket bolt (a): 78 N·m (8.0 kgf-m,
58 lbf-ft)
5) Check that engraved lines “C” and “F” on sprockets
are opposite each other and aligned with mating face
“G” of cylinder head cover when matching marks
IMP311140053-01 (dot) “H” and “I” on sprockets are located as shown
in figure.
Installation
Installation is in the reverse order of removal with special “H” “I”
attention to the following steps.
“C” “F” “G”
1) Check that matching mark (key way) “A” on the “G”
crankshaft drive gear points to 12 o’clock position
(towards cylinder head).
2) Install the driven gear (1) on the cylinder block so
that matching mark “A” aligns with matching mark
“B” on the driven gear as shown in illustration.
6 (a)
IDG211140083-02
6) As shown in figure, position timing chain on driven

gear sprocket with GOLD plate (7) of chain aligned
“B” with matching mark “B” on driven gear, then engage
1
“A” timing chain with exhaust sprocket with one GOLD
plate (8) of chain aligned with matching mark “H” of
exhaust sprocket.
7) As shown in figure, engage timing chain with intake
sprocket with another GOLD plate (8) of chain
IDG211140081-01 aligned with matching mark “I” of intake sprocket.
3) Install pin (2) and sprocket (3) on exhaust camshaft.
8 8
Install pin (4) and sprocket (5) on intake camshaft.
NOTE “H” “I”

When installing camshaft timing sprocket,
position side of sprocket with two engraved
lines “C”, “D”, “E” and “F” facing down
toward engine holder as shown in figure.
“D” “E”
“C” “F”
7
3
5
2 4
“B”
IDG211140082-01
IDG211140084-01
8) Apply engine oil to the timing chain guide (9). Install 12) Apply engine oil to timing chain.
the timing chain guide, then tighten bolts securely. Remove stopper (15) from tensioner adjuster to
release plunger.
15
9
(b)
IMP311140054-01
9) Apply engine oil to chain tensioner (10). IMP311140055-01
Insert spacer (11) into chain tensioner. 13) Turn crankshaft in normal running direction two
Install chain tensioner as shown in the figure. complete turns and check that crankshaft matching
mark (key way) “A” points toward the top and at the
same time, engraved lines “C” and “F” on sprockets
aligns with cylinder head cover mating face “G”.
11
“C” “F”
“G” “G”
10
IMP311140064-03
10) With latch of tensioner adjuster pushed in and

plunger pushed back into body, insert stopper
between latch and body.
After inserting stopper, check to make sure that
plunger will not come out.
13 15
12 14
13
IDG211140087-01
12. Plunger 14. Body

“A”
13. Latch 15. Stopper
11) Install timing chain tensioner adjuster.

Tighten bolt and nut to specified torque.
IDG211140089-01
Tightening torque
14) Install oil pump drive sprocket (16) and tighten bolt to
Timing chain tensioner adjuster bolt/nut (b): 10
specified torque.
N·m (1.0 kgf-m, 7.4 lbf-ft)
NOTE
Tightening torque Timing Chain Tensioner / Chain Guide

Oil pump drive sprocket bolt (c): 78 N·m (8.0 • Check chain tensioner shoe for wear or damage.
kgf-m, 58 lbf-ft) If excessive wear or other damage is found, replace it.
• Check chain guide shoe for wear or damage.
If excessive wear or other damage is found, replace it.
16
(c)
IMP311140056-01
Timing Chain, Chain Tensioner and Camshaft IDG211140093-01

Sprockets Inspection
CENNP3131406014
NOTE Camshaft Timing Sprocket
Check teeth of sprocket for wear or damage.
If any component is worn excessively, If excessive wear or other damage is found, replace it.
cracked, defective or damaged in any way, it
must be replaced.
Timing Chain
Inspect timing chain for wear or damage.
If excessive wear or other damage is found, replace it.
IDG211140094-01
Driven Gear and Drive Gear Bearing

• Inspect drive gear and driven gear for wear or other
damage.
IDG211140092-01
• Inspect driven gear bearing for pitting, rough or other
Tensioner Adjuster damage.
Inspect tensioner adjuster for smooth operation. Replace if necessary.
Replace if fault is noted.
Check oil delivery passage to tensioner.
I9J011140182-01 IDG211140091-01
1. Latch 3. Oil passage

2. Tooth surface
Camshaft, Tappet and Shim Removal and 5) Remove tappets and tappet shims.
Installation
CENNP3131406015 NOTE
Removal All tappets and tappet shims must be
1) Remove the power unit. installed in their original positions.
Refer to “Power Unit Removal and Installation” For ease of assembly, lay out tappets and
(Page 1D-9). record shim thickness for each individual
2) Remove the timing chain and chain tensioner. cylinder/valve position.
Refer to “Timing Chain, Chain Tensioner and
Camshaft Sprockets Removal and Installation”
(Page 1D-14).
3) Remove the bolts securing camshaft housing to
cylinder head, then remove each camshaft housing.
NOTE
For ease of assembly, note position of each
individual camshaft housing.
IMP311140065-02
Installation
1) Apply engine oil around tappets.
2) Install tappets and tappet shims.
IMP311140034-02
4) Remove intake camshaft (1) and exhaust camshaft

(2).
1 IMP311140066-02
3) Apply engine oil to surface of each camshaft lobe

IMP311140035-01 and journal, then place them onto cylinder head.
NOTE
Before installing camshafts, turn crankshaft
until the matching mark (key way) “A” on the
crankshaft drive gear points to 12 o’clock
(toward cylinder head).
6) Check position of camshaft housing. Install housings

as indicated by these marks.
NOTE
Embossed marks are provided on each
camshaft housing indicating position and
direction of installation.
“E”
IMP311140038-02
“F”
“G”
“A”
IDG211140103-01
“E”: I: Intake side, E: Exhaust side

“F”: Position from flywheel magneto side
“G”: Pointing to flywheel magneto side
IMP311140057-01
7) Lightly seat all housing bolts.
4) Adjust relative position between sprockets and chain
According to numerical order in figure, tighten bolts
so that matching marks (dot) “B” on timing sprockets
to 1/3 of specified torque, then 2/3 of specified
are as shown in figure and engraved lines “C” on
torque and finally to full specified torque.
sprockets align with cylinder head cover mating face
“D”. NOTE
Apply engine oil lightly to housing bolt.
“B” “B”
“C”
“C” Tightening torque
“D”
“D” Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
8.1 lbf-ft)
“17” “20” “10” “9” “2” “1” “6” “5” “14” “13”
IDG211140101-01
“B”: Matching mark

“C”: Engraved line
“D”: Cylinder head cover mating face
“19”
5) Install camshaft housing pins as shown in the figure.
1 “18” “21” “12” “11” “4” “3” “8” “7” “16” “15”
IMP311140114-01
8) Install timing chain.

(Page 1D-14).
9) Adjust tappet clearance.
Refer to “Tappet Clearance Inspection and
Adjustment” in Section 0B (Page 0B-7).
IMP311140039-01
1. Pin
Camshaft, Tappet and Shim Inspection Camshaft Journal Wear

CENNP3131406016 Check camshaft journals and camshaft housings for
NOTE pitting, scratches, wear or damage.
If any component is worn excessively, If any of the above conditions are found, replace
cracked, defective or damaged in any way, it camshaft or cylinder head with housing.
must be replaced.
NOTE
Cam Face Camshaft housing and cylinder head must be
Inspect cam face for scratches and wear. replaced as a set.
If any of the above conditions are found, replace
camshaft.
Cam Wear
Using micrometer, measure cam height.
If measurement exceeds service limit, replace camshaft.
Special tool
(A): 09900–20202 (Micrometer (25 – 50 mm))
Cam height “a” I9J011140030-01

Standard Service limit
39.510 – 39.670 mm 39.410 mm Camshaft Journal Oil Clearance
IN
(1.5555 – 1.5618 in) (1.5516 in) Check journal oil clearance using Plastigauge as follows.
39.420 – 39.580 mm 39.320 mm
EX 1) Clean housing and camshaft journals.
(1.5520 – 1.5583 in) (1.5480 in)
2) Install camshaft to cylinder head.
3) Place Plastigauge across the full width of camshaft
journal (parallel to camshaft).
(A)
Special tool
(A): 09900–22303 (Plastigauge (0.025 –
0.076 mm))
(A)
“a”
IDG211140105-01
Camshaft Runout
Support camshaft on a surface plate using a set of V-
blocks.
Measure runout using a dial gauge. IMP311140040-01
If measurement exceeds service limit, replace camshaft.
Special tool
(A): 09900–20607 (Dial gauge)
(B): 09900–20701 (Magnetic stand)
Camshaft runout
Service limit: 0.10 mm (0.004 in)
(B) (A)
IDG211140106-02
4) Install camshaft housing. Tighten housing bolts in 3 If journal oil clearance exceeds the service limit,
steps (1/3 of specification, 2/3 of specification, full measure camshaft journal (outside dia.) and
torque specification) in the indicated order. camshaft housing (inner dia.). Based on
measurements, replace camshaft and/or cylinder
Tightening torque
head with camshaft housing.
Camshaft housing bolt: 11 N·m (1.1 kgf-m, 8.1
lbf-ft) Camshaft journal outside diameter No.1 – No.4
Standard: 22.959 – 22.980 mm (0.9039 – 0.9047
NOTE in)
Do not rotate camshaft while Plastigauge is
Camshaft journal outside diameter No.5
installed.
Standard: 25.934 – 25.955 mm (1.0210 – 1.0219
in)
Camshaft journal (housing) inside diameter No.1
“17” “20” “10” “9” “2” “1” “6” “5” “14” “13” – No.4
Standard: 23.000 – 23.021 mm (0.9055 – 0.9063
in)
“19”
Camshaft journal (housing) inside diameter No.5
Standard: 26.000 – 26.021 mm (1.0236 – 1.0244
in)
Special tool
“18” “21” “12” “11” “4” “3” “8” “7” “16” “15”
(B): 09900–20202 (Micrometer (25 – 50
IMP311140115-01
mm))
(B): 09912–66310 (Micrometer (0 - 25 mm))
5) Remove camshaft housing.
6) Using scale (1) on Plastigauge envelope, measure
Plastigauge (2) at its widest point.
(B)
Camshaft journal oil clearance No.1 – No.4
Standard: 0.020 – 0.062 mm (0.0008 – 0.0024 in)
Camshaft journal oil clearance No.5
Standard: 0.045 – 0.087 mm (0.0018 – 0.0034 in)
IDG211140109-01
2 1
IDG211140184-02
1. Scale 2. Plastigauge
I9J011140200-02
Wear of Tappet and Shim Cylinder head tappet bore

Check tappet and shim for pitting, scratches, or damage. Standard: 31.000 – 31.025 mm (1.2205 – 1.2215 in)
If any above conditions are found, replace component.
I9J011140076-01
I9J011140031-01
Measure cylinder head bore and tappet outside diameter
to determine cylinder head to tappet clearance.
If clearance exceeds service limit, replace tappet or
cylinder head.
Special tool
: 09900–20202 (Micrometer (25 – 50 mm))
Cylinder head bore to tappet clearance
Standard: 0.025 – 0.066 mm (0.0010 – 0.0026 in)
Tappet outer diameter
Standard: 30.959 – 30.975 mm (1.2189 – 1.2195 in) I9J011140032-01
Cylinder Head Assembly Components

CENNP3131406017
11 (a) 10
9
12 (b)
6
1
IMP311140071-01
1. Intake valve 5. Valve stem seal 9. Tappet : 70 Nm (7.1 kgf-m, 52 lbf-ft)
2. Exhaust valve 6. Valve spring 10. Tappet shim : 25 Nm (2.5 kgf-m, 18 lbf-ft)
3. Valve guide 7. Valve spring retainer 11. Cylinder head bolt (10 mm) : Apply engine oil.
4. Valve spring seat 8. Valve cotter 12. Cylinder head bolt (8 mm)
Cylinder Head Removal and Installation

CENNP3131406018
Removal
1) Prior to removing cylinder head assembly;
• Remove the power unit.
(Page 1D-9).
• Remove the timing chain. (A)

(Page 1D-14).
• Remove the IN. and EX. camshafts. IDG211140112-01
Refer to “Camshaft, Tappet and Shim Removal

and Installation” (Page 1D-18). Installation
Installation is in reverse order of removal paying special
• Remove bolts and oil pump (1).
Refer to “Oil Pump Removal and Installation” in
Section 1E (Page 1E-3). NOTICE
• Remove oil relief valve (2). A previously used gasket may leak
combustion gas and/or cooling water,
resulting in engine damage.
Do not reuse gasket once removed.

Always use a new gasket.
1
1) Insert the dowel pins (1) and place a new cylinder
head gasket (2) into position on the cylinder.
2
2
IDG211140186-01
2) Loosen and remove eighteen cylinder head bolts in

the order indicated in figure.
Remove cylinder head assembly and head gasket.
NOTE
Use special tool (10 mm deep socket wrench) 1
when loosening cylinder head bolts.
IMP311140076-01
Special tool
(A): 09919–16010 (Deep socket wrench (10 NOTE
mm)) Before installing cylinder head gasket, apply
sealant to both surfaces of the hatched areas
“6” “4” “15” “7” “8” “3” shown in illustration.
“2”
“5” “1”
“9” : Sealant 99000–31140 (SUZUKI Bond
“13” 1207B (100 g))
“11”
“12”
“14” “18” “17” “16” “10”
IMP311140003-02
IDG211140187-02
2) Position cylinder head on cylinder. d) Finally tighten all cylinder head bolts to specified
torque according to sequence in figure.
NOTE
Tightening torque
Use special tool (10 mm deep socket wrench)
Cylinder head bolt (Final step) [10 mm]: 70
when tightening cylinder head bolts.
N·m (7.1 kgf-m, 52 lbf-ft)
Special tool Cylinder head bolt (Final step) [8 mm]: 25
(A): 09919–16010 (Deep socket wrench (10 N·m (2.5 kgf-m, 18 lbf-ft)
mm))
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.
(A)
Tightening torque
Cylinder head bolt (1st step) [10 mm]: 35
Cylinder head bolt (1st step) [8 mm]: 12 N·m
(1.2 kgf-m, 8.9 lbf-ft) IDG211140115-01
4) Install the IN. and EX. camshafts.

“13” “15” “4” “12” “16” Refer to “Camshaft, Tappet and Shim Removal and
“17” “11”
“14” Installation” (Page 1D-18).
“18”
“10” 5) Install the oil pump and oil relief valve.
“6” Refer to “Oil Pump Removal and Installation” in
“8” Section 1E (Page 1E-3).
6) Install the timing chain.
(Page 1D-14).
Cylinder Head Disassembly and Assembly

“7” CENNP3131406019
“5” “1” “2” “3” “9” Disassembly
IMP311140004-02
1) Using valve lifter and attachment, remove valve
b) Loosen all cylinder head bolts to 0 Nm (0 kgf-m,
cotters (1) while compressing valve spring.
0 lbf-ft.) according to reverse sequence in figure.
c) Again tighten all cylinder head bolts to 50 Special tool
percent (%) of specified torque according to (A): 09916–19030 (Valve lifter)
sequence in figure. (B): 09916–14910 (Valve lifter attachment)
(C): 09916–84511 (Tweezers)
Tightening torque
Cylinder head bolt (3rd step) [10 mm]: 35
Cylinder head bolt (3rd step) [8 mm]: 12 N·m
(A)
(1.2 kgf-m, 8.9 lbf-ft)
(B)
IDG211140116-02
Assembly
(C) Reassemble is in the reverse order of disassembly
paying special attention to the following steps.
(A)
(B) 6
5
2
4
1
I9J011140209-01 3
2) Remove valve spring retainer (2), valve spring (3) I9J011140212-03
and valve (4). 1) Install valve spring seat (1) to cylinder head.
2) After applying engine oil to stem seal (2) and spindle
1 2 3 5 6 4 of special tool (A), fit stem seal to spindle.
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
(6). Removing the stem seal can be damaged,
causing oil to get down past the seal.
NOTE
Reassemble each valve and valve spring in Do not reuse stem seal once removed.
their original positions. Always install new seal.
Special tool
(A): 09917–98221 (Valve guide stem seal
installer attachment)
5 (B): 09916–57350 (Valve guide installer
handle)
6
(B)
(A)
I9J011140211-02
2
I9J011140033-03
3) Apply engine oil to stem seal, valve guide bore and 6) Hold valve spring compressed with special tool and
valve stem. install valve cotters (6).
4) Install valve (3) to valve guide. Make sure valve cotters are properly seated in
groove “A”.
NOTE
NOTE
Reassemble each valve and valve spring to
their original position. When compressing the valve spring, be
careful not to damage the tappet hole.
Special tool
(C): 09916–19030 (Valve lifter)
(D): 09916–14910 (Valve lifter attachment)
(E): 09916–84511 (Tweezers)
(C)
I9J011140034-01
5) Install valve spring (4), and valve retainer (5).

(D)
NOTE
Set valve spring in place with narrow spiral
IDG211140117-03
area facing valve seat.
(E)
“C” (C)
“A” (D)
6
6
“A”
I9J011140036-02
“B”
“D”
I9J011140035-01
“A”: Large-pitch “C”: Valve spring retainer side

“B”: Small-pitch “D”: Valve spring seat side
Cylinder Head Components Inspection and • Check water jackets. If clogged or obstructed, clean
Servicing water jackets.
CENNP3131406020
NOTE
If cracks, excessive wear or other damage is
found on any component, replace
component.
Cylinder Head
• Remove all carbon from combustion chambers.
NOTE
• Do not use any sharp edged tool to scrape
carbon off cylinder head or its
components. IMP311140028-03
• Be careful not to scuff or nick metal Cylinder head distortion

surfaces when decarbonizing.
• Using a straightedge and thickness gauge, measure
cylinder head distortion (gasket surface) at a total of
six locations as shown.
If measurement exceeds service limit, resurface or
replace cylinder head.
Special tool
Cylinder head distortion
I9J011140037-01
• Check cylinder head for cracks in intake and exhaust

ports, combustion chambers, and head surface.
• Check valve seat, if cracks or other damage is found,
IMP311140029-02
(A)
IMP311140027-01
IDG211140121-01
Manifold seating faces distortion Valve guide inside diameter

Using a straightedge and thickness gauge, check Using a small bore gauge, measure valve guide inside
cylinder head to manifold seating faces. diameter.
Valve guide inside diameter
Standard (IN., EX.): 6.000 – 6.012 mm (0.2362 –
Special tool 0.2367 in)
Manifold seating faces distortion
(A) I9J011140040-01
IDG211140122-01 Valve guide to valve stem clearance

Standard (IN.): 0.020 – 0.047 mm (0.0008 – 0.0019 in)
Valve and Valve Guide Standard (EX.): 0.045 – 0.072 mm (0.0018 – 0.0028 in)
Valve guide to valve stem clearance Service limit (IN.): 0.070 mm (0.0028 in)
Using a micrometer and bore gauge, take diameter Service limit (EX.): 0.090 mm (0.0035 in)
readings on valve stems and guides to check guide to
stem clearance. Valve stem deflection
Be sure to take readings at more than one place along If unable to measure valve guide inside diameter, check
the length of each stem and guide. “Valve stem deflection”.
If measurement exceeds service limit, replace valve and/ If measurement exceeds service limit, replace valve.
or valve guide. If measurement still exceeds service limit with new
Refer to “Valve guide replacement” (Page 1D-31). valve, replace valve guide.
Measure valve stem deflection as follows;
Special tool
(A): 09912–66310 (Micrometer (0 - 25 mm)) 1) Install valve into valve guide.
2) Position valve head at approx. 5 mm away from
Valve stem outside diameter valve seat.
Using micrometer, measure valve stem outside 3) Move valve stem end in the direction “a” – “b”, and
diameter. measure deflection.
Valve stem outside diameter Special tool
Standard (IN.): 5.965 – 5.980 mm (0.2348 – 0.2354 in) (A): 09900–20607 (Dial gauge)
Standard (EX.): 5.940 – 5.955 mm (0.2339 – 0.2344 in) : 09900–20701 (Magnetic stand)
Valve stem deflection
Service limit (IN.): 0.14 mm (0.0055 in)
Service limit (EX.): 0.18 mm (0.0071 in)
“a”
“b ”
(A)
(A)
I9J011140039-02
IDG211140123-02
Valve stem end Valve head radial runout

Inspect valve stem end face for pitting and wear. Measure valve head radial runout.
If pitting or wear is found, valve stem end may be To measure runout, rotate valve slowly.
resurfaced. If measurement exceeds service limit, replace valve.
Use caution when resurfacing, do not grind away stem
Special tool
end chamfer.
(A): 09900–20607 (Dial gauge)
When chamfer has been worn away, replace valve.
(B): 09900–21304 (Steel “V” block set)
: 09900–20701 (Magnetic stand)
Valve head radial runout
(A)
I9J011140041-01
Valve stem runout

(B)
Measure valve stem runout.
I9J011140043-03
If measurement exceeds service limit, replace valve.
Special tool Valve head thickness
(A): 09900–20607 (Dial gauge) Measure thickness “a” of valve head.
(B): 09900–20701 (Magnetic stand) If measurement exceeds service limit, replace valve.
(C): 09900–21304 (Steel “V” block set)
Valve head thickness
Valve stem runout Standard (IN.): 1.0 mm (0.04 in)
Service limit: 0.05 mm (0.0020 in) Standard (EX.): 1.2 mm (0.05 in)
Service limit (IN.): 0.7 mm (0.03 in)
Service limit (EX.): 0.7 mm (0.03 in)
(A)
(B)
(C)
I9J011140042-02
“a”
45°
I9J011140044-01
Valve seat contact width Valve seat servicing

Measure valve seat contact width as follows: If valve seat contact width is out of specification, reface
1) Remove all carbon from valve and seat. valve seat as follows:
2) Coat valve seat evenly with prussian blue (or Valve seat angle
equivalent). Intake side: 15°/45°/60°
3) Install valve into valve guide. Exhaust side: 15°/45°
4) Put valve lapper on valve.
Special tool
(A): 09916–10912 (Valve lapper)
˚
˚ ˚
˚ ˚
IDG211140125-01
To reface a valve seat, use the following valve seat

(A) cutting tool.
• Valve seat cutter 45° (Neway 122)
• Solid pilot (Neway, N-120-6.0)
IMP311140030-02
5) Rotate valve while gently tapping valve contact area • Handle (Neway, N-505) (09916-54910)
against seat. NOTE
6) Continue until a pattern is on valve seat face with Turn cutter clockwise, never
prussian blue. counterclockwise.
7) Measure valve seat contact width “b”.
1) Remove all carbon from valve and valve seat.
Valve seat contact width “b”
Standard (IN., EX.): 1.1 – 1.3 mm (0.04 – 0.05 in) 2) Using 45° angle cutter, reface valve seat.
3) Check valve seat contact width “a”.
If measurement exceeds specification, repair valve
Refer to “Valve seat contact width” (Page 1D-30).
seat.
Too high (wide)
Refer to “Valve seat servicing” (Page 1D-30).
“a”
“b”
I9J011140047-01
I9J011140045-01
Too low (narrow)
“a”
I9J011140048-01
• If width “a” is too high (or wide), reface valve seat Valve guide replacement
using 15° angle cutter.
NOTE
• If width “a” is too low (or narrow), reface valve seat
using 60° angle cutter (Intake side). Be careful not to damage cylinder head when
replacing valve guide.
• If width “a” is too low (or narrow), reface valve seat
using 45° angle cutter (Exhaust side).
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
IDG211140126-01
(A): 09916–46020 (Valve guide remover)
4) Clean up any burrs using 45° angle cutter very
lightly.
NOTE
Cut seat areas minimally only.
Do not cut more than necessary. (A)
5) Lap valve on seat in two steps, first with coarse grit

lapping compound applied to face and the second
with fine grit compound.
6) Recheck valve seat contact width “a”.
NOTE I9J011140050-01
2) Ream valve guide hole with ø 11 mm reamer to true

Clean and assemble cylinder head and valve
hole and remove burrs.
components.
Fill intake and exhaust ports with solvent to NOTICE
check for leaks between valve seat and valve.
If any leaks occur, inspect valve seat and Improper handling of the reamer will cause
face for burrs or other things that could damage to the valve guide hole.
prevent valve from sealing.
When refinishing or removing the reamer
from the valve guide hole, always turn it
clockwise.
Special tool
(B): 09916–38210 (Valve guide reamer (ø 11
mm))
(C): 09916–34542 (Valve guide reamer
handle)
(C)
IMP311140031-01
(B)
IDG211140128-01
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 Valve spring free length
distorted. Standard (IN., EX.): 42.73 mm (1.682 in)
• Use special tools to drive new valve guide into Service limit (IN., EX.) 41.02 mm (1.615 in)
hole.
Drive in new valve guide until special tool (valve
guide installer attachment) contacts cylinder head.
• After installing, check valve guide protrusion “a”.
Special tool
(D): 09916–57350 (Valve guide installer
handle)
(E): 09917–87810 (Valve guide installer IMP311140117-01
attachment)
Valve guide protrusion “a” Valve spring preload
Standard (IN., EX.): 13.3 – 13.7 mm (0.52 – 0.54 Measure valve spring preload.
in) If lower than service limit, replace valve spring.
Valve spring preload
Standard (IN., EX.): 164 – 190 N (16.7 – 19.4 kgf, 36.8
– 42.7 lbf) at 32.6 mm (1.28 in)
Service limit (IN., EX.): 151 N (15.1 kgf, 33.3 lbf) at
32.6 mm (1.28 in)
(D)
“a” (E)
I9J011140052-01
4) Ream valve guide bore with ø 6 mm reamer.
NOTE
Clean and oil valve guide bore after reaming.
I9J011140055-01
Special tool
Valve spring squareness
(F): 09916–37810 (Valve guide reamer (ø 6
Use a square and surface plate to check each spring for
mm))
squareness (clearance between end of valve spring and
(C): 09916–34542 (Valve guide reamer
square).
handle)
If measurement exceeds service limit, replace valve
spring.
Valve spring squareness “a”
Service limit (IN., EX.): 2.0 mm (0.08 in)
(C)
(F) “a”
IDG211140129-02
I9J011140056-02
Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Components

CENNP3131406021
10 11
14 9 (a)
5
4
3
8 2
16 (b)
15 (c) 6
7
13
12 17
1
IMP311140011-01
1. Cylinder block 7. Conrod bearing 13. Dowel pin : 25 Nm (2.5 kgf-m, 18 lbf-ft)
2. Piston ring set 8. Conrod cap 14. Crankcase : 52 Nm (5.3 kgf-m, 38 lbf-ft)
3. Piston 9. Conrod cap bolt 15. Crankcase (inside) bolt : Apply engine oil.
4. Piston pin 10. Oil seal 16. Crankcase (outside) bolt : Apply Molybdenum oil solution.
5. Circlip 11. Crankshaft 17. Thrust bearing

6. Conrod 12. Crankshaft main bearing : 17 Nm (1.7 kgf-m, 13 lbf-ft), then
plus turn in 60 degrees.
Pistons, Piston Rings, Connecting Rods, 4) Remove all conrod cap bolts and conrod caps (5).
Cylinder and Crankshaft Disassembly and
NOTE
Assembly
CENNP3131406022 For proper assembly, mark cylinder number
Disassembly on all pistons, conrods, and conrod caps,
1) Before performing service work in this section: using quick drying paint.
• Remove power unit.
(Page 1D-9).
• Remove timing chain.
(Page 1D-14).
4 3 2 1
• Remove cylinder head.
Refer to “Cylinder Head Removal and Installation”
(Page 1D-23).
2) Remove driven gear (1).
IDG211140134-02
IMP311140067-01
3) Remove ten crankcase (outside) bolts (2). IMP311140118-01

Remove ten crankcase (inside) bolts (3).
5) Remove crankshaft (6).
Remove crankcase (4) from cylinder block.
Remove oil seal (7) from crankshaft.
3
6
2 7
4
IMP311140042-02
IMP311140072-02
6) Mark cylinder number on pistons using quick dry

paint.
Push piston (with conrod) out through the top of
cylinder bore.
NOTE NOTE
• To prevent damage to piston rings, Reassemble each piston, piston pin and
decarbon top of cylinder bore wall before conrod in their original combination and
removing piston. position.
• Reassemble each conrod cap to its
original position after removing piston
from bore.
4 3 2 1
IMP311140120-01
Assembly
Assembly is in the reverse order of disassembly paying
IMP311140043-02 special attention to the following points.
7) Remove two compression rings (top and 2nd) and oil
ring from piston. Mark cylinder number on conrod NOTICE
using quick dry paint. If any of the parts is reinstalled into a position
different from the original position, engine
problems could occur.
If original components are not replaced, each

piston, piston pin and conrod is to be
assembled and installed in its original order
1 and position.
Piston to conrod
• Apply engine oil to piston pin (1), piston pin bore and
conrod (2).
IDG211140138-01 • Assemble conrod (2) to piston (3) as shown in figure
8) Remove piston pin circlips (8) as shown. and insert piston pin (1) through piston and conrod.
• Install piston pin circlips (4).
IMP311140119-01
9) Remove piston pin (9) from conrod.

NOTE NOTE
• “92J” mark on conrod and up mark “A” on When installing spacer, do not allow spacer
piston dome must face toward flywheel ends to overlap in groove.
side.
• Always use new piston pin circlip.
“A”
• Install so that circlip end gap comes within
such range as indicated by arrow.
End gap of the circlip should not be
aligned with the cutaway in the piston pin
bore.
“B”
“C”
“A”
I9J011140012-01
“A”: Incorrect “B”: Correct

92J
2) Install the piston rings.

“B”
• Apply engine oil to piston rings.
• Install 2nd ring (3) and 1st ring (4) to piston.
IMP311140044-02
“A”: Up mark “C”: Flywheel side

“B”: Circlip end gap direction “RN”
“R” 4
3
1 “D”
4 IDG211140142-01
3
4 NOTE
• 1st ring (4) and 2nd ring (3) differ in shape
2 as shown in figure.
• Also indicated in figure, the 1st and 2nd
ring are marked “D” with the letter “R” or
IMP311140045-01 “RN” which must face towards top of
piston.
Piston ring to piston
1) Install the oil ring.
4
• Apply engine oil to piston rings.
4
• Install spacer (1) first, then side rails (2) to piston.
1
3 3
IDG211140188-01
3) Position piston rings so gaps are staggered at

approximately 90 degree angles as shown.
2
I9J011140011-01
2) Apply engine oil to piston and cylinder walls.

“D” 3) Insert piston and conrod assembly (4) into cylinder
bore from cylinder head side using special tool.
“G” “H”
NOTE
Position the up mark “A” on piston head to
flywheel side “B”.
Special tool
(A): 09916–77310 (Piston ring compressor)
“F” “E”
IMP311140032-02
“D”: Up mark “G”: 2nd ring and oil ring spacer

“E”: 1st ring “H”: Oil ring upper side rail (A)
“F”: Oil ring lower side rail
Piston to cylinder
1) Install conrod bearing (1) to conrod (2) and cap (3).
NOTICE
• If the bearing is reinstalled into a position IDG211140144-01

If original bearings are not replaced, “B”

assemble each bearing to its original 4
position.
• If oil is present between the bearing’s
outside surface and conrod surface, the
bearing could heat up to very high
temperature, resulting in seizure. “A”
Be sure to thoroughly wipe off any trace of IMP311140033-02

oil that is present between the bearing’s “A”: Up mark “B”: Flywheel side
outside surface and conrod surface.
Crankshaft to cylinder
Install crankshaft main bearings (1) in cylinder and
crankcase.
Apply engine oil to bearings.
3 2
NOTICE
• If the bearing is reinstalled into a position
1
If original bearings are not replaced,
assemble each bearing to its original
IDG211140143-01 position.
• If oil is present between the bearing’s
outside surface and crank bearing holder
surface, the bearing could heat up to very
high temperature, resulting in seizure.
Be sure to thoroughly wipe off any trace of

oil that is present between the bearing’s
outside surface and crank bearing holder
surface.
NOTE Crankshaft
• Assemble main bearing half containing oil NOTE
groove/hole to cylinder block.
Assemble the main bearing half without oil • Replace the oil seal with new one.
groove to crankcase. • Install upper oil seal with its spring/lipped
• Align bearing tab “A” with notch in side facing inward.
cylinder and crankcase.
1) Apply engine oil to upper oil seal lip.
Install upper oil seal (1) to crankshaft.
2) Apply engine oil to crank pin and crankshaft main
1 1 journal and install crankshaft in cylinder.
NOTE
When installing crankshaft to cylinder, be
sure to fit tab of upper oil seal in groove of
cylinder.
IMP311140068-01
“A”
IDG211140149-01
“C” “B”
IMP311140069-02
“A”: Bearing tab “B”: Oil hole “C”: Oil groove
Thrust bearing
Apply engine oil to the thrust bearings and install them in
cylinder block overlapping both sides of the No.4 main
journal.
Oil grooves “A” on the thrust bearing must face towards
crank webs.
IMP311140058-01
3) Install conrod cap.

1
a) Apply molybdenum oil solution to crank pin and
conrod bearing.
b) Install dowel pins (2) and conrod cap (3) (with
bearing) to conrod with embossed mark on the
cap toward flywheel side.
“A”
IDG211140148-02
1. Thrust bearing “A”: Oil groove

NOTE c) Finally tighten bolts 60 degrees turn from the

Reassemble each conrod cap to its original point of step (b) using an angular torque gauge.
position. Tightening torque
Do not mix them in position. Conrod cap bolt (Final step): 60 degrees
NOTE
3 2 Purchase a commercially available angular
torque gauge for this step of tightening bolts.
60°
IDG211140151-03
A
B
IDG211140154-01
d) Pour approx. 2 ml of engine oil to each side

surface of the conrod big end for initial
3
lubrication.
Crankcase to cylinder
1) Clean mating surface of cylinder and crankcase.
Apply suzuki bond to mating surface of crankcase as
IDG211140152-02 shown.
3. Conrod cap “B”: Embossed mark (>)
NOTE
“A”: Flywheel side
Apply bond to mating surface only.
4) Apply engine oil to conrod bolts. Do not allow bond to contact surface of
Tighten conrod cap bolts in three steps as follows. bearing.
a) Lightly seat all conrod bolts at first, then tighten
bolts 12 Nm (1.2 kgf-m, 8.9 lbf-ft) of specified
1207B (100 g))
torque.
Tightening torque
Conrod cap bolt (1st step): 12 N·m (1.2 kgf-
m, 8.9 lbf-ft)
b) Tighten bolts 17 Nm (1.7 kgf-m, 13 lbf-ft) of
specified torque.
“A”
“A”
Tightening torque
Conrod cap bolt (2nd step): 17 N·m (1.7 kgf-
m, 13 lbf-ft)
IMP311140123-01
“A”: Apply bond “–” marked line.
IDG211140153-01
2) Install five dowel pins (1). NOTE

After tightening crankcase bolts, check to be
sure that crankshaft rotates smoothly when
1 turned by hand.
Cylinder head
Refer to “Cylinder Head Removal and Installation” (Page
1D-23).
Timing chain
Refer to “Timing Chain, Chain Tensioner and Camshaft
Sprockets Removal and Installation” (Page 1D-14).
IDG211140156-02
3) Install crankcase to cylinder. Oil pump

Apply engine oil to crankcase bolts. Refer to “Oil Pump Removal and Installation” in Section
Tighten crankcase bolts in three steps following the 1E (Page 1E-3).
order indicated below.
Power unit
NOTE
Refer to “Power Unit Removal and Installation” (Page
Tighten 10 mm thread diameter bolts first 1D-9).
(following the order shown in figure), then
tighten 8 mm thread diameter bolts. Cylinder, Piston and Piston Ring Inspection and
Tightening torque Servicing
CENNP3131406023
Crankcase (inside) bolt (10 mm thread diameter) NOTE
[1st step]: 11 N·m (1.1 kgf-m, 8.1 lbf-ft)
Crankcase (inside) bolt (10 mm thread diameter)
found on any component, replace
[2nd step]: 21 N·m (2.1 kgf-m, 15 lbf-ft)
component.
[Final step]: 52 N·m (5.3 kgf-m, 38 lbf-ft) Cylinder Distortion
Tightening torque Using a straightedge and thickness gauge, measure
Crankcase (outside) bolt (8 mm thread cylinder distortion (gasket surface) at a total of six
diameter): 25 N·m (2.5 kgf-m, 18 lbf-ft) locations as shown.
replace cylinder.
“17” “7” “8”
“18” Special tool
“4”
Cylinder distortion
“14”
“13”
“3”
“11” “12”
“1” “2”
“15”
“16”
“5”
“6”
“19” IMP311140047-01
“9” “10” “20”

IMP311140046-02
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
telescoping gauge for this measurement.
(A)
Check the following:

IDG211140159-01 • Difference between measurements at the two
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)
IMP311140048-02
Driven Gear / Bearing

• Inspect driven gear for wear or other damage.
Replace if necessary. IMP311140073-01
• Inspect driven gear bearing for pitting, rough or other

damage.
Replace if necessary. “a”
4 “b”
3
2
1
I9J011140060-01
“a”: 50 mm (1.97 in) “b”: 90 mm (3.54 in)
IMP311140121-01
1. Driven gear 3. O-ring

2. Plug 4. Circlip
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.
Piston to Cylinder Clearance Identification of Oversize Piston / Piston Ring

1) Measure the piston diameter at a point 26.5 mm One oversize piston/piston ring components, 0.50 mm is
(1.04 in) above the piston skirt at a right angle to the available. Oversize piston/piston ring are marked as
piston pin bore. shown, below.
Special tool Piston

(A): 09900–20204 (Micrometer (75 – 100 Oversize I.D. mark
mm)) 0.50 mm 50
Piston skirt diameter
Standard: 85.970 – 85.990 mm (3.3846 – 3.3854
in)
“A”
“a”
(A)
I9J011140061-02
“a”: 8.5 mm (0.33 in)
2) Measure the cylinder bore at 50 mm (1.97 in) below IMP311140049-01
the cylinder head gasket surface at a right angle to “A”: I.D. mark
the crankshaft pin.
1st and 2nd Piston ring
NOTE Oversize I.D. mark
Purchase a commercially available 0.50 mm 50
telescoping gauge (1) for this measurement.
1st, 2nd ring
Cylinder bore diameter
Standard: 86.000 – 86.020 mm (3.3858 – 3.3866 “B”
in)
50 mm I9J011140063-03
1 (1.97 in)
“B”: I.D. mark
Oil ring
Oversize I.D. mark
0.50 mm One white paint
IMP311140112-01 Oil ring spacer

3) Calculate the piston/cylinder clearance (Clearance
equals difference between piston diameter and
cylinder bore measurements).
If clearance exceeds service limit, replace piston
and/or cylinder or bore cylinder.
Piston to cylinder clearance
Standard: 0.020 – 0.040 mm (0.0008 – 0.0016 in) “C”
I9J011140064-02
“C”: I.D. mark
Piston Piston Ring

Visual inspection Piston ring end gap
Inspect piston for faults, cracks or other damage. Measure piston ring end gap with piston ring in the
Damaged or faulty piston(s) should be replaced. lowest position of cylinder bore.
If measurement exceeds service limit, replace piston
Piston ring to groove clearance ring.
Before checking, piston grooves must be clean, dry and
Special tool
free of carbon.
Fit piston ring into piston groove, and measure clearance
between ring and ring groove using thickness gauge. Piston ring end gap
If measurement exceeds service limit, replace piston Standard (1st): 0.20 – 0.35 mm (0.008 – 0.014 in)
and/or piston ring. Standard (2nd): 0.35 – 0.50 mm (0.014 – 0.020 in)
Service limit (1st): 0.70 mm (0.028 in)
Special tool
Service limit (2nd): 1.00 mm (0.039 in)
Piston ring to groove clearance (A)
Standard (1st): 0.030 – 0.070 mm (0.0012 – 0.0028 in)
Standard (2nd): 0.020 – 0.060 mm (0.0008 – 0.0024 in) 1
2
1
I9J011140066-02
1. Cylinder 2. Piston ring

(A)
Measure piston ring free end gap using vernier calipers.
If measurement exceeds service limit, replace piston
ring.
IMP311140050-01
1. Piston ring
Standard (1st): Approx. 11.6 mm (0.46 in)
Standard (2nd): Approx. 11.5 mm (0.45 in)
Piston ring groove width
Standard (1st): 1.22 – 1.24 mm (0.048 – 0.049 in)
Standard (2nd): 1.51 – 1.53 mm (0.059 – 0.060 in)
Standard (Oil): 2.51 – 2.53 mm (0.099 – 0.100 in)
Piston ring thickness
Standard (1st): 1.17 – 1.19 mm (0.046 – 0.047 in)
Standard (2nd): 1.47 – 1.49 mm (0.058 – 0.059 in)
IMP311140116-01
Piston Pin and Conrod Inspection

CENNP3131406024
Piston Pin
Visual inspection
• Check piston pin, conrod small end bore and piston
pin hole for wear or damage.
If badly worn or damaged, replace component.
• Apply engine oil on piston pin so that the piston pin
can move smoothly in the piston pin hole.
(B)
If improper condition is found, replace the piston pin
and/or piston. I9J011140069-02
Piston pin clearance

Check the piston pin clearance in the conrod small end.
(B)
Replace the conrod if its small end is badly worn or
damaged or if clearance exceeds service limit.
Measure the following item:
Special tool
(A): 09912–66310 (Micrometer (0 - 25 mm))
(B): 09900–20605 (Dial calipers (10 – 34 mm))
I9J011140070-02
Piston pin outside diameter

Standard: 20.997 – 21.000 mm (0.8267 – 0.8268 in) Conrod big end side clearance
Service limit: 20.980 (0.8260 in) Measure conrod big end side clearance with conrod
installed on crank pin as shown.
Piston pin hole diameter If measurement exceeds service limit, replace conrod
Standard: 21.006 – 21.014 mm (0.8270 – 0.8273 in) and/or crankshaft.
Service limit: 21.040 (0.8283 in)
Special tool
Conrod small end bore (A): 09900–20803 (Thickness gauge)
Standard: 21.003 – 21.013 mm (0.8269 – 0.8273 in)
Conrod big end side clearance
Pin clearance in piston pin hole Standard: 0.100 – 0.250 mm (0.0039 – 0.0098 in)
Standard: 0.006 – 0.017 mm (0.0002 – 0.0007 in) Service limit: 0.35 mm (0.0138 in)
Service limit: 0.040 (0.0016 in)
Conrod big end width
Pin clearance in conrod small end Standard: 21.950 – 22.000 mm (0.8642 – 0.8661 in)
Standard: 0.003 – 0.016 mm (0.0001 – 0.0006 in)
Service limit: 0.050 (0.0020 in) Crank pin width
Standard: 22.100 – 22.200 mm (0.870 – 0.8740 in)
(A)
(A)
I9J011140068-02
IDG211140164-01
Crank Pin and Conrod Bearing Inspection Conrod Big End Oil Clearance
CENNP3131406025 Check conrod big end oil clearance as follows:
Crank Pin Diameter
Inspect crank pin for uneven wear or damage. 1) Clean surface of conrod (1), conrod cap (2), conrod
Measure crank pin for out-of-round “a” – “b” or taper “c” – bearings and crank pin.
“d” with micrometer. 2) Install conrod bearing (3) onto conrod and conrod
If crank pin is damaged, out-of-round “a” – “b” or taper cap.
“c” – “d” is out of service limit, replace crankshaft.
NOTE
Special tool
(A): 09900–20202 (Micrometer (25 – 50 mm)) • Reassemble each bearing and conrod cap
to their original position.
Crank pin outside diameter • Do not apply oil to bearing.
Standard: 43.982 – 44.000 mm (1.7316 – 1.7323 in)
Out-of-round and taper
1
2
(A)
A ab
3
B IDG211140166-02
3) Place a piece of Plastigauge on crank pin parallel to

IDG211140165-01 crankshaft. Avoid placing Plastigauge over oil hole.
Conrod Bearing Visual Inspection Special tool

Inspect bearing shell for proper contact pattern and (A): 09900–22303 (Plastigauge (0.025 –
signs of fusion, pitting, burning or flaking. 0.076 mm))
Bearing shells found in defective condition must be
replaced.
(A)
I9J011140071-01
IMP311140059-01
4) Install conrod cap (with bearing) to conrod with the c) Finally tighten bolts 60 degrees turn from the
embossed mark (4) on cap toward flywheel side. point of step b) using an angular torque gauge.
Tightening torque
“A” Conrod cap bolt (Final step): 60 degrees
NOTE
Purchase a commercially available angular
torque gauge for this step of tightening bolts.
IMP311140060-01
60°
4. Embossed mark (>) “A”: Flywheel side
5) 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 12 Nm (1.2 kgf-m, 8.9 lbf-ft) of specified
torque. IDG211140170-02
Tightening torque NOTE

Conrod cap bolt (1st step): 12 N·m (1.2 kgf- Do not rotate conrod with Plastigauge in
m, 8.9 lbf-ft) place.
b) Tighten bolts 17 Nm (1.7 kgf-m, 13 lbf-ft) of
specified torque. 6) Remove conrod and conrod cap from crank pin.
7) Using scale (5) on Plastigauge envelope, measure
Tightening torque Plastigauge width at its widest point.
Conrod cap bolt (2nd step) (a): 17 N·m (1.7 If measurement exceeds service limit, replace
kgf-m, 13 lbf-ft) conrod bearing.
Conrod big end oil clearance
Standard: 0.032 – 0.050 mm (0.0013 – 0.0020 in)
(a)
IMP311140061-01
IMP311140062-01
5. Scale
Crankshaft Inspection Out-of-Round and Taper (Uneven Wear) of Journals

CENNP3131406026 An unevenly worn crankshaft journal shows up as a
Crankshaft Runout difference in diameter at a cross section or along its
Using a dial gauge, measure runout at center journal. length (or both).
If measurement exceeds service limit, replace This difference, if any, is determined by taking
crankshaft. micrometer readings.
Special tool If any journal is badly damaged or if measurements
(A): 09900–20607 (Dial gauge) exceed service limit, replace crankshaft.
(B): 09900–20701 (Magnetic stand) Special tool
Crankshaft runout (A): 09900–20203 (Micrometer (50 – 75 mm))
Service limit: 0.04 mm (0.002 in) Out-of-round and taper
(A) Out-of-round: A – B
Taper: a – b
Crankshaft journal outside diameter
Standard: 57.994 – 58.012 mm (2.2832 – 2.2839 in)
IDG211140173-02
Crankshaft Thrust Play

1) Measure thrust play with crankshaft, thrust bearing, ab
A
journal bearing and crankcase/cylinder block
assembled in a normal manner. B
Tighten crankcase bolts to specified torque.
IDG211140175-01
Tightening torque
Crankcase (inside) bolt (10 mm): 52 N·m (5.3
kgf-m, 38 lbf-ft)
Crankcase (outside) bolt (8 mm): 25 N·m (2.5
kgf-m, 18 lbf-ft)
2) Use a dial gauge to read displacement in axial
(thrust) direction of crankshaft.
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)
IDG211140174-01
Crankshaft Main Bearing Inspection

CENNP3131406027
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. 1 1
Always replace both bearing halves, never replace only
one half of a bearing set.
IMP311140070-01
“A”
I9J011140073-01
Crankshaft Journal Oil Clearance

Check clearance using Plastigauge according to the “C” “B”
following procedure.
NOTE IMP311140069-02
“A”: Bearing tab “B”: Oil hole “C”: Oil groove

Assemble each bearing in its original
position before checking clearance.
3) Install crankshaft to cylinder.
1) Clean surface of bearing holder (crankcase, and 4) Place a piece of Plastigauge across full width of
cylinder), bearing, and main bearing journal. bearing (parallel to crankshaft) on journal.
2) Install main bearing (1) to cylinder and crankcase. Do not place Plastigauge over oil hole.
Special tool
NOTE
(A): 09900–22303 (Plastigauge (0.025 –
• Align tab “A” of bearing with notch in 0.076 mm))
cylinder and crankcase.
NOTE
• Do not apply engine oil to bearing.
Do not rotate crankshaft while Plastigauge is
• Install main bearing half with oil hole/
installed.
groove towards cylinder side.
(A)
IDG211140178-01
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
NOTE Standard: 0.020 – 0.040 mm (0.0008 – 0.0016 in)
Tighten 10 mm thread diameter bolts first
(following the order shown in figure), then
tighten 8 mm thread diameter bolts. 2
Tightening torque
[1st step]: 11 N·m (1.1 kgf-m, 8.1 lbf-ft)
[2nd step]: 21 N·m (2.1 kgf-m, 15 lbf-ft)
[Final step]: 52 N·m (5.3 kgf-m, 38 lbf-ft)
Tightening torque
IDG211140180-01
Crankcase (outside) bolt (8 mm thread
diameter): 25 N·m (2.5 kgf-m, 18 lbf-ft) 2. Scale
NOTE 9) If measurement exceeds service limit, replace

Crankcase must be torqued to specification crankshaft main bearing.
in order to assure proper compression of
NOTE
Plastigauge and accurate reading of
clearance. For bearing replacement, see the “Selection
of Main Bearings” (Page 1D-49).
“19” “5” “15” “1” “11” “3” “13” “17” Selection of Main Bearings
Whenever a bearing requires replacement, select a new
“9” “7”
bearing according to following procedure.
1) First, check journal diameter.
As shown in figure, upper (flywheel side) crank web
of No.2 cylinder has five stamped code numerals.
“10” “8” The numerals (1, 2 and 3) represent the journal
diameters shown below.
“4” “18” Numeral stamped Journal diameter
“20” “6” “16” “2” “12” “14” 58.0061 – 58.0120 mm
IMP311140051-03 1
(2.28370 – 2.28393 in)
58.0001 – 58.0060 mm
2
(2.28346 – 2.28370 in)
57.9940 – 58.0000 mm
3
(2.28322 – 2.28346 in)
“E”
“D”
“C”
“B”
“A”
IMP311140052-01
“A”: No.1 journal code “D”: No.4 journal code

“B”: No.2 journal code “E”: No.5 journal code
“C”: No.3 journal code
2) Next, check bearing holder inside diameter without

bearing.
As shown in figure, the cylinder block PORT side has
five stamped code letters.
The letters (A, B and C) represent the bearing holder
inside diameters shown below.
Crank bearing holder inside
Code
diameter (w/o bearing)
62.0000 – 62.0060 mm “L”
A
(2.44094 – 2.44118 in) IMP311140122-01
62.0061 – 62.0120 mm “L”: Color mark
B
(2.44118 – 2.44141 in)
62.0121 – 62.0180 mm 4) Select crankshaft main bearing referring to the below
C
(2.44142 – 2.44165 in) table.
For example, If number stamped on crank web is “1”
and alphabet stamped on cylinder block is “B”, install
“J” a new bearing painted in “Black” to it’s journal.
“I”
“H” Numeral stamped on crank
“G”
“F” web (journal outside diameter)
1 2 3
Code A Green Black No color
stamped B Black No color Yellow
on
cylinder
block
(Bearing C No color Yellow Blue
holder
“K” inside
IDG211140182-01
diameter)
“F”: No.1 holder code “I”: No.4 holder code
“G”: No.2 holder code “J”: No.5 holder code NOTE
“H”: No.3 holder code “K”: Flywheel side
Measure crankshaft journal oil clearance
3) There are five main bearings available, each of again after installing new bearing selected.
differing thickness. Refer to “Crankshaft Journal Oil Clearance”
To distinguish them, a color mark is painted at the (Page 1D-48).
position indicated in figure.
Each color represents the following thickness Crankshaft Drive Gear Inspection
measured at the center of the bearing. CENNP3131406028
Color mark Bearing thickness Inspect drive gear. Replace crankshaft if the drive gear is
1.990 – 1.994 mm damaged or worn.
Green
(0.0783 – 0.0785 in)
1.993 – 1.997 mm
Black
(0.0785 – 0.0786 in)
1.996 – 2.000 mm
No color mark
(0.0786 – 0.0787 in)
1.999 – 2.003 mm
Yellow
(0.0787 – 0.0789 in)
2.002 – 2.006 mm
Blue
(0.0788 – 0.0790 in)
IDG211140183-01
1E-1 Power Unit Lubrication:
Power Unit Lubrication

Power Head
General Description
Engine Lubrication Description
CENNP3131501001
A camshaft driven trochoid type pump provides engine oil to all power unit components requiring lubrication.
Oil from the oil pan is drawn through the oil strainer and passed through a spin-on type oil filter before entering the
main oil gallery.
A pressure regulator (relief valve) is positioned between the oil pump and oil filter to maintain oil pressure at a constant
level.
From the main gallery, oil flow is directed through either drilled internal passages or by splash method to those
surfaces requiring lubrication.
Schematic and Routing Diagram

Engine Oil Lubrication Chart
CENNP3131502001
OIL PRESSURE
No.1 No.1
No.1 JOURNAL No.1 JOURNAL SWITCH
CAM FACE CAM FACE
No.1
No.2 No.2 CRANK JOURNAL
No.2 JOURNAL No.2 JOURNAL
CAM FACE CAM FACE
No.1 CRANK PIN No.1 PISTON

No.3 No.3
CAM FACE CAM FACE
No.2
CRANK JOURNAL
No.4 No.4
CAM FACE CAM FACE
No.5 JOURNAL No.5 JOURNAL No.3

CRANK JOURNAL
CHAIN TENSIONER
CAMSHAFT LOWER HOUSING No.4

CRANK JOURNAL
CYLINDER HEAD No.4 CRANK PIN No.4 PISTON
No.5
OIL FILTER
CRANK JOURNAL
OIL RELIEF
OIL PUMP
VALVE
OIL STRAINER
OIL PAN
IDG211150001-04
Power Unit Lubrication: 1E-2

Oil Pressure Check
CENNP3131504001
Refer to “Oil Pressure Check” in Section 0B (Page 0B-20).
Oil Change Reminder System

CENNP3131504002
Refer to “Oil Change Reminder System Description” in Section 1A (Page 1A-15).
Low Oil Pressure Caution System

CENNP3131504003
Refer to “Caution System Description” in Section 1A (Page 1A-6).
Powerhead Lubrication System Diagnosis

CENNP3131504004

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
Removal
• Assemble washer (1), pin (2), driven sprocket (3) and
Refer to “Power Unit Removal and Installation” in
circlip (4) to oil pump shaft.
Section 1D (Page 1D-9).
NOTE
Hold camshaft by placing a wrench on
IGG211150001-02
• Install oil pump (5) to cylinder head block, then tighten

three bolts to the specified torque.
Tightening torque
Oil pump bolt (a): 11 N·m (1.1 kgf-m, 8.1 lbf-ft)
IDG211150002-01
1. Oil pump drive sprocket

(a)
2) Remove bolt securing oil pump drive sprocket to

camshaft, then remove oil pump drive sprocket.
5
3) Remove three bolts and oil pump assembly (1).
IMP311150007-01
• Install oil pump drive sprocket (6) and tighten bolt to

1 the specified torque.
Tightening torque
Oil pump drive sprocket bolt (b): 78 N·m (8.0 kgf-
m, 58 lbf-ft)
IDG211150003-01
4) Remove circlip (2), driven sprocket (3), pin (4) and

washer.
6
(b)
4
2
IMP311150008-01
IDG211150014-01
Inspection Oil Pump Component Parts Oil Pressure Switch Removal and Installation
CENNP3131506002 CENNP3131506003
Oil Pump Removal
1) Remove ring gear cover.
NOTICE
Disassembling the oil pump can lead to in Section 1D (Page 1D-2).
troubles.
2) Loosen screw (1) and disconnect blue lead wire (2)
from oil pressure switch (3).
The oil pump is a nonrepairable component.
Do not attempt to disassemble the oil pump.
It must be replaced as a complete unit if it is
defective.
3
Inspect outer/inner rotors and oil pump body for wear or
other damage. Replace if necessary.
Drive / Driven Sprocket

Inspect teeth of sprocket for wear or other damage.
INP313150001-01
3 1
IMP311150002-01
INP313150002-02
3) Remove oil pressure switch from cylinder block.
Installation
• Before installing oil pressure switch, wrap screw
threads with sealing tape (1), then tighten switch to
specified torque.
NOTE
Cut off any excess sealing tape from switch
threads before installation.
Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.6 lbf-
ft)
1
I9J011150002-01
NOTE
(a)
• You should remove oil pressure switch
lead when perform the oil pressure switch
inspection.
Then diagnostic code of oil pressure
switch will be displayed while performing
the inspection.
Connect the oil pressure switch lead wire
to engine body ground by using an
appropriate jumper wire before the engine
starts (turning on the main switch).
INP313150003-01 So that the diagnostic code won’t be
• Start engine and check oil pressure switch for oil displayed.
leakage. After the engine starts, disconnect the
Reseal switch if oil leakage is found. jumper wire from switch lead wire.
• Cover the oil pressure switch with the cap. • For cancellation of the “self-diagnostic
indication”, refer to “Self-Diagnostic
Oil Pressure Switch Inspection System Description” in Section 1A (Page
CENNP3131506004 1A-9).
NOTE
Before checking the oil pressure switch, 3) After the engine starts, disconnect the jumper wire
make sure the engine oil pressure is within from switch lead wire.
specification. 4) Check the continuity between the switch terminal
and engine body ground.
1) Loosen screw (1) and disconnect blue lead wire (2)
from oil pressure switch (3). Special tool
3 1 Continuity ( )
Oil pressure switch continuity
2
Engine running: Infinity
Engine stopped: Continuity
INP313150002-02
2) Connect the oil pressure switch lead wire to engine

body ground by using an appropriate jumper wire.
I9J011150003-01
5) If measurement exceeds specification, replace oil

pressure switch.
6) After testing oil pressure switch, reinstall parts
removed earlier.
IDG211150018-01
Oil Strainer Removal and Installation Oil Strainer Related Parts Inspection
CENNP3131506005 CENNP3131506006
Removal • Inspect oil strainer. Replace strainer if cracked,
Refer to “Engine Holder / Oil Pan / Driveshaft Housing / damaged or other abnormal conditions.
Mounts Disassembly” in Section 2A (Page 2A-6). If clog or obstruction, clean oil strainer.
• Check condition of O-rings. Replace O-ring if nicked,
Installation
cut, worn or other abnormal condition.
Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Assembly” in Section 2A (Page 2A-8).
IDG211150013-02
1F-1 Power Unit Cooling System:
Power Unit Cooling System

Power Head
General Description
Water Cooling System Description
CENNP3131601001
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 head.
Engine 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

CENNP3131601002
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

CENNP3131601003
If cylinder water pressure is high when thermostat is closed, the valve will open to relieve the pressure.
1 2
IMP311160001-01
1. Water pressure valve cover 2. Water pressure valve

Power Unit Cooling System: 1F-2

Cooling Water Circulation Chart
CENNP3131602001
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.
RETURN HOSE
When open
THERMOSTAT
CYLINDER CYLINDER HEAD
FUEL
VAPOR
SEPARATOR EXHAUST
WATER JACKET
ENGINE HOLDER
PILOT
ENGINE HOLDER
WATER HOLE
OIL PAN OIL PAN

WATER
PRESSURE
DRIVESHAFT VALVE
WATER TUBE
HOUSING
WATER PUMP
PROPELLER WATER INTAKE

EXHAUST OUTLET
WATER
IMP311160002-01

Powerhead Cooling System Diagnosis
CENNP3131604001

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 Installation
Removal
1) Remove the three bolts (1) securing the thermostat
• Assemble thermostat (1) and thermostat cover (2) to
cover (2), then remove the cover.
water outlet pipe (3) and tighten bolts (4) to specified
2) Remove the thermostat (3). torque.
Tightening torque
Thermostat cover bolt (a): 10 N·m (1.0 kgf-m, 7.4
lbf-ft)
1 3
2
4 (a) 3
1
IMP311160003-01
IMP311160004-01

place.
Power Unit Cooling System: 1F-4
Thermostat Inspection Water Pressure Valve Removal and Installation

CENNP3131606002 CENNP3131606003
Inspect the thermostat in the following procedures: Removal
1) Remove the thermostat. 1) Remove the side cover.
Refer to “Thermostat Removal and Installation” Refer to “Side Cover Removal and Installation” in
(Page 1F-3). Section 2A (Page 2A-3).
2) Inspect the thermostat. 2) Remove the two bolts (1), water pressure valve
If salt deposits, corrosion, wear or other damage is cover (2) and water pressure valve (3).
found, clean or replace.
IDG211160005-01
IDG211160004-01
3) Check thermostat opening temperature as follows:

a) Insert a length of thread between thermostat
valve/body and suspend thermostat in a 3
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: 58 – 62 °C (136.4 – 143.6 °F)
IMP311160006-01
IMP311160005-01
1. Thermometer 3. Thermostat
2. Heater
If thermostat valve does not open as specified

above, or sticks in any position, replace it.
Installation Water Pressure Valve Related Item Inspection

CENNP3131606004
1) Install O-ring (1) to water pressure valve cover (2). Inspect the water pressure valve in the following
procedures:
1) Remove the water pressure valve.
Refer to “Water Pressure Valve Removal and
2
Installation” (Page 1F-4).
1 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.
IDG211160009-01
2) Install water pressure valve (3) and water pressure

valve cover (2) to oil pan and secure with bolts (4).
3 2
IMP311160008-01
3) Install the water pressure valve.

Refer to “Water Pressure Valve Removal and
Installation” (Page 1F-4).
IMP311160007-01
Water Pump Removal and Installation
CENNP3131606005
3) Install the side cover. Refer to “Water Pump Removal and Installation” in
Refer to “Side Cover Removal and Installation” in Section 3A (Page 3A-7).
Water Pump Related Item Inspection
CENNP3131606006
Refer to “Water Pump and Related Item Inspection” in
Water Tube Removal and Installation

CENNP3131606007
Removal
Mounts Disassembly” in Section 2A (Page 2A-6).
Installation
Mounts Assembly” in Section 2A (Page 2A-8).
Water Tube Related Item Inspection

CENNP3131606008
Mounts Related Component Inspection” in Section 2A
(Page 2A-13).
Fuel System: 1G-1
Fuel System
Power Head
Precautions
Precautions on Fuel System Service
CENNP3131700001
! 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
CENNP3131701001
The fuel injection system 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 30° BTDC on the exhaust 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
Cylinder temperature sensor: speed.
Informs ECM of cylinder temperature.
Exhaust manifold temperature sensor:
Informs ECM of exhaust manifold temperature.
Fuel amount compensation
IAT sensor:
Informs ECM of intake air temperature.
TPS (Throttle position sensor):
Multi-point sequential timing
Informs ECM of throttle opening angle.
Battery voltage:
Constantly monitored by the ECM.
O2 sensor:
Informs ECM of oxygen concentration in exhaust gas. Signal Signal Signal Signal
Others
CMP sensor:
Informs ECM of camshaft angle. Fuel injector
Neutral switch:
Informs ECM of shift position (neutral or in-gear).
9
1 CPU “A”
2 7 A A A A
4
3 6
5
IMP311170024-02
1. Battery charge coil 6. Ignition switch

2. Rectifier/regulator 7. ECM main relay
3. 60 A fuse 8. Fuel injector
4. 30 A fuse 9. ECM
5. Battery “A”: Sensor/switch signal input
Fuel System: 1G-3
Fuel Injection Timing Chart

CKP sensor
signal
140° 220° 40° 40°

180° 100° 140°
CMP sensor
signal
CMP sensor - 6 signals / 720° (crankshaft 2 rotation)
TDC TDC TDC
TDC TDC
TDC TDC TDC
TDC TDC
Injection time duration Injection end timing: 30° BTDC on Ex.stroke
No.1 Injection
signal
No.3 Injection
signal
No.4 Injection
signal
No.2 Injection
signal
Cm.: Compression, Ep.: Explosion, Ex.: Exhaust, In.: Intake,
IMP311170052-01
Fuel Injection Control Mode

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. (The operation is called
“lean burn control”.)
When accelerating:
The fuel injection amount is controlled to increase.
When decelerating:
The fuel injection amount is controlled to decrease.
The fuel injection is also cut off on very rapid engine deceleration.
1G-4 Fuel System:
Fuel Delivery System Components Description

CENNP3131701002
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, fuel pressure regulator (located in the fuel vapor separator), delivery pipe, fuel
injectors 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 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. 295 kPa (3.01 kgf/
cm2, 42.8 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
5
1
4
8
9 6
7
“A”
15 11
10
14
3
12
13
INP313170002-01
1. Fuel tank 5. Fuel vapor separator 9. Evaporation hose 13. Throttle body
2. Primer bulb 6. Float 10. Fuel delivery pipe 14. Intake manifold
3. Low pressure fuel filter 7. High pressure fuel pump 11. Fuel injector 15. Fuel cooler
4. Low pressure fuel pump 8. Fuel pressure regulator 12. Intake silencer “A”: To atmosphere
Fuel System: 1G-5
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 to the 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 the ECM.
“B”
“A”
“C” “C”
7
1
4
“D”
“E”
“F”
IMP311170002-03
1. High pressure fuel pump 5. Float chamber “B”: Fuel outlet “F”: Fuel drain
2. Suction filter 6. Fuel pressure regulator “C”: Fuel vapor
3. Needle valve 7. Fuel outlet filter “D”: Cooling water inlet
4. Float “A”: Fuel inlet “E”: Cooling water outlet
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 constant fuel pressure to the injectors 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. 295 kPa (3.01 kgf/cm2, 42.8 psi.).
By-pass fuel is returned to the fuel vapor separator chamber.
VALVE CLOSED VALVE OPENED

(below 295 kPa) (over 295 kPa)
1 1
2 2
“A” “A”
3 “C”
“B”
IDG211170020-02
1. Fuel pressure regulator 3. Float chamber “B”: To float chamber

2. Air passage “A”: From high pressure fuel pump “C”: By-pass fuel
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 electromagnetic valve is open.
IMP311170004-01
1. Fuel injector
Fuel System: 1G-7
High Pressure Fuel Pump Control System Description

CENNP3131701003
To supply the optimum fuel amount, the ECM controls the fuel pump drive duty cycle, a repeated “ON”/“OFF” signal, at
a specified rate (1000 times a second).
Based on engine speed and battery voltage, the ECM determines the optimum duty cycle (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. Fuel pump
Cylinder temp. sensor:

IDG211170021-01
7 1
2
4
8
5
6 “A”
6 FP
9
3
IMP311170025-02
1. ECM 6. 60 A fuse
2. CPU 7. Battery charge coil
3. High pressure fuel pump 8. Rectifier/Regulator
4. ECM main relay 9. Ignition switch
5. 30 A fuse “A”: Sensor/switch signal input
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)
I9J011170008-01
Control Modes
Before start:
For 3 seconds after the ignition switch is turned “ON”, the fuel pump is controlled to operate at a 100% duty cycle to
initially pressurize the high pressure fuel line.
1G-8 Fuel System:
When cranking:
The fuel pump is controlled to operate at a 50 – 100% duty cycle.
The duty cycle changes depending on cylinder temperature.
When running (normal operation):

The fuel pump is controlled to operate at a 50 – 100% duty cycle based on the current engine speed and battery
voltage.
Air Intake Components Description

CENNP3131701004
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.
3
“A”
1
6 4
5
INP313170003-01
1. Throttle body 3. IAC valve 5. MAP sensor 7. Air intake silencer

2. Intake manifold 4. Throttle position sensor 6. IAT sensor “A”: Air-flow
Throttle Body
• The throttle body consists of the main bore, throttle
valve and TPS (Throttle position sensor). 2
• The throttle body adjusts the intake air amount with
the throttle valve which is connected to the throttle
lever linkage. 1
NOTE
Do not try to adjust or remove any of the
throttle body component parts (throttle
position sensor, throttle valve, throttle stop
screw, etc.). INP313170004-01
These components have been factory 1. Throttle body 2. TPS

adjusted to precise specifications.
Fuel System: 1G-9
Idle Air Control System Description

CENNP3131701007
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
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
1G-10 Fuel System:
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. 10% 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-12).
Water in Fuel Alert System Description

CENNP3131701006
Refer to “Water in Fuel Alert System Description” in Section 1A (Page 1A-15).

Fuel Pressure Inspection 1) Relieve fuel pressure in fuel feed line.
CENNP3131704001 Refer to “Fuel Pressure Relief Procedure” (Page 1G-
! WARNING 14).
Gasoline is a flammable material that can 2) Loosen the clamp and place a large cloth over the
cause fire hazard or burns. end of fuel feed hose (1).
Disconnect the high pressure fuel feed hose (1) from
Before starting the following procedure, be the fuel delivery pipe union (2).
sure to observe “Precautions on Fuel System
Service” (Page 1G-1) in order to reduce the
risk or fire and personal injury. 1
INP311170002-02
Fuel System: 1G-11
3) Connect special tools (pressure gauge, pressure 8) Check for any signs of fuel leakage.
hose and pressure joint) between fuel feed hose (1) 9) Measure fuel pressure at cranking or idle speed
and fuel delivery pipe union (2) as shown in the operation.
figure.
Clamp the hose securely to ensure that no leaks Fuel pressure
occur during checking. Standard: Approx. 295 kPa (3.01 kgf/cm2, 42.8
psi.)
! WARNING 10) Stop engine and wait 5 minutes.
Gasoline is a flammable material that can Check the residual fuel pressure in line.
cause fire hazard or burns. Residual fuel pressure
Standard: 200 kPa (2.04 kgf/cm2, 29.0 psi.) or
A small amount of fuel may be released when more
the fuel feed hose is disconnected.
Place container under the fuel feed hose or ! WARNING
fuel delivery pipe with a shop cloth so that
the released fuel is caught in the container or Gasoline is a flammable material that can
absorbed by the cloth. Place the fuel soaked cause fire hazard or burns.
cloth in an approved container.
The fuel feed line is under high fuel pressure,
make sure to release fuel pressure according
Special tool
to the fuel pressure relief procedures
(A): 09912–58442 (Fuel pressure gauge)
mentioned earlier.
(B): 09912–58432 (Fuel pressure hose)
Use the following procedures to remove the
(C): 09912–58490 (3-way joint & hose)
fuel pressure gauge.
(A) • Place a container under the joint to catch
the fuel.
• Cover the joint with rag and loosen joint
(C) (B)
nut slowly to gradually release any
residual fuel pressure.
11) After checking fuel pressure, remove fuel pressure

gauge.
1
2
INP311170001-01
4) Ensure the emergency stop switch lock plate is in

place.
Shift into “Neutral” position.
5) Squeeze fuel primer bulb until you feel resistance.
6) Turn ignition switch “ON” for 3 seconds (to operate
the fuel pump), then turn it “OFF”. 4
7) Repeat this (“ON” and “OFF”) procedure 3 or 4 times
to pressurize the fuel system and then check the fuel
IDG211170067-02
pressure.
4. Joint nut
12) Reconnect fuel line.

OFF 13) With the engine not running and ignition switch “ON”,
ONON
OFF
check the fuel system for leaks.
START
INP312170003-01
1G-12 Fuel System:
Fuel System Diagnosis

CENNP3131704002

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 Neutral switch failure Replace.
hard to start. Shift position sensor failure Replace.
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 Neutral switch failure Replace.
engine tends to stall. Shift position sensor failure Replace.
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-13
Fuel Injection System Troubleshooting Step 4

CENNP3131704003
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/Y” wire terminal of the fuel injector
Check fuel injector operating sound. connector and body ground.
• Check each injector for operating sound at engine
Is resistance infinity?
cranking. ((Page 1G-21))
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/Y” 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 off, disconnect connectors from • Measure voltage between each “O/B”, “B/Br”, “R/
fuel injectors. W”, “Lg/Y” wire terminal of fuel injector connector
• Check for proper connection to fuel injector at each and body ground with ignition switch turned “ON”.
terminal.
Is voltage 0 V?
• If good condition, check all fuel injector for
resistance. ((Page 1G-21)) Yes Go to step 6.
Are all injectors in good condition? No “O/B”, “B/Br”, “R/W”, and/or “Lg/Y” 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”, “45”, “39” terminal of ECM and body
ignition switch turned “ON”. ground. ((Page 1G-23))
Is voltage 10 – 14 V? Is voltage 40 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/Y” wire(s)
power source and ground circuit. are open circuit.
1G-14 Fuel System:
Fuel Pressure Relief Procedure Fuel Line Removal and Installation
CENNP3131706001 CENNP3131706002
After making sure that engine is cold, relieve fuel Pay special attention to the following points when
pressure as follows: removing or installing fuel hoses.
! WARNING
2) Disconnect high pressure fuel pump sub harness
connector (1). Gasoline is a flammable material that can
3) Remove fuel hose guard (2). cause fire hazard or burns.
in Section 1D (Page 1D-2). Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” (Page 1G-1) in order to reduce the
risk or fire and personal injury.
• The fuel feed line is under high pressure, use special

1
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.
– Check fuel hose routing.
2 Refer to “Fuel Hose Routing” in Section 4B (Page
INP313170001-01 4B-1).
4) Disconnect four ignition coil connectors (3). – Check for fuel leakage.
Refer to “Fuel Leakage Check Procedure” (Page
1G-14).
Fuel Line Inspection

CENNP3131706003
Visually inspect fuel lines for evidence of fuel leakage,
3 cracking, deterioration, or damage. Make sure all clamps
are secure. Replace parts as needed.
Fuel Leakage Check Procedure

CENNP3131706004
After performing any fuel system service, always be sure
INP313170005-01 there is no fuel leakage by checking as follows.
5) Crank the engine 5 – 10 times (3 seconds each time) 1) Squeeze fuel primer bulb until you feel resistance.
to dissipate the fuel pressure in lines.
2) Shift into “Neutral” position.
6) Make sure fuel pressure has been relieved by
3) Ensure emergency stop switch lock plate is in place.
pinching the high pressure fuel hose (4) between
finger tips (the line should feel soft, without 4) Turn ignition switch “ON” for 3 seconds (to operate
pressure). fuel pump), then turn it “OFF”.
Repeat this (“ON” and “OFF”) procedure 3 or 4 times
to pressurize the fuel system.
4 5) Once pressurized, check all connections and
components for any signs of leakage.
OFF
ONON
OFF
START
INP313170006-01
7) Upon completion of servicing, connect ignition coil INP312170003-01
connectors and high pressure fuel pump sub

harness connector.
Fuel System: 1G-15
Inspection of Fuel Hose Connections High Pressure Fuel Pump Operating Sound
CENNP3131706005
Note that the fuel hose connection varies with each type
Inspection
CENNP3131706006
of pipe. Be sure to connect and clamp each hose 1) Install the emergency stop switch lock plate into
correctly by referring to the figure. position.
• For type “A” (short barbed end) pipe, the hose must 2) Shift into “Neutral”.
completely cover pipe.
3) Turn ignition switch “ON” and check for fuel pump
Type “A”
operating sound.
1
2 NOTE
Fuel pump operating sound is low because
the pump is inside the fuel vapor separator. If
you cannot hear the pump sound clearly, use
a sound scope or long blade screw driver.
“a” 3
Fuel pump operating sound
I9J011170012-01 Sounds for approx. 3 seconds only
1. Clamp (Clip) 3. Joint pipe (each time the ignition switch is turned to the
2. Hose “a”: 3 – 7 mm (0.1 – 0.3 in) “ON” position)
• For type “B” (bent end) pipe, hose must cover the
straight part of pipe by 20 – 30 mm (0.8 – 1.2 in).
Type “B”
“b”
“a”
I9J011170013-01
INP313170007-01
“a”: 3 – 7 mm (0.1 – 0.3 in) “b”: 20 – 30 mm (0.8 – 1.2 in) 4) If no pump operating sound is heard:
a) Turn ignition switch to the “OFF” position, check
• For type “C” pipe, hose must fit up against the flanged
for contact failure in the lead wire connector.
part of pipe.
Type “C” b) Check that the drive voltage is outputting from
the ECM and no abnormal conditions exist in the
engine wiring harness.
c) If inspection in steps “a” and “b” are OK, replace
the high pressure fuel pump.
“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-16 Fuel System:
Fuel Vapor Separator Removal and Installation

CENNP3131706007
Removal
7 6
2) Remove intake manifold.
Refer to “Intake Manifold Removal and Installation”
3) Detach drain hose (1) and evaporation hose (2).
IMP311170032-01
1 7) Disconnect high pressure fuel pump sub harness

(8).
8
2
IMP311170029-01
4) Unfasten cable clamp binding lead wire.

Disconnect lead wire connector (3).
IMP311170033-01
3 3
8) Disconnect fuel inlet hose (9), fuel outlet hose (10),
drain hose (1) and evaporation hose (2) from fuel
vapor separator.
10
9
2
INP313170008-01 1
5) Detach evaporation hose.
Remove three bolts (4) and fuel vapor separator (5).
IMP311170034-02
4
Installation
5
4 attention to the following points.
• Install the fuel vapor separator, then tighten the bolts
securely.
4 place.
INP313170009-01
• Check hose and wire routing.
6) Disconnect water inlet hose (6) and water outlet Refer to “Fuel Hose Routing” in Section 4B (Page 4B-
hose (7). 1) and “Water Hose Routing” in Section 4B (Page 4B-
5).
• Check for fuel leakage.
Refer to “Fuel Leakage Check Procedure” (Page 1G-
14).
Fuel System: 1G-17
Fuel Vapor Separator Disassembly and 4) Disconnect the high pressure fuel pump lead wire
Assembly connector.
CENNP3131706008
Disassembly
1) Remove five screws (1).
Remove the separator cover (2) with the high
pressure fuel pump from separator case (3).
1 2
IMP311170010-01
5) Remove the high pressure fuel pump (10), bush (11),

joint (12) and bush (13) from the separator cover.
3
6) Remove the fuel outlet filter (14) from separator
cover.
IMP311170007-02
2) Remove the spacer (4) and suction filter (5).
4 13
12
5
11
14 10
IMP311170011-01
7) Remove the screw (15) and valve seat (16).

IMP311170008-01
3) Remove the screw (6) and float pin (7).

Remove the float (8) and needle valve (9).
15
16
6
IMP311170012-01
IMP311170009-01
9 8
7
IDG211170036-02
1G-18 Fuel System:
8) Remove the fuel pressure regulator assembly (17) 2) Install the fuel pressure regulator assembly (6) to
from separator cover. separator cover.
Remove in sequence the large O-ring (18), holder
(19), O-ring (20) and washer (21).
17 IMP311170016-01
IMP311170013-01 High pressure fuel pump

Connect the pump lead wire connector, then install the
filter (1), bush (2), joint (3), bush (4) and high pressure
fuel pump (5).
20
21 NOTE
Apply fuel to the joint and bush before
19 installing.
18
2
IMP311170014-01 3
4
Assembly
1
Assembly is in the reverse order of disassembly with 5
special attention to the following steps.
Fuel pressure regulator

1) Assemble the fuel pressure regulator in the following
IMP311170017-01
sequence:
O-ring (1), holder (2), fuel pressure regulator (3),
washer (4) and O-ring (5).
NOTE
Apply fuel to the O-rings before installing.
5
4
3
IMP311170010-01
2
IMP311170015-01
Fuel System: 1G-19
Float / Float pin Setting float height

• Install the valve seat (1), then tighten screw (2) To correct specification, bend only adjustment tab (1).
securely.
NOTE
• Install the needle valve (3), float (4) and float pin (5),
When adjusting the tab, do not bend to the
then tighten screw (6) securely.
point that it applies pressure to the needle
and seat.
4
2
3
6
1
1 5
IMP311170018-01
NOTE
IMP311170020-01
After assembling, check for smooth and free
float movement. Separator cover / Separator case
1) Install the seal ring (1) and then apply Suzuki Bond
evenly to only the outside mating surface of the
separator case as shown in the figure.
1207B (100 g))
NOTE
• Clean mating surfaces before applying
bond.
• Do not apply bond to seal ring, groove or
inside mating surface.
IMP311170019-01
Checking float height

Measure the float height.
Float height “a”
Standard: 47 ± 3.0 mm (1.85 ± 0.12 in)
1
1
“A”
“a”
IDG211170049-02
1. Seal ring “A”: Outside
IAJ611170037-01
1G-20 Fuel System:
2) Install the suction filter (2), spacer (3) and separator Inspection of Fuel Vapor Separator Component
case (4) and then tighten the screws securely. Parts
CENNP3131706009
NOTE
3
2
found on any component, replace the
component.
Needle Valve / Valve Seat

Inspect the needle valve and valve seat for grooves,
other damage or dirt.
Replace or clean if necessary.
IMP311170021-01
IAJ611170044-01
Float
IMP311170022-01 Inspect the float for cracks or other damage.
Final assembly check
place.
IDG211170052-01
Filter
Check fuel suction filter and fuel outlet filter for evidence
of dirt and contamination.
If present, replace or clean and check for presence of
dirt in fuel tank.
IDG211170053-01
Fuel System: 1G-21
Separator Cover and Case Fuel Injector Inspection with Injector in Place
Inspect the separator cover and case. CENNP3131706010
Replace if cracked, damaged or other abnormal 1) Using a sound scope or equivalent, check the
conditions. operating sound of the fuel injector when the engine
is running or cranking.
Injector operating sound cycle should vary according
to engine speed.
If no sound or an unusual sound is heard, check
injector circuit (wire or connector) or injector.
“C l i c k ”
IMP311170023-01
Fuel Pressure Regulator

Inspect the fuel pressure regulator for damage or
corrosion.
Replace if cracked, damaged or other abnormal INP313170010-01
conditions. 1. Injector body
2) Disconnect the lead wire connector from the fuel

injector.
3) Connect a digital tester between the terminals of the
injector and measure resistance.
If out of specification, replace the fuel injector.
Special tool
Resistance (Ω)
IAJ611170048-01
Fuel injector resistance
Standard: 11.5 – 12.5 Ω at 20 °C
INP313170011-01
4) Connect the lead wire connector to the fuel injector

securely.
1G-22 Fuel System:
Individual Fuel Injector Operating Sound

Inspection
CENNP3131706011
1) Disconnect the ignition coil lead wire connectors
from all of the ignition coils.
2) Disconnect the fuel injector lead wire connector and
connect the test cord.
Special tool
(A): 09930–89260 (Injector test cord (A))
(A)
“Click”
INP313170012-01
3) Connect B/Y wire to body ground.

4) Momentarily touch Gr wire to the starter motor
magnetic switch terminal “B” (connected to battery
positive (+) terminal) and check for injector operating
sound.
If out of specification, replace fuel injector.
NOTICE
If battery power is applied too long in any of
the following tests, the coil of the fuel injector
may burn.
Fuel injector test must be completed within

few seconds to avoid burning of the coil.
Fuel injector operating sound

“Click”
Gr
B/Y
INP313170013-02
1. Starter motor magnetic switch “B” terminal

Fuel System: 1G-23
Fuel Injector Operating Signal Inspection

CENNP3131706012
(A) (B)
(A) (B)
3
(C)
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
(C)
(A)
3
39 41 43 46
55
INP313170014-02

2. Wire harness
Special tool
(B): 09900–25011 (Circuit tester set)
(C): 09900–25007 (Peak volt adapter)
DC voltage ( )
1) Disconnect all ignition coil connectors from the ignition coils.
2) Connect the test cord between the ECM and wire harness as shown in the figure, then turn ignition switch “ON”.
3) Connect the peak volt adapter to multi circuit tester.
4) Connect the tester probe (“–”, Black) to body ground.
5) 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/Y
6) 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-12) and “Fuel Injection System Troubleshooting” (Page 1G-13).
Fuel injector operating signal
Standard: Approx. 40 V or over
1G-24 Fuel System:
Fuel Injector Removal and Installation 6) Remove two nuts and fuel delivery pipe (3) (with fuel
CENNP3131706013 injectors).
Removal
1) Remove STBD side cover. ! WARNING
Section 2A (Page 2A-3). Gasoline is a flammable material that can
cause fire hazard or burns.
Refer to “Fuel Hose Guard Removal and Installation” A small amount of fuel may be released when
in Section 1D (Page 1D-2). the fuel injector is removed from delivery
3) Relieve fuel pressure in the fuel feed line. pipe.
Refer to “Fuel Pressure Relief Procedure” (Page 1G- Place a shop cloth under fuel injector before
14). removal to absorb any fuel released.
4) Loosen the clamp and place a large cloth over the Dispose of fuel soaked cloth in appropriate
end of the fuel feed hose (1). container.
Slowly pull the fuel feed hose from the fuel delivery
pipe.
Drain any excess fuel in the hose into a suitable
container.
INP313170018-01
7) Remove each fuel injector from delivery pipe.
INP313170016-01
5) Unfasten cable tie binding lead wire.

Disconnect four fuel injector connectors (2).
2
INP313170019-01
2
INP313170017-01
Fuel System: 1G-25
Installation • Apply a thin coat of fuel to injector O-rings, then install

Installation is in the reverse order of removal with special the injectors into the delivery pipe (4) and intake
attention to the following points. manifold.
Tighten the delivery pipe nuts (5) to the specified
! WARNING torque and make sure that the injectors can rotate
freely.
Failure to take proper precaution when
reinstalling fuel injector can result in fuel Tightening torque
leakage or damage. Fuel delivery pipe nut (a): 23 N·m (2.3 kgf-m, 17
lbf-ft)
Do not re-use O-ring and cushion once
removed.
Always use new parts. 4
• Replace the O-ring (1) with a new one using care to

avoid nicks or cuts during installation.
5 (a)
2
INP313170021-01
• Reconnect the fuel feed hose and fuel line securely.

1 3 • Connect the lead wire connector to the injectors
IMP311170039-01 securely.
1. O-ring 3. Cushion • Check hose and wire routing.
2. Grommet Refer to “Fuel Hose Routing” in Section 4B (Page 4B-
1) and “Water Hose Routing” in Section 4B (Page 4B-
• Replace the cushion (3) with a new one and install to 5).
the intake manifold. • Check for fuel leakage.
Refer to “Fuel Leakage Check Procedure” (Page 1G-
14).
INP313170020-01
1G-26 Fuel System:
Low Pressure Fuel Pump Removal and Installation

Installation Installation is in the reverse order of removal with special
CENNP3131706014 attention to the following points.
NOTICE
Disassembling the low pressure fuel pump NOTE
can lead to troubles. • Before installing the fuel pump, rotate the
crankshaft to bring the No.1 (top cylinder)
The low pressure fuel pump is a piston to Top Dead Center on the
nonrepairable component. compression stroke.
Do not attempt to disassemble the low
• Do not reuse O-ring once removed.
pressure fuel pump.
Always use a new O-ring.
It must be replaced as a complete unit if it is
defective. • Install low pressure fuel pump, then tighten two bolts,
pre-coated with thread lock, to the specified torque.
Removal
1) Disconnect the fuel inlet hose (1) and outlet hose (2) Tightening torque
from low pressure fuel pump (3). Low pressure fuel pump bolt (a): 10 N·m (1.0 kgf-
m, 7.4 lbf-ft)
2) Remove two bolts (4).
4 (SUZUKI Thread Lock 1342H (50g))
2
3 (a)
IMP311170050-01
(a)
3) Remove fuel pump.
Note the position before removing the O-ring (5). IMP311170051-01
• Connect the fuel inlet and outlet hoses.
IDG211170063-02
Fuel System: 1G-27
Low Pressure Fuel Pump Inspection Water Detection Switch Inspection

CENNP3131706015 CENNP3131706016
NOTICE Inspect the water detection switch using the following
Disassembling the low pressure fuel pump procedures.
can lead to troubles. 1) Remove the low pressure fuel filter.
Remove filter cup.
The low pressure fuel pump is a Refer to “Low Pressure Fuel Filter Inspection” in
nonrepairable component. Section 0B (Page 0B-15).
Do not attempt to disassemble the low 2) Connect the tester probes to the lead wire terminals
pressure fuel pump. as shown.
It must be replaced as a complete unit if it is 3) Check if continuity/infinity can be measured by
defective. moving float, checking each position.
If out of specification, replace the switch (fuel filter
Low Pressure Fuel Pump
case) with a new one.
Inspect the low pressure fuel pump.
If leakage, cracks, damage or other abnormal condition Special tool
is found, replace fuel pump assembly. (A): 09900–25011 (Circuit tester set)
Continuity ( )
Float position Tester indication
Raise the float fully up Continuity
Lower the float completely. Infinity
IDG211170065-01
(A)
I9J011170072-01
IDG211170066-02
1. Float 2. Stopper
4) Assemble and re-install the fuel filter.

Refer to “Low Pressure Fuel Filter Inspection” in
1H-1 Ignition System:
Ignition System
Power Head
General Description
Ignition System Description
CENNP3131801001
The ignition system is a fully transistorized, electronic microcomputer timing advanced type.
This system is totally battery powered, with the ECM controlling the 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 54
3
IGT3
3
Gr/Y 66
IGT4
Lg/R 53
+12 V
Ign.3
+12 V
Ign.4
3 GND
IGT +BAT
2
INP313180001-01
1. ECM 2. Ignition coil 3. Spark plug

Ignition System: 1H-2
Ignition Control Description

CENNP3131801002
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:
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
DF115B/DF115BZ: 0° ± 5° BTDC (at 700 r/min) – 14° BTDC (at 5500 r/min)
Ignition timing
DF140B/DF140BZ: 0° ± 5° BTDC (at 700 r/min) – 15° BTDC (at 6000 r/min)
Firing order 1—3—4—2
Ignition Timing Chart

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

CKP sensor
signal
40° 40°
140° 220° 180° 100° 140°
CMP sensor
signal
CMP sensor - 6 signals / 720°(crankshaft 2 rotation)
TDC TDC TDC

TDC TDC
TDC TDC TDC
TDC TDC
Spark timing
No.1 Ignition
signal
No.3 Ignition
signal
No.4 Ignition
signal
No.2 Ignition
signal
Cm.: Compression, Ep.: Explosion, Ex.: Exhaust, In.: Intake, TDC: Top Dead Center
IMP311180008-03
Ignition Timing 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° ± 5° BTDC to provide stable engine operation at the specified
idling/trolling speed.
• When running (normal operation)
The ignition timing ranges between 0° BTDC at full-close throttle and 14° BTDC (DF115B/DF115BZ) or 15° BTDC
(DF140B/DF140BZ) at full-open throttle during normal operation.
• 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
CENNP3131803001

Ignition System Symptom Diagnosis
CENNP3131804001

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.
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

CENNP3131804002
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-12). 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-13). 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. Refer to “Ignition Timing
Inspection”. Is result OK?
Yes System is in good condition.
No Check input signals related to this system.

Spark Plug Removal and Installation 5) Check the ignition timing while operating the engine
CENNP3131806001 in neutral gear at 1000 r/min.
Refer to “Spark Plug Removal and Installation” in
Also, check that increasing engine speed advances
ignition timing.
If check result is not as specified, check the following
Spark Plug Inspection points.
CENNP3131806002
Refer to “Spark Plug Inspection and Cleaning” in Section • MAP sensor
0B (Page 0B-6). • Throttle position sensor
• ECM and circuit voltage
Ignition Timing Inspection
CENNP3131806003 Ignition timing
NOTE Approx. 2° BTDC at 1000 r/min
Before checking the ignition timing, make
sure idle speed is adjusted within
specification. (A)

2) Connect the H.T cord adapter between No.1 ignition
coil and spark plug.
3) Start engine and allow to warm up.
4) Attach the timing light cord to the H.T cord adapter.
INP313180002-01
Special tool
(A): 09930–89350 (H.T cord adapter)
(B): 09930–76311 (Timing light)
(B)
(A)
IMP311180001-02
Ignition Coil Removal and Installation 5) Connect the wiring harness connector to the ignition
CENNP3131806004 coil and measure the ignition operating signal.
Removal Refer to “Ignition Coil Operating Signal Inspection”
1) Disconnect the battery cables from the battery. (Page 1H-8).
2) Remove fuel hose guard. • If any failure exists, check for open circuit, short
Refer to “Fuel Hose Guard Removal and Installation” circuited battery, short circuited lead and
in Section 1D (Page 1D-2). connector’s contact condition for each circuit.
3) Disconnect the ignition coil connector (1). • If there is no spark even with the wiring harness
4) Remove the ignition coil (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).
• 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
2 inspection again.
GND
IGT +BAT
1
INP313180003-01
Installation
Ignition Coil Inspection

CENNP3131806005
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. IMP311180006-01
Special tool
DC voltage ( )
1) Turn the ignition switch OFF.
2) Disconnect the ignition coil connector.
3) Check for continuity between the GND (–) terminal
on the wiring harness side connector and the engine
body ground.
4) Turn the ignition switch to the ON position. Check for
battery voltage by measuring between the BAT (+)
terminal and GND terminal on the wiring harness
side connector.
Ignition Coil Operating Signal Inspection

CENNP3131806006
Special tool
(B): 09900–25011 (Circuit tester set)
(C): 09900–25007 (Peak volt adapter)
DC voltage ( )
4 (A) (B)
(A) (B)
3
(C)
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
(C)
2 3 4
66 67
53 54 68
(A)
INP313180004-01

1) Disconnect all injector connectors from the fuel CKP Sensor Inspection
injectors. CENNP3131806007
Refer to “CKP Sensor Inspection” in Section 1C (Page
2) Connect the test cords as shown in figure, then turn 1C-12).
ignition switch ON.
CMP Sensor Inspection
CENNP3131806008
Special tool Refer to “CMP Sensor Inspection” in Section 1C (Page

(A): 09930–88730 (36-pin test cord set) 1C-13).
3) Connect the peak volt adapter to multi circuit tester. Ignition Switch Inspection
4) Connect the tester probe (“+”, Red) to each terminal. CENNP3131806009
Refer to “Ignition Switch Inspection” in Section 1I (Page
Wire color
Ignition coil Terminal 1I-17).
(engine harness)
No.1 68 O
No.2 54 Bl ECM Main Relay Inspection
CENNP3131806010
No.3 66 Gr/Y Refer to “ECM Main Relay Inspection” in Section 1A
No.4 53 Lg/R (Page 1A-49).
5) Connect the tester probe (“–” Black) to No.67

terminal (or to body ground).
6) 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. 4 V
Starting System: 1I-1
Starting System
Power Head
General Description
Electric Starter System Description
CENNP3131901001
The starting circuit consists of the battery, starting motor, ignition switch, neutral switch, starter motor relay, ECM and
related electrical wiring.
These components are connected electrically as shown in the figure.
In the circuit shown in the figure below, the magnetic switch coils and starter motor 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.
1
5 4 3
R
6
R
G
8 7
R
Y/G
W
9
21
10 2 W
15
12 13 14
PUSH FREE ST IG OFF

W
GND B 19
STOP G 11
BATT W
IG Gr W
START Br 16
20
17 B.Z
RESET O
PUSH TURN Br
B/Bl Br
B/Bl Y/G
Br Br
Bl/R
B G
B B
18
INP313190001-01
1. Starter motor relay 7. Shift lever 13. 60 A fuse (Load) 19. ECM
2. Battery 8. Ring gear 14. 60 A fuse (Main) 20. Neutral switch
3. Magnetic switch 9. Starter motor 15. Main relay 21. 15 A fuse
4. Pull-in coil 10. Pinion and over-running clutch 16. Neutral switch
5. Hold-in coil 11. 30 A fuse (Starter motor relay) 17. Ignition switch
6. Plunger 12. 30 A fuse (ECM) 18. Emergency stop switch
1I-2 Starting System:
Keyless start model
1
5 4 3
R
6
R
G
8 7
R
Y/G
W
9
21
10 2 W
15
EMER PWR
12 13 14
EMER PWR
(PUSH)
W
NORMAL
NORMAL
19
(PUSH)
11
IG ON
START PWR BATT IG
O R/W W Gr
20
Br
B/Bl Y/G
16
B/Bl “B”
Br Br
Bl/R
B G
B B
18 Gr
“A” B
G
22 W
P/W
P/W
P/W
P/W
W
W
R/W
INP313190002-01
1. Starter motor relay 7. Shift lever 13. 60 A fuse (Load) 19. ECM
2. Battery 8. Ring gear 14. 60 A fuse (Main) 20. Neutral switch
3. Magnetic switch 9. Starter motor 15. Main relay 21. 15 A fuse
4. Pull-in coil 10. Pinion and over-running clutch 16. Neutral switch 22. Keyless control unit
5. Hold-in coil 11. 30 A fuse (Starter motor relay) 17. Main switch “A”: To ECM
6. Plunger 12. 30 A fuse (ECM) 18. Emergency stop switch “B”: From keyless control unit
Starter Motor Operation Condition Description

CENNP3131901002
The starter motor relay is controlled by the ECM.
• The starter motor relay will only engage when the ignition switch is turned to “START” position if the all of the
following conditions are satisfied.
– Lock plate is attached to emergency stop switch.
– Neutral switch is in “ON” position.
– Engine is not already operating.
• After returning the ignition switch to the “ON” position from “START”, the starter motor continues to run for 5
seconds until engine starts.
NOTE
The continuous operating time of the starter motor is set at 5 seconds.
When this time is exceeded, the starter motor will automatically stop.
If the motor stops, wait about ten seconds for the motor to cool down and try again.
Start-In-Gear Protection System Description When attempting to start the engine, the ECM does not
CENNP3131901003 provide an injector operating signal when a shift lever in-
To avoid accidental movement of the boat at the time of gear position is detected.
engine starting, the system prohibits starter motor
operation when the shift position is “IN” gear.
Control by Neutral Switch “N”

A switch to detect “Neutral” gear position is located on “R” “F”
the clutch lever holder and operated by the clutch control
1
lever.
Neutral switch is ON in “Neutral” and OFF in “Forward” 2
or “Reverse”.
When attempting to start the engine, the ECM detects
the shift position using the neutral switch.
When the neutral switch is OFF, the ECM does not
provide a starter motor relay operating signal. INP313190010-01
1. Clutch lever “F”: Forward

2. Shift position sensor “R”: Reverse
“N”: Neutral
“N”
“R” “F” Operation by neutral switch on engine starting

1 Operation
Shift High
Fuel Starter
position Ignition pressure
injection motor
fuel pump
Neutral Yes Yes Yes Yes
2 Forward / No No
Yes No
Reverse (*1:Yes) (*1:Yes)
INP313190009-01
1. Clutch lever “N”: Neutral *1: If it is in neutral judged by the ECM according to the
2. Neutral switch “R”: Reverse
shift position sensor signal.
“F”: Forward
Operation by shift position sensor on engine

Control by Shift Position Sensor
starting
A shift position sensor is installed on the clutch lever
Operation
holder and detects the shift position.
Shift High
This sensor is a variable resistor that changes resistance Fuel Starter
position Ignition pressure
in accordance with the shift position. injection motor
fuel pump
The resistance changes (increase / decrease) the
Neutral Yes Yes Yes Yes
voltage signal output from the sensor to the ECM. Based
Forward / No No
on the sensor voltage, the ECM calculates and detects Yes Yes
Reverse (*2:Yes) (*2:Yes)
shift position.
*2: If it is in neutral judged by the ECM according to ON
signal from the neutral switch.
Component Location
Starting System Components Location
CENNP3131903001

Starter System Troubleshooting
CENNP3131904001
! 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.
Malfunction of shift position sensor. Shift position sensor inspection.
Fuse blown. Replace.
Defective ignition switch. Ignition switch inspection. Replace.
Open circuit between starter motor relay Repair.
and ignition switch.
Defective emergency stop switch. Replace. Emergency stop switch inspection.
Lead wire disconnected or loose. Retighten.
Poor contacting action of ignition switch Magnetic switch inspection.
and starter magnetic switch.
Defective starter motor relay. Main relay and starter motor relay inspection.
Poor magnetic switch lead wire Check connector connection.
connector connection.
Open circuit between starter motor relay Repair.
and 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 switchReplace 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.
starter 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
CENNP3131906001
Removal
NOTICE
If the 12 V electrical system is shorted while
servicing the starter motor, the engine
electrical circuits could be damaged
seriously.
2
Prior to removing starter motor, disconnect
the battery cable at the battery.
INP313190004-01
1) Remove the ring gear cover. 5) Remove the dowel pins (3).
2) Remove the main harness GND lead wire and the
negative (–) battery cable.
Remove the positive (+) battery cable and the main
harness (R) lead wire.
INP313190005-01
Installation
• Install the starter motor and tighten starter motor
INP313190011-01 mounting bolts securely.
3) Disconnect the red lead wire connector (1) from “S” Tightening torque
terminal of starter motor magnetic switch. Starter motor mounting bolt (a): 50 N·m (5.1 kgf-
m, 37 lbf-ft)
Starter motor mounting bolt (b): 23 N·m (2.3 kgf-
m, 17 lbf-ft)
Starter motor cable nut (c): 8.6 N·m (0.88 kgf-m,
6.3 lbf-ft)
(a)
1
(c)
INP313190003-01 (b)
4) Remove the starter motor (2).
INP313190012-01

place.
Starter Motor Test Check that the plunger and pinion remain out. If the
CENNP3131906002 plunger and pinion return inward, replace the
! CAUTION magnetic switch.
• Sparks resulting from short circuit
between the positive (+) and negative (–)
terminals during connections to the
battery could cause a burn.
Be careful not to short-circuit the positive

(+) and negative (–) cables and connect
them only to the correct terminals.
• If the cable used for the test is not
adequately thick, the cable may become
extremely hot due to large current flowing I9J011190003-01
through it and you could get burned.
Plunger and Pinion Return Test
Be sure to connect the battery and the Disconnect the negative lead from the switch/motor
starting motor with a lead wire of the same body.
size as original equipment. Check that the plunger and pinion return inward.
If the plunger and pinion don't return inward, replace the
NOTICE magnetic switch.
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
NOTE
Before testing, disconnect the brush lead
I9J011190004-01
from terminal “M”.
Connect the battery to the magnetic switch as shown in No-Load Performance Test
the figure. NOTE
• Check that the plunger and pinion (over-running Before performing the following test, secure
clutch) move outward. the starter motor to the test bench.
If the plunger and pinion don’t move, replace the
magnetic switch. 1) Connect a battery and ammeter to the starter motor
as shown.
1
3
2) Check that the starter rotates smoothly and steadily
with the pinion moving out. Check that the ammeter
4
indicates the specified current.
Specified current (No-load performance test)
Within 90 A at 11 V
I9J011190002-02
1. Terminal “S” 3. Terminal “B”

2. Terminal “M” 4. Brush lead
• While connected as above with the plunger out,

disconnect the negative lead from terminal “M”. I9J011190005-01
Starter Motor Components

CENNP3131906003
1 (a) 3
7 2
14
4 5
16 18 19 20 21
15 17
12
10 13
9 (b) 11
IMP311190006-02
1. Nut 8. Screw 15. Planetary gear : 8.6 Nm (0.88 kgf-m, 6.3 lbf-ft)
2. Screw 9. Through bolt 16. Pinion shaft : 6.0 Nm (0.61 kgf-m, 4.4 lbf-ft)
3. Magnetic switch 10. Rear housing 17. Internal gear : Apply grease.
4. Rubber packing 11. Brush holder assembly 18. Pinion set : Apply SUZUKI Thread Lock 1342H.
5. Plate 12. Armature 19. Stopper
6. Shift lever 13. Yoke 20. Ring
7. Front housing 14. Rubber seal 21. Cap
Starter Motor Disassembly and Assembly 3) Remove the magnetic switch (4).
CENNP3131906004
Disassembly
When overhauling the starting motor, it is recommended 4
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
degreasing tank or with a grease dissolving solvent.
These parts should be cleaned with compressed air or
wiped with clean cloth.
NOTE
Before disassembling the starting motor, be IGG211190005-01
sure to put match marks at three locations 4) Remove the rubber packing (5) and plate (6).
(“A”, “B” and “C”) as shown in the figure at
right to avoid any possible component
alignment mistakes.
6
5
“A”
“C” “B”
IGG211190006-01
5) Remove the long through bolts (7) and the starter

motor assembly (8).
IGG211190003-02
1) Remove the nut (1) from the magnetic switch, then 7

disconnect the connecting wire (2).
2) Remove the two screws (3) securing the magnetic
switch.
2 1
3 7
IGG211190034-02
IGG211190004-01
IGG211190035-02
6) Remove the screws (9) and the rear housing (10). 9) Remove the planetary gears (14) from the internal
gear.
Remove the rubber seal (15).
10 15
9
14
IGG211190036-02
7) Slide the armature (11) free from the yoke (12).

IGG211190039-02
10) Remove the shift lever (16), pinion/pinion shaft (17)

and internal gear (18) from the front housing.
12 16
11
17
IGG211190037-02
8) Remove the brush holder assembly (13) (with

brushes). 18
IGG211190040-02
11) Pry the cap (19) off using a flat-blade screwdriver.
13
19
IGG211190038-02
IGG211190012-03
12) Using appropriate tool and mallet; push the pinion 13) Using flat-blade screw drivers, pry the stopper ring
stopper (20) down by tapping the top side of tool. (21) off.
NOTE
20
Use one driver to set the ring on one side and
then use another driver to lift the ring up and
remove.
21
IGG211190013-03
21 IGG211190015-01
20
“a”
INP313190006-01
20. Pinion stopper

21. Stopper ring
“a”: Pinion shaft
IGG211190016-01
“B” 14) Remove the pinion (22) and the stopper (20).
Remove the pinion shaft (23) from the internal gear
(24).
NOTE
The stopper may remain in the pinion during
disassembly.
“A”
24
IGG211190014-01 20
“A”: Tool “B”: Mallet

23
! WARNING
removing stopper ring can cause personal
injury. 22
Wear safety glasses when disassembling and IGG211190042-02
assembling the stopper ring.

Assembly 4) Install the cap (6) to the pinion.

Assembly is in the reverse order of disassembly with
special attention to the following steps. 6
Reassemble the starter motor, refer to “Starter Motor
Components” (Page 1I-9).
Pinion
1) Assemble the pinion shaft(1), internal gear (2) and
pinion (3), then install the pinion stopper (4).
4 1
IGG211190021-01
Brush holder
3
• While holding the brush out, slide the commutator into
the brush holder.
2
• When installing the armature, take care to avoid
breaking the brushes.
IGG211190018-01
2) Install the stopper ring (5) into the groove of the

pinion shaft.
IGG211190043-03
Magnetic switch
• Apply thread lock to the magnetic switch securing
IGG211190019-01 screws before threading.
NOTE : Thread lock cement 99000–32160
Replace deformed ring with new ones. (SUZUKI Thread Lock 1342H (50g))
• Install the magnetic switch, then securely tighten it
3) Attach the appropriate puller “C” to the pinion as with screws.
shown in figure.
Pull the pinion up until the stopper ring is firmly
seated in the groove of the pinion shaft.
IMP311190012-01
“C”
IGG211190020-03
“C”: Puller
Starter Motor Components Inspection and NOTE

Servicing Remove all particles of mica and metal using
CENNP3131906005
Armature and Commutator compressed air.
• Inspect the commutator surface. If surface is gummy Commutator undercut “a”
or dirty, clean with # 500 grit emery paper (1). Standard: 0.5 mm (0.02 in)
1
3
“a”
2
I9J011190024-01
I9J011190022-01
2. Mica 3. Segment
• Measure the commutator outside diameter. If the
measurement exceeds the service limit, replace the
armature. • Check for continuity between the commutator (4) and
the armature core (5)/shaft (6).
Commutator outside diameter Replace the armature if continuity is indicated.
Standard: 29.4 mm (1.16 in)
Service limit: 28.4 mm (1.12 in) Special tool
Continuity ( )
4
6
IMP311190013-01
• Check that the mica (insulator) (2) between the 5

segments (3) is undercut to specified depth “a”.
If the measurement exceeds the service limit, cut to
the specified depth. (A)
(A)
IMP311190014-01
! WARNING
4. Commutator 5. Armature core 6. Shaft
Failure to following proper precautions
during use of the compressed air may cause • Check for continuity between adjacent commutator
severe personal injury. segments. Replace armature if no continuity is
indicated.
Wear safety glasses when using compressed
air.
Continuity ( )
I9J011190026-01
Brushes Shift Lever

Check the length of each brush (1). Inspect the shift lever for wear. Replace if necessary.
If brushes are worn down to the service limit, they must
be replaced.
Brush length
IGG211190024-01
Pinion and Over-Running Clutch

• Inspect the pinion for wear, damage or other abnormal
1 conditions.
IDG211190033-01 Check that the clutch locks up when turned in the
direction of drive and rotates smoothly in reverse
Brush Holder direction. Replace if necessary.
Check brush holder continuity.
Replace the brush holder if the tester doesn't show the
below.
Special tool
Continuity ( )
Brush holder continuity
Continuity
Brush holder positive (+) to brush
No IGG211190025-01
holder negative (–)
Brush holder positive (+) to base plate • Inspect spline teeth for wear or other damage.
No Inspect the pinion for smooth movement. Replace if
(ground)
necessary.
(+) (–)
IKJ611190017-01 IGG211190026-01
1. Base plate
Gear Armature Shaft Bush

Inspect planetary gears and internal gear for wear, Inspect the bushing for wear or other damage.
damage or other abnormal conditions. Replace if necessary.
IGG211190031-02
IGG211190027-01
Magnetic Switch
Pinion Shaft / Pinion Shaft Bushing Push in the plunger and release. The plunger should
• Inspect the pinion shaft for wear, damage or other return quickly to its original position.
abnormal conditions. Replace if necessary. Replace if necessary.
• Inspect the pinion shaft bushing for wear or other
damage.
IGG211190032-05
1. Plunger
IGG211190029-01
Pull-in coil open circuit test
Check for continuity across the magnetic switch “S”
Front Housing terminal (1) and “M” terminal (2).
• Inspect the front housing for wear, damage or other If no continuity exists, the coil is open and should be
abnormal conditions. Replace if necessary. replaced.
• Inspect the bearing for wear or other damage. Special tool
Replace if necessary. (A): 09900–25011 (Circuit tester set)
Continuity ( )
2 (A)
1
IGG211190030-01
I9J011190038-02
1. Terminal “S” 3. Terminal “B”

2. Terminal “M”
Hold-in coil open circuit test Ignition Switch Inspection

Check for continuity across the magnetic switch “S” CENNP3131906006
terminal (1) and coil case (4). Inspect ignition switch using following procedures:
If no continuity exists, the coil is open and should be 1) Disconnect the ignition switch from remo-con wiring
replaced. harness.
2) Check continuity between wiring leads at the key
Special tool
positions shown in the chart.
If out of specification, replace ignition switch.
Tester knob indication Normal key start model (Side mount type)
Continuity ( )
Switch lead wires
4 Key position
B G W Gr Br O
OFF
(A)
3
ON
2
START
1
FREE
PUSH
I9J011190039-01
: Continuity
1. Terminal “S” 3. Terminal “B” IDG211190040-01
2. Terminal “M” 4. Coil case
Contact points test (OFF) (ON)

Put the plunger on the under side and then push the FREE (START)
magnetic switch down.
At this time, check for continuity between terminal “B”
and terminal “M”.
Continuity indicates proper condition. If no continuity PUSH
exists, replace the magnetic switch.
Special tool
Continuity ( )
Bl B W Gr
(A)
Br G O
G
Bl B
Br Br Gr
I9J011190040-01 INP313190007-01
Normal key start model (Top mount type) Keyless start model
Key Switch Lead Wires Switch Lead Wires

Key Position
Position B G W Gr Br O O (1) R/W (2) W (3) Gr (4)
OFF ON (emergency key)
ON and Push
ON (emergency key)
START Neutral
Continuity
Push (knob)
Continuity
while pushing ON / OFF (knob)
OFF
ON
: Continuity
Knob
PUSH
START
START/STOP
PUSH ON/OFF
PUSH
START
STOP PUSH
ON
START
STOP
START
ON
OFF
BZR
GND STOP BATT+ IGN START RESET
(PUSH)
B G W Gr Br O
ON(EMER)
ON / PUSH
(EMER)
1 NEUTRAL
PUSH
(KNOB)
BZ ON / OFF
(KNOB)
START PWR BAT+ IGN
O R/W W Gr
BI B W Gr
G Br O B B
INN111190001-01 R/W
G
(1)
B
G Bz
L/W L
O B
Br B
R/W
R/W
L/W
Gr
Br
W
G
B
Br G R/W R/W
Bl/W W Gr B
(3) (2) (4)

INP313190014-01
1. Emergency key
Starter Motor Relay Inspection

CENNP3131906007
Inspect the starter motor relay using the following
procedures:
1) Remove the starter motor relay from the fuse box.
INP313190008-01
1. Starter motor relay

(5).
NOTICE Special tool

If the 12 V power supply wire is connected to (A): 09900–25011 (Circuit tester set)
wrong terminal or touched to each other, the Tester knob indication
power supply wire, tester may be damaged. Continuity ( )
Be careful not to touch 12 V power supply Neutral switch function

wires to each other or with other terminals. Shift position Tester indicates
Neutral Continuity
Special tool Forward Infinity
(A): 09900–25011 (Circuit tester set) Reverse Infinity
Continuity ( )
Starter motor relay function
Neutral
Continuity
Reverse Forward
12 V power not applied No 1
3
2
5
INP313190013-01
12 V 1. Clutch lever
CONT
4 (A)
(A)
IDG211190039-01
3) Measure the resistance between relay terminals (4) Y/G

and (5).
If out of specification, replace starter motor relay.
Tester knob indication Br
Resistance (Ω)
Starter motor relay solenoid coil resistance
I9J011190047-03
Standard: 145 – 190 Ω
3) If out of specification:
• 1st:
(A) Check switch position adjustment, readjust if
necessary.
• 2nd:
Replace neutral switch.
Refer to “Neutral Switch Removal and Installation”
I9J011190044-02 NOTE
After installing the neutral switch, check for
Neutral Switch Removal and Installation correct function by operating the clutch
CENNP3131906008
Refer to “Neutral Switch Removal and Installation” in lever.
Neutral Switch Inspection

CENNP3131906009
1) Disconnect the neutral switch lead wire connector
(2poles).
2) Check continuity/infinity between Yellow/Green and
Brown lead wires while operating the clutch lever.
1K-1 Charging System:
Charging System
Power Head
General Description
Charging System Description
CENNP3131B01001
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 39 A (468 W) at 3000 r/min
Regulated voltage
Standard: 14.2 – 15.2 V
2
9
W W
W W
W
To ECM
To ECM
R/B To fuel injector W
W
To ignition coil W
B
To high pressure fuel pump Gr
Others
4
M
To ignition switch 8 7 6
To starter relay
– +
5
IDG2111B0001-07
1. Flywheel (Magneto) 4. Starter motor 7. Load fuse 60 A

2. Battery charge coil 5. Battery 8. ECM fuse 30 A
3. Rectifier/Regulator 6. Main fuse 60 A 9. Main relay
Battery Requirement Description

CENNP3131B01002
Refer to “Battery Requirement” in Section 0A (Page 0A-6).
Charging System: 1K-2
Component Location
Charging System Components Location
CENNP3131B03001

Charging System Diagnosis
CENNP3131B04001

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
CENNP3131B06001
NOTE
Flywheel bolt (1) is a left hand thread.
1 (a)
2
4
12
13
15 3
14
16
9
10
11
11
INP3131B0002-02
1. Bolt 6. Bolt 11. Wiring harness assembly 16. Fuse (30A, 15A, 10A)
2. Washer 7. Connector holder 12. Fuse case upper cover : 245 Nm (25 kgf-m, 181 lbf-ft)
3. Flywheel 8. Rectifier/Regulator 13. O-ring : Apply engine oil.
4. Key 9. Gasket 14. Fuse (60A) : Apply SUZUKI Bond 1207B

5. Battery charge coil 10. Electric parts holder 15. Relay
Flywheel Removal and Installation 3) Using special tool, loosen the flywheel from
CENNP3131B06002 crankshaft.
Removal
Special tool
! CAUTION (B): 09930–39220 (Flywheel remover)
removing flywheel may result in personal
injury and/or damage to electronic
components.
Prior to removing flywheel, disconnect

battery cables from battery.

(B)
2) Loosen the flywheel bolt 2 – 3 turns in clockwise INP3131B0004-02
direction. 4) Remove the flywheel bolt (1), washer (2), flywheel

(3) and key (4).
NOTE
Flywheel bolt is left hand thread.
1
NOTE 2
Do not remove flywheel bolt at this time.

This bolt prevents damage to the crankshaft
when using flywheel remover tools.
3
Special tool
(A): 09930–49220 (Flywheel holder)
4
IMP3111B0004-01
(A)
INP3131B0003-02
Installation 1) Remove the flywheel.

Installation is in the reverse order of removal with special Refer to “Flywheel Removal and Installation” (Page
attention to the following points. 1K-4).
• Degrease flywheel and crankshaft mating surfaces 2) Disconnect the battery charge coil lead wire
with cleaning solvent. connectors (1).
• Apply engine oil lightly to flywheel bolt before 3) Remove the harness bracket bolt (2).
installing. 4) Remove four bolts and battery charge coil (3).
IMP3111B0005-01
• Tighten flywheel bolt to specified torque.

INP3131B0006-02
Special tool
(A): 09930–49220 (Flywheel holder) Installation
Tightening torque attention to the following points.
Flywheel bolt (a): 245 N·m (25 kgf-m, 181 lbf-ft)
• Apply suzuki bond 1207B to the coil securing bolts.
1207B (100 g))
• Install the battery charge coil, then tighten bolts
securely.
(A)
INP3131B0005-02
• After installing flywheel and torquing bolt to

specification, check air gap between CKP sensor and
flywheel reluctor bars.
Refer to “CKP Sensor Removal and Installation” in
IMP3111B0008-01
• Check that coil lead wires are routed properly and

Battery Charge Coil Removal and Installation away from hot or rotating parts.
CENNP3131B06003
Removal For wire routing, refer to “Wiring Harness Routing
Diagram” in Section 4A (Page 4A-4).
! CAUTION • Install the flywheel and tighten the flywheel bolt to
Failure to take proper precaution when specified torque.
removing electrical parts may result in Refer to “Flywheel Removal and Installation” (Page
personal injury and/or damage to electronic 1K-4).
components.
Prior to removing electrical parts, disconnect

Battery Charge Coil Inspection 3) Disconnect the EX. Manifold temp. sensor lead wire
CENNP3131B06004 connector (2).
Measure battery charge coil resistance in the following
procedure.
1) Disconnect battery charge coil leads from rectifier/
regulator.
2) Measure resistance between leads in the 2
combinations shown.
If measurement exceeds specification, replace
battery charge coil.
Special tool
1
Tester knob indication INP3131B0007-01
Resistance (Ω)
4) Remove the bolt securing starter motor band, then
Battery charge coil resistance remove the ground lead wire (3) of rectifier/regulator.
Terminal for tester probe connection Resistance
White 1 to White 2
White 2 to White 3 0.15 – 0.25 Ω
White 3 to White 1
INP3131B0008-01
5) Disconnect the battery charge coil lead wire

connectors (4) and remove the bolt (5).
W
W
W
4
5
IMP3111B0014-01
Rectifier / Regulator Removal and Installation

CENNP3131B06005 IMP3111B0011-01
Removal
! CAUTION
removing electrical parts may result in
personal injury and/or damage to electronic
components.
Prior to removing electrical parts, disconnect

1) Remove PORT side cover.

2) Remove the nut and the Regulator lead wire (Gr) (1).
6) Remove the rectifier/regulator (6). NOTE

If the tester reads 1.4 V or below when the
tester probes are not connected, replace its
battery.
6
AC 2 AC 3
AC 1
(+)
(–) AC AC AC
INP3131B0009-01 Gr
7) Remove the gasket.
Installation
B
• Replace the gasket with a new one.
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-4).
IDG2111B0019-04
Rectifier / Regulator Inspection 3) Connect all lead wires of rectifier/regulator.
CENNP3131B06006
Inspect the rectifier/regulator in the following procedures:
1) Disconnect all lead wires of rectifier/regulator.
2) Measure voltage between leads in the combinations
shown.
If measurement exceeds specification, replace
rectifier/regulator.
Special tool
Diode test ( )
Unit: V
Tester probe (+)
+ – AC 1 AC 2 AC 3
+ — 0.6 – 0.9 0.3 – 0.6 0.3 – 0.6 0.3 – 0.6
Tester – * — * * *
probe AC 1 * 0.3 – 0.6 — * *
(–) AC 2 * 0.3 – 0.6 * — *
AC 3 * 0.3 – 0.6 * * —
*: 1.4 V or more (tester’s battery voltage)

Main Fuse Inspection

CENNP3131B06007
Inspect the main fuse in the following procedures.
1) Remove the main fuse (1) from fuse box.
1
INP3131B0001-01
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 Diagnostic Information and Procedures ..........2B-16

2
Precautions............................................................. 2-1 Diagnose PTT System Malfunction...................2B-16
Precaution for Mid Unit ......................................... 2-1 Service Instructions ...........................................2B-17
Checking PTT Fluid Level (One-Cylinder
Housing and Bracket............................... 2A-1 Type) ...............................................................2B-17
Precautions...........................................................2A-1 Checking PTT Fluid Level (Three-Cylinder
Precaution for Housing and Bracket ................... 2A-1 Type) ...............................................................2B-17
Service Instructions.............................................2A-2 Air Bleeding from PTT Unit ...............................2B-18
Side Cover Components ..................................... 2A-2 Setting Trim Down Position Limit ......................2B-18
Side Cover Removal and Installation .................. 2A-3 Setting Tilt Up Limit Position .............................2B-19
Engine Holder / Oil Pan / Driveshaft Housing Power Trim and Tilt Unit Removal and
/ Mounts Components ....................................... 2A-4 Installation (One-Cylinder Type) .....................2B-20
Engine Holder / Oil Pan / Driveshaft Housing Power Trim and Tilt Unit Removal and
/ Mounts Disassembly ....................................... 2A-6 Installation (Three-Cylinder Type)...................2B-23
Engine Holder / Oil Pan / Driveshaft Housing Power Trim and Tilt Unit Components (One-
/ Mounts Assembly............................................ 2A-8 Cylinder Type).................................................2B-27
Engine Holder / Oil Pan / Driveshaft Housing Power Trim and Tilt Unit Components (Three-
/ Mounts Related Component Inspection ........ 2A-13 Cylinder Type).................................................2B-28
Clutch Shaft Bearing and Oil Seal Power Trim and Tilt Unit Disassembly (One-
Replacement ................................................... 2A-14 Cylinder Type).................................................2B-29
Driven Gear Bearing and Oil Seal Power Trim and Tilt Unit Reassembly (One-
Replacement ................................................... 2A-16 Cylinder Type).................................................2B-30
Clamp / Swivel / Steering Bracket Power Trim and Tilt Unit Components
Components.................................................... 2A-17 Cleaning and Inspecting (One-Cylinder
Clamp / Swivel / Steering Brackets Type) ...............................................................2B-32
Disassembly.................................................... 2A-19 Power Trim and Tilt Motor Removal and
Clamp / Swivel / Steering Brackets Assembly .. 2A-21 Installation (One-Cylinder Type) .....................2B-33
Clamp / Swivel / Steering Brackets Related Power Trim and Tilt Unit Disassembly (Three-
Components Inspection .................................. 2A-24 Cylinder Type).................................................2B-34
Power Trim and Tilt Unit Reassembly (Three-
Power Trim and Tilt ................................. 2B-1 Cylinder Type).................................................2B-36
Precautions...........................................................2B-1 Power Trim and Tilt Unit Components
Precaution for Power Trim and Tilt...................... 2B-1 Cleaning and Inspecting (Three-Cylinder
Type) ...............................................................2B-40
General Description .............................................2B-1
Power Trim and Tilt Motor Removal and
Power Trim and Tilt Description .......................... 2B-1
Installation (Three-Cylinder Type)...................2B-41
Principles of Power Trim and Tilt Operation
Power Trim and Tilt Motor Disassembly and
Description (One-Cylinder Type) ...................... 2B-4
Assembly.........................................................2B-42
Principles of Power Trim and Tilt Operation
PTT Motor Related Items Inspection.................2B-43
Description (Three-Cylinder Type) .................... 2B-9
PTT Motor Relay Inspection..............................2B-45
Schematic and Routing Diagram......................2B-15 PTT Switch Inspection ......................................2B-46
Power Trim and Tilt System Diagram ............... 2B-15
2-1 Precautions:
Precautions
Mid Unit
Precautions
Precaution for Mid Unit
CENNP3132000001
Housing and Bracket: 2A-1
Housing and Bracket

Mid Unit
Precautions
Precaution for Housing and Bracket
CENNP3132100001
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 dismantling housing and bracket, inspect mountings and bolts for damage and wear. Replace
if necessary.
• Check the condition of the zinc anodes on lower section of mid unit. Replace if necessary.
2A-2 Housing and Bracket:
Side Cover Components
CENNP3132106001
13 16 28 28
1
30 24
30
23
18
29
3 27
17 17 2
25
20
21
24
16
5
21 14
4 17
6 20 19
22 19 25
20 26
21
19 18
23
23
15 11
3
12
8 10
7
IMP311210001-04
1. Side cover STBD 12. Cushion 23. Pin

2. Side cover PORT 13. Engine cover hook lever STBD 24. Bushing
3. Screw 14. Engine cover hook lever PORT 25. Bolt
4. Screw 15. Engine cover hook lever 26. Cushion
5. Grommet 16. Engine cover hook shaft 27. Side cover seal
6. Clamp 17. Engine cover hook 28. Pin
7. Water plug 18. Latch 29. Hose adapter
8. Gasket 19. Bolt 30. Pin
9. Front panel 20. Wave washer : Apply water resistant grease.
10. Bolt 21. Washer
11. Washer 22. Spring
Side Cover Removal and Installation

CENNP3132106002
8
Removal
1) Remove eight screws (1) and STBD side cover (2).
2
INP313210001-02
1 Installation
IMP311210042-01 attention to the following point.
2) Unfasten cable clamp (3). • Tighten side cover screws to the specified torque.
Remove three screws (4) and PORT side cover (5).
Tightening torque
Side cover screw: 3.0 N·m (0.31 kgf-m, 2.2 lbf-ft)
INP313210002-01
3) Disconnect PTT switch lead wire connector.
INP313210003-01
4) Remove flush water hose (6) from front panel (7).
INP313210004-01
5) Remove front panel (8).

Engine Holder / Oil Pan / Driveshaft Housing / Mounts Components

CENNP3132106003
16 (a)
15
38
14
37
19
3
13
40 (e) 2
5 (b)
4
36 18 (a)
6 13 20
17
7 1
39 22 (e)
13
35
33
34 21
8 27
26 11
9
30 (c)
12 (e)
28 (d)
25 10
24
23
31 29
32 (d)
IMP311210002-03
1. Engine holder 17. Washer 33. Oil level gauge guide case
2. Bearing 18. Bolt 34. Gasket
: Retighten the bolt before power unit installing.
3. Oil seal 19. Engine holder gasket 35. Bolt
4. Oil seal 20. Water return union 36. O-ring
5. Plug 21. O-ring 37. Oil level gauge guide
6. Circlip 22. Bolt 38. Oil level gauge
7. Bearing 23. Upper mount 39. Clamp
8. Oil seal 24. Washer 40. Bolt
9. Clutch Shaft 25. Upper mount bolt : 23 Nm (2.3 kgf-m, 17 lbf-ft)
10. Oil strainer 26. Upper mount plate : 20 Nm (2.0 kgf-m, 15 lbf-ft)
11. O-ring 27. Upper thrust mount : 50 Nm (5.1 kgf-m, 37 lbf-ft)
12. Bolt 28. Nut : 80 Nm (8.2 kgf-m, 59 lbf-ft)
13. Dowel pin 29. Upper mount cover : 10 Nm (1.0 kgf-m, 7.4 lbf-ft)
14. Gasket 30. Bolt : Apply engine oil.
15. Mount case cover 31. Washer : Apply water resistant grease.
16. Bolt 32. Nut : Apply thread lock 1342H.
9
7
3 (a) 8
10
6 6
5 (b)
2
11 17
12
4 18
13 14
15
19
24
24 23
18
16 (c) 20
21
22 (d)
28 27
29
34 35
26
25 (d)
30
31
36
32
38 37
39
33 (e)
IMP311210003-02
1. Gasket 17. Bushing 33. Bolt

2. Gasket 18. Washer 34. Lower mount bracket
3. Oil drain plug 19. Water tube 35. Lower thrust mount
4. Oil pan 20. Bushing 36. Bush (w/transomX)
5. Bolt 21. Spacer (w/transomX) 37. Circlip (w/transomX)
6. Dowel pin 22. Bolt 38. Bonding wire
7. Indicator tube cover 23. Driveshaft housing 39. Screw
8. O-ring 24. Dowel pin : 13 Nm (1.3 kgf-m, 9.6 lbf-ft)
9. Indicator tube 25. Bolt : 23 Nm (2.3 kgf-m, 17 lbf-ft)
10. Exhaust pipe 26. Lower mount cover : 10 Nm (1.0 kgf-m, 7.4 lbf-ft)
11. O-ring 27. Nut : 50 Nm (5.1 kgf-m, 37 lbf-ft)
12. Water plug 28. Washer : 60 Nm (6.1 kgf-m, 44 lbf-ft)
13. Water pressure valve 29. Stopper : Apply water resistant grease.
14. O-ring 30. Lower mount : Apply thread lock 1342H.
15. Water pressure valve cover 31. Washer : Apply sealant.
16. Bolt 32. Washer
Engine Holder / Oil Pan / Driveshaft Housing / 6) Remove STBD/PORT lower mount nuts (6) and
Mounts Disassembly lower mount bolts (7).
CENNP3132106004 Remove lower mounts (8).
2) Remove the lower unit.
3) Remove four bolts (1) securing oil level gauge guide
case (2), then remove oil level gauge guide case.
7 8 6
IDG211210010-01
1 6
7
IMP311210047-01
8
IDG211210011-01
4) Remove the screw and bonding wire (3). 7) Remove two upper mount nuts (9) and washers.
IDG211210008-01
IMP311210005-01
5) Remove the bolt (4) securing the STBD/PORT lower 8) Remove driveshaft housing with oil pan.
mount covers, then detach the lower mount covers
(5).
5
IMP311210048-01
IMP311210004-01
9) Remove four bolts and mount case cover (10). 13) Remove four bolts (17) and the engine holder (18).
18
17
10
IMP311210006-01 IDG211210018-01
10) Remove the gasket (11) and upper thrust mount

(12).
18
11 12
17
IMP311210008-01
14) Remove the dowel pins (19) and gasket (20).

IMP311210007-01
11) Remove two nuts (14) securing upper mount plate

(13), then remove upper mount plate (13).
19
13
20
IDG211210087-01
14 15) Remove oil strainer bolts (21) and oil strainer (22).
IDG211210016-01
12) Remove four bolts (16) securing upper mount cover

(15), then remove upper mount assemblies. 22
16
21
15 15 IMP311210009-01
IDG211210017-02
16) Loosen and remove the clutch shaft plug (23). 19) Remove two bolts, water pressure valve cover (27)
and water pressure valve (28).
23
27 28
IDG211210025-04
17) Push the clutch shaft (24) down to free it from the IMP311210049-01
engine holder. 20) Remove the pins (29) and water tube (30).
29
24
30
29
IDG211210064-03 IDG211210022-02
18) Remove eight bolts (25) and oil pan (26).

Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Assembly
CENNP3132106005
26
special attention to the following points.
Driveshaft Housing
• Install water tube (1).
25
IDG211210021-03
IDG211210026-01
Water Pressure Valve Clutch Shaft

• Install O-ring (2) to pressure valve cover (4). • Slide the clutch shaft (9) into place.
• Install pressure valve (3) and pressure valve cover (4)
to oil pan and secure with bolts.
Refer to “Water Pressure Valve Removal and 9
Installation” in Section 1F (Page 1F-4).
2
IDG211210043-03
4 • Tighten the clutch shaft plug (10), pre-coated with

4
thread lock, to the specified torque.
Tightening torque
IDG211210045-03
Clutch shaft plug (a): 22 N·m (2.2 kgf-m, 16 lbf-ft)
Oil Pan / Driveshaft Housing : Thread lock cement 99000–32160
• Install two dowel pins (5) to driveshaft housing (6). (SUZUKI Thread Lock 1342H (50g))
• Install the oil pan (7) to driveshaft housing (6) by
aligning the water tube with the oil pan water passage. 10 (a)
Tighten the eight bolts (8) securely.
NOTE
Apply sealant to mating surfaces of
driveshaft housing and oil pan.
: Sealant 93691–80030 (SUZUKI Silicone Seal

(100 g))
7 IMP311210038-01
Engine Holder
• Apply engine oil to O-rings (11), then install new O-
rings to oil strainer (12).
• Install oil strainer to engine holder, then tighten bolts
securely.
5 6 12
IDG211210027-03
12
11
7
8 6 IDG211210029-03
IDG211210028-04
• Install two dowel pins (13) and gasket (14) to oil pan. Upper Mount
• Place washer (18) and upper mount (19) on upper
NOTICE
mount bolts (17).
Previously used gasket may leak oil and/or
cooling water, resulting in engine damage. NOTE
Install the washer (18) to the mount bolt as its
Do not reuse gasket. Always assemble with a chamfered side faces to the bolt head as
new gasket. shown in the figure.
13 14
18
13
19
17
IDG211210030-03
IDG211210033-04
• Install engine holder (15) to oil pan, then securely • Install the upper mount plate (20) into the upper
tighten it with bolts (16). mount bolts.
NOTE • Apply thread lock to threads of upper mount plate nuts
(21), then install the upper mount plate nuts (21).
Retighten the bolt (16) before power unit
Do not tighten plate nuts at this time.
installing.
NOTE
Set the upper mount plate (20) in place with
16 the “UP” mark upward.
UP
15 20
IMP311210010-01
15
IDG211210035-03
16 17
IDG211210032-05
20 21
21
IMP311210011-01
• Install upper mount covers (22), then tighten upper • Install upper thrust mount (24).
mount cover bolts (23), pre-coated with thread lock, to
the specified torque.
NOTE 24
Rib of upper mount cover (22) must be
placed outside.

Tightening torque
Upper mount cover bolts (b): 50 N·m (5.1 kgf-m,
37 lbf-ft) IDG211210039-03
• Install gasket (25) and mount case cover (26), then

tighten four bolts (27) to the specified torque.
Tightening torque
Mount case cover bolt (d): 23 N·m (2.3 kgf-m, 17
lbf-ft)
22
25
IDG211210037-03
23 (b)
IDG211210040-04
22 22 27 (d) 26
IMP311210012-01
• Tighten upper mount plate nuts (21), pre-coated with

IDG211210041-04
Tightening torque
Upper mount plate nut (c): 80 N·m (8.2 kgf-m, 59
lbf-ft)
21 (c)
IMP311210013-01
Oil Pan / Driveshaft Housing

• Install engine holder/oil pan to steering bracket.
• Install washer (28) and upper mount nut (29), then
tighten two nuts, pre-coated with thread lock, to the
specified torque.
Tightening torque
Upper mount nut (e): 80 N·m (8.2 kgf-m, 59 lbf-ft)
(SUZUKI Thread Lock 1342H (50g)) 34 (f)
IDG211210047-03
• Install lower mount covers (37) to driveshaft housing,

28 then tighten mount cover bolts (38), pre-coated with
Tightening torque
Lower mount cover bolt (g): 50 N·m (5.1 kgf-m, 37
29 (e) lbf-ft)
IMP311210014-01
Lower Mount / Bolt / Nut

• Place washer (30), damper (31), lower mount (32) 37
and washer (33) into driveshaft housing.
• Install lower mount bolt (34) and washer (35), then
tighten mount bolt with nut (36), pre-coated with
Tightening torque
Lower mount bolt (f): 60 N·m (6.1 kgf-m, 44 lbf-ft) 38 (g)
IMP311210016-01
Bonding Wire
NOTE • Reattach the bonding wire (39), then tighten screw
Install the washer (35) to the mount bolt as its securely.
chamfered side faces to the bolt head as
shown in the figure.
36
39
IDG211210049-04
• Install the lower unit.

35 33
31 30 Section 3A (Page 3A-6).
34 (f) 32
IMP311210015-01
• Install the power unit.
Engine Holder / Oil Pan / Driveshaft Housing / Oil Strainer

Mounts Related Component Inspection • Inspect the oil strainer. Replace the strainer if
CENNP3132106006
cracked, damaged or other abnormal conditions are
found.
Mounts Disassembly” (Page 2A-6) and “Engine Holder /
If clogged or obstructed, clean the oil strainer.
Oil Pan / Driveshaft Housing / Mounts Assembly” (Page
2A-8). • Check condition of O-ring. Replace O-ring if nicked,
cut, worn or other abnormal condition are found.
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.
• Check water passage. If clogged or obstructed, clean
water passage.
• Visually check the clutch shaft bearing. Replace if
IDG211150013-02
pitted, noisy, rough or other abnormal conditions are
found.
Oil Pan / Driveshaft Housing
• Check the clutch shaft oil seal. Replace the oil seal if
• Check oil pan, driveshaft housing.
nicked, cut, worn or other abnormal conditions are
If cracks, defects or other damage is found, replace it.
found.
IDG211210053-01
IMP311210017-01
Mount Case Cover

• Inspect the mount case cover. Replace the mount
case cover if cracked, damaged or other abnormal
conditions are found.
IDG211210051-01
Mounts Clutch Shaft Bearing and Oil Seal Replacement

CENNP3132106007
• Check upper, lower and thrust mounts.
If excessive wear, corrosion or other damage is found, 1) Remove the engine holder.
replace mount. Refer to “Engine Holder / Oil Pan / Driveshaft
Housing / Mounts Disassembly” (Page 2A-6).
• Inspect mount cover. Replace mount cover if cracked,
damaged or other abnormal conditions are found. 2) Extract oil seal (1) with oil seal remover.
NOTICE
Removing the oil seal can cause damage to
the seal lips, causing oil to leak.
Do not reuse oil seal once removed.

Always use a new oil seal.
Special tool
(A): 09913–50121 (Oil seal remover)
IDG211210054-01
(A)
Water Tube / Water Tube Grommet

• Check water tube.
If a clog or obstruction is found, clean water tube.
If cracks, corrosion or other damage is found, replace
water tube.
• Check water tube grommet. 1
If excessive wear or other damage is found, replace
grommet. IMP311210039-01
3) Remove circlip (2).
IDG211210055-01
IDG211210057-01
4) Remove bearing (3) with special tool and sliding 6) Apply water resistant grease to outer circumference
hammer. of oil seal (5).
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)
(C): 09930–30104 (Sliding hammer) 5
IDG211210060-02
(B)
7) Install circlip (6).
Install clutch shaft (7).
(C) Tighten the clutch shaft plug (8), pre-coated with
IMP311210041-01
Tightening torque
5) Apply engine oil to outer circumference of bearing
Clutch shaft plug (a): 20 N·m (2.0 kgf-m, 15 lbf-
(4).
ft)
Install bearing (4) into engine holder.
7 8 (a)
6
IDG211210059-02
IMP311210018-01
8) Reassemble the engine holder.

Refer to “Engine Holder / Oil Pan / Driveshaft
Housing / Mounts Assembly” (Page 2A-8).
Driven Gear Bearing and Oil Seal Replacement 4) Apply water resistant grease to outer circumference
CENNP3132106008 of oil seal.
1) Remove the engine holder. 5) Install the oil seal into the engine holder.
Refer to “Engine Holder / Oil Pan / Driveshaft
Housing / Mounts Disassembly” (Page 2A-6). NOTE
2) Remove bearing (1) with special tool and sliding Install driveshaft upper and driven gear oil
hammer. seals with lip (spring side) facing as shown in
figure.
NOTICE
Removing the bearing can cause damage to : Grease 99000–25350 (SUZUKI Water
the ball retainer. Resistant Grease EP2 (250 g))
If the removed bearing is re-used, problem
will occur in the reduction system.
Do not re-use the bearing once removed.

Always use a new bearing.
Special tool
(A): 09941–64511 (Bearing remover)
(B): 09930–30104 (Sliding hammer)
IDG211210061-01
1 6) Apply engine oil to outer circumference of bearing

(1). Install bearing into engine holder.
(A)
(B)
IMP311210019-01
3) Extract oil seal (2) with oil seal remover.

Special tool
(C): 09913–50121 (Oil seal remover)
1
IMP311210020-01
7) Reassemble the engine holder.

(C) Refer to “Engine Holder / Oil Pan / Driveshaft
Housing / Mounts Assembly” (Page 2A-8).
2
IMP311210040-01
Clamp / Swivel / Steering Bracket Components

CENNP3132106009
DF115B / DF115BZ
4 (a)
5
15 14
13
12 (b) 16
25
26
1 26
28 32
23 34 (c)
27 33
35
22 12 (b)
24 29
13
31 36
2
30
38
16 37
39 (e)
17
18 22 3
19 23
20
6
10
21
7 (f)
11
8 (d)
10
9
IMP311210021-03
1. STBD clamp bracket 17. Oil seal 33. Cotter pin

2. PORT clamp bracket 18. Washer 34. Nut
3. Clamp bracket shaft 19. Shim 35. Tilt lock lever PORT
4. Nut 20. Lower mount bracket 36. Rubber
5. Washer 21. Circlip 37. Bonding wire
6. Anode 22. Bushing 38. Screw
7. Bolt 23. Washer 39. Bolt
8. Bolt 24. Grease nipple : 43 Nm (4.4 kgf-m, 32 lbf-ft)
9. Washer 25. Tilt lock lever : 48 Nm (4.9 kgf-m, 35 lbf-ft)
10. Bushing 26. Bushing : 28 Nm (2.9 kgf-m, 21 lbf-ft)
11. Lower shaft 27. Spring : 50 Nm (5.1 kgf-m, 37 lbf-ft)
12. Bolt 28. Link : 23 Nm (2.3 kgf-m, 17 lbf-ft)
13. Washer 29. Spring : 10 Nm (1.0 kgf-m, 7.4 lbf-ft)
14. Steering bracket 30. Bracket : Apply SUZUKI thread lock 1342H.
15. Washer 31. Screw : Apply SUZUKI water resistance grease.
16. Bushing 32. Washer
DF140B / DF140BZ
15
4 (a) 13
5
12 (b)
16
14
25
26
26
1 28 32
23
27
35 33 34 (c)
22 24 29
12 (b)
31 36
13
30 2
38
16 3
37
17
18 41 (e)
22
19 23
9 (d)
20
40 (g)
21 6 39
10
8 7 (f)
11 9 (d)
10
IMP311210022-04
1. STBD clamp bracket 18. Washer 35. Tilt lock lever PORT
2. PORT clamp bracket 19. Shim 36. Rubber
3. Clamp bracket shaft 20. Lower mount bracket 37. Bonding wire
4. Nut 21. Circlip 38. Screw
5. Washer 22. Bushing 39. Tilt pin
6. Anode 23. Washer 40. Nut
7. Bolt 24. Grease nipple 41. Bolt
8. PTT unit 25. Tilt lock lever : 43 Nm (4.4 kgf-m, 32 lbf-ft)
9. Bolt 26. Bushing : 48 Nm (4.9 kgf-m, 35 lbf-ft)
10. Bushing 27. Spring : 28 Nm (2.9 kgf-m, 21 lbf-ft)
11. Lower shaft 28. Link : 50 Nm (5.1 kgf-m, 37 lbf-ft)
12. Bolt 29. Spring : 23 Nm (2.3 kgf-m, 17 lbf-ft)
13. Washer 30. Bracket : 10 Nm (1.0 kgf-m, 7.4 lbf-ft)
14. Steering bracket 31. Screw : 20 Nm (2.0 kgf-m, 15 lbf-ft)
15. Washer 32. Washer : Apply SUZUKI thread lock 1342H.
16. Bushing 33. Cotter pin : Apply SUZUKI water resistance grease.
17. Oil seal 34. Nut
Clamp / Swivel / Steering Brackets Disassembly 7) Remove bolt (11) and trim sensor (12).
CENNP3132106010 Cut the cable tie (13) securing sensor lead wire.
1) Remove engine holder/oil pan and driveshaft
housing.
Refer to “Engine Holder / Oil Pan / Driveshaft 12
Housing / Mounts Disassembly” (Page 2A-6).
2) Remove screw and bonding wire (1) from lower
mount bracket.
3) Remove circlip (2). 13 11
2 IMP311210026-01
8) Slide the lower trim sensor cam plate (14) off.

9) Remove the upper trim sensor cam (15) from clamp
bracket shaft.
1
15
IMP311210023-01
4) Remove lower mount bracket (3), shims (4), and

washer (5) from the steering bracket.
14
5 IDG211210069-02
4 10) Connect the special tool to PTT motor and raise the
swivel bracket.
3 Special tool
: 09945–79310 (PTT cable extension)
IMP311210024-01 Remove circlip (16) and push out tilt cylinder upper
5) Lift steering bracket (6) upward to remove from rod (17).
swivel bracket.
Remove washer (7) and upper bushing (8).
6) Remove swivel bracket seal (9) and lower bushing
(10).
17
6 10
9
16
7
8
IDG211210092-01
IMP311210025-01
11) Remove nut and tilt pin (18). 13) Remove screw and bonding wire (25) from swivel
Remove PTT cylinder lower shaft bolts (19). bracket.
Remove bolts and anode (20). Slide STBD clamp bracket (26) off clamp bracket
Remove screw and bonding wire (21). shaft.
Remove PTT unit.
Refer to “Power Trim and Tilt Unit Removal and
Installation (Three-Cylinder Type)” in Section 2B
(Page 2B-23).
18
19
25
20 21 26
IDG211210070-03
12) Using flat blade screw driver, drive locking edge of

lock washer (22) to clamp bracket side.
Remove the two STBD motor mounting bolts (23).
Remove the clamp bracket shaft nut (24) and IDG211210073-04
washer. 14) Remove the bolt (27) securing clamp bracket shaft to
PORT clamp bracket.
Remove PORT motor mounting bolt.
22
27
24
23
IMP311210027-01
IMP311210028-01
15) Pull PORT clamp bracket (30) outward to remove

clamp bracket and bracket shaft (28) from swivel
bracket (29).
Remove washer (31) and bushing (32) from each
side of swivel bracket.
29 30
28
32 31
31 32
IMP311210029-01
Clamp / Swivel / Steering Brackets Assembly • Apply thread lock to threads of shaft bolt (6) before
CENNP3132106011 threading it to PORT clamp bracket.
Assembly is in the reverse order of disassembly with Install the shaft bolt (6), then tighten it securely.
• Tighten PORT motor mounting bolt (7).
Clamp Bracket / Swivel Bracket : Thread lock cement 99000–32160
NOTE
Before installing clamp bracket to swivel
bracket, apply grease to clamp bracket shaft
and bushings. 6
: Grease 99000–25350 (SUZUKI Water Resistant

Grease EP2 (250 g))
• Insert PORT and STBD bushings (2) into the swivel
bracket (1).
7
IMP311210030-01
1 • Install PTT unit assembly.

Installation (One-Cylinder Type)” in Section 2B (Page
2B-20) or “Power Trim and Tilt Unit Removal and
Installation (Three-Cylinder Type)” in Section 2B
(Page 2B-23).
• Install washer (8), STBD clamp bracket (9), lock
2 2 washer (10) and clamp bracket shaft nut (11).
IDG211210076-02
• Tighten clamp bracket shaft nut (11) to the specified
• Assemble PORT clamp bracket (4), washer (5), clamp torque.
bracket shaft (3) and swivel bracket (1).
Tightening torque
Clamp bracket shaft nut (a): 43 N·m (4.4 kgf-m, 32
lbf-ft)
9
3
4
5
1
IDG211210077-02
IMP311210031-01
10
11 (a)
IMP311210032-01
• After tightening clamp bracket shaft nut to the

specified torque, bend lock washer (10) edge toward
nut to secure nut. 3
4
5
10
IMP311210034-01
Steering Bracket
IMP311210033-01 • Apply water resistant grease to steering bracket shaft.
Trim Sensor and Trim Sensor Cam : Grease 99000–25350 (SUZUKI Water
• Install the upper trim sensor cam (1) engaging its
locating pin “A” with the clamp bracket shaft hole “B”. NOTE
Apply grease to bushings, oil seal lip and
pilot shaft portion of steering bracket.
1
• Install upper bushing (1) and washer (2) to swivel
“A”
bracket.
• Install lower bushing (3) and swivel bracket seal (4) to
swivel bracket.
“B” NOTE
Install bracket seal (4) with oil seal lip (spring
side) facing downward.
IDG211210099-02
• Install the lower trim sensor cam plate (2). • Install steering bracket (5) to swivel bracket.
5
2
IDG211210096-03
• Install the trim sensor assembly (3), then secure it 2

with bolts (4). 1
• Secure white taping point of sensor lead wire with
3
cable tie (5).
4
“A”
IDG211210098-02
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
lower mount bracket (3) upward on the splines until it grease through each grease nipple.
contacts the shim. : Grease 99000–25350 (SUZUKI Water Resistant
Grease EP2 (250 g))
IMP311210035-01
• Install circlip (4) to retain lower mount bracket. IMP311210050-02
• Install lower thrust mount (5) to lower mount bracket.
IMP311210036-01
IDG211210081-02
Bonding Wire
Reattach bonding wires to swivel bracket and tighten
screws securely.
IDG211210082-02
Clamp / Swivel / Steering Brackets Related Clamp Bracket Shaft

Components Inspection Check clamp bracket shaft.
CENNP3132106012 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. I9J011210120-01
Bracket
Check clamp brackets, steering bracket and swivel
bracket.
If cracks or other damage is found, replace bracket (s).
IDG211210085-02
Oil Seal
Check swivel bracket seal. If excessive wear or other
damage is found, replace seal.
IMP311210037-01
I9J011210118-01
Power Trim and Tilt: 2B-1
Power Trim and Tilt

Mid Unit
Precautions
Precaution for Power Trim and Tilt
CENNP3132200001
! 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.
General Description
Power Trim and Tilt Description
CENNP3132201001
• There are two kinds of PTT system on these models.
One is three-cylinder type (DF140B/DF140BZ) and the other is one-cylinder type (DF115B/DF115BZ).
• The power trim and tilt system components are an electric motor, a pump unit, a fluid reservoir and trim/tilt
cylinder(s).
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.
• 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 from ECM terminals
No.22 or 23 and the output signal from terminals No.26 or 27.
NOTE
With the ignition switch in the OFF position, and the PTT switch operated, the tilt/trim will operate.
With the ignition switch in the OFF position, operating the PTT switch will supply a 12 V power signal
to the ECM.
When this signal is received, the ECM operates the main relay (ON), allowing the ECM drive signal to
feedback to the ECM and the PTT relay circuit.
Thus the PTT system functions only 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.
2B-2 Power Trim and Tilt:
Power Trim and Tilt Hydraulic Diagram
One-cylinder type
1
2
3
20 19
18 17 4
21
5
22
14 6
7
15 16
11 8
13
12 9
10
I9J011220001-02
1. PTT motor 9. Free piston 17. “DOWN” relief valve

2. Tilt rod 10. Lower cylinder chamber 18. Spool valve No.1
3. Oil reservoir 11. Manual release valve 19. Check valve No.1
4. Tilt cylinder upper chamber 12. Thermal valve 20. Check valve No.2
5. Floating tube 13. 2-way valve 21. Spool valve No.2
6. Trim cylinder upper chamber 14. Gear pump 22. “DOWN” pressure main check valve
7. Tilt piston 15. “UP” pressure main check valve
8. Trim piston 16. “UP” relief valve
Three-cylinder type
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 (One-Cylinder Type)

CENNP3132201002
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.
Trim / Tilt Up Circuit

• When the PTT switch is operated “UP” position, the electric motor and gear pump (1) will rotate on clockwise
direction.
• Pressurized oil will open check valve (2), oil will flow from the reservoir to spool valve (3) via the pump and spool
valve (4).
• Operation of spool valve (3) in the “DOWN” direction will cause the main check valve (5) to open.
• Oil in the upper chamber of the cylinder will return to the pump via a 2-way valve.
Then the oil pressure will rise and open the “UP” pressure main check valve (6), then allowing oil to flow to the lower
chamber of cylinder.
This makes the piston rod push up and the engine tilt up.
• Oil flows from the reservoir to the pump through check valve (2).
Oil flows through the “DOWN” pressure main check valve (5) and returns to the pump.
• When the trim motor stops, both the “DOWN” pressure main check valve (5) and the “UP” pressure main check
valve (6) will close to retain tilt/trim position.
• In the trim area, the trim piston and floating tube are moving with the piston rod.
• When full tilt up position is attained, sustained operation of the “UP” relay will cause oil flow to be returned to the
reservoir through the “UP” relief valve (7).
2
4
3 7
5 1 6
I9J011220002-01
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.
• Check valve (1) will open; oil will flow from the reservoir to the spool valve (2).
This makes spool valve (3) move to downward, and causes the “UP” pressure main check valve (4) to open.
• Oil in the lower chamber will return to pump, and then oil pressure increase will open the “DOWN” pressure main
check valve (5), allowing oil flow to the upper chamber of cylinder.
This makes the piston rod push down and the engine will tilt down.
• Oil flows from the reservoir to the pump through check valve (1).
Surplus oil in the pump flows through the “DOWN” relief valve (6) and returns to the reservoir.
• When the trim motor stops, both the “DOWN” pressure main check valve (5) and the “UP” pressure main check
valve (4) will close to retain tilt/trim position.
• In the trim area, the trim piston and floating tube are moving with the piston rod.
• When full trim/tilt down position is attained, sustained operation of the “DOWN” relay will cause oil to be returned to
the reservoir through the “DOWN” relief valve (6).
6
2
I9J011220003-02
Shock Absorber Circuit

Shock valve
Should the lower unit strike an underwater object while in motion, the piston will rise abruptly, creating a sudden high
impact pressure in the upper cylinder chamber (1). The shock valve (2) will then open, allowing oil to flow into the area
between the tilt ram piston (3) and the free piston (4), thereby dampening (absorbing) the impact.
Return valve
When the point of impact has passed, propeller thrust and motor weight will force the tilt ram piston back downward.
The oil from between the ram piston (3) and the free piston (4) is then expelled through the return valve (5) before
flowing into the upper cylinder chamber (1).
1
5
I9J011220004-01
Manual Release Circuit (Manual Valve)

Turn the manual valve a maximum of three full turns counterclockwise.
When the manual release valve (1) is loosened, oil will flow unimpeded (without resistance) through the internal pump
tubes, thereby facilitating manual tilting or lowering of the outboard. To hold the engine in a selected position, the
manual valve must be closed again.
: Tilt “DOWN”
: Tilt “UP”
I9J011220005-02
Thermal Valve
As temperature goes up, oil pressure will increase and the oil in PTT unit will expand.
High oil pressure in the upper cylinder chamber (1) caused by rising temperature will release the thermal valve (2) and
make the oil flow to the reservoir to prevent damage to the PTT unit.
I9J011220006-01
Principles of Power Trim and Tilt Operation Description (Three-Cylinder Type)

CENNP3132201003
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
CENNP3132202001
8 9 11 12 7
R M
R
2
W B BATT
10 6
W/R
Lbl
P
P/B
W
B B/W
3
1 4
Lg
P
Lbl
Gr
W
P
Lbl
P
22 23
START
24 27 OFF
ON
5
B GND
ECM
W BATT
36 26 Gr IGN
Br START
12
B/Bl
INP313220001-01
1. PTT switch (Remote control box) 5. Ignition switch 9. ECM fuse 30 A

2. PTT switch (Side cover) 6. Battery 10. PTT switch fuse 15 A
3. PTT motor relay 7. Starter motor 11. Load fuse 60 A
4. PTT motor 8. ECM main relay 12. Main fuse 60 A

Diagnose PTT System Malfunction
CENNP3132204001

Motor will not trim/tilt at Blown fuse for PTT system. Inspection and replace.
all (No up, no down). (Main: 60 A, Load: 60 A, PTT switch: 15
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 (One-Cylinder Type) 5) Reinstall oil filler plug.
CENNP3132206001
1) Raise the engine to the full-tilt up position. Checking PTT Fluid Level (Three-Cylinder Type)
2) Lower the manual tilt lock lever (1). CENNP3132206002
1) Raise the engine to a full-tilt up position.
2) Lower the manual tilt lock lever (1).
IDG211220002-02
3) Remove the oil filler plug (2).

IDG211220037-02
3) Remove the oil filler plug (2).
IMP311220019-01
4) If oil can be seen at filler plug level, the reservoir is

full. IDG211220038-01
If fluid level is low, refill with the recommended PTT 4) If oil can be seen at filler plug level, the reservoir is
fluid. full.
If fluid level is low, refill with the recommended PTT
NOTICE
fluid.
Mixing of different fluids may cause chemical
reaction and deterioration. NOTICE
Mixing of different fluids may cause chemical
To ensure consistent pump operation, never reaction and deterioration.
mix different types of PTT fluid.
To ensure consistent pump operation, never
Recommended PTT fluid mix different types of PTT fluid.
• 99000-22810 (PTT Fluid (1 Liter))
• Dexron III automatic transmission fluid or Recommended PTT fluid
equivalent • 99000-22810 (PTT Fluid (1 Liter))
• Dexron III automatic transmission fluid or
equivalent
I9J011220008-01
“A”
2
IMP311220002-02
IDG211220039-02
3) Check PTT fluid level, topping off if necessary.
“A”: Oil level (when full tilted)
4) Reinstall oil filler plug.
5) Reinstall oil filler plug (2). Setting Trim Down Position Limit
CENNP3132206004
Once the ECM has been replaced or the trim sensor
Air Bleeding from PTT Unit removed and reinstalled, the resetting of the trim down
CENNP3132206003
position limit should be performed.
1) Check that the manual release valve (1) is tightened Perform this set-up after the current position setting has
to the specified torque. been cancelled, as explained in the following procedure.
NOTE
Canceling The Trim Down Position Limit Setting
Do not over tighten manual release valve.
1) Turn ignition switch to the “ON” position.
Tightening torque 2) Pull out the emergency stop switch lock plate.
Manual release valve (a): 3.5 N·m (0.36 kgf-m,
2.6 lbf-ft)
Direction of rotation
Counterclockwise: Open
Clockwise: Close
1 (a)
IEH511220005-01
3) Make sure that remote control lever is in “Neutral”.

(Check that the neutral switch is in the “ON”
position.)
IDG211220004-01
2) Operate the PTT switch, raising and lowering the

motor up and down (full tilt position to full trim down
position) 4 to 5 times.
NOTICE
If the PTT is operated while the manual
release valve is open, the inner parts of the
manual release valve will break off.
Ensure that the manual release valve is

completely closed.
4) Top mount type: Setting Tilt Up Limit Position

Using the throttle only function of the remote control CENNP3132206005
box, move the remote control lever forward until the If the outboard motor contacts the motor well of the boat
caution buzzer sounds one time. during full tilt up operation, the upper limit setting should
Side mount type: be reset. Perform this set-up after the current position
Using the throttle only function of the remote control setting has been canceled, as explained in the following
box, move the warm-up lever upward until the procedure.
caution buzzer sounds one time.
Canceling Tilt Up Position Limit Setting
Raise the motor until tilt position.
“NEUTRAL” “NEUTRAL”
NOTE
Before canceling the upper limit setting, raise
the motor at any position of the tilt range.
2) Pull out the emergency stop switch lock plate.
I9J011220055-01
5) Return the throttle to the fully closed position.

6) Install the lock plate on the emergency switch.
Setting The Trim Down Position Limit

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. IEH511220005-01
3) Pull out the emergency stop switch lock plate. 3) Make sure that remote control lever is in “Neutral”.
(Check that the neutral switch is in “ON” position.)
4) Make sure that remote control lever is in “Neutral”.
(Check that the neutral switch is in the “ON”
position.)
5) Top mount type:
Using the throttle only function of the remote control
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
mode is active.
6) Press the “DOWN” side of the PTT switch three
times within three seconds. The buzzer will sound
one time briefly indicating the setting has been
accepted.
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
that the setting of the down limit is properly set.
4) Top mount type: Power Trim and Tilt Unit Removal and
Using the throttle only function of the remote control Installation (One-Cylinder Type)
box, move the remote control lever forward until the CENNP3132206006
caution buzzer sounds one time. Removal

Side mount type: 1) Remove side covers and front panel.
Using the throttle only function of the remote control Refer to “Side Cover Removal and Installation” in
box, move the warm-up lever upward until the Section 2A (Page 2A-3).
caution buzzer sounds one time. 2) Raise the engine to the full tilt up position and lower
the manual tilt lock lever (1).
! WARNING
“NEUTRAL” “NEUTRAL”
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)
I9J011220055-01
5) Return the throttle to the fully closed position.

6) Install the lock plate on the emergency switch.
Setting Tilt Up Position Limit

2) Press the UP side of the PTT switch so that the 1
optimum full tilt up 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 “ON” position.) IDG211220006-01
5) Top mount type:
box, move the control handle forward until the
mode is active.
Side mount type:
box, move the warm-up lever upward until the
mode is active.
6) Press the “UP” side of PTT switch three times within
three seconds. IMP311220003-01
The buzzer will sound one time briefly indicating the
setting has been accepted.
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
that the settings of both the trim down limit and tilt up
limit is properly set.
3) Remove the tilt rod snap ring (2) and push the tilt
cylinder upper shaft pin (3) out.
IMP311220022-01
6) Remove two bolts and anode (4). Remove the screw

IMP311220020-01 securing bonding wire (5).
4) Lower the tilt rod to the full down position and
disconnect the battery cable.
4
IMP311220004-01
7) Remove PTT cylinder lower shaft bolts (6).

IMP311220021-01

Cut cable tie binding PTT motor cable and trim
sensor lead wire.
Disconnect PTT motor cable connector. 6 6
Remove bolt securing cable clamp.
IDG211220011-02
8) Remove two STBD motor mounting bolts (7).

Using flat screw driver, drive locking edge of lock
washer (8) to clamp bracket side.
Loosen and remove the clamp bracket shaft nut (9).
Remove the screw and bonding wire (10) from
swivel bracket.
INP313220004-03
10
8
9
7
IMP311220005-02
INP313220005-02
9) Slide the STBD clamp bracket (11) off clamp bracket • Tighten clamp bracket shaft nut (3) to the specified
shaft, then remove PTT unit with lower shaft. torque.
Tightening torque
lbf-ft)
• After tightening clamp bracket shaft nut to the
specified torque, bend lock washer edge toward nut to
secure nut.
11
IMP311220023-01 3 (a)
Installation
• Lower tilt rod to full down position.
• Apply water resistant grease to the tilt cylinder lower
IMP311220006-02
shaft (2) and lower shaft bushings (1).
Install the lower shaft (2) and bushings (1) to PTT unit. • Tighten lower shaft bolts (4), pre-coated with thread
lock, to the specified torque.
Resistant Grease EP2 (250 g)) : Thread lock cement 99000–32160
Tightening torque
PTT cylinder lower shaft bolt (b): 50 N·m (5.1 kgf-
m, 37 lbf-ft)
1
2
IDG211220013-01
• Place the PTT unit (with lower shaft) in position, then

install the clamp bracket. 4 (b)
IMP311220007-01
• Install anode (5) and bonding wire, then tighten bolts

securely. Install bonding wire (6), then tighten screw
securely.
IMP311220024-01
5
IMP311220008-01
• Apply water resistant grease to tilt rod upper bushings • Final assembly check
(7), then install bushings in tilt rod. Perform the following checks to ensure proper and
Operate the PTT motor to extend the PTT rod upward. safe operation of repaired unit:
Align the tilt rod with the hole in the swivel bracket as – All parts removed have been returned to their
the tilt rod extends. original positions.
: Grease 99000–25350 (SUZUKI Water – Wire routing matches service manual illustration.
Power Trim and Tilt Unit Removal and
Installation (Three-Cylinder Type)
CENNP3132206007
7
Removal
7
2) Raise the engine to the full tilt up position and lower
the manual tilt lock lever (1).
! WARNING
IMP311220025-01
• Apply water resistant grease to the PTT rod upper servicing a PTT unit can cause severe
shaft (8), then insert the shaft through the swivel personal injury.
bracket and tilt rod.
Secure the upper shaft with the snap ring (9). During the removal or installation of PTT unit,
: Grease 99000–25350 (SUZUKI Water the engine must be firmly secured and its
Resistant Grease EP2 (250 g)) weight fully supported by the hoist. (See
below)
IDG211220018-02
• Route the PTT motor cable and trim sensor lead wire
IDG211220040-02
in through side cover seal.
4A (Page 4A-4).
IMP311220003-01
INP313220004-03
3) Remove the tilt rod snap ring (2) and push the tilt
cylinder upper shaft pin (3) out.
IMP311220022-01
6) Remove two bolts and anode (4). Remove the screw

IDG211220041-02 securing bonding wire (5).
4) Lower the tilt rod to the full down position and
disconnect the battery cable.
4
IMP311220004-01
7) Remove the tilt pin. Remove PTT cylinder lower

IDG211220042-01 shaft bolts (6).
Cut cable tie binding PTT motor cable and trim
sensor lead wire.
Disconnect PTT motor cable connector.
Remove bolt securing cable clamp. 6 6
IDG211220046-03
INP313220004-03
INP313220005-02
8) Remove two STBD motor mounting bolts (7). • Place the PTT unit (with lower shaft) in position, then
Using flat screw driver, drive locking edge of lock install the clamp bracket.
washer (8) to clamp bracket side.
Loosen and remove the clamp bracket shaft nut (9).
Remove the screw and bonding wire from swivel
bracket.
9
IDG211220049-01
• Tighten the clamp bracket shaft nut (4) to the specified

torque.
7
IDG211220045-03
Tightening torque
9) Slide the STBD clamp bracket (10) off the clamp
lbf-ft)
bracket shaft, then remove the PTT unit with lower
shaft. • After tightening clamp bracket shaft nut (4) to the
specified torque, bend lock washer (3) edge toward
nut to secure nut.
10
4 (a)
IDG211220047-03
Installation IDG211220051-01
Installation is in the reverse order of removal with special • Tighten two lower shaft bolts (5), pre-coated with
attention to the following points. thread lock, to the specified torque.
• Lower tilt rod to full down position.
• Apply water resistant grease to the tilt cylinder lower (SUZUKI Thread Lock 1342H (50g))
shaft (1) and lower shaft bushings (2).
Install the lower shaft (1) and bushings (2) to PTT unit. Tightening torque
PTT cylinder lower shaft bolt (b): 50 N·m (5.1 kgf-
: Grease 99000–25350 (SUZUKI Water m, 37 lbf-ft)
1
5 (b)
2
IMP311220009-01
IDG211220048-02
• Install anode (6) and bonding wire, then tighten bolts • Route the PTT motor cable and trim sensor lead wire
securely. Install bonding wire (7), then tighten screw in through side cover seal.
securely. Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-4).
6
IMP311220010-01
• Apply water resistant grease to tilt rod upper bushings INP313220004-03
(8), then install bushings in tilt rod. • Final assembly check

Operate the PTT motor to extend the PTT rod upward. Perform the following checks to ensure proper and
Align the tilt rod with the hole in the swivel bracket as safe operation of repaired unit:
the tilt rod extends. – All parts removed have been returned to their
: Grease 99000–25350 (SUZUKI Water original positions.
Resistant Grease EP2 (250 g)) – Wire routing matches service manual illustration.
IDG211220053-01
• Apply water resistant grease to the PTT rod upper

shaft (9), then insert the shaft through the swivel
bracket and tilt rod.
Secure the upper shaft with the snap ring (10).
10
IDG211220054-01
Power Trim and Tilt Unit Components (One-Cylinder Type)

CENNP3132206008
1 (a)
9
2
10
5 3
4
6
11
7 18
19 13
12
20
14 14
8
21
15
22
16
17
23
D
FW 25
24 26
IDG211220095-02
1. Joint 8. Manifold assembly 15. Brush holder 22. Pump assembly

2. Reservoir 9. Field case 16. Screw 23. Bolt
3. Plug 10. O-ring 17. Oil seal 24. Bolt
4. O-ring 11. Armature 18. Drive joint 25. Bolt
5. Bolt 12. Brush set 19. Filter 26. Manual valve
6. Clamp 13. Breaker assembly 20. O-ring : 108 Nm (11 kgf-m, 80 lbf-ft)
7. O-ring 14. Spring 21. O-ring : Apply thread lock to the thread area.
Power Trim and Tilt Unit Components (Three-Cylinder Type)

CENNP3132206009
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
D
FW 30
29 31
IDG211220056-04
1. Manifold assembly 10. Free piston 19. Spring 28. Bolt

2. Piston assembly 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 : 235 Nm (24 kgf-m, 173 lbf-ft)
6. O-ring 15. O-ring 24. Filter : 170 Nm (17 kgf-m, 125 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 (One- 4) Remove the manual release valve snap ring (1),
Cylinder Type) then unscrew the manual release valve (2).
CENNP3132206010
NOTE
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
compressed air. 2
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. 1 2
NOTE
I9J011220012-01
To prevent damage to the PTT cylinder use
wood blocks, vise jaw protectors, etc., 5) Remove the PTT motor assembly (3).
between the vise jaws and PTT components Refer to “Power Trim and Tilt Motor Removal and
before tightening vise. Installation (One-Cylinder Type)” (Page 2B-33).
Note the position of drive joint (4) and O-ring (5),
before removing them.
4
IDG211220020-02
I9J011220013-01
2) Connect the PTT cable extension to PTT motor
cable connector. 6) Remove the three bolts securing the PTT pump
assembly (6), then detach the PTT pump assembly
Special tool from PTT cylinder body.
(A): 09945–79310 (PTT cable extension) Note the position of O-rings (7), before removing
3) Connect the PTT cable extension leads (G, Bl) to them.
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.
7
(A)
6
I9J011220014-01
I9J011220011-01
7) Using special tool, unscrew the upper eye (8). Power Trim and Tilt Unit Reassembly (One-
Special tool Cylinder Type)
CENNP3132206011
(B): 09945–69010 (PTT rod holder) Assembly is in the reverse order of disassembly with
special attention to following points.
8 NOTE
• Do not reuse O-rings and seals once
removed.
Always use new parts.
• Lubricate all components and O-rings with
PTT fluid before assembly.
(B)
• Do not reuse PTT fluid, always refill with
new fluid.
I9J011220016-01
Reservoir
8) Remove the four bolts securing the reservoir (9),
• Apply PTT fluid to reservoir seal, then install reservoir.
then detach the reservoir from the PTT body.
• Tighten four bolts securely.
Tightening torque
9 Reservoir bolt (a): 5.0 N·m (0.51 kgf-m, 3.7 lbf-ft)
I9J011220015-01
9) Remove the O-ring (10).

(a)
I9J011220018-01
Upper Eye
• Apply thread lock super 1333B to threads of upper
eye before threading it onto tilt rod.
10
: Thread lock cement 99000–32020 (SUZUKI
Thread Lock Super 1333B (50 g))
• Tighten upper eye to the specified torque.
Tightening torque
I9J011220017-01
Upper eye (a): 108 N·m (11 kgf-m, 80 lbf-ft)
Special tool
(A): 09945–69010 (PTT rod holder)
(a)
(A)
I9J011220019-01
PTT Pump Assembly PTT Motor

• Install five new O-rings (1) to PTT body assembly. • Install the PTT motor.
Refer to “Power Trim and Tilt Motor Removal and
NOTE Installation (One-Cylinder Type)” (Page 2B-33).
Lubricate O-rings with PTT fluid before
installing. PTT Fluid
• Pour recommended PTT fluid into reservoir to the
• Install PTT pump assembly, then tighten three bolts specified level.
(a) (b) to the specified torque. Refer to “Checking PTT Fluid Level (One-Cylinder
Tightening torque Type)” (Page 2B-17).
PTT pump assembly bolt (a): 8.0 N·m (0.82 kgf-
m, 5.9 lbf-ft) Air Bleeding
PTT pump assembly bolt (b): 5.5 N·m (0.56 kgf- Before installing the PTT unit on the outboard motor, use
m, 4.1 lbf-ft) the following procedure to bleed air from the system.
1) Support the PTT unit in an upright position in a vise.
2) Fill the reservoir with PTT fluid to the specified level,
then install oil filler plug.
1
(a) (a)
(b)
IMP311220018-01
Manual Release Valve I9J011220022-01
• Oil and install the manual release valve (1). 3) Tighten the manual release valve to the specified
Tighten the valve to the specified torque. torque.
• Install snap ring (2). Tightening torque
Tightening torque Manual release valve: 3.5 N·m (0.36 kgf-m, 2.6
Manual release valve (a): 3.5 N·m (0.36 kgf-m, 2.6 lbf-ft)
lbf-ft) 4) Connect the PTT cable extension to the PTT motor
cable connector.
Special tool
(A): 09945–79310 (PTT cable extension)
1 1 (a)
5) Connect the two extension cable lead wires (Bl to
positive/G to negative) to the battery as shown in the
illustration.
Operate the PTT motor until the PTT rod is in the
fully trimmed down position (completely retracted).
2 If the rod does not come down completely, push it in
by hand while operating the motor.
I9J011220021-01
NOTICE
release valve is open, the inner parts of the

completely closed.
(A)
I9J011220023-01
I9J011220025-01
6) Reverse the two extension cable lead wires (G to
positive/Bl to negative). • Inspect reservoir for cracks, nicks or damage.
Operate the PTT motor until the PTT rod is in the full Replace if necessary.
tilt up position (fully extended). • Inspect reservoir seal for cuts, nicks or wear.
If the rod does not come up completely, pull it up by
hand while operating the motor.
(A)
I9J011220026-01
I9J011220024-01
• Inspect manual release valve for damage. Replace if
7) Remove the reservoir oil filler plug and fill with PTT necessary.
fluid to the specified level. • Inspect O-rings for cuts, nicks or tears.
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-18).
Power Trim and Tilt Unit Components Cleaning

and Inspecting (One-Cylinder Type) IDG211220022-01
CENNP3132206012
Arrange all components on a clean sheet of paper.
NOTE
• Do not lay PTT components out on a rag,
as dirt or lint may be transferred to these
items which may cause possible system
operating problems.
• If excessive wear, cracks, defective or
other damage is found on any component,
replace component.
• Inspect PTT pump assembly for cracks, nicks,

stripped threads and any other imperfections.
• Inspect lower shaft and upper shaft for bends, twists 3) Remove the four screws securing the PTT motor (1)
or other damage. Replace if necessary. to the PTT pump assembly.
• Inspect all bushings for excessive wear or other
damage. Replace if necessary.
If bushing fit is loose when installing, replace bushing.
• Inspect upper and lower shaft for bent, twist or other
IDG211220025-01
4) Detach the PTT motor from PTT pump assembly.

Note the position of drive joint (2) and O-ring (3) and
remove them.
IDG211220023-01
Power Trim and Tilt Motor Removal and

Installation (One-Cylinder Type)
CENNP3132206013
Removal
1) Remove Power Trim and Tilt unit. 3
Refer to “Power Trim and Tilt Unit Removal and 2
Installation (One-Cylinder Type)” (Page 2B-20).
NOTE
I9J011220031-01
Before removing PTT motor, wash the PTT
body with a stiff bristle brush and hot, soapy Installation
water to remove sand or dirt. Dry the PTT Installation is in the reverse order of removal with special
body with compressed air. attention to following points.
• Ensure that the drive joint (1) is aligned and firmly
2) Place the lower section of the PTT unit in a vise. inserted into the gear pump assembly.
• Fit new O-ring (2) to PTT motor.
DO NOT OVER TIGHTEN.
NOTE
2
wood blocks, vise jaw protectors, etc.,
between the vise jaws and PTT components
before tightening vise.
4
1
3
I9J011220032-02
• 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.
IDG211220024-02
• Ensure that the faces of the PTT motor and pump unit 2) Connect the PTT cable extension to PTT motor
are free of dirt or debris. cable connector.
When attaching the PTT motor to the PTT pump
Special tool
assembly (3), ensure that the tip of armature shaft (4)
(A): 09945–79310 (PTT cable extension)
fits firmly into the drive joint (1).
• Tighten the four screws (a) to the specified torque. 3) Connect the PTT cable extension leads (G, Bl) to
battery and operate PTT motor until tilt rod is at
Tightening torque maximum stroke (full-tilt up position). Unscrew the
PTT motor screws (a): 5 N·m (0.51 kgf-m, 3.7 lbf- filler plug and drain PTT oil into a suitable container.
ft)
(A)
(a)
(a)
IDG211220058-01
IDG211220026-01
4) Remove the three screws securing reservoir (1),
• Pour recommended PTT fluid into reservoir until the then detach the reservoir (1) from cylinder body.
specified level. Note the position of O-ring (2) and remove it.
• Perform the air bleeding procedure.
Refer to “Power Trim and Tilt Unit Reassembly (One-
1
Cylinder Type)” (Page 2B-30).
Power Trim and Tilt Unit Disassembly (Three-

Cylinder Type)
CENNP3132206014
NOTE
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
compressed air. IDG211220059-01

DO NOT OVER TIGHTEN.
NOTE
wood blocks, vise jaw protectors, etc.,
1
2
IDG211220062-01
IDG211220057-02
5) Remove the PTT motor assembly (3).

Refer to “Power Trim and Tilt Motor Removal and 10
Installation (Three-Cylinder Type)” (Page 2B-41). 12
9
Note the position of drive joint (4) and O-ring (5),
before removing them.
5
3
9 11
IDG211220064-04
8) Using special tool, unscrew the PTT cylinder head

(13).
4 Special tool
(B): 09944–09820 (PTT cylinder cap tool)
IDG211220060-01
6) Remove the manual release valve snap ring (6),

then unscrew the manual release valve (7).
(B)
13
IDG211220065-02
7 9) Pull the tilt rod/piston assembly (14) out of the tilt

6
cylinder.
Remove the free piston (15) from the tilt cylinder.
IDG211220061-01
7) Remove the three bolts securing the PTT pump

assembly (8), then detach the PTT pump assembly 14
from PTT cylinder body.
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
them. 15
IDG211220066-01
10) Unscrew the piston retaining nut from the bottom of

8 the tilt rod and remove the washer.
Carefully retain and account for four shock valves,
each composed of spring, rod and ball.
IDG211220063-01
IDG211220067-01
11) Remove the piston assembly and PTT cylinder head Power Trim and Tilt Unit Reassembly (Three-
from the tilt rod by sliding them down and off the rod Cylinder Type)
end. CENNP3132206015
NOTE
• Do not reuse O-rings and seals once
removed.
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.
IDG211220068-01
12) Using special tool, unscrew the trim cylinder head. Tilt Rod
• When tightening the piston retaining nut on the tilt rod
Special tool
piston, apply thread lock to the threads.
(C): 09944–09810 (PTT trim cap tool)
Tighten the nut to the specified torque.
Tightening torque
Piston retaining nut (a): 100 N·m (10 kgf-m, 74
lbf-ft)
(C)
IDG211220069-02
(a)
13) Pull the trim rod/piston assembly out of the trim
cylinder.
IMP311220011-01
IDG211220070-01
Installing Tilt Rod / Piston Trim Rod

• Pour 100 ml (3.4 oz) of PTT fluid into cylinder. • Pour PTT fluid into the trim cylinder until it is topped
• Insert the free piston into cylinder and push it down to off.
the bottom of the cylinder. • Insert the trim rod/piston assembly into cylinder and
• Pour PTT fluid into the cylinder until it is topped off. thread the trim cylinder head by hand until fully
seated.
• Insert the tilt rod/piston into cylinder and thread the tilt
cylinder head by hand until fully seated. • Tighten the trim cylinder head to the specified torque
using special tool.
• Tighten the cylinder head to the specified torque using
special tool. Tightening torque
Trim cylinder head (a): 170 N·m (17 kgf-m, 125
Free piston
lbf-ft)
Special tool
Top OFF (B): 09944–09810 (PTT trim cap tool)
Cylinder
(a) Upper edge

(B)
IDG211220072-01
Tightening torque
Tilt cylinder head (a): 235 N·m (24 kgf-m, 173 lbf-
ft)
IDG211220074-03
Special tool
(A): 09944–09820 (PTT cylinder cap tool)
PTT Pump Assembly
• Install new five O-rings and orifice collars to PTT
cylinder body.
(A)
NOTE
Lubricate O-rings with PTT fluid before
installing.
(a) • Install PTT pump assembly, then tighten three screws

to the specified torque.
Tightening torque
IDG211220073-02
PTT pump case screw (a): 8.5 N·m (0.87 kgf-m,
6.3 lbf-ft)
O-ring /
Orifice collar
O-ring
(a)
O-ring /
Orifice collar
IMP311220014-03
PTT Fluid
• Pour recommended PTT fluid into reservoir to the
specified level.
Refer to “Checking PTT Fluid Level (Three-Cylinder
O-ring / Valve
Type)” (Page 2B-17).
Air Bleeding
Before installing the PTT unit on the outboard motor, use
the following procedure to bleed air from the system.
1) Support the PTT unit in an upright position in a vise.
2) Fill the reservoir with PTT fluid to the specified level,
IMP311220015-02 then install oil filler plug.
Manual Release Valve
Oil level (When full-tilted)
• Oil and install the manual release valve (1).
Tighten the valve to the specified torque.
• Install snap ring (2).
Tightening torque
Manual release valve (a): 3.5 N·m (0.36 kgf-m, 2.6
lbf-ft)
IDG211220078-01
1 (a) 3) Tighten the manual release valve to the specified
torque.
Tightening torque
Manual release valve: 3.5 N·m (0.36 kgf-m, 2.6
1 2 lbf-ft)
4) Connect the PTT cable extension to the PTT motor
cable connector.
IDG211220076-01
Special tool
PTT Motor (A): 09945–79310 (PTT cable extension)
• Install the PTT motor.
Refer to “Power Trim and Tilt Motor Removal and
Installation (Three-Cylinder Type)” (Page 2B-41).
Reservoir
• Install new O-ring (1) and reservoir, then tighten bolts
to the specified torque.
Tightening torque
Reservoir bolt (a): 5 N·m (0.51 kgf-m, 3.7 lbf-ft)
(a)
IDG211220077-01
5) Connect the two extension cable lead wires (G to 6) Reverse the two extension cable lead wires (Bl to
positive/Bl to negative) to the battery as shown in the positive/G to negative). Operate the PTT motor until
illustration. the PTT rod is in the full tilt up position (fully
Operate the PTT motor until the PTT rod is in the extended). If the rod does not come up completely,
fully trimmed down position (completely retracted). pull it up by hand while operating the motor.
If the rod does not come down completely, push it in
by hand while operating the motor.
NOTICE
release valve is open, the inner parts of the (A)

completely closed.
IDG211220080-01
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.
(A)
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
IDG211220079-01 2B-18).
Power Trim and Tilt Unit Components Cleaning • Inspect the PTT cap seal and O-ring.
and Inspecting (Three-Cylinder Type) Replace if cuts, nicks, or excessive wear is found.
CENNP3132206016
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.
• 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
IDG211220096-01
• Inspect manual release valve for damage. Power Trim and Tilt Motor Removal and
Inspect manual release valve O-ring. Installation (Three-Cylinder Type)
Replace if nicked or cut. CENNP3132206017
Removal
1) Remove Power Trim and Tilt unit.
Installation (Three-Cylinder Type)” (Page 2B-23).
NOTE
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.

IDG211220085-02
• Inspect lower rod. DO NOT OVER TIGHTEN.
If bending, cracks, corrosion or other damage is
found, replace lower rod. NOTE
• Inspect upper shaft for bent, twist or other damage. To prevent damage to the PTT cylinder use
Replace if necessary. wood blocks, vise jaw protectors, etc.,
IDG211220097-01
• Inspect all bushings for excessive wear or other

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
IDG211220088-01
4) Detach the PTT motor from PTT pump assembly. • Check the level of PTT fluid contained in the PTT
Note the position of drive joint (2) and O-ring (3) and pump assembly. If level is low, add recommended
remove them. 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 the specified torque.
2
Tightening torque
PTT motor screws (a): 5 N·m (0.51 kgf-m, 3.7 lbf-
ft)
IDG211220089-01
Installation
attention to following points.
• Ensure that the drive joint (1) is aligned and firmly
inserted into the gear pump assembly. (a)
• Fit new O-ring (2) to PTT motor.
IDG211220092-02
• Pour recommended PTT fluid into reservoir until the

specified level.
• Perform the air bleeding procedure.
Refer to “Power Trim and Tilt Unit Reassembly
(Three-Cylinder Type)” (Page 2B-36).
Power Trim and Tilt Motor Disassembly and

Assembly
CENNP3132206018
IDG211220090-01
Disassembly
1) For correct assembly, scribe an alignment mark on
the field case and brush holder.
2 2) Slide cable protector tube upward.
3) Remove the screw securing the motor cable holder
4 (1), then slide motor cable holder and grommets (2)
out as shown in figure.
2
1
1
3
IDG211220091-01
I9J011220034-01
4) Remove the two screws (3) securing the field case to Assembly
the brush holder. Assembly is in the reverse order of disassembly with
• Install new O-ring (1).
• Install armature (2) to brush holder first. When
installing the armature, use care to avoid breaking the
3
brushes.
1
I9J011220035-01
5) Slide the field case upward and away from the brush
holder.
NOTE
When separating field case from brush
holder, push the PTT motor cables into brush
holder as the field case is removed. I9J011220038-01
• Match up previously scribed alignment marks.

• When assembling field case to brush holder, pull out
on the PTT motor cables as the field case is
assembled into position.
• Apply silicone seal to PTT motor cable holder and
grommets and install cable holder screw.
Seal (100 g))
I9J011220036-01
6) Disconnect PTT motor cables from brush holder.

Remove armature from field case. Note the position
of the O-ring encircling the brush holder.
I9J011220039-01
PTT Motor Related Items Inspection

CENNP3132206019
Armature and Commutator
• Check for continuity between the commutator and the
I9J011220037-01 armature core/shaft. Replace armature if continuity is
indicated.
Special tool
Continuity ( )
• Ensure that the mica (insulator) between commutator

segments are undercut “a” to the specified depth.
(A) If undercut is less than service limit, cut to the
specified depth.
! WARNING
Failure to following proper precautions
during use of the compressed air may cause
severe personal injury.
I9J011220040-01
• Check continuity between adjacent commutator Wear safety glasses when using compressed
segments. air.
Replace armature if no continuity is indicated.
NOTE
(A) Remove all particles of mica and metal using
compressed air.
Commutator undercut
Standard: 1.6 – 1.9 mm (0.063 – 0.074 in)
“A”
I9J011220041-01 “a”
• Inspect the commutator surface.
If surface is gummy or dirty, clean with 400 grit emery “B”
paper (1). I9J011220043-01
• Measure commutator outside diameter. “A”: Segment “B”: Mica
If measurement exceeds service limit, replace
armature. Brushes
Special tool • Check the length of each brush.
(B): 09900–20101 (Vernier calipers (150 If brushes are worn down to the service limit, they
mm)) must be replaced.
Commutator outside diameter Special tool
Standard: 22.0 mm (0.87 in) (B): 09900–20101 (Vernier calipers (150
Service limit: 21.0 mm (0.83 in) mm))
Brush length
INP313220003-01
INP313220002-01
PTT Motor Relay Inspection

CENNP3132206020 5 6
2
1) Remove the PTT motor relay from the electric parts 1
holder.
Refer to “Wire harness Removal and Installation” in
2) Check the resistance between each two terminals.
3 4
Special tool
Resistance (Ω)
PTT relay coil resistance (A)
IDG211220098-03
Between “terminal (1)” and “terminal (4)”: 16 – 24
Ω 1. Terminal 1 (UP coil) 4. Terminal 4 (GND)
2. Terminal 2 (DN coil) 5. Terminal 5 (For UP)
Between “terminal (2)” and “terminal (4)”: 16 – 24
3. Terminal 3 (Power) 6. Terminal 6 (For DN)
Ω
Special tool
Continuity ( )
PTT relay function

Continuity
1 2 12 V power not applied No
5) If inspection in step 2 and/or step 3, 4 fails, replace

PTT motor relay.
4 6) Install the PTT motor relay to the electric parts
3
holder.
Refer to “Electric Parts Holder Removal and
(A)
IDG211220027-03
NOTICE
If the 12 V power supply wire is connected to
wrong terminal or touched to each other, the
power supply wire, tester may be damaged.


(4).
(4).
PTT Switch Inspection

CENNP3132206021
Test continuity between the switch lead wires at each of
the three switch positions.
If out of the specification, replace PTT switch.
Special tool
Continuity ( )
Tester probe connection Tester
Red (+) Black (–) indicates
DN side
Terminal (2) Terminal (1) Continuity
depressed
UP side
Terminal (3) Terminal (1) Continuity
depressed
Not Terminal (2)
Terminal (1) Infinity
depressed Terminal (3)
IMP311220013-01
3 (Lbl)
2 (R) 1 (Lg)
INP313220006-01
Section 3
Lower Unit
CONTENTS
Precautions .................................................3-1 Trim Tab Adjustment.........................................3A-24

Precautions............................................................. 3-1 Lower Unit Gears - Shimming and Adjustment ..3A-25
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 Pinion Bearing Removal and Installation ..........3B-13
Lower Unit Disassembly...................................... 3A-9 Lower Unit Related Items Inspection ................3B-14
Pinion Bearing Removal and Installation .......... 3A-12 Propeller Shaft Oil Seal Replacement...............3B-17
Lower Unit Related Item Inspection .................. 3A-14 Driveshaft Oil Seal Replacement ......................3B-17
Propeller Shaft Oil Seal Replacement............... 3A-16 Lower Unit Assembly ........................................3B-18
Driveshaft Oil Seal Replacement ...................... 3A-17 Trim Tab Adjustment.........................................3B-25
Lower Unit Assembly ........................................ 3A-18 Lower Unit Gears - Shimming and Adjustment ..3B-26
3-1 Precautions:
Precautions
Lower Unit
Precautions
General Precautions
CENNP3133000001
Precaution for Lower Unit

CENNP3133000002
! 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
CENNP3133104001
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
CENNP3133106001
(b)
9
2
(a)
1
8 7 (c)
4 6
5
3
10
12 16
11
13
14 12
15
14
17
15
INP313310001-01
1. Clutch lever 8. Clutch holder 15. Cotter pin

2. Bushing 9. Shift position sensor bracket 16. Clutch shaft
3. Bushing 10. Clutch shaft arm 17. Clutch rod
4. Grease nipple 11. E-ring : 23 Nm (2.3 kgf-m, 17 lbf-ft)
5. Ball 12. Bushing : 10 Nm (1.0 kgf-m, 7.4 lbf-ft)
6. Spring 13. Clutch lever link : 18 Nm (1.8 kgf-m, 13 lbf-ft)
7. Plug 14. Washer : Apply water resistant grease.
1 2
6
3 (d) 14 (c) 12
13
15
4 17 16
10 8
5 18
7
10 19
9
20
33
32 31
11 21
23 30
22
24
25
26
27
34
36
29 (a)
28 (a) 35 (b)
36
38
37
IMP311310001-05
1. Oil seal cover 12. Bushing 23. Exhaust seal plate 34. Trim tab
2. Oil seal 13. Water pump case 24. Union 35. Bolt
3. Bolt 14. Bolt 25. Hose 36. Screw
4. Shift rod guide housing 15. Dowel pin 26. Nipple 37. Water filter PORT
5. O-ring 16. Key 27. Gearcase 38. Water filter STBD
6. Shift rod 17. Water pump case sealing 28. Bolt : 55 Nm (5.6 kgf-m, 41 lbf-ft)
7. Magnet 18. Inner sleeve 29. Bolt : 23 Nm (2.3 kgf-m, 17 lbf-ft)
8. Bushing 19. Water pump impeller 30. Dowel pin : 17 Nm (1.7 kgf-m, 13 lbf-ft)
9. Shifter yoke 20. Under panel 31. Anode : 7.0 Nm (0.71 kgf-m, 5.2 lbf-ft)
10. Pin 21. Gasket 32. Washer : Apply water resistant grease.
11. Horizontal slider 22. Exhaust seal rubber 33. Bolt : Apply sealant.
2 (b)
1
3
4 49
52
51
5 50
6 48 54
7 53 (c)
8
9
10
8
11
25
12 23 (b)
26 19
14 24
15 (d) 13
29 20
27
22 21
30 (a)
47
28
35 45
43 46
42
16
33 44
34 40
36
37 32 38 39
40
41
31
17
18 (d)
IMP311310002-04
1. Driveshaft 17. Gasket 33. Thrust washer 49. Propeller

2. Bolt 18. Plug 34. Shim 50. Propeller bush
3. Driveshaft oil seal housing 19. Ring 35. Bearing 51. Spacer
4. Oil seal 20. Oil seal protector 36. Forward gear bearing housing 52. Washer
5. O-ring 21. Oil seal 37. Pin 53. Propeller nut
6. Shim 22. Bearing 38. Clutch dog forward spacer 54. Cotter pin
7. Bearing 23. Bolt 39. Spring : 120 Nm (12 kgf-m, 89 lbf-ft)
8. Washer 24. Propeller shaft bearing housing 40. Large detent ball : 23 Nm (2.3 kgf-m, 17 lbf-ft)
9. Washer 25. Bearing 41. Small detent ball : 55 Nm (5.6 kgf-m, 41 lbf-ft)
10. Wave washer 26. O-ring 42. Connector pin : 10 Nm (1.0 kgf-m, 7.4 lbf-ft)
11. Driveshaft collar 27. Shim 43. Clutch dog shifter : Apply water resistant grease.
12. Dowel pin 28. Reverse gear 44. Dog pin : Apply Outboard Motor Gear Oil.
13. Pinion bearing 29. Pinion 45. Dog spring : Apply thread lock1342H.
14. Gasket 30. Pinion nut 46. Propeller shaft
15. Plug 31. Forward gear 47. Thrust washer
16. Gearcase 32. Bearing 48. Stopper
Propeller Removal and Installation Installation

CENNP3133106002
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 the 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 (5.6 kgf-m, 41 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 CENNP3133106003
2 Refer to “Propeller / Propeller Nut and Cotter Pin
6 3 Inspection” in Section 0B (Page 0B-16).
I9J011310002-02
Lower Unit Removal and Installation Installation

CENNP3133106004
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) Make sure the clutch is in “Neutral” position.

1
2) Remove bolt and trim tab (1).
IMP311310019-01
2) Ensure that shift rod (2) is at “Neutral” position.
NOTE
1 Before installing lower unit, bring shift to

Neutral position by turning shift rod right or
left.
IDG211310001-01
3) Remove seven bolts (2) and separate gearcase (3)

from driveshaft housing.
2 Front
direction
2
3
IDG211310004-03
3) Insert two dowel pins (3).

IDG211310002-01
4) Apply water resistant grease to driveshaft and shift
rod splines.
5) Apply a light coating of sealant to mating surfaces of
gearcase and driveshaft housing.
Seal (100 g))
IDG211310005-02
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 CENNP3133106005
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).
2) Loosen four bolts (1), then remove water pump case
(2).
Neutral
INP313310002-01
NOTE 1
In order for shift rod and clutch rod splines to IDG211310008-01

be aligned correctly, clutch rod may need to 3) Remove impeller (3), impeller key (4), under panel
be turned slightly right or left. (5) and dowel pins (6).
Keep impeller key (4) for reuse and discard the plate
7) Apply sealant to seven gearcase bolts and tighten
gasket.
them to the specified torque.
Seal (100 g))
3
Tightening torque
Gearcase bolt (a): 55 N·m (5.6 kgf-m, 41 lbf-ft)
6
5 6
IDG211310009-01
(a) 4) Remove inner sleeve (7), sealing (8).
NOTE
5
To facilitate the removal of inner sleeve from
pump case, warm up the entire case using a
IMP311310020-02
heater like hair dryer.
8) Shift the clutch control lever to “Forward” and
“Reverse” position from “Neutral” position to check
proper gear engagement.
IDG211310011-02
Installation
1) Place the dowel pins (1), 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 is aligned.
8
1 5
IDG211310014-01
3 4 NOTE
Before installing water pump case assembly,
apply water resistant grease lightly on pump
1
case inner sleeve and under panel for initial
2 lubrication.
IDG211310012-01
3) Place the sealing (7) into groove of the pump case

(6).
NOTE
Do not reuse sealing once removed.
Always use new sealing.
IDG211310015-01
5) Install the pump case assembly (9) while rotating

driveshaft clockwise to flex the impeller vanes in the
6
correct direction.
Securely tighten the four pump case bolts (10) to the
specified torque.
IDG211310013-01 Tightening torque
4) Install inner sleeve (8) into the pump case, ensuring Water pump case bolt (a): 17 N·m (1.7 kgf-m, 13
that projection of inner sleeve and groove of pump 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.

10 (a)
IDG211310016-01
6) Install the Lower Unit.

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

CENNP3133106006 CENNP3133106007
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. 3A-6).
• Inspect pump case. Replace if cracked, distorted or 2) Remove the water pump and related parts.
other abnormal conditions are noted. Refer to “Lower Unit Removal and Installation” (Page
• Inspect pump inner sleeve. Replace if worn, cracked, 3A-6) and “Water Pump Removal and Installation”
distorted, corroded or other abnormal conditions are (Page 3A-7).
noted. 3) Place a drain pan under oil drain plug. Remove oil
• Inspect under panel. Replace if cracked, distorted, drain plug (1) first then oil level plug (2) and allow
corroded or other abnormal conditions are noted. gear oil to drain.
Inspect oil for water, contaminates or metal.
NOTE
2
1
IDG211310019-01
4) Remove the propeller.

Refer to “Propeller Removal and Installation” (Page
3A-5).
IDG211310017-01 5) Remove the bolts (3) and shift rod guide housing
assembly (4).
IDG211310018-01
IDG211310020-01
6) Remove two bolts (5) securing the propeller shaft

bearing housing to the gearcase.
IDG211310021-01
7) Using special tools, pull out the propeller shaft 10) Lift out driveshaft assembly (11).
bearing housing. Remove the driveshaft collar (12), washer (13), wave
Remove the propeller shaft and bearing housing washer (14), washer (with tab) (15) and washer (16)
assembly (6). from driveshaft.
Special tool
(A): 09930–30104 (Sliding hammer)
(B): 09930–30161 (Propeller shaft remover)
16
11
15
14
13
12
(A)
6 IMP311310022-02
(B)
11) Remove the pinion (17).
IDG211310022-02
8) Hold the pinion nut securely, then fit special tool to

the driveshaft and loosen the pinion nut. Remove
pinion nut (7).
Special tool
(C): 09921–29410 (Driveshaft holder)
17
IMP311310023-01
12) Remove the forward gear (18) and thrust bearing

(19).
7
(C)
IDG211310023-01
9) Remove the four (4) bolts (8) securing driveshaft oil

seal housing (9), then remove oil seal housing and 19
pinion back-up shim (10).
18
IMP311310024-01
9
10
IMP311310021-01
13) Remove the bearing thrust washer (20) and back-up b) Remove horizontal slider (28).
shim (21). c) Remove forward gear thrust washer (29).
d) Remove the spring (30) from the clutch dog
shifter (31).
29
21
20
30
IMP311310025-01
31
14) Remove the forward gear bearing housing (22). 28
Account for dowel pin (23). IMP311310028-01
e) Push the dog pin (32) out of the clutch dog

shifter (31).
22 23
IMP311310026-01
15) To disassemble propeller shaft components, refer to

IMP311310029-02
following.
f) Remove clutch dog shifter (31) and connector
a) Slide propeller shaft away from reverse gear (24)
pin (33) from propeller shaft.
and bearing housing assembly (25).
Account for the reverse gear back-up shim (26)
and reverse gear thrust washer (27).
33
25
24
31
32
IMP311310030-02
27 26
IMP311310027-01
g) Remove large detent ball (34), detent spring Pinion Bearing Removal and Installation
(35), large detent ball (34) and two small detent CENNP3133106008
balls (36) from connector pin (33). NOTICE

needle rollers and outer race. If the removed
bearing is re-used, problem will occur in the
lower unit.
33
Do not reuse pinion bearings once removed.
Always use new one.
36 Removal and Installation Tools

To remove the pinion bearing from the gearcase, use the
following special tools.
34 35 34
IMP311310031-02 Special tool
16) To disassemble shift rod components, refer to (A): 09951–59910 (Shaft (removal and
following. installation))
(B): 09951–38710 (Plate)
a) Remove oil seal cover (37).
(C): 01500–0840A (Bolt)
b) Slide shift rod (38) out of shift rod guide housing (D): 09951–19220 (Attachment)
(39). (E): 09930–30104 (Sliding hammer)
c) Remove oil seals (40) from shift rod guide
housing. (B)
(E)
(A)
(C) (D)
I9J011310018-03
IMP311310005-03
d) Remove the shifter yoke (41) from the shift rod

(38) by driving out the pin (42).
IMP311310006-03
Removal Installation
1) Disassemble the lower unit.
NOTE
Refer to “Lower Unit Disassembly” (Page 3A-9).
2) Place the attachment (D) inside the pinion bearing. • Before installing bearing, ensure that
inside of gearcase is clean and free of
3) Insert the removal shaft (A) into attachment (D).
debris.
4) Thread sliding hammer (E) into top of removal shaft
• Ensure that the bearing stamped mark
(A).
faces upward.
5) Put wood block under pinion bearing.
6) Drive the pinion bearing out downwards by striking 1) Set the installer shaft (A), plate (B), attachment (D),
top of shaft (A) with sliding hammer (E). and pinion bearing as shown in the figure.
2) Place the installer shaft (A) (with pinion bearing on
end of installer shaft) into the gearcase.
3) Secure the plate (B) by tightening the bolt (C).
(E)
4) Thread the sliding hammer (E) into the top of the
installer shaft (A).
5) Drive the pinion bearing down into position by gently
striking the installer shaft (A) until the coupler
touches plate.
(A) 6) Assemble the lower unit.
Refer to “Lower Unit Assembly” (Page 3A-18).
(E)
(D)
(B)
1
2
(A) (C)
IDG211310037-03
1. Pinion bearing 2. Wood block IDG211310038-02
(E)
(C)
(A)
(B)
(D)
IDG211310039-04
1. Pinion bearing
Lower Unit Related Item Inspection Gears / Bearing

CENNP3133106009
• Inspect forward, reverse and pinion 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. • Inspect forward gear bearing housing.
Replace if cracked, damaged or other abnormal
NOTE conditions are noted.
• If any component is worn excessively, • Inspect forward gear bearing.
cracked, defective or damaged in any way, Replace bearing if pitted, noisy, rough or other
it must be replaced. abnormal conditions are noted.
• Thoroughly wash all metal components
with cleaning solvent and dry with
compressed air.
Gearcase
• Inspect the gearcase. Replace if cracked, damaged or
other abnormal conditions are noted.
• Visually check the pinion bearing. Replace bearing if
pitted, rough or other abnormal conditions are noted.
NOTE
IDG211310042-01
If removal and replacement are required,
refer to “Pinion Bearing Removal and
Installation” (Page 3A-12).
IDG211310043-01
IDG211310041-01
Propeller Shaft Components Propeller Shaft Bearing Housing

• Inspect horizontal slider and connector pin. • Inspect housing. Replace if cracked, damaged or
Replace if wear, damage or other abnormal condition. other abnormal conditions are noted.
• Inspect detent balls. Replace if wear, damage or other • Inspect reverse gear bearing and propeller shaft
abnormal conditions are noted. bearing. Replace bearing if pitted, noisy, rough or
• Inspect clutch dog shifter. Replace if chipped, worn, other abnormal conditions are noted.
damaged or other abnormal conditions are noted. • Check condition of oil seal and O-ring. Replace oil
• Inspect dog pin. Replace if bent, worn or other seal and O-ring if nicked, cut, worn or other abnormal
abnormal conditions are noted. conditions are noted.
• Inspect propeller shaft/splines. Replace if worn,
twisted, damaged or other abnormal conditions are
noted.
IDG211310045-01
IDG211310044-01
• Check detent spring by measuring its free length. If

free length is not within specifications, replace detent
spring.
Detent spring free length “a”
“a”
IDG211310046-01
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 oil seal cover. Replace if nicked,
cut, worn or other abnormal conditions are noted.
IDG211310050-01
IMP311310007-01
IDG211310051-01
Propeller Shaft Oil Seal Replacement

CENNP3133106010
1) Remove the propeller shaft bearing housing.
IMP311310008-01
Refer to “Lower Unit Disassembly” (Page 3A-9).
2) Remove the retaining ring (1) and washer (2).
Driveshaft Oil Seal Housing
• Inspect housing. Replace if cracked, damaged or 1
• Check condition of oil seals. Replace if nicked, cut,
worn or other abnormal conditions are noted.
• Inspect O-ring. Replace if worn, nicked, cut or other
abnormal conditions are noted.
2
IDG211310052-01
IDG211310049-01
3) Extract seals (3) with oil seal remover. Driveshaft Oil Seal Replacement
CENNP3133106011
NOTICE 1) Remove the driveshaft oil seal housing.
Removing the oil seal can cause damage to Refer to “Lower Unit Disassembly” (Page 3A-9).
the seal lips, causing oil to leak. 2) Using special tool, remove two oil seals out of the
Do not reuse the oil seal once removed. driveshaft oil seal housing.
Always use new one.
Special tool
Special tool (A): 09913–50121 (Oil seal remover)
(A): 09913–50121 (Oil seal remover) NOTICE
Do not reuse the oil seal once removed.
Always use new one.
(A)
(A)
IDG211310053-01
4) Apply water resistant grease to the outer

circumference of the oil seals.
IDG211310055-01
5) Using an oil seal installer, drive the two oil seals (one
3) Apply water resistant grease to the outer
at a time) into the propeller shaft bearing housing.
circumference of the oil seals.
The lipped portion of the seals 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.
“A” With the lips facing away from driveshaft bearing,
place seal in position and drive it into the oil seal
housing.
“A”
IDG211310054-02
“A”: Direction of propeller
6) Install the washer and retaining ring.

7) Assemble the propeller shaft bearing housing. IDG211310056-02
Refer to “Lower Unit Assembly” (Page 3A-18). “A”: Direction of water pump case
5) Assemble the driveshaft oil seal housing.

Refer to “Lower Unit Assembly” (Page 3A-18).
Lower Unit Assembly Forward Gear

CENNP3133106012 Place the forward gear back-up shim (1), thrust washer
Assembly is in reverse order of disassembly with special (2), forward gear thrust bearing (3) in position, then
attention to the following points. install forward gear (4).
NOTICE
Failure to correctly adjust the gear position
1
will result in lower unit damage.
Before final assembly of lower unit, be 2
absolutely certain that all gear contact, shim
adjustments and tolerances are correct.
Refer to “Lower Unit Gears - Shimming and
Adjustment” (Page 3A-25).
NOTE
• Make sure that all parts used in assembly IDG211310058-01
are clean and lubricated.
• It is recommended that all seals, gaskets
and O-rings be replaced with new on
assembly.
• After assembly, check parts for tightness
and smoothness of operation.
Forward Gear Bearing Housing

3
Install dowel pin (1) and forward gear bearing housing
(2). 4
IDG211310059-01
2 1
Pinion
• Degrease tapered portion of pinion.
• Place pinion (1) in gearcase.
IDG211310057-01
IDG211310060-01
Driveshaft Driveshaft Oil Seal Housing

• Assemble the washer (1), washer (with the tab) (2), • Apply water resistant grease to the driveshaft oil seal.
wave washer (3), washer (4) and driveshaft collar (5)
to the driveshaft.
• Degrease tapered portion of driveshaft.
• Apply water resistant grease to O-ring (1), then install
O-ring into groove on the driveshaft oil seal housing
(2).
1
2
3 2
4
1
5
IMP311310032-02
• After installing driveshaft collar, fit the convex part of

the collar in the concave part of the driveshaft by
IDG211310064-01
turning collar.
• Install the driveshaft oil seal housing on the gearcase.
• Lower the driveshaft assembly (6) down into the
Apply thread lock to four bolts (3), then tighten bolts to
gearcase until the bottom of shaft protrudes through
the specified torque.
center of pinion.
Tightening torque
NOTE Driveshaft oil seal housing bolt (a): 23 N·m (2.3
The washer tab must be located into groove kgf-m, 17 lbf-ft)
on the gearcase.
3 (a)
IMP311310033-01
IMP311310039-01
• Install bearing outer race (7) and pinion back-up shim
(8) to driveshaft.
8
7
IMP311310034-01
Pinion Nut • Insert two small detent balls (3), large detent ball (4),
• Apply thread lock to the threads of pinion nut (1) detent spring (5) and large detent ball (6) into
before threading it onto driveshaft. connector pin (7). Then depress detent ball (6) and
temporarily insert stopper pin “A” into dog pin hole of
: Thread lock cement 99000–32160 connector pin, as shown in the figure.
• Tighten pinion nut to the specified torque. 7
NOTE
It is recommended the original pinion nut be
used for the purposes of shimming during
repair. A new pinion nut should be used on
final assembly.
6
3
Special tool 5
(A): 09921–29410 (Driveshaft holder) 4
Tightening torque IDG211310068-01
Pinion nut (a): 120 N·m (12 kgf-m, 89 lbf-ft) NOTE

Temporarily insert a water pump case dowel
pin “A” into the connector pin to prevent the
detent ball from falling out.
“A”
(A)
1 (a)
IDG211310069-03
IMP311310009-01
• Insert the connector pin (7) (with detent balls) into
propeller shaft (1).
Propeller Shaft • Align the holes in the shifter dog and connector pin
• Slide the clutch dog shifter (2) onto the propeller shaft and then slide the dog pin (8) through both dog and
(1). connector pin. (save the temporarily installed dowel
pin “A” pushed out as the dog pin is inserted.)
NOTE
The side of the clutch dog shifter marked
with the letter “R” must face towards reverse
gear.
IMP311310017-01
IMP311310010-01
• Install the dog pin retaining spring (9), ensuring that it • Using special tools, install the propeller shaft and
fits snugly into the groove on the dog shifter. housing assembly in the gearcase.
Special tool
(A): 09922–59410 (Propeller shaft housing
installer)
(B): 09922–59420 (Housing installer handle)
(A)
IMP311310011-01
Propeller Shaft / Bearing Housing

• Place the forward thrust washer (1) and reverse thrust
washer (2) on the propeller shaft. (B)
• Install back-up shim (3) and reverse gear (4) to IDG211310073-01
propeller shaft bearing housing (5). • When the housing is fully seated, apply thread lock to
• Slide propeller shaft into reverse gear and propeller bolts, then tighten bolts to the specified torque.
shaft bearing housing.
Tightening torque
Propeller shaft bearing housing bolt (a): 23 N·m (
2.3 kgf-m, 17 lbf-ft)
4
1 5
3 (a)
IDG211310071-02
• Assemble horizontal slider (6) to connector pin.

• Apply water resistant grease to the bearing housing
O-ring (7).
: Grease 99000–25350 (SUZUKI Water IMP311310043-01
Checking Propeller Shaft Thrust Play
Check propeller shaft thrust play.
7 Refer to “Lower Unit Gears - Shimming and Adjustment”
(Page 3A-25).
Special tool
(A): 09951–09530 (Gear adjusting gauge)
6
(A)
IDG211310072-02
NOTE
Before installing the propeller shaft/bearing
housing assembly, move the shifter dog to
bring the horizontal slider to the “Neutral”
position. IDG211310075-01
Shift Rod Guide Housing • Install pin (9) to shift rod, then slide shift rod guide
• Apply water resistant grease to the outer housing onto shift rod.
circumference of the oil seals (1).
• Install the oil seals into the shift rod guide housing (2).
• Install the O-ring (3) to the shift rod guide housing.
IMP311310013-01
2
NOTE
Before install the shift rod guide housing
3 assembly, be sure to put the horizontal slider
(10) in the neutral position.
IMP311310012-02
• Attach magnets (4), bushing (5) and shifter yoke (6) to “A”
shift rod (7), then insert pin (8). 11
10
IMP311310014-01
10. Horizontal slider

11. Forward gear bearing housing
“A”: Shift rod center
IMP311310018-01
• Apply water resistant grease to the shift rod guide
housing O-ring.
Front
direction
IMP311310042-02
NOTE
Before installing the shift rod guide housing
assembly, bring the shifter yoke to the
“Neutral” position by turning the shift rod
right or left.
• Install the shift rod guide housing assembly (12) by Leakage Check
aligning the shifter yoke with the groove in horizontal Check for leakage of oil seal and O-ring when applying
slider, then tighten two housing bolts (13) to the specified pressure inside of the gearcase.
specified torque. 1) Install the test tool into the oil level hole.
Tightening torque 2) Connect the air pump to the tester.
Shift rod guide housing bolt (a): 7.0 N·m (0.71 3) Rotate driveshaft and propeller shaft clockwise
kgf-m, 5.2 lbf-ft) several times and then apply specified pressure for
the test.
NOTICE
Failure to correctly apply the test pressure
will result in oil seal damage.
IMP311310044-01
Do not exceed pressure of 110 kPa (1.12 kgf/
cm2, 16.0 psi.).
NOTE
12
Apply low initial pressure of 20 – 40 kPa (0.20
– 0.41 kgf/cm2, 2.9 – 5.8 psi.) first, then apply
specified pressure.
Special tool
(A): 09950–69512 (Gearcase oil leakage
13 (a) tester)
(B): 09952–99320 (Hand air pump)
IMP311310015-02
Leakage pressure test
• Turn the shift rod from the “Neutral” position to the
100 kPa (1.01 kgf/cm2, 14.5 psi.)
“Forward” and “Reverse” position to check proper
gear engagement.
• Apply enough water resistant grease on oil seal
before putting oil seal cover (14) so that there is no
space between them.
(A)
14
(B)
IDG211310083-01
4) Once stabilized, pressure should remain steady for

at least 5 min.
If pressure does not fall, sealing performance is
correct.
Water Pump
IMP311310016-01 Install the water pump and related parts.
3A-6) and “Water Pump Removal and Installation” (Page
3A-7).
Propeller
Install the propeller.
Refer to “Propeller Removal and Installation” (Page 3A-
5).
Lower Unit
Install the Lower Unit.
3A-6).
Trim Tab Adjustment

CENNP3133106013
The trim tab counteracts or minimizes propeller torque
pull felt through the steering system.
If the steering is pulls to the starboard or port side, adjust
the trim tab with the following procedure.
1) Loosen the trim tab bolt (1).
IDG211310084-01
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 to the left.
I9J011310010-03
3) Tighten the bolt of trim tab to the specified torque.

Tightening torque
Trim tab bolt: 23 N·m (2.3 kgf-m, 17 lbf-ft)
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

CENNP3133106014
If the lower unit has been rebuilt or has had components replaced, shimming for the correct gear contact and
driveshaft thrust play 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)
0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85
Pinion back-up shim (1) 1.00
0.90 0.95 1.00 1.05 1.10 1.15
0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90
Forward gear back-up shim (2) 1.10
0.95 1.00
Forward gear thrust washer (3) 9.0 9.0
Propeller shaft reverse thrust
1.5 1.7 1.9 2.1 2.3 2.4 2.6 2.7 2.8 1.5
washer (4)
1.00 1.10 1.20 1.30 1.35 1.40 1.45 1.50
Reverse gear back-up shim (5) 1.00
1.55 1.60 1.65 1.70 1.75
3
5
2
IMP311310035-03
1. Pinion 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 Back-Up Shim Adjustment Adjusting driveshaft thrust play
Prior to adjustment 1) Assemble special tool to driveshaft as shown in the
1) Install standard pinion back-up shim thickness figure.
modified according to ± design specification mark on
Special tool
the gear. For example, if “A” is “+0.05”, install shim
0.05 mm thinner than design specification of 1.00
mm. If “A” is “–0.05”, install shim 0.05 mm thicker
than design specification of 1.00 mm.
(A)
“A”
IDG211310104-01
IMP311310036-04
“A”: ± design spec. mark
2) To check driveshaft thrust play, push forward gear
2) Correctly assemble driveshaft oil seal housing, inward and fix it by hand. Slowly push driveshaft
driveshaft, forward gear, forward gear back-up shim, downward, then read maximum thrust play.
pinion and related components. Driveshaft thrust play
Refer to “Lower Unit Assembly” (Page 3A-18). 0.4 – 0.6 mm (0.016 – 0.024 in)
Do not install reverse gear at this time.
• If the thrust play measured is larger than the
NOTE specification, add the amount over the
Forward gear back-up shim is temporary so specification to the temporary use forward gear
that any of the shims, such as a standard back-up shim and install this shim.
one, can be used. • If the thrust play measured is smaller than the
specification, subtract the amount less than the
specification from the temporary use forward gear
back-up shim and install this shim.
IDG211310088-01
3) Tighten pinion nut to the specified torque.

Tightening torque
Pinion nut: 120 N·m (12 kgf-m, 89 lbf-ft)
Checking and adjusting tooth contact pattern Optimum tooth contact

(Pinion and forward gear) The optimum tooth contact is shown in the figure. A shim
Check tooth contact pattern using the following adjustment may be necessary to obtain this contact
procedure. pattern.
1) To assess tooth contact, apply a light coat of
NOTE
prussian blue on the convex surface of the forward
gear. Driveshaft thrust play should be checked
when increasing or decreasing shim
2) Install the propeller shaft and housing assembly
thickness to adjust tooth contact.
(minus reverse gear and internal components).
3) Push the propeller shaft inward and hold it in
position. Optimum tooth contact
“a”
“b”
“A”
Push
“C”
“B”
I9J011310014-02
“A”: Heel “a”: Approx. 1/3 of tooth width

“B”: Convex side “b”: Approx. 1 mm (0.04 in)
IDG211310091-01
“C”: Toe
4) Using the driveshaft holder tool, rotate the driveshaft
5 – 6 times. Example [A]
Special tool Incorrect topside toe contact.
(A): 09921–29410 (Driveshaft holder) Correction measures.
• Decrease thickness of forward gear shim.
• Slightly increase pinion back-up shim thickness.
NOTICE
(A)
Setting the tooth contact in the top side toe
contact may cause damage and chipping on
forward and pinion.
Do not set the tooth contact as such top side
toe contact.
Example of incorrect
IDG211310092-01
5) Carefully remove the propeller shaft and housing to

check the tooth contact pattern. “C”
“A”
“a” “A”
“B” I9J011310015-01
“C”
“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] Reverse Gear Back-Up Shim Adjustment

Incorrect bottom side toe contact. After adjusting the forward gear tooth contact pattern,
Correction measures. follow the procedure below to adjust the reverse gear.
• Increase thickness of forward gear shim. 1) Correctly assemble and install reverse gear, reverse
• Slightly decrease pinion back-up shim thickness. gear back-up shim, propeller shaft, propeller shaft
bearing housing and related components.
NOTICE
NOTE
Setting the tooth contact in the bottom side
toe contact may cause chipping on pinion. Reverse gear back-up shim is temporary so
Do not set the tooth contact as such bottom that any of the shims, such as a standard
side toe contact. one, can be used.
2) Screw a slide hammer assembly onto the propeller

Example of incorrect shaft and strike it a few gentle outward taps.
Special tool
(A): 09930–30161 (Propeller shaft remover)
“C” (B): 09930–30104 (Sliding hammer)
“A”
I9J011310016-01
Rechecking Driveshaft Thrust Play

After obtaining optimum tooth contact, driveshaft thrust
play should be measured.
1) Assemble special tools to driveshaft as shown in the
figure.
(A)
Special tool
(A): 09951–09530 (Gear adjusting gauge) (B)
IDG211310095-03
3) Remove the adapters (1) from special tool.

Special tool
(A) (C): 09951–99310 (Gear holder)
1
(C)
1
IMP311310036-04
2) To check driveshaft thrust play, push forward gear

inward and fix it by hand. Slowly push driveshaft
downward, then read maximum thrust play.
Designate this amount of driveshaft thrust play as
IDG211310096-03
(A).
NOTE
Driveshaft thrust play (A) must be known to
adjust reverse gear shim.
Driveshaft thrust play (A)

0.4 – 0.6 mm (0.016 – 0.023 in)
4) Install the gear holder to the propeller shaft bearing Reverse gear back-up shim adjustment is correct if
housing and then attach it to the propeller shaft as (B) is equal to (A).
shown. • If (B) is less than (A), reduce reverse gear back-
5) Turning bolt (2) counterclockwise to pull reverse up shim thickness.
gear outward, tighten lightly the bolt after having
stopped. Do not over tighten. 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.
NOTE
Maintain the forward gear thrust washer at
(C)
standard thickness (9.0 mm) and use only the
propeller shaft reverse thrust washer to
adjust thrust play.
(C)
Propeller shaft thrust play
Approx. 0.2 – 0.4 mm (0.0079 – 0.0160 in)
IDG211310097-05
1) Assemble the gear adjusting gauge to the propeller
shaft.
(C)
Special tool
(A)
IDG211310106-03
6) Assemble special tool to driveshaft as shown in the

figure.
Special tool IDG211310099-01
(A): 09951–09530 (Gear adjusting gauge) 2) Push propeller shaft inward.
3) Hold the shaft in and set the dial gauge pointer to
zero.
4) Slowly pull the shaft outward and read the maximum
(A)
thrust play on the dial gauge.
• If the measurement is more than the specification,
increase the propeller shaft reverse thrust washer
thickness.
• If the measurement is less than the specification,
reduce the propeller shaft reverse thrust washer
thickness.
IMP311310036-04
7) Slowly push driveshaft downward, then read

maximum thrust play.
Designate this measurement as driveshaft thrust
play (B).
Driveshaft thrust play
0.4 – 0.6 mm (0.016 – 0.024 in)
8) Compare driveshaft thrust play (B) to driveshaft
thrust play (A).
Refer to “Rechecking Driveshaft Thrust Play” (Page
3A-28).
3B-1 Left Hand Rotation Unit:
Left Hand Rotation Unit

Lower Unit

Diagnose Lower Unit Malfunction
CENNP3133204001
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.
Left Hand Rotation Unit: 3B-2
Lower Unit Components
CENNP3133206001
(b)
9
2
(a)
1
8 7 (c)
4 6
5
3
10
12 16
11
13
14 12
15
14
17
15
INP313310001-01
1. Clutch lever 8. Clutch holder 15. Cotter pin

2. Bushing 9. Shift position sensor bracket 16. Clutch shaft
3. Bushing 10. Clutch shaft arm 17. Clutch rod
4. Grease nipple 11. E-ring : 23 Nm (2.3 kgf-m, 17 lbf-ft)
5. Ball 12. Bushing : 10 Nm (1.0 kgf-m, 7.4 lbf-ft)
6. Spring 13. Clutch lever link : 18 Nm (1.8 kgf-m, 13 lbf-ft)
7. Plug 14. Washer : Apply water resistant grease.
1 2 6
3 (d) 14 (c) 12
13
15
4 17 16
10 8
5 18
7
10 9 19
20
33
32 31
11 21
23 30
22
24
25
26
27
34
36
29 (a)
28 (a) 35 (b)
36
38
37
IMP311320018-03
1. Oil seal cover 12. Bushing 23. Exhaust seal plate 34. Trim tab
2. Oil seal 13. Water pump case 24. Union 35. Bolt
3. Bolt 14. Bolt 25. Hose 36. Screw
4. Shift rod guide housing 15. Dowel pin 26. Nipple 37. Water filter PORT
5. O-ring 16. Key 27. Gearcase 38. Water filter STBD
6. Shift rod 17. Water pump case sealing 28. Bolt : 55 Nm (5.6 kgf-m, 41 lbf-ft)
7. Magnet 18. Inner sleeve 29. Bolt : 23 Nm (2.3 kgf-m, 17 lbf-ft)
8. Bushing 19. Water pump impeller 30. Dowel pin : 17 Nm (1.7 kgf-m, 13 lbf-ft)
9. Shifter yoke 20. Under panel 31. Anode : 7.0 Nm (0.71 kgf-m, 5.2 lbf-ft)
10. Pin 21. Gasket 32. Washer : Apply water resistant grease.
11. Horizontal slider 22. Exhaust seal rubber 33. Bolt : Apply sealant.
2 (b)
1
3
54 58 (c)
4 57
56
5 55 59
6
7 53 21 (b)
8
17
9
10 18
8 19
20
11 22
15 23
25
13 33 24
12 (d) 14 26
27
28
29
34 (a) 30
31
32
35
16 36
37
52
38
39
40 49 51
42 41 50
43
48
46
13
12 (d)
44 45
47
IMP311320002-04
1. Driveshaft 23. Bearing 45. Small detent ball

2. Bolt 24. O-ring 46. Spring
3. Driveshaft oil seal housing 25. Shim 47. Large detent bell
4. Oil seal 26. Washer 48. Dog pin
5. O-ring 27. Bearing 49. Connector pin
6. Shim 28. Thrust washer 50. Clutch dog shifter
7. Bearing 29. Shim 51. Dog spring
8. Washer 30. Thrust washer 52. Propeller shaft
9. Washer 31. Forward gear thrust bearing 53. Stopper
10. Wave washer 32. Forward gear 54. Propeller
11. Driveshaft collar 33. Pinion 55. Propeller bush
12. Plug 34. Pinion nut 56. Spacer
13. Gasket 35. Reverse gear 57. Washer
14. Pinion bearing 36. Bearing 58. Propeller nut
15. Dowel pin 37. Reverse gear retainer 59. Cotter pin
16. Gearcase 38. Thrust bearing : 120 Nm (12 kgf-m, 89 lbf-ft)
17. Ring 39. Thrust washer : 23 Nm (2.3 kgf-m, 17 lbf-ft)
18. Oil seal protector 40. Shim : 55 Nm (5.6 kgf-m, 41 lbf-ft)
19. Oil seal 41. Bearing : 10 Nm (1.0 kgf-m, 7.4 lbf-ft)
20. Bearing 42. Reverse gear bearing housing : Apply water resistant grease.
21. Bolt 43. Pin : Apply Outboard Motor Gear Oil.
22. Propeller shaft bearing housing 44. Spacer : Apply thread lock 1342H.
Propeller Removal and Installation Installation

CENNP3133206002
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 the 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 (5.6 kgf-m, 41 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 CENNP3133206003
2 Refer to “Propeller / Propeller Nut and Cotter Pin
6 3 Inspection” in Section 0B (Page 0B-16).
I9J011310002-02
Lower Unit Removal and Installation Installation

CENNP3133206004
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) Make sure the clutch is in “Neutral” position.

1
2) Remove bolt and trim tab (1).
IMP311310019-01
2) Ensure that shift rod (2) is at “Neutral” position.
NOTE
1 Before installing lower unit, bring shift to

Neutral position by turning shift rod right or
left.
IDG211320001-01
3) Remove seven bolts (2) and separate gearcase (3)

from driveshaft housing.
2 Front
direction
2
3
IDG211320004-02
3) Insert two dowel pins (3).

IDG211320002-01
4) Apply water resistant grease to driveshaft and shift
rod splines.
5) Apply a light coating of sealant to mating surfaces of
gearcase and driveshaft housing.
Seal (100 g))
IDG211320005-02
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 CENNP3133206005
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).
2) Loosen four bolts (1), then remove water pump case
(2).
Neutral
INP313310002-01
NOTE 1
In order for shift rod and clutch rod splines to IDG211320008-01

be aligned correctly, clutch rod may need to 3) Remove impeller (3), impeller key (4), under panel
be turned slightly right or left. (5) and dowel pins (6).
Keep impeller key (4) for reuse and discard the
7) Apply sealant to seven gearcase bolts and tighten
gasket.
them to the specified torque.
Seal (100 g))
3
Tightening torque
Gearcase bolt (a): 55 N·m (5.6 kgf-m, 41 lbf-ft)
6
5 6
IDG211320009-01
(a) 4) Remove inner sleeve (7), sealing (8).
NOTE
5
To facilitate the removal of inner sleeve from
pump case, warm up the entire case using a
IMP311310020-02
heater like hair dryer.
8) Shift the clutch control lever to “Forward” and
“Reverse” position from “Neutral” position to check
proper gear engagement.
IDG211320107-02
Installation
1) Place the dowel pins (1), 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 is aligned.
8
1 5
IDG211320013-03
3 4 NOTE
Before installing water pump case assembly,
apply water resistant grease lightly on pump
1
case inner sleeve and under panel for initial
2 lubrication.
IDG211320011-01
3) Place the sealing (7) into groove of the pump case

(6).
NOTE
IDG211320014-01
5) Install the pump case assembly (9) while rotating

driveshaft clockwise to flex the impeller vanes in the
6
correct direction.
Securely tighten the four pump case bolts (10) to the
specified torque.
IDG211320012-01 Tightening torque
4) Install inner sleeve (8) into the pump case, ensuring Water pump case bolt (a): 17 N·m (1.7 kgf-m, 13
that projection of inner sleeve and groove of pump 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.

10 (a)
IDG211320015-01
6) Install the Lower Unit.

3B-6).
Water Pump and Related Item Inspection Lower Unit Disassembly

CENNP3133206006 CENNP3133206007
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 water pump and related parts.
other abnormal conditions are noted. Refer to “Lower Unit Removal and Installation” (Page
• Inspect pump inner sleeve. Replace if worn, cracked, 3B-6) and “Water Pump Removal and Installation”
distorted, corroded or other abnormal conditions are (Page 3B-7).
noted. 3) Place a drain pan under oil drain plug. Remove oil
• Inspect under panel. Replace if cracked, distorted, drain plug (1) first then oil level plug (2) and allow
corroded or other abnormal conditions are noted. gear oil to drain.
Inspect oil for water, contaminates or metal.
NOTE
2
1
IDG211320018-01
4) Remove the propeller.

Refer to “Propeller Removal and Installation” (Page
3B-5).
IDG211320016-01 5) Remove the bolts (3) and shift rod guide housing
assembly (4).
IDG211320017-01
IDG211320019-01
6) Remove two bolts (5) securing the propeller shaft

bearing housing to the gearcase.
IDG211320020-01
7) Using special tools, pull out the propeller shaft 10) Lift out driveshaft assembly (11).
bearing housing. Remove the propeller shaft and Remove the driveshaft collar (12), washer (13), wave
bearing housing assembly (6). washer (14), washer (with tab) (15) and washer (16)
from driveshaft.
Special tool
(A): 09930–30104 (Sliding hammer)
(B): 09930–30161 (Propeller shaft remover)
16
11
15
14
(A)
13
12
6
IMP311310022-02
(B)
11) Remove the pinion (17).
IDG211320021-02
8) Hold the pinion nut securely, then fit special tool to

the driveshaft and loosen the pinion nut. Remove
pinion nut (7).
Special tool
(C): 09921–29410 (Driveshaft holder)
17
IMP311310023-01
12) Remove reverse gear (18) (with reverse gear

7 retainer (19)) and thrust bearing (20).
(C)
20
IDG211320022-01
9) Remove the four (4) bolts (8) securing driveshaft oil

seal housing (9), then remove oil seal housing and
pinion back-up shim (10).
19
18
9 IMP311320003-01
10
IMP311310021-01
13) Remove the reverse gear (18) from reverse gear 16) To disassemble propeller shaft components, refer to
retainer (19). following.
a) Slide propeller shaft away from forward gear (25)
18
and bearing housing assembly (26).
19
26
IMP311320004-01
14) Remove the bearing thrust washer (21) and back-up 25

shim (22). IMP311320007-01
b) Remove the forward gear (27), forward gear

thrust bearing (28), forward gear thrust washer
(29), forward gear back-up shim (30).
28
27
22
21
IMP311320005-01
30
15) Remove the reverse gear bearing housing (23) and 29
IMP311320008-01
dowel pin (24).
c) Remove the propeller shaft thrust washer (31),
propeller shaft thrust bearing (32), bearing
washer (33) and shim (34) from propeller shaft
bearing housing.
34
33
32
31
23 24
IMP311320006-01
IMP311320009-01
d) To disassemble propeller shaft components, g) Remove large detent ball (41), detent spring
refer to following. (42), large detent ball (41) and two small detent
Remove horizontal slider (35) and spacer (36). balls (43) from connector pin (40).
Remove the spring (37) from the clutch dog
shifter (38). 40
36
43
38
41 42 41
37
IMP311320013-01
35
17) To disassemble shift rod components, refer to
IMP311320010-01 following.
e) Push the dog pin (39) out of the clutch dog a) Remove oil seal cover (44).
shifter (38).
b) Slide shift rod (45) out of shift rod guide housing
(46).
c) Draw the oil seal (47) out of shift rod guide
housing.
IMP311320011-01
f) Remove the clutch dog shifter (38) and

connector pin (40) from propeller shaft.
40
IMP311320014-02
d) Separate the shifter yoke (49) from shift rod (45)

by driving out the pin (48).
39 38
IMP311320012-01
IMP311320015-01
Pinion Bearing Removal and Installation Removal

CENNP3133206008
NOTICE 1) Disassemble the lower unit.
Refer to “Lower Unit Disassembly” (Page 3B-9).
2) Place the attachment (D) inside the pinion bearing.
needle rollers and outer race. If the removed
bearing is re-used, problem will occur in the 3) Insert the removal shaft (A) into attachment (D).
lower unit. 4) Thread sliding hammer (E) into top of removal shaft
(A).
Do not reuse pinion bearings once removed. 5) Put wood block under pinion bearing.
Always use new ones.
6) Drive the pinion bearing out downwards by striking
Removal and Installation Tools top of shaft (A) with sliding hammer (E).
To remove the pinion bearing from the gearcase, use the
following special tools.
Special tool (E)
(A): 09951–59910 (Shaft (removal and
installation))
(B): 09951–38710 (Plate)
(C): 01500–0840A (Bolt)
(D): 09951–19220 (Attachment)
(E): 09930–30104 (Sliding hammer) (A)
(B)
(E)
(A) (D)
1 2
IDG211320041-03
1. Pinion bearing 2. Wood block
(C) (D)
I9J011310018-03
Installation Lower Unit Related Items Inspection

CENNP3133206009
NOTE ! WARNING
• Before installing bearing, ensure that Failure to following proper precautions
inside of gearcase is clean and free of during use of the compressed air may cause
debris. severe personal injury.
• Ensure that the bearing stamped mark
faces upward. Wear safety glasses when using compressed
air.
1) Set the installer shaft (A), plate (B), attachment (D),
and pinion bearing as shown in the figure. NOTE
2) Place the installer shaft (A) (with pinion bearing on
end of installer shaft) into the gearcase. • If any component is worn excessively,
cracked, defective or damaged in any way,
3) Secure the plate (B) by tightening the bolt (C).
it must be replaced.
4) Thread the sliding hammer (E) into the top of the
• Thoroughly wash all metal components
installer shaft (A).
with cleaning solvent and dry with
5) Drive the pinion bearing down into position by gently compressed air.
striking the installer shaft (A) until the coupler
touches plate. Gearcase
6) Assemble the lower unit. • Inspect the gearcase. Replace if cracked, damaged or
Refer to “Lower Unit Assembly” (Page 3B-18). other abnormal conditions are noted.
• Visually check the pinion bearing. Replace bearing if
pitted, rough or other abnormal conditions are noted.
(E)
NOTE
If removal and replacement are required,
refer to “Pinion Bearing Removal and
(B)
Installation” (Page 3B-13).
(A) (C)
IDG211310038-02
(E)
IDG211320045-01
(C)
(A)
(B)
(D)
IDG211310039-04
1. Pinion bearing
Gears / Bearing
• Inspect forward, reverse and pinion teeth and
engaging dogs.
Replace gears if damaged, worn or other abnormal
conditions are noted.
• Inspect forward gear thrust bearing.
Replace bearing if pitted, noisy, rough or other
IDG211320048-03
• Check detent spring by measuring its free length. If

free length is not within specifications, replace detent
spring.
Detent spring free length “a”
IDG211320046-01 “a”
Reverse Gear Bearing Housing / Retainer

• Inspect the reverse gear retainer and reverse gear
bearing housing.
Replace if cracked or damaged. I9J011310062-01
• Visually check each bearings. Replace if pitted, noisy Propeller Shaft Bearing Housing
or rough.
• Inspect housing. Replace if cracked, damaged or
• Inspect forward gear bearing and propeller shaft
bearing. Replace bearing if pitted, noisy, rough or
• Check condition of oil seal and O-ring. Replace oil
seal and O-ring if nicked, cut, worn or other abnormal
IDG211320047-01
Propeller Shaft Components

• Inspect horizontal slider and connector pin.
Replace if wear, damage or other abnormal condition.
• Inspect detent balls. Replace if wear, damage or other
• Inspect clutch dog shifter. Replace if chipped, worn,
IDG211320049-01
damaged or other abnormal conditions are noted.
• Inspect dog pin. Replace if bent, worn or other
• Inspect propeller shaft/splines. Replace if worn,
twisted, damaged or other abnormal conditions are
noted.

• Inspect housing. Replace if cracked, damaged or
• Check condition of oil seals. Replace if nicked, cut,
worn or other abnormal conditions are noted.
• Inspect O-ring. Replace if worn, nicked, cut or other
IDG211320050-01
Shift Rod Guide Housing Components

• Inspect shift rod guide housing.
Replace if cracked, damaged or other abnormal
• Inspect shifter yoke. Replace if worn, damaged or
other abnormal conditions are noted. IDG211320053-01
• Inspect shift rod/splines. Replace if worn, twisted,
damaged or other abnormal conditions are noted. Driveshaft
• Inspect O-ring. Replace if nicked, cut, torn, swollen or • Inspect driveshaft/splines. Replace if worn, twisted,
other abnormal conditions are noted. damaged or other abnormal conditions are noted.
• Inspect oil seal and oil seal cover. Replace if nicked, • Inspect driveshaft bearing, replace if pitted, noisy,
cut, worn or other abnormal conditions are noted. rough or other abnormal conditions are noted.
IMP311310007-01
IDG211320054-01
IMP311320023-01
IDG211320055-01
Propeller Shaft Oil Seal Replacement 4) Apply water resistant grease to the outer
CENNP3133206010 circumference of the oil seals.
1) Remove the propeller shaft bearing housing.
Refer to “Lower Unit Disassembly” (Page 3B-9). : Grease 99000–25350 (SUZUKI Water
2) Remove the retaining ring (1) and washer (2).
5) Using an oil seal installer, install the two oil seals
(one at a time) into the propeller shaft bearing
1
housing.
The lipped portion of the seal must face towards the
propeller. Apply water resistant grease to the seal
lips.
2 “A”
IDG211320056-01
3) Extract the seals (3) with oil seal remover.
NOTICE
IDG211320058-02
Do not reuse the oil seal once removed. “A”: Direction of propeller
Always use new one.
6) Install the washer and retaining ring.
Special tool
7) Assemble the propeller shaft bearing housing.
Refer to “Lower Unit Assembly” (Page 3B-18).
Driveshaft Oil Seal Replacement

CENNP3133206011
1) Remove the driveshaft oil seal housing.
Refer to “Lower Unit Disassembly” (Page 3B-9).
(A)
2) Using special tool, remove two oil seals out of the
driveshaft oil seal housing.
3 Special tool
NOTICE
IDG211320057-01
Do not reuse the oil seal once removed.

Always use new one.
(A)
IDG211320059-01
3) Apply water resistant grease to outer circumference Reverse Gear Bearing Housing
of oil seals. • Install dowel pin (1) and reverse gear bearing housing
: Grease 99000–25350 (SUZUKI Water (2) in position.
4) Grease the inner lips of oil seal.
With the lips facing away from driveshaft bearing,
place seal in position and drive it into the oil seal
housing.
“A”
2 1
IDG211320061-01
Reverse Gear
• Place reverse gear back-up shim (1) and bearing
thrust washer (2) in position.
• Assemble the reverse gear thrust bearing (3), reverse
IDG211320060-02
gear retainer (4) and reverse gear (5), then install
reverse gear/retainer assembly.
“A”: Direction of water pump case
5) Assemble the driveshaft oil seal housing.

Refer to “Lower Unit Assembly” (Page 3B-18).
1
Lower Unit Assembly

CENNP3133206012
NOTICE
Failure to correctly adjust the gear position 2
will result in lower unit damage. IDG211320062-01
Before final assembly of lower unit, be
absolutely certain that all gear contact, shim
adjustments and tolerances are correct. 3
(Refer to “Lower Unit Gears - Shimming and 4
Adjustment” (Page 3B-26).)
NOTE
• 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 5
assembly. IDG211320063-01
• After assembly, check parts for tightness

and smoothness of operation.
Pinion • Install bearing outer race (7) and pinion back-up shim
• Degrease tapered portion of pinion. (8) to driveshaft.
• Place pinion (1) in gearcase.
8
7
1 IMP311310034-01
IDG211320064-01
Driveshaft • Apply water resistant grease to the driveshaft oil seal.
• Assemble the washer (1), washer (with the tab) (2), : Grease 99000–25350 (SUZUKI Water
wave washer (3), washer (4) and driveshaft collar (5) Resistant Grease EP2 (250 g))
to the driveshaft.
• Apply water resistant grease to O-ring (1), then install
• Degrease tapered portion of driveshaft. O-ring into groove on the driveshaft oil seal housing
(2).
1 2
2
3
4
1
IMP311310032-02
• After installing driveshaft collar, fit the convex part of IDG211320068-01

the collar in the concave part of the driveshaft by • Install the driveshaft oil seal housing on the gearcase.
turning collar. Apply thread lock to four bolts (3), then tighten bolts to
• Lower the driveshaft assembly (6) down into the the specified torque.
gearcase until the bottom of shaft protrudes through
Tightening torque
center of pinion.
Driveshaft oil seal housing bolt (a): 23 N·m (2.3
NOTE kgf-m, 17 lbf-ft)
The washer tab must be located into groove : Thread lock cement 99000–32160
on the gearcase. (SUZUKI Thread Lock 1342H (50g))
3 (a)
IMP311310039-01
IMP311310033-01
Pinion Nut Propeller Shaft

• Apply thread lock to the threads of pinion nut (1) • Slide the clutch dog shifter (2) onto the propeller shaft
before threading it onto driveshaft. (1).
: Thread lock cement 99000–32160 NOTE
The side of the clutch dog shifter marked
• Tighten pinion nut to the specified torque. with the letter “R” must face towards reverse
gear.
NOTE
It is recommended the original pinion nut is
used for the purposes of shimming during
repair. A new pinion nut should be used on
final assembly.
Special tool
(A): 09921–29410 (Driveshaft holder)
Tightening torque
Pinion nut (a): 120 N·m (12 kgf-m, 89 lbf-ft)
IMP311320016-01
• 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 “A” into dog pin hole of
connector pin, as shown in the figure.
(A) 7
1 (a)
IMP311310009-01
6
3
5
4
IDG211320072-01
NOTE
Temporarily insert a water pump case dowel
pin “A” into the connector pin to prevent the
detent ball from falling out.
“A”
IDG211310069-03
• Insert the connector pin (7) (with detent balls) into Forward Gear / Propeller Shaft / Bearing Housing
propeller shaft (1). Assemble the propeller shaft in the following sequence.
• Align the holes in the clutch dog shifter and connector • Apply water resistant grease to O-ring (1), then install
pin and then slide the dog pin (8) through both clutch the O-ring into the groove on the propeller shaft
dog shifter and connector pin. (save the temporarily bearing housing.
installed dowel pin “A” pushed out as the dog pin is
inserted.)
IMP311310017-01
• Install the dog pin retaining spring (9), ensuring that it

IDG211320076-01
fits snugly into the groove on the dog shifter.
• Install shim (2), bearing washer (3), propeller shaft
thrust bearing (4), propeller shaft thrust washer (5)
into propeller shaft bearing housing (6).
2
3
4
5
6
IMP311320017-01
• Install the spacer (10) to propeller shaft. IDG211320077-02
• Install forward gear back-up shim (7), forward gear

thrust washer (8), forward gear thrust bearing (9) and
forward gear (10) to propeller shaft bearing housing.
9
10
10
IDG211320075-01
7
8
IDG211320078-02
• Slide propeller shaft assembly (11) into forward gear • When the housing is fully seated, apply thread lock to
and propeller shaft bearing housing. bolts, then tighten bolts to the specified torque.
• Assemble horizontal slider (12) to connector pin. Tightening torque
Propeller shaft bearing housing bolt (a): 23 N·m (
2.3 kgf-m, 17 lbf-ft)
(a)
12
IDG211320079-01
NOTE
Before installing propeller shaft/bearing
housing assembly, move shifter dog to bring
horizontal slider to the neutral position. IMP311310043-01
• To hold the correct bearing position, pull propeller Checking Propeller Shaft Thrust Play
shaft backward and then install propeller shaft and Check propeller shaft thrust play.
housing assembly in the gearcase. Refer to “Lower Unit Gears - Shimming and Adjustment”
(Page 3B-26).
NOTE
Special tool
To make the bearing housing fully seated in (A): 09951–09530 (Gear adjusting gauge)
the gearcase, tap the housing gently with
plastic mallet.
(A)
IDG211320082-01
IDG211320080-02
Shift Rod Guide Housing NOTE

• Apply water resistant grease to the outer Before install the shift rod guide housing
circumference of the oil seals (1). assembly, be sure to put the horizontal slider
• Install the oil seals into the shift rod guide housing (2). (10) in the neutral position.
• Install the O-ring (3) to the shift rod guide housing.
10
11
1 “A”
IMP311320019-01
3 10. Horizontal slider

11. Reverse gear bearing housing
“A”: Shift rod center
IMP311310012-02
• Apply water resistant grease to the shift rod guide
• Attach magnets (4), bushing (5) and shifter yoke (6) to housing O-ring.
shift rod (7), then insert pin (8).
Front
direction
IMP311310018-01
• Install pin (9) to shift rod, then slide shift rod guide IMP311320020-02
housing onto shift rod.
NOTE
Before installing the shift rod guide housing
assembly, bring the shifter yoke to the
“Neutral” position by turning the shift rod
right or left.
• Install the shift rod guide housing assembly (12) by

aligning the shifter yoke with the groove in horizontal
slider, then tighten two housing bolts (13) to the
specified torque.
IMP311310013-01 Tightening torque
Shift rod guide housing bolt (a): 7.0 N·m (0.71
kgf-m, 5.2 lbf-ft)
IMP311320022-01
Leakage Check
Check for leakage of oil seal and O-ring when applying
specified pressure inside of the gearcase.
12
1) Install the test tool into the oil level hole.
2) Connect the air pump to the tester.
3) Rotate driveshaft and propeller shaft clockwise
several times and then apply specified pressure for
the test.
13 (a) NOTICE
Failure to correctly apply the test pressure
IMP311310015-02
will result in oil seal damage.
• Turn the shift rod from the “Neutral” position to the
“Forward” and “Reverse” position to check proper Do not exceed pressure of 110 kPa (1.12 kgf/
gear engagement. cm2, 16.0 psi.).
• Apply enough Water Resistant Grease on oil seal
before putting oil seal cover (14) so that there is no NOTE
space between them. Apply low initial pressure of 20 – 40 kPa (0.20
: Grease 99000–25350 (SUZUKI Water – 0.41 kgf/cm2, 2.9 – 5.8 psi.) first, then apply
Resistant Grease EP2 (250 g)) specified pressure.
Special tool
(A): 09950–69512 (Gearcase oil leakage
14 tester)
(B): 09952–99320 (Hand air pump)
Leakage pressure test
100 kPa (1.01 kgf/cm2, 14.5 psi.)
IMP311310016-01
(A)
(B)
IDG211320090-01
4) Once stabilized, pressure should remain steady for

at least 5 min.
If pressure does not fall, sealing performance is
correct.
Water Pump
Install the water pump and related parts.
3B-6) and “Water Pump Removal and Installation” (Page
3B-7).
Propeller
Install the propeller.
Refer to “Propeller Removal and Installation” (Page 3B-
5).
Lower Unit
Install the Lower Unit.
3B-6).
Trim Tab Adjustment

CENNP3133206013
The trim tab counteracts or minimizes propeller torque
pull felt through the steering system.
If the steering is pulls to the starboard or port side, adjust
the trim tab with the following procedure.
1) Loosen the trim tab bolt (1).
IDG211320091-01
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 to the left.
I9J011310010-03
3) Tighten the bolt of trim tab to the specified torque.

Tightening torque
Trim tab bolt: 23 N·m (2.3 kgf-m, 17 lbf-ft)
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

CENNP3133206014
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)
0.50 0.55 0.60 0.65 0.70 0.75 0.80
Pinion back-up shim (1) 1.00
0.85 0.90 0.95 1.00 1.05 1.10 1.15
0.55 0.60 0.65 0.70 0.75 0.80 0.85
Forward gear back-up shim (2) 1.00
0.90 0.95 1.00
0.60 0.70 0.80 0.90 0.95 1.00 1.05
Propeller shaft thrust shim (3) 1.00
1.10 1.15
0.55 0.60 0.65 0.70 0.75 0.80 0.85
Reverse gear back-up shim (4) 1.00
0.90 0.95 1.00 1.10 1.20 1.30 1.40
2
3
IMP311320021-01
1. Pinion back-up shim 3. Propeller shaft thrust shim

2. Forward gear back-up shim 4. Reverse gear back-up shim
Reverse Gear / Pinion Back-Up Shim Adjustment Adjusting driveshaft thrust play
Prior to adjustment 1) Assemble special tool to driveshaft as shown in the
1) Install standard pinion back-up shim thickness figure.
modified according to ± design specification mark on Special tool
the gear. For example, if “A” is “+0.05”, install shim (A): 09951–09530 (Gear adjusting gauge)
0.05 mm thinner than design specification of 1.00
mm. If “A” is “–0.05”, install shim 0.05 mm thicker
than design specification of 1.00 mm.
(A)
“A”
IDG211320108-01
IMP311310036-04
“A”: ± design spec. mark
2) To check driveshaft thrust play, push reverse gear
2) Correctly assemble driveshaft oil seal housing, inward and fix it by hand. Slowly push driveshaft
driveshaft, reverse gear, reverse gear back-up shim, downward, then read maximum thrust play.
pinion and related components. Driveshaft thrust play
Refer to “Lower Unit Assembly” (Page 3B-18). 0.6 – 0.8 mm (0.023 – 0.031 in)
Do not install forward gear at this time.
• If the thrust play measured is larger than the
NOTE specification, add the amount over the
Reverse gear back-up shim is temporary so specification to the temporary use reverse gear
that any of the shims, such as a standard back-up shim and install this shim.
one, can be used. • If the thrust play measured is smaller than the
specification from the temporary use reverse gear
IDG211320095-01

Tightening torque
Forward Gear Shim 4) Install forward gear and propeller shaft housing
After adjusting reverse gear, follow the procedure below assembly into gearcase, then tighten both bearing
to adjust forward gear. housing retaining bolts to the specified torque.
Tightening torque
Adjusting driveshaft thrust play
Propeller shaft bearing housing bolt: 23 N·m (
1) Correctly assemble driveshaft oil seal housing, 2.3 kgf-m, 17 lbf-ft)
driveshaft, reverse gear, pinion and related
components.
Tightening torque
3) Correctly assemble forward gear, forward gear
bearing, forward gear back-up shim, propeller shaft,
propeller shaft thrust bearing, propeller shaft bearing
housing and related components.
When assemble forward gear and propeller shaft
housing assembly, place the special tool between
IDG211320100-01
clutch dog shifter and forward gear as shown in the
5) Assemble special tools to driveshaft as shown in the
figure.
figure.
NOTE Special tool
• Forward gear back-up shim is temporary (B): 09951–09530 (Gear adjusting gauge)
so that any of the shims, such as a
standard one, can be used.
• Before installing special tool, move shifter
dog to reverse position. (B)
• Set the special tool in place with thin

washer facing the clutch dog.
Special tool
(A): 09951–09020 (Gear adjust spring set)
(A)
INP313320001-01
6) To check driveshaft thrust play, slowly push

driveshaft downward, then read maximum thrust
play.
Driveshaft thrust play
0.4 – 0.6 mm (0.016 – 0.023 in)
IDG211320098-03
• If the backlash measured is larger than the
specification, add the amount over the
specification to the temporary use forward gear
(A)
• If the backlash measured is smaller than the
specification from the temporary use forward gear
IDG211320099-01
Checking and adjusting tooth contact pattern 4) Carefully remove the propeller shaft and housing to
(Pinion and forward gear) check the tooth contact pattern.
Check tooth contact pattern using the following
procedure. “A”
“a”
1) To assess tooth contact, apply a light coat of “B”
prussian blue on the convex surface of the forward
“C”
gear.
2) Install the special tool as shown in the figures. “F”
Install forward gear and propeller shaft housing
“G”
assembly into gearcase, then tighten both bearing “D”
housing retaining bolts to the specified torque.
“E”
Tightening torque I9J011310013-02
Bearing housing: 23 N·m (2.3 kgf-m, 17 lbf-ft)
“A”: Concave side “E”: Tooth bottom
Special tool “B”: Convex side “F”: Toe
(A): 09951–09020 (Gear adjust spring set) “C”: Heel “G”: Tooth contact pattern
“D”: Tooth top “a”: Tooth width
(A)
Optimum tooth contact
The optimum tooth contact is shown in the figure. A shim
adjustment may be necessary to obtain this contact
pattern.
NOTE
Gear backlash should be checked when
IDG211320102-04 increasing or decreasing shim thickness to
adjust tooth contact.
(A)
Optimum tooth contact
“a”
“b”
“A”
“C”
IDG211320103-02 “B”
I9J011310014-02
3) Using the driveshaft holder tool, rotate the driveshaft
“A”: Heel “a”: Approx. 1/3 of tooth width
5 – 6 times.
“B”: Convex side “b”: Approx. 1 mm (0.04 in)
Special tool “C”: Toe
(B): 09921–29410 (Driveshaft holder)
(B)
IDG211320104-04
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 increase pinion back-up 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. Approx. 0.2 – 0.4 mm (0.0079 – 0.0160 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
“C”
“A” (A)
I9J011310015-01
Example [B]
Incorrect bottom side toe contact.
Correction measures.
• Increase thickness of forward gear shim.
• Slightly decrease pinion back-up 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.
Do not set the tooth contact as such bottom 4) Slowly pull the shaft outward and read the maximum
side toe contact. thrust play on the dial gauge.
• 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-4

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 Water Hose Routing............................................4B-5
Wiring Diagram ................................................... 4A-1
4
4-1 Precautions:
Precautions
Wire / Hose Routing
Precautions
Precautions for Wire / Hose Routing
CENNP3134000001
Component Location
Electrical Component Location
CENNP3134003001
Wire Routing: 4A-1
Wire Routing
Wire / Hose Routing

Wiring Diagram
CENNP3134102001
Refer to “Wire Color Symbols” in Section 0A (Page 0A-2).
HI
DIGITAL GAUGE DIAGRAM Bl OIL PRESSURE SWITCH
ALTERNATOR LO
(OPTION)
CKP
SENSOR BATTERY
CHARGE COIL B/R FUEL PUMP (H)
4A-2 Wire Routing:
TERMINATOR Gr M
GPS
ANTENNA MAP W
R CAP
B Gr SENSOR B/W
SDS
Y
B
GAUGE
O/Y
B/Bl
Bl CONNECTOR STARTER
W CONNECTOR P/Y R KNOCK SENSOR
B W/Y
B
MOTOR
Bl/B
B
G/W
R
B
B
Bl
B
Bl/B
G/W
R
B/Bl
/ IAC IAT SENSOR CYLINDER TEMP
R
P/W
Lg/B
P/W
O/Y
VALVE R SENSOR
B/W R
R
Bl MULTI Bl
B R B Lg/W
W Gr B B B/W B/W
B FUNCTION B W/Bl Y/Bl CMP SENSOR
R Y Y Gr/R B/Bl
/ B Gr Gr/R
GAUGE Gr R/Y
W/Y O/Bl
B
W/Bl
R/B
B/W
B B B THROTTLE Br/Y Gr
R O Gr
POSITION SENSOR B/W W W B O/B #1
R R Gr W W
W W OXH B Gr/Bl
R/B
3A
FUEL
OX Gr B/W
B/W
IGNITION INJECTOR
GND W Gr
+B W Lg/Bl COIL #1
TERMINATOR MAIN STATER FUSE BOX
RELAY RELAY O2 SENSOR
GAUGE SDS
FUSE
CONNECTOR CONNECTOR
15A 30A 30A 15A 15A 60A 60A
ENGINE CONTROL MODULE
CAP
P/W
Bl/B
G/W
B
B/Bl
G
R
W
W
W
W
R
Gr
Gr
Gr
Y
Y/G
W/R
P/B
O/Y
Gr/R
B/R
W
R
B/R
Gr
Gr
R
Y/G
Bl/B
G/W
Y
B
P/W
O/Y
B/Bl
B
R
V
Y
Br
Bl
B/R
G/Y
Y/B
G/W
B/Br
O/Bl
Y/Bl
R/G
B/W
P/Bl
W/B
Y/G
R/B
Bl/B
B/Bl
B/Lg
R/Bl
Br/Y
Lg/Y
Lg/B
Lg/R
Lg/Bl
Gr
Lg/W
B Bl Gr #2
P
Gr
B
B
B/Br
P
B
O
Bl
R/Y
W
Gr
Lg
P/W
W/Y
P/Y
W/Bl
Lbl
O/Y
O/B
R/W
P/B
V/W
Bl/W
O/W
B
Bl/R
W/Y
W/G
METER
Gr/Y
Gr/Bl
ILLUMINATION FUEL
SWITCH B
IGNITION INJECTOR
Gr
R/G
COIL #2
B
B
TROLL MODE
SWITCH
R/G
Gr Gr
R/G
B B METER EX-MANI TEMP
DN UP
B SENSOR
Gr
V/W B
R/G B/W B
B
R/G
Gr TRIM
R/G
Gr W/Y W/Y W/Y
B METER B V B
Y/G
B/Bl
B
R/G R/G MONITOR/

B B
TACHOMETER B
Y/G
RECTIFIER &
B/Bl
Gr Gr W Gr
TACHOMETER Bl/B Bl/B W Gr R/W #3
B B G/Y G/Y
G/Y F W REGULATOR
Y Y WITH LED P P R B
G/W G/W
G/W N B
FUEL
Gr/Y
R
10A IGNITION INJECTOR
NEUTRAL SWITCH X
PTT SWITCH NEUTRAL SWITCH COIL #3
REMOTE CONTROL BOX DN UP N ON B
F.R OFF R
(SIDE) Y P/Bl
Bl B/W
SHIFT POSITION SENSOR
PUSH FREE ST IG OFF
GND B
IGNITION SWITCH
STOP G
BATT W
IG Gr
Br Br Bl/B W/Y
Bl/B Bl/B Bl/B
START Br Br Br Br B G/Y V
G/Y G/Y G/Y Lg/R Gr
Br P
Bl/B Bl/B
P/W P/W P/W Lg/Y #4
G/W G/Y
G/W G/W G/W
BZ O Lbl
Lb Lbl W/Y P/W
W/Y W/Y W/Y
RESET Lg W B G/W
V V V
Gr
R P Lbl Lbl
Lb Lb Lb FUEL
PUSH TURN P P P P IGNITION COIL #4
O O O O/W O/W O/W
Gr Gr W W W W W W INJECTOR
Bl Bl Br Br/W Br Br Br Br
Br Y Y/B Y/B Y/B
G G G Bl/R Bl/R Bl/R
B G CAUTION BUZZER Gr Gr Gr B/Bl B/Bl B/Bl
B B Bl Bl/W Bl/W Bl/W Bl/W Bl/W
B B B B B B B
B
EMERGENCY W
W W
STOP SWITCH
LOCK PLATE IN RUN W/G
W Br,Br/W KEYLESS B/Lg
LOCK PLATE OFF STOP R/Bl
JOINT START SYSTEM B
B
W/Y
R
CONNECTOR #1
B/W
WATER IN
BONDER #3
B/W Lg
B R FUEL SWITCH
P
B
A
W/Y
B/W
R
W/R
PTT
P
Lbl
Gr
W/Y
RELAY
R
B/W
Y
Gr/R P Lbl B/Bl R W
BONDER #2
B
R
W
B B
B/W B/W M (DF140B/140BZ Only)
P
JOINT Y
Lbl
W/R
PTT CONNECTOR #1 B
BATTERY
12V 100AH TRIM SENSOR MOTOR DN UP
B/W
PTT SWITCH Br Br Br Br
BONDER #1
X X
DF115B/115BZ DF140B/140BZ
INP313410002-02
Side mount remote control model Top mount remote control model
R/G
B R/G
Gr B
B Gr
B
EMERGENCY LIGHTING LIGHTING
STOP SWITCH B
MAIN SWITCH Gr SWITCH B
LOCK PLATE IN RUN SWITCH R/G Gr
LOCK PLATE OFF STOP B R/G
TROLL MODE B TROLL MODE
R/G
SWITCH
R/G
B
Gr Gr B SWITCH
B
B B METER Gr Gr Gr B
UP DN
R/G
R/G
B B METER Gr
UP DN
EMER PWR
EMER PWR
(PUSH) R/G R/G
B B
NORMAL
R/G
R/G
R/G
R/G
NORMAL
(PUSH) Gr Gr TRIM Gr Gr TRIM
B
B
B
IG ON B B METER W/Y W/Y W/Y B B METER W/Y W/Y W/Y
B V B B V B
B
REMOTE CONTROL EMERGENCY
SRART PWR BAT+ IGN
BOX NEUTRAL SWITCH R/G
O R/W W Gr
R/G STOP SWITCH R/G R/G
B B LOCK PLATE IN RUN B B
B
B MAIN B
BZ Gr Gr LOCK PLATE OFF STOP Gr Gr
G
B B TACHOMETER Bl/B Bl/B SWITCH B B TACHOMETER Bl/B Bl/B
G/Y G/Y G/Y G/Y
DN
Y Y WITH LED P P Y Y WITH LED P P
Br
G/W G/W G/W G/W
Gr
Bl
Br
PTT SWITCH
10A EMER PWR 10A
UP
BUZZER
Br
EMER PWR
O
(PUSH)
R/W
Bl/W
NORMAL
PTT NORMAL ECM PWR

(PUSH)
ECM PWR SWITCH RELAY
KEYLESS IG ON
Gr
Bl
RELAY KEYLESS
CONTROL DN UP
SRART PWR BAT+ IGN CONTROL
UNIT NEUTRAL O R/W W Gr UNIT NEUTRAL
SWITCH SWITCH
R/W
N ON B B N ON
B/Lg W/G P/B W B Y G B B/Lg W/G P/B W B Y
Br
Gr
Bl/W
G
F, R OFF F, R OFF
R/W
G
Bl
P/B
G
Bl
P/B
B/Lg
B/Lg
W
W
P/B
NEUTRAL SWITCH
R/W
W W
B
W
SHIFT SHIFT
R/W
Bl/W
P/B
B
Br
Y
Gr
B
Y
Gr
P/B O
W
W
W/G
W/G
P/B
R/W
POSITION Br Br Br POSITION
Gr
G
R/W
SENSOR SENSOR
B
W
B
W
R/W
Bl/W
Gr
G
R/W
Bl/W
Br
R/W
B
W
G
Gr
R/W
Bl/W
B
Y
B
Y
Br
B
Bl
Bl
B
R/W
Y
Y
B
B
Y/G
Y/G
Bl
Bl
Br
Br
W
W
SELECT SELECT
DUMMY DUMMY
G
G
Bl
Gr
Bl
Gr
B
P/Bl
B/W
P/Bl
B/W
B/Bl
B/Bl
B
Y/G
Y/G
R
R
BZ
R/W
R/W
KEYLESS KEYLESS
BUZZER BUZZER
W/G W/G
B/Lg W/G W B/Lg W/G W
Keyless start model
120
120
B/Lg R B/Lg R
W/Y W/Y
B B
Bl/B Bl/B
G/Y G/Y
Lbl Lbl P Lbl Lbl P
Lg W/R G/W Lg W/R G/W
R P P R P P
Lbl Lbl
O O O O
W W W W W W
Br Br Br Br Br Br
W W/R Y
A W W/R Y
A
G G G G G G
R/W Gr Gr R/W Gr Gr
Bl/W Bl/W Bl/W Bl/W Bl/W Bl/W
B B B B B B
W W
W
W
W
B/Lg, B/Lg B/Lg, B/Lg
R R
W
FUSE 120 120

15A
W
W
Wire Routing:
INP313410004-01
4A-3
4A-4 Wire Routing:
Wiring Harness Routing Diagram

CENNP3134102002
(a)
1 2
INP313410005-01
1. Regulator lead wire (Gr) 4. PTT motor relay holder

2. Main harness (R) 5. PTT motor relay
3. Cap : 4.5 Nm (0.46 kgf-m, 3.3 lbf-ft)
Wire Routing: 4A-5
3
(a)
2
4
4 1 (c)
16 (b)
13 15
14
5
6
7
12
8
9 10 11
“A”
“B”
INP313410006-01
1. Starter motor 8. Washer 15. Washer

2. Flywheel 9. Cushion 16. EX. manifold temp. sensor
3. Main harness (R) 10. Washer “A”: Route the PTT switch lead wire through
upper of the flush hose.
4. Battery cable (positive (+)) 11. Main harness terminal “B”: Route the rectifier/regulator lead wire (Gr)
: Set the terminals as shown. behind the Ex. temp sensor connector.
5. Main harness (Ground) 12. Bolt : 8.6 Nm (0.88 kgf-m, 6.3 lbf-ft)
: Set the back of each terminal together.
6. Battery cable (negative (–)) 13. Bolt : 7.8 Nm (0.80 kgf-m, 5.8 lbf-ft)
7. Electric parts holder 14. Cushion : 9.9 Nm (1.0 kgf-m, 7.3 lbf-ft)
4A-6 Wire Routing:
3 11
1
10
“A”
8 (a)
“B”
“C”
INP313410007-01
1. Battery charge coil 6. Bolt 11. PTT switch lead wire

2. Clamp 7. Connector holder “A”: Pass the main harness through the harness
guide of the connector holder.
3. Band 8. Cylinder temp. sensor “B”: Pass the oil pressure lead wire beside the
: Bind the O2 sensor lead wire and water sub harness connector.
return hose with band.
4. Clamp 9. MAP sensor “C”: Clamp the oil pressure lead wire, sub
harness and the knock sensor lead wire.
5. Bracket 10. IAT sensor : 7.8 Nm (0.80 kgf-m, 5.8 lbf-ft)
Wire Routing: 4A-7
(c)
16 (b)
1
12
11
13
3
4
2 5 14
15
6 (a)
7
8
9
10
INP313410001-01
1. Sub-wiring harness 8. Fuel hose 15. Battery cable

2. Evaporation hose bracket 9. Battery cable 16. Oil pressure switch
: Set the lead wire terminal horizontally.
3. Bolt 10. Remote control harness : 22 Nm (2.2 kgf-m, 16 lbf-ft)
: Tighten together evaporation hose
bracket and harness bracket.
4. Bracket 11. Clamp : 13 Nm (1.3 kgf-m, 9.6 lbf-ft)
: Clamp the main harness and the trim
sensor lead wire.
Trim sensor lead wire turn and clamp.
5. Clamp 12. Trim sensor lead wire : 1.5 Nm (0.15 kgf-m, 1.1 lbf-ft)
6. Knock sensor 13. Neutral switch connector
7. Grommet 14. Shift position sensor connector
4A-8 Wire Routing:
“A”
INP313410008-01
1. Ignition coil 3. Band

: Clamp in concavity of the delivery pipe.
Set the lock parts of band as shown in the figure.
2. CMP sensor “A”: Clamp the lead wire of injector at the center of white taping.
Wire Routing: 4A-9
“B”
3 “A”
INP313410009-01
1. CKP sensor 4. PTT motor connector “A”: Set the white line of battery cable outside.
: Pass the PTT motor connector inside of
the main harness and battery cable.
2. Clamp 5. IAT sensor “B”: Pass the battery cable through the guide of
: Clamp the shift position sensor lead wire, : Set the lock part of connector upward. parts holder.
neutral switch lead wire and shift actuator
lead wire.
3. Cable holder 6. Air intake silencer case
4A-10 Wire Routing:
“B”
7 6
4 5
“A”
“C”
“D”
1 2 3
View “D”
IMP311410011-03
1. Trim sensor 5. Side cover seal “B”: Inside

2. Trim sensor cam 6. PTT motor cable “C”: Outside
3. Clamp 7. Trim sensor lead wire
: Bind the trim sensor lead wire to swivel
bracket at white taping position.
4. PTT switch “A”: Align the taping point of harness with the
edge of side cover seal.
Fuel / Water Hose Routing: 4B-1
Fuel / Water Hose Routing

Wire / Hose Routing
Precautions
Precautions for Fuel / Water Hose Routing
CENNP3134200001
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
CENNP3134202001
5 7
View “B” View “A”
4 2
5 4 7 “B” “A”
“C”
2 1
7
View “C”
3 7
8
6
9
10 5
INP312420005-01
1. Fuel vapor separator 6. Fuel drain hose

2. Fuel hose (Low pressure fuel pump to fuel vapor separator) 7. Clamp
: Clamp the evaporation hose at the marking point.
3. Low pressure fuel pump 8. Water hose (3-way joint to fuel vapor separator)
4. Fuel hose (Fuel vapor separator to fuel delivery pipe) 9. 3-way joint
5. Evaporation hose 10. Water hose (Fuel vapor separator to engine holder)
4B-2 Fuel / Water Hose Routing:
4
6 (a)
16
7
3
5
“A”
1
8 7
7
9
12 (b)
14
14
10 6 (a)
14
13
11
15
14 2
INP313420003-01
1. Fuel vapor separator 11. Low pressure fuel filter

2. Evaporation hose 12. Fuel filter nut
3. Fuel hose (Fuel vapor separator to fuel delivery pipe) 13. Fuel hose (Joint to low pressure fuel filter)
4. Breather hose 14. Clamp
: Clamp the fuel hose at the marking point.
5. Fuel delivery pipe 15. Drain hose
6. Fuel delivery pipe plug 16. Intake manifold
7. Fuel injector “A”: White marking
8. Fuel hose (Low pressure fuel pump to fuel vapor separator) : 35 Nm (3.6 kgf-m, 26 lbf-ft)
9. Low pressure fuel pump : 10 Nm (1.0 kgf-m, 7.4 lbf-ft)
10. Fuel hose (Low pressure fuel filter to low pressure fuel pump)
5
“A”
INP313420001-01
1. Fuel hose (Joint to low pressure fuel filter) 5. Fuel hose (low pressure fuel pump to fuel vapor separator)
2. Low pressure fuel filter 6. Breather hose
3. Fuel hose (Low pressure fuel filter to low pressure fuel pump) “A”: Yellow marking
4. Low pressure fuel pump
3
2
4
1
5
7
6
INP313420004-01
1. Fuel hose (Joint to low pressure fuel filter) 4. Low pressure fuel pump
2. Low pressure fuel filter 5. Fuel hose (low pressure fuel pump to fuel vapor separator)
3. Fuel hose (Low pressure fuel filter to low pressure fuel pump) 6. Breather hose
: Set mark on fuel hose upward.
Water Hose Routing

CENNP3134202002
“A”
4
2
2 1
3 4 1 VIEW “A”
INP313420005-01
1. Water hose (3-way joint to fuel vapor separator) 3. Water hose (3-way joint to water inspection tube)
2. Water hose (Fuel vapor separator to engine holder) 4. Clamp
2
1
8
7
5
4
3
8
IMP311420005-05
1. Water return hose 5. Water return hose union

2. Thermostat cover 6. O-ring
3. Water hose (Fuel vapor separator to engine holder) 7. Water flush hose
4. Engine holder 8. Clamp
: Clamp the water flush hose at the marking point.
6
1
2 3
INP313420002-01
1. Water hose (Fuel vapor separator to engine holder) 5. Water return hose
2. Clamp 6. Water return hose union
: Clamp the water hose at the marking point.
3. Water hose (3-way joint to water inspection tube) 7. Thermostat cover
4. Water flush hose
Prepared by
January, 2022
Manual No. 99500-99L10-01E
Printed in Japan
412
TOP
99500-99L10-01E
99500-99L10-01E
BOTTOM
No. 2599 99500-99L10-01E DF115B/BZ_DF140B/BZ S/M Cover14 (16 mm) 5/0 2022/1/13 DIC502 Pantone 186 Pantone 3590 Black

DF115B 140B 99500-99l10-01e

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WARNING / CAUTION / NOTICE / NOTE

© COPYRIGHT SUZUKI MOTOR CORPORATION 2021

Precautions ...............................................00-1 Precautions........................................................... 00-1

General Information ................................ 0A-1 Scheduled Maintenance ......................................0B-1

Wire Color Symbols

Bl (Blue Color) Bl/B

Warning, Caution and Information Label Locations

1. Label, engine cover 2. Label S.I.G.P.

Outboard Motor Identification Number Location Fuel and Oil Recommendations

Use only unleaded gasoline. Do not use fuel

1. Model 3. Serial number Suzuki recommends that you use Suzuki

API Classification SAE Viscosity Grade

Break-In Procedures NOTICE

Throttle Recommendation If the standard propeller fails to meet the above

Battery Requirement Powerhead Direction of Rotation Description

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

Tightening Torque Specifications

Thread Tightening torque

Special Tools and Equipment

93691–80030 99000–25350 99000–31140 99000–32020 99000–32160

01500–0840A 09900–20101 09900–20202 09900–20203 09900–20204

09900–20605 09900–20607 09900–20701 09900–20803 09900–21304

09900–22303 09900–25007 09900–25011 09912–58432 09912–58442

09912–58490 09912–66310 09913–50121 09915–47341 09915–64512

09915–64530 09915–64550 09915–77311 09915–78211 09916–10912

09916–14910 09916–19030 09916–34542 09916–37810 09916–38210

09916–46020 09916–49040 09916–57350 09916–68010 09916–77310

09916–84511 09917–47020 09917–49610 09917–87810 09917–98221

09919–16010 09921–29410 09922–59410 09922–59420 09923–73210

09930–30104 09930–30161 09930–39220 09930–49220 09930–76311

09930–88730 09930–89260 09930–89290 09930–89350 09933–39810

09941–64511 09944–09810 09944–09820 09945–69010 09945–79310

09950–69512 09951–09020 09951–09530 09951–19220 09951–38710

09951–59910 09951–99310 09952–99320

Maintenance and Tune-Up

Before every use Change engine oil

Engine Oil Change

“A”: Upper limit “B”: Lower limit

2 8) Start engine and allow it to run for several minutes at

IMP311020005-01 Engine Oil Filter Replacement

6) Pour recommended engine oil into oil filler opening,

4) Screw the new filter on by hand until filter O-ring

Refer to “Oil Change Reminder System NOTICE

Gear Oil Change To avoid a possible low gear oil level,

3) Remove the spark plugs (1).

Spark Plug Gap

Spark Plug Inspection and Cleaning

Confirm the thread size and reach when

1. Shim “B”: Spark plug hole

5) After removing shim, measure thickness of original

2. Camshaft housing bolt

Tappet clearance specifications

Failure to take proper precautions when

When installing or removing the tappet shim:

• Use a magnet to remove and install shim.

6) Install shim with the identification number facing

9) Recheck tappet clearance.