For 03 model SUPPLEMENTARY SERVICE MANUAL J10-01E

Transcription

1 For 03 model SULEMENTARY SERVICE MANUAL J10-01E

2 DF90/115/140 K3 (2003) MODEL FOREORD This supplementary service manual describes the outline, technical data and servicing procedures for the K3 (2003) models outboard motor. lease read and thoroughly familiarize yourself with this informati before using it for your service activities. NOTE: Use this supplement with the following service manual: DF90/115/(140) Service Manual ( /no, J0-01E) CONTENTS SECIFICATIONS (DF90T/115T/115) 2 SECIFICATIONS (DF140T/140/140Z) 4 SERVICE DATA (DF90T/115T/115) 6 SERVICE DATA (DF140T/140/140Z) 13 TIGHTENING TORQUE 20 ECM 21 ECM MAIN RELAY AND STARTER MOTOR RELAY 21 ATTERY CHARGE COIL 22 RECTIFIER & REGULATOR 22 EXHAUST CAM SHAFT (FOR DF115 ONLY) 23 REMOTE CONTROL CALE HOLDER 23 CYLINDER HEAD INSTLLATION 24 CRANKCASE TO CYLINDER INSTLLATION 25 UER MOUNT 26 DRIVE SHAFT 26 ROELLER SHAFT EARING HOUSING 26 DF115 AND DF EXHAUST VALVE 27 ATER UM CASE 27 ECM 27 IRING DIAGRAM 28 IRE ROUTING 29 ATER HOSE ROUTING 31

3 2 DF90/115/140 K3 ( 03) model *SECIFICATIONS (DF90T/115T/115) * These specificatis are subject to change without notice. DF90T DF115T/115 RE-FIX DIMENSIONS & EIGHT 09001F 11501F Overall length (frt to back) Overall width (side to side) Overall height L eight (without engine oil) Transom height UL L UL L UL kg (Ibs) kg (Ibs) mm (inch type) mm (inch type) 779 (30.7) 481 (18.9) 1556 (61.3) 1683 (66.3) (416) (427) 539 (20) 666 (25) ERFORMANCE Maximum output Recommended operating range Idle speed k (S) r/min r/min 66.2 (90) 84.6 (115) ± 25 (in-gear : approx. 625) OERHEAD Engine type 4-stroke DOHC Number of cylinders 4 ore 84.0 (3.31) Stroke 88.0 (3.46) Total displacement cm 3 (cu in) 1950 (119.0) Compressi ratio : Spark plug Igniti system Fuel supply system Exhaust system Cooling system Lubricati system NGK KR6E Full-transistorized igniti Multi-point sequential electric fuel injecti Through prop exhaust ater cooled et sump by trochoid pump Starting system Electric Throttle ctrol Remote ctrol

4 DF90/115/140 K3 ( 03) model 3 DF90T DF115T/115 FUEL & OIL Fuel Suzuki highly recommends that you use alcohol-free unleaded gasoline R + M with a minimum pump octane rating of 87 ( method) or 91 2 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane ctent may be used. Engine oil AI classificati SE, SF, SG, SH, SJ Viscosity rating Engine oil amounts Gear oil Gearcase oil capacity RACKET Trim angle Number of trim positi Maximum tilt angle LOER UNIT L (US/Imp. qt) ml (US/Imp. oz) degree 5.5 (5.8 / 4.8) : Oil change ly 5.7 (6.0 / 5.0) : Oil filter change SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) 1050 (35.5 / 37.0) TT system TT system 75 Reversing system Gear Transmissi Forward-Neutral-Reverse Reducti system evel gear Gear ratio Drive line impact protecti 12 : 25 (2.08) Spline drive rubber hub ropeller lade Diam. (in) itch (in) REDUCTION SYSTEM 1st reducti gear ratio (Crankshaft drive gear: Driven gear) 2nd reducti gear ratio (Lower unit gear) Total reducti gear ratio 29 : 36 (1.24) 12 : 25 (2.08) 2.59 ( )

5 4 DF90/115/140 K3 ( 03) model *SECIFICATIONS (DF140T/140/140Z) * These specificatis are subject to change without notice. DF140T/140 DF140Z RE-FIX DIMENSIONS & EIGHT 14001F 14001Z Overall length (frt to back) Overall width (side to side) Overall height L eight (without engine oil) Transom height UL L UL L UL kg (Ibs) kg (Ibs) mm (inch type) mm (inch type) 779 (30.7) 481 (18.9) 1611 (63.4) 1738 (68.4) (410) (421) 539 (20) 666 (25) ERFORMANCE Maximum output Recommended operating range Idle speed k (S) r/min r/min 103 (140) ± 50 (in-gear: approx. 700) OERHEAD Engine type 4-stroke DOHC Number of cylinders 4 ore 86 (3.39) Stroke 88 (3.46) Total displacement cm 3 (cu in) 2044 (124.6) Compressi ratio : Spark plug Igniti system Fuel supply system Exhaust system Cooling system Lubricati system NGK KR6E Full-transistorized igniti Multi-point sequential electric fuel injecti Through prop exhaust ater cooled et sump by trochoid pump Starting system Electric Throttle ctrol Remote ctrol

6 DF90/115/140 K3 ( 03) model 5 DF140T/140 DF140Z FUEL & OIL Fuel Suzuki highly recommends that you use alcohol-free unleaded gasoline R + M with a minimum pump octane rating of 87 ( method) or 91 2 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane ctent may be used. Engine oil AI classificati SE, SF, SG, SH, SJ Viscosity rating SAE10-40 Engine oil amounts Gear oil Gearcase oil capacity RACKET Trim angle Number of trim positi Maximum tilt angle LOER UNIT L (US/Imp. qt) ml (US/Imp. oz) degree 5.5 (5.8/4.8) : Oil change ly 5.7 (6.0/5.0) : Oil filter change SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) 1050 (35.5/37.0) TT system TT system 75 Reversing system Transmissi Reducti system Gear ratio Drive line impact protecti ropeller shaft rotati (when shift into forward) ropeller : Aluminum propeller : Stainless steel propeller Gear Forward-Neutral-Reverse evel gear 12 : 23 (1.92) Spline drive rubber hub clockwise counterclockwise lade Diam. (in) itch (in) / REDUCTION SYSTEM 1st reducti gear ratio (Crankshaft drive gear: Driven gear) 2nd reducti gear ratio (Lower unit gear) Total reducti gear ratio 29 : 36 (1.24) 12 : 23 (1.92) 2.38 ( ) 29 12

7 6 DF90/115/140 K3 ( 03) model *SERVICE DATA (DF90T/115T/115) * These service data are subject to change without notice. DF90T DF115T/115 OERHEAD Recommended operating range r/min Idle speed **Cylinder compressi **Cylinder compressi max. difference between any two cylinders **Engine oil pressure Engine oil Engine oil amounts Thermostat operating temperature r/min ka (kg/cm 2, psi) ka (kg/cm 2, psi) ka (kg/cm 2, psi) L (US/Imp. qt) C ( F) 625 ± 25 (in-gear : approx. 625) (13 17, ) 100 (1.0, 14) ( , 78 85) at 3000 r/min. (at normal operating temp.) AI classificati SE, SF, SG, SH, SJ Viscosity rating SAE (5.8 / 4.8) : Oil change ly 5.7 (6.0 / 5.0) : Oil filter change ( ) ** Figures shown are guidelines ly, not absolute service limits.

8 DF90/115/140 K3 ( 03) model 7 DF90T DF115T/115 CYLINDER HEAD / CAMSHAFT ** New K3 service data Cylinder head distorti 0.05 (0.002) Manifold seating faces distorti 0.10 (0.004) Cam height IN ( ) ( ) (1.4496) (1.5244) EX ( ) ** ( ) (1.4173) ** (1.5244) Camshaft journal oil clearance Top, 2nd, 3rd, 4th 5th ( ) (0.0047) ( ) (0.0047) Camshaft journal (housing) inside diameter Top, 2nd, 3rd, 4th ( ) (0.9122) 5th ( ) (1.0304) Camshaft journal outside diameter Top, 2nd, 3rd, 4th ( ) (0.9004) 5th ( ) (1.0175) Camshaft runout 0.10 (0.004) Cylinder head bore to tappet clearance ( ) (0.0059) Tappet outer diameter ( ) Cylinder head bore ( )

9 8 DF90/115/140 K3 ( 03) model DF90T DF115T/115 VALVE/VALVE GUIDE Valve diameter Tappet clearance (Cold engine cditi) Valve seat angle Valve guide to valve stem clearance Valve guide inside diameter IN EX IN EX IN EX IN,EX IN 33 (1.3) EX 28 (1.1) ( ) ( ) 15, 45, 60 15, ( ) (0.0028) ( ) (0.0035) ( ) Valve guide protrusi Valve stem outside diameter Valve stem end deflecti Valve stem runout Valve head radial runout IN,EX IN EX IN EX IN,EX IN,EX 13.5 (0.53) ( ) ( ) 0.14 (0.006) 0.18 (0.007) 0.05 (0.002) 0.08 (0.003) Valve head thickness IN 1.0 (0.04) 0.7 (0.03) EX 1.20 (0.05) 0.7 (0.03) Valve seat ctact width IN EX ( ) ( ) Valve spring free length 42.7 (1.68) 41.0 (1.61) Valve spring tensi N (kg, Ibs) ( , ) for 32.6 mm (1.28 in) N (kg, Ibs) 151 (15.1, 33.3) for 32.6 mm (1.28 in) Valve spring squareness 2.0 (0.08)

10 DF90/115/140 K3 ( 03) model 9 DF90T DF115T/115 CYLINDER/ISTON/ISTON RING Cylinder distorti ist to cylinder clearance Cylinder bore Cylinder measuring positi ist skirt diameter ist measuring positi Cylinder bore wear ist ring end gap ist ring free end gap ist ring to groove clearance ist ring groove width ist ring thickness in clearance in pist pin hole 1st 2nd 1st 2nd 1st 2nd 1st 2nd Oil 1st 2nd 0.05 (0.002) ( ) (0.0039) ( ) 50 (2.0) from cylinder top surface ( ) 26.5 (1.04) from pist skirt end (0.0039) ( ) 0.70 (0.028) ( ) 1.00 (0.039) Approx (0.44) 9.0 (0.354) Approx (0.43) 8.8 (0.347) ( ) 0.12 (0.005) ( ) 0.10 (0.004) ( ) ( ) ( ) ( ) ( ) ( ) (0.0016) ist pin outside diameter ist pin hole diameter in clearance in crod small end ( ) (0.8260) ( ) (0.8283) ( ) (0.0020) Crod small end bore ( )

11 10 DF90/115/140 K3 ( 03) model DF90T DF115T/115 CRANKSHAFT / CONROD Crod small end inside diameter Crod big end oil clearance Crod big end inside diameter ( ) ( ) (0.0026) ( ) Crank pin outside diameter ( ) Crank pin outside diameter difference (out of round and aper) (0.0004) Crod bearing thickness ( ) Crod big end side clearance Crod big end width Crank pin width ( ) (0.0138) ( ) ( ) Crankshaft center journal runout 0.04 (0.002) Crankshaft journal oil clearance ( ) (0.0026) Crankcase bearing holder inside diameter ( ) Crankshaft journal outside diameter ( ) Crankshaft journal outside diameter difference (out of round and taper) (0.0004) Crankshaft bearing thickness ( ) Crankshaft thrust play ( ) 0.35 (0.014) Crankshaft thrust bearing thickness ( )

12 DF90/115/140 K3 ( 03) model 11 DF90T DF115T/115 ELECTRICAL Igniti timing Degrees at r/min TDC 1 TDC 44 TDC 3 TDC 44 Over revoluti limiter r/min 6200 CK sensor resistance CM sensor resistance rimary Igniti coil resistance Secdary k No.2 No.3 : (including H.T.cord and spark plug cap) No.1 No.4 : (including H.T.cord and spark plug cap) High tensi cord resistance kω /m at 20 C Approx.16 attery charge coil resistance attery charge coil output (12V) att Standard spark plug Type Gap NGK KR6E ( ) Fuse amp. rating A Main fuse : 60 Sub fuse : 30 Recommended battery capacity (12V) Ah (kc) 100 (360) or larger Fuel injector resistance IAC valve resistance 8 12 IAT sensor / Cylinder temp. sensor / Ex- mani. temp. sensor (Thermistor characteristic) ECM main relay resistance Starter relay coil resistance TT motor relay coil resistance kω at 25 C STARTER MOTOR Max. ctinuous time of use Motor output rush length Commutator undercut Sec k (0.63) 12.0 (0.47) ( ) 0.2 (0.01) Commutator outside diameter 29.0 (1.14) 28.0 (1.10) Commutator outside diameter difference 0.05 (0.002) 0.40 (0.016)

13 12 DF90/115/140 K3 ( 03) model DF90T DF115T/115 TT MOTOR rush length 9.8 (0.39) 5.5 (0.22) Commutator outside diameter 22.0 (0.87) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION hen the abnormality occurs in a signal from sensor, switch, etc., the CHECK ENGINE lamp the mitor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding. RIORITY * FAILED ITEM CODE LAM FLASHING ATTERN FAIL-SAFE SYSTEM ACTIVATING 1 MA sensor CK sensor 4 2 YES YES 3 IAC valve / y-pass air screw adjustment 3 1 NO 4 CM sensor CT switch Cylinder temp. sensor IAT sensor 2 3 YES NO YES YES 8 MA sensor 2 (ressure detect passage) 3 2 NO 9 Rectifier & regulator (Over-charging) Exhaust manifold temp. sensor 1 5 NO YES 11 Fuel injector 4 3 NO * If more than two items fail at ce, the self-diagnostic indicati appears according to priority order. The indicati repeats three times.

14 DF90/115/140 K3 ( 03) model 13 *SERVICE DATA (DF140T/140/140Z) * These service data are subject to change without notice. DF140T/140 DF140Z OERHEAD Recommended operating range r/min Idle speed **Cylinder compressi **Cylinder compressi max. difference between any three cylinders **Engine oil pressure Engine oil Engine oil amounts Thermostat operating temperature r/min. ka (kg/cm 2, psi) ka (kg/cm 2, psi) ka (kg/cm 2, psi) L (US/Imp. qt) C ( F) 700 ± 50 (in-gear : approx.700) (12 16, ) 100 (1.0, 14) ( , 64 71) at 3000 r/min. (at normal operating temp.) AI classificati SE, SF, SG, SH, SJ Viscosity rating SAE (5.8/4.8) : Oil change ly 5.7 (6.0/5.0) : Oil filter change ( ) ** Figures shown are guidelines ly, not absolute service limits.

15 14 DF90/115/140 K3 ( 03) model DF140T/140 DF140Z CYLINDER HEAD/CAMSHAFT Cylinder head distorti 0.05 (0.002) Manifold seating faces distorti 0.10 (0.004) Cam height IN ( ) (1.5520) EX ( ) (1.5441) Camshaft journal oil clearance Top, 2nd, 3rd, 4th 5th ( ) (0.0047) ( ) (0.0047) Camshaft journal (housing) inside diameter Top, 2nd, 3rd, 4th ( ) (0.9122) 5th ( ) (1.0304) Camshaft journal outside diameter Top, 2nd, 3rd, 4th ( ) (0.9004) 5th ( ) (1.0175) Camshaft runout 0.10 (0.004) Cylinder head bore to tappet clearance ( ) (0.0059) Tappet outer diameter ( ) Cylinder head bore ( )

16 DF90/115/140 K3 ( 03) model 15 DF140T/140 DF140Z VALVE/VALVE GUIDE Valve diameter Tappet clearance (Cold engine cditi) Valve seat angle Valve guide to valve stem clearance Valve guide inside diameter IN EX IN EX IN EX IN,EX IN 33 (1.2992) EX 28 (1.1024) ( ) ( ) 15, 45, 60 15, ( ) (0.0028) ( ) (0.0035) ( ) Valve guide protrusi Valve stem outside diameter Valve stem end deflecti Valve stem runout Valve head radial runout IN,EX IN EX IN EX IN,EX IN,EX 13.5 (0.5315) ( ) ( ) 0.14 (0.0055) 0.18 (0.0071) 0.05 (0.0020) 0.08 (0.0031) Valve head thickness IN 1.0 (0.0394) 0.7 (0.0276) EX 1.20 (0.0472) 0.7 (0.0276) Valve seat ctact width IN EX ( ) ( ) Valve spring free length (1.6823) (1.6150) Valve spring tensi N (kg, Ibs) ( , ) for 32.6 mm (1.28 in.) N (kg, Ibs) 151 (15.1, 33.3) for 32.6 mm (1.28 in.) Valve spring squareness 2.0 (0.079)

17 16 DF90/115/140 K3 ( 03) model DF140T/140 DF140Z CYLINDER/ISTON/ISTON RING Cylinder distorti ist to cylinder clearance Cylinder bore Cylinder measuring positi ist skirt diameter ist measuring positi Cylinder bore wear ist ring end gap ist ring free end gap ist ring to groove clearance ist ring groove width ist ring thickness in clearance in pist pin hole 1st 2nd 1st 2nd 1st 2nd 1st 2nd Oil 1st 2nd 0.05 (0.0020) ( ) (0.0039) ( ) 50 (1.969) from cylinder top surface ( ) 26.5 (1.043) from pist skirt end (0.0039) ( ) 0.70 (0.0276) ( ) 1.00 (0.0394) Approx (0.4567) 9.3 (0.3661) Approx (0.4528) 9.2 (0.3622) ( ) 0.12 (0.0047) ( ) 0.10 (0.0039) ( ) ( ) ( ) ( ) ( ) ( ) (0.0016) ist pin outside diameter ist pin hole diameter in clearance in crod small end ( ) (0.8260) ( ) (0.8283) ( ) 0.05 (0.002) Crod small end bore ( )

18 DF90/115/140 K3 ( 03) model 17 DF140T/140 DF140Z CRANKSHAFT/CONROD Crod small end inside diameter Crod big end oil clearance Crod big end inside diameter ( ) ( ) (0.0026) ( ) Crank pin outside diameter ( ) Crank pin outside diameter difference (out of round and taper) (0.0004) Crod bearing thickness ( ) Crod big end side clearance Crod big end width Crank pin width ( ) (0.0138) ( ) ( ) Crankshaft center journal runout 0.04 (0.0016) Crankshaft journal oil clearance ( ) (0.0026) Crankcase bearing holder inside diameter ( ) Crankshaft journal outside diameter ( ) Crankshaft journal outside diameter difference (out of round and taper) 0.01 (0.0004) Crankshaft bearing thickness ( ) Crankshaft thrust play ( ) 0.35 (0.0138) Crankshaft thrust bearing thickness ( )

19 18 DF90/115/140 K3 ( 03) model DF140T/140 DF140Z ELECTRICAL Igniti timing Degrees at r/min TDC 5 TDC 45 Over revoluti limiter r/min 6500 CK sensor resistance CM sensor resistance rimary Igniti coil resistance Secdary k No.2 No.3 : (including H.T.cord and spark plug cap) No.1 No.4 : (including H.T.cord and spark plug cap) High tensi cord resistance kω/m at 20 C Approx.16 attery charge coil resistance attery charge coil output (12V) att Standard spark plug Type Gap NGK KR6E ( ) Fuse amp. rating A Main fuse : 60 Sub fuse : 30 Recommended battery capacity (12V) Ah (kc) 100 (360) or larger Fuel injector resistance IAC valve resistance 8 12 IAT sensor / Cylinder temp. sensor / Ex- mani. temp. sensor (Thermistor characteristic) ECM main relay resistance Starter relay coil resistance TT motor relay coil resistance kω at 25 C STARTER MOTOR Max. ctinuous time of use Motor output rush length Commutator undercut Sec k (0.63) 12.0 (0.47) ( ) 0.2 (0.008) Commutator outside diameter 29 (1.14) 28 (1.10) Commutator outside diameter difference 0.05 (0.002) 0.40 (0.016)

20 DF90/115/140 K3 ( 03) model 19 DF140T/140 DF140Z TT MOTOR rush length 9.8 (0.39) 5.0 (0.20) Commutator outside diameter 22.0 (0.87) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION hen the abnormality occurs in a signal from sensor, switch, etc., the CHECK ENGINE lamp the mitor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding. RIORITY * FAILED ITEM CODE LAM FLASHING ATTERN FAIL-SAFE SYSTEM ACTIVATING 1 MA sensor CK sensor 4 2 YES YES 3 IAC valve/y-pass air screw adjustment 3 1 NO 4 CM sensor CT switch Cylinder temp. sensor IAT sensor 2 3 YES NO YES YES 8 MA sensor 2 (ressure detect passage) 3 2 NO 9 Rectifier & regulator (Over-charging) Exhaust manifold temp. sensor 1 5 NO YES 11 Fuel injector 4 3 NO * If more than two items fail at ce, the self-diagnostic indicati appears according to priority order. The indicati repeats three times.

21 20 DF90/115/140 K3 ( 03) model TIGHTENING TORQUE Tightening Torque Important Fasteners ITEM THREAD DIAMETER * Tightening torques have been changed from the middle of 2003 year model. TIGHTENING TORQUE N. m kg-m Ib.-ft Cylinder head cover bolt 6 mm Cylinder head bolt 8 mm *25 *2.5 * mm Crankcase bolt 8 mm mm Crod cap nut 8 mm Camshaft housing bolt 6 mm Camshaft timing sprocket bolt 10 mm Timing chain guide bolt 6 mm Intake manifold bolt / nut 8 mm Oil pressure switch Fuel delivery pipe bolt 8 mm Fuel delivery pipe plug / uni bolt 12 mm Fuel return pipe bolt (nut) 8 mm Low pressure fuel pump bolt 6 mm Thermostat cover bolt 6 mm Flywheel bolt 16 mm Starter motor mounting bolt 8 mm mm Engine oil filter Engine oil drain plug 12 mm Oil relief valve Engine holder upper bolt 8 mm Engine holder bolt 8 mm mm ower unit mounting bolt 10 mm Driveshaft housing bolt 10 mm Upper mount nut Frt 12 mm Rear 12 mm Upper mount cover bolt 10 mm Lower mount bolt / nut 12 mm Clamp bracket shaft nut 22 mm ater pump case bolt 8 mm *23 *2.3 *16.5 Gearcase bolt 10 mm ropeller shaft bearing housing bolt 8 mm *23 *2.3 *16.5 DF90/ ini nut 14 mm DF ropeller nut 18 mm

22 DF90/115/140 K3 ( 03) model 21 ECM DF90/115 For EU model and general market model, the map of fuel injecti has been changed. For U. S. model, the moti under operati of the emergency stop switch has been changed. The IAC valve operating duty at idle speed (625 r/min) has been changed from 15 % to 30 %. This duty can be mitored by using the Suzuki Diagnostic System (SDS). DF140 For U. S. model, the moti under operati of the emergency stop switch has been changed. NOTE: EC model and general model have not been changed. NOTE: From 2003 year model, ECM identificati code recorded in its memory has been changed. Use the Suzuki Diagnostic System (SDS) updated by the database versi 4.10 (program versi 4.00) in order to communicate with the ECM 2003 year model DF90/115/140. ECM MAIN RELAY AND STARTER MOTOR RELAY! : Digital tester " Tester range : # (Ctinuity) (1) Discnect relay from wire. (2) Check ctinuity between terminal 1 and 2 each time 12 V is applied. Cnect positive (+) side to terminal 4, and negative ( ) side to terminal 3. Relay functi : V 12 V power Ctinuity Applied Yes Not applied No ECM main relay 4 $ e careful not to touch 12 V power supply wires to each other or with other terminals.

23 22 DF90/115/140 K3 ( 03) model ATTERY CHARGE COIL attery charge coil has been changed in shape of cnector. Measure battery charge coil resistance.! : Digital tester % Tester range : Ω (Resistance) 1. Discnect battery charge coil leads from rectifier & regulator. 2. Measure resistance between leads in the combinatis shown. attery charge coil resistance : 1 Terminal for tester probe cnecti Resistance 2 3 hite 1 to hite 2 hite 2 to hite 3 hite 3 to hite Ω If out of specificati, replace battery charge coil. RECTIFIER & REGULATOR Rectifire & Regulator has been changed in shape of cnector.! : ocket tester % Tester range : 1 kω (Resistance) 1. Discnect all lead wires of rectifier & regulator. 2. Measure resistance between leads in combinatis shown. NOTE: The values given below are for a SUZUKI pocket tester. As thyristors, diodes, etc. are used inside this rectifier & regulator, the resistance values will differ when an ohmmeter other than SUZUKI pocket tester is used. Rectifier & regulator resistance : Tester probe + (Red) : kω lack hite hite 1 hite 2 hite 3 Tester probe - (lack) lack hite hite 1 hite 2 3~60 4~80 4~80 1~20 0.5~10 0.5~10 0.5~100 4~80 5~ ~100 4~80 5~ ~100 4~80 5~100 5~ hite 3 4~80 0.5~10 5~100 5~100 If measurement exceeds specificati, replace rectifier & regulator.

24 DF90/115/140 K3 ( 03) model 23 EXHAUST CAMSHAFT (FOR DF115 ONLY) The profile of exhaust cam has been changed. As the result of this change, cam height has been changed. Cam height (DF115 exhaust cam) Standard : mm ( in) : mm ( in) Cam height The indentificati (dent) mark has been added the top end of the late camshaft. Added dent mark REMOTE CONTROL CALE HOLDER The remote ctrol cable holder, stopper and bolt have been changed. The remote ctrol cable rubber has been added between the holder and stopper. Holder Rubber Stopper olt

25 24 DF90/115/140 K3 ( 03) model CYLINDER HEAD INSTALLATION Installati is in reverse order of removal with special attenti to the following steps. $ Do not re-use gasket ce removed. Always use a new gasket. 1. Insert dowel pins and place cylinder head gasket into positi cylinder. 2. ositi cylinder head cylinder. 3. Apply engine oil lightly to cylinder head bolts and tighten them gradually as follows. (a) Tighten all bolts to 50 percent (%) of specified torque according to numerical order in figure. & Cylinder head bolt : 1 st step 10 mm 35 N.m (3.5 kg-m, 25.5 lb.-ft.) 8 mm 12 N.m (1.2 kg-m, 8.5 lb.-ft.) (b) Loosen all bolts to 0 N.m (0 kg-m, 0 lb.-ft.) according to reverse order in figure. (c) Again tighten all bolts to 50 percent (%) of specified torque according to numerical order in figure. & Cylinder head bolt : 3 rd step 10 mm 35 N.m (3.5 kg-m, 25.5 lb.-ft.) 8 mm 12 N.m (1.2 kg-m, 8.5 lb.-ft.) (d) Finally tighten all bolts to specified torque according to numerical order in figure. & Cylinder head bolt : Final step 10 mm 70 N.m (7.0 kg-m, 50.5 lb.-ft.) 8 mm 25 N.m (2.5 kg-m, 18.0 lb.-ft.) NOTE: Use special tool (10 mm deep socket wrench) when tightening cylinder head bolts.! : Deep socket wrench (10 mm)

26 DF90/115/140 K3 ( 03) model 25 CRANKCASE TO CYLINDER INSTALLATION 1. Clean mating surface of cylinder and crankcase. 2. Apply Suzuki d to mating surface of crankcase as shown in figure. ' : Suzuki d 1207 $ Apply bd to mating surface ly. Do not allow bd to ctact surface of bearing. 3. Install five (5) dowel pins Install crankcase to cylinder. 5. Apply engine oil lightly to crankcase bolts. 6. Tighten crankcase bolts in three (3) steps according to the order shown below and in figure. NOTE: After tightening crankcase bolts, check to be sure that crankshaft rotates smoothly when turned by hand. & Crankcase bolt : 1st step 8 mm 5 N.m (0.5 kg-m, 3.5 lb.-ft.) 10 mm 11 N.m (1.1 kg-m, 8.0 lb.-ft.) 2nd step 8 mm 20 N.m (2.0 kg-m, 14.5 lb.-ft.) 10 mm 45 N.m (4.5 kg-m, 31.0 lb.-ft.) Final step 8 mm 25 N.m (2.5 kg-m, 18.0 lb.-ft.) 10 mm 56 N.m (5.6 kg-m, 40.5 lb.-ft.) Tightening order

27 26 DF90/115/140 K3 ( 03) model UER MOUNT FOR DF90/115 The upper mount has been changed in shape of core metal. In accordance with this change, the thrust stopper washer has been changed in diameter. Upper mount A A Ê 32 mm Ê 24 mm Early Late Thrust stopper washer Ê 32 mm Ê 22 mm Early Late DRIVESHAFT The drive shaft has been changed in length. Early Late 59 mm 49 mm mm (L) mm (UL) Early mm (L) mm (UL) Late ROELLER SHAFT EARING HOUSING The propeller shaft bearing has been changed in number and size. Early Number : 2 pieces Length A : 20 mm Late 1 piece 30 mm A hen installing the bearing, stamped mark of bearing must face outside. lace bearing in the positi shown figure. Stamped mark side 32.5 mm

28 DF90/115/140 K3 ( 03) model 27 DF115 AND DF140 This secti describes servicing procedures which differ from those of the DF115/140 K2 models. Identificati mark EXHAUST VALVE The exhaust valve has been changed in surface treatment. The identificati mark has been added the valve head. ATER UM CASE The sleeve has been added inside of water pump case. Added sleeve ECM The moti under operati of the emergency stop switch has been changed.

29 28 DF90/115/140 K3 ( 03) model R/G R/G R/G R/G R/G MONITOR TACHO- METER l-tue -TUE REMOTE CONTROL OX USH TURN G r O Z M + M TT MOTOR + F USH FREE START IG OFF GND STO ATT IG START UZZER CANCEL U TT SITCH DN U DN -TUE O r Y/ l/r l/ #1 #2 #3 #4 R/G R/G R/G R/G METER Y Y /Y /Y l/ G/Y G/ O Y Y l-tue TT SITCH Lbl R Lbl Y Y r G G G r r O l l CAUTION UZZER (OVERHEAT / OIL RESSURE/ ATTERY VOLTAGE / DIAGNOSIS) r Y/G /R / Lg/ CT SITCH ENGINE CONTROL MODULE Lg/R G O Lbl O r Y G l l/ G/Y G/ Lbl /Y /Y Y Lbl Lbl R/ / R/ R / r Y/G l ATTERY CHARGE COIL MA SENSOR ALTERNATOR CK SENSOR COMMUNICATION CONNECTOR FUSE 30A FUSE 60A R R R STARTER MOTOR R Y/G R R / l R V/ Y/ l O/ /Y R/ Lg V IGNITION COILS #1 O l /R Lbl R /R Lbl Lbl Lbl /G METER ILLUMINATION SITCH TRIM METER R Y IGNITION SITCH EMERGENCY STO SITCH Lock plate IN RUN Lock plate OFF STO IRE COLOR Lbl Lg r l G O R Y /G / /Y : lack : rown : lue : een : ay : Light blue : Light green : Orange : ink : Red : hite : Yellow : lack with een tracer : lack with hite tracer : lack with Yellow tracer G/Y G/ Lg/ Lg/ Lg/Y O/ O/G / R/ R/G R/ /Y /R Y/G Y/ TT MOTOR RELAY U TT MOTOR RELAY DN NEUTRAL SITCH N ON F,R OFF : een with Yellow tracer : een with hite tracer : Light green with lack tracer : Light green with hite tracer : Light green with Yellow tracer : Orange with lack tracer : Orange with een tracer : ink with lack tracer : Red with een tracer : Red with lue tracer : Red with hite tracer : hite with Yellow tracer : hite with Red tracer : Yellow with een tracer : Yellow with hite tracer OIL RESSURE SITCH 1.0kgf/cm 2 or less ON CA IAC VALVE STARTER MOTOR RELAY ECM MAIN RELAY IAT SENSOR / TRIM SENDER r / JOINT CONNECTOR ATTERY 12V 100AH DN U TT SITCH HIGH RESSURE FUEL UM / FUEL INJECTORS CYLINDER TEM SENSOR Lg/ / / O/G O/G CM SENSOR EX-MANI TEM SENSOR #4 RECTIFIER & REGULATOR #2 #3 Y IRING DIAGRAM R/ /G l Lg/R G/Y G/ l/r /R O/G O/ R/ O V/ / O/Y Y R Lg/ l/ O Y/ l/ r / Lg/ / /Y Lg l /G Y O/Y

30 DF90/115/140 K3 ( 03) model 29 IRE ROUTING ECM Cushi Fuse terminal nut Fuse terminal bolt Main fuse terminal Electric parts holder Sub fuse(30a) To starter magnetic switch "" terminal Red lead wire Main harness TT motor relay plate TT motor relay cable GND TT motor relay "U" TT motor relay "DON" To remo-c cnector Electric parts holder Communicati cnector / Cap ECM main relay Starter relay ECM cnector hite lead wire (To 30A fuse) Joint cnector To igniti coil and fuel injector Main wiring harness

31 30 DF90/115/140 K3 ( 03) model attery cable + Harness lead wire + attery cable - Starter motor bolt Starter motor Communicati cnector / Cap Main fuse (60 A) Tighten nut with rect & regulator out put white lead and 30 A fuse white lead wire. A Spare main fuse Sub fuse (30 A) (with spare) DETAIL A Starter magnetic switch "S" terminal TT motor relay "U" attery cable Harness lead wire GND TT motor relay "DON" TT cable Starter relay ECM main relay ENGINE SIDE Tighten bolt with TT ground lead wire and main harness ground lead wire. Tighten bolt with starter motor band and rect & regulator ground lead wire. Cylinder temp. sensor Clamp: Fix cylinder temp. sensor lead wire. CM sensor Igniti coil No.1 Igniti coil No.2 Rectifier & regulator Main harness Clamp Fix rect & regulator lead wire and temp. sensor lead wire. Exhaust manifold temp. sensor hen installing sensor, apply water resistant grease to sensor o-ring.

32 DF90/115/140 K3 ( 03) model 31 ATER HOSE ROUTING Thermostat cover hite paint mark ater return hose ater return hose ater return pipe (Engine holder) ilot water tube ater hose (Fuel return pipe to ater return pipe)

33 repared by Marine & ower roducts Divisi September, 2002 Manual No J10-01E rinted in Japan 32

34 rinted in Japan K3 TK