Suzuki DF 40 Manuel utilisateur

For '03 model

SUPPLEMENTARY

SERVICE

MANUAL

99501-87J20-01E

CONTENTS

DF40/50 “K3” (2003) MODEL

SPECIFICATIONS ___________________________________________ 2

SERVICE DATA _____________________________________________ 4

ECM MAIN RELAY ___________________________________________ 9

EXHAUST MANIFOLD TEMPERATURE SENSOR AND

CYLINDER TEMPERATURE SENSOR ___________________________ 9

CYLINDER BLOCK __________________________________________ 10

BUZZER ___________________________________________________ 10

NEUTRAL SWITCH BRACKET _________________________________ 11

UNDER OIL SEAL HOUSING __________________________________ 11

FORWARD GEAR THRUST WASHER ___________________________ 11

EXHAUST CAM SHAFT_______________________________________ 12

WIRING DIAGRAMS _________________________________________ 13

WIRE ROUTING _____________________________________________ 14

FOREWORD

This supplementary service manual describes the outline, technical data and servicing procedures

for the “K3” (2003) models outboard motor.

Please read and thoroughly familiarize yourself with this information before using it for your service

activities.

NOTE:

Use this supplement with the following service manual:

DF40/50 Service Manual ( P/no, 99500-87J0 •-01E)

2 DF40/DF50 “K3”(‘03) model

GENERAL INFORMATION

SPECIFICATIONS

Item Unit Data

DF40T DF50T/50WT

DIMENSIONS & WEIGHT

Overall length (front to back) mm (in) 756 (29.8)

Overall width (side to side) mm (in) 382 (15.0)

Overall height Smm (in) 1263 (49.7)

Lmm (in) 1390 (54.7)

Weight

(without engine oil)

Skg (Ibs) 106 (234)

Lkg (Ibs) 109 (240)

Transom height Smm (in. type) 401 (15)

Lmm (in. type) 528 (20)

PERFORMANCE

Maximum output kW (PS) 29.4 (40)

Recommended operating range

r/min

Idle speed r/min

36.8 (50)

5200 –5800 5900 –6500

850 ± 50 (in-gear: approx. 850)

POWERHEAD

Engine type 4-stroke DOHC

Number of cylinders 3

Bore mm (in) 71.0 (2.80)

Stroke mm (in) 68.6 (2.70)

Total displacement cm3(cu in) 815 (49.7)

Compression ratio : 1 10

Spark plug NGK DCPR6E

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

PRE-FIX 04001F 05001F

DF40QH DF50WQH

852 (33.5)

382 (15.0)

—

1390 (54.7)

—

110 (243)

—

528 (20)

852 (33.5)

382 (15.0)

—

1390 (54.7)

—

110 (243)

—

528 (20)

756 (29.8)

382 (15.0)

1263 (49.7)

1390 (54.7)

106 (234)

109 (240)

401 (15)

528 (20)

Twist grip Remote control Twist grip

UL kg (Ibs) —

UL mm (in. type) —

—

113 (249)

655 (25)

112 (247)

655 (25)

UL mm (in) ——1517 (59.7)1517 (59.7)

DF40/DF50 “K3”(‘03) model 3

Item Unit Data

DF40T DF50T/50WT

FUEL & OIL

Fuel Suzuki highly recommends that you use alcohol-free unleaded gasoline

with a minimum pump octane rating of 87 ( 2 method) or 91

(Research method). However, blends of unleaded gasoline and alcohol

with equivalent octane content may be used.

Engine oil API classification SE, SF, SG, SH, SJ

Viscosity rating 10W-40

Engine oil amounts L (US/Imp. qt) 2.2 (2.3/1.9) : Oil change only

2.4 (2.5/2.1) : Oil filter change

R + M

ml (US/Imp. oz)

Gear oil

Gearcase oil capacity

SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil)

610 (20.6/21.5)

BRACKET

Trim angle PTT system

Number of trim position PTT system

Maximum tilt angle degree 73°

LOWER UNIT

Reversing system Gear

Transmission Forward-Neutral-Reverse

Reduction system Bevel gear

Gear ratio 11 : 25 (2.27)

Drive line impact protection Spline drive rubber hub

Propeller Blade ×Diam. (in) ×Pitch (in)

These specifications are subject to change without notice.

S : Aluminum propeller

SS : Stainless steel propeller

3×11-1

2×9 (S900)

3×11-1

2×10 (S1000)

3×11-1

2×11 (S1100)

3×11-5

8×12 (S1200)

3×11-1

2×13 (S1301, SS1300)

3×11-3

8×14 (S1400, SS1400)

3×11-1

4×15 (S1500)

3×11-1

8×16 (S1600, SS1600)

3×11 ×17 (S1700)

Adjustable

DF40QH DF50WQH

Manual trim and gas

assisted tilt system

Manual trim and gas

assisted tilt system

PTT system

5 PTT system 5

4 DF40/DF50 “K3”(‘03) model

SERVICE DATA

POWERHEAD

Recommended operating range r/min 5200 –5800

Idle speed 850 ± 50 (in-gear: approx.850)r/min

5900 –6500

*Cylinder compression 1300 –1600 (13 –16, 185 –228)kPa (kg/cm2, psi)

*Cylinder compression max.

difference between any other

cylinders

100 (1.0, 14)

kPa (kg/cm2, psi)

*Engine oil pressure 300 –380 (3.0 –3.8, 43 –54) at 4000 r/min

(at normal operating temp.)

kPa (kg/cm2, psi)

Engine oil

Engine oil amounts L (US/Imp. qt)

Thermostat operating

temperature 58 –62 (136 –144)

°C (°F)

API classification SE, SF, SG, SH, SJ

Viscosity rating SAE 10W-40

2.2 (2.3/1.9) : Oil change only

2.4 (2.5/2.1) : Oil filter change

* Figures shown are guidelines only, not absolute service limits.

Item Unit Data

DF40T/40QH DF50T/50WT/50WQH

ENGINE OIL PUMP

0.31 (0.012)mm (in)

LimitRadial clearance

0.15 (0.006)mm (in)

LimitSide clearance

CYLINDER HEAD/CAMSHAFT

0.05 (0.002)mm (in)

Limit

Cam height mm (in) 37.530–37.690 (1.4776–1.4839) 38.230–38.390 (1.5051–1.5114)

Cylinder head distortion

0.10 (0.004)mm (in)

Limit

Manifold seating faces

distortion

STD

Limit mm (in) 37.430 (1.4736) 38.130 (1.5012)

mm (in) 37.740–37.900 (1.4858–1.4921) 37.740–37.900 (1.4858–1.4921)

STD

Limit mm (in) 37.640 (1.4819) 37.640 (1.4819)

0.045 –0.087 (0.0018 –0.0034)

mm (in)

Camshaft journal oil

clearance

STD

Limit 0.120 (0.0047)mm (in)

Camshaft

journal (hous-

ing) inside

diameter

Top,

2nd,

3rd,

4th

mm (in)

STD

Limit mm (in)

23.000 –23.021 (0.9055 –0.9063)

23.171 (0.9122)

Camshaft

journal outside

diameter

Top,

2nd,

3rd,

4th

mm (in)

STD

Limit mm (in)

22.934 –22.955 (0.9029 –0.9037)

22.784 (0.8970)

0.10 (0.004)mm (in)

Limit

Camshaft runout

Cylinder head bore to

tappet clearance

0.025 –0.062 (0.0010 –0.0024)mm (in)

STD

0.150 (0.0059)mm (in)

Limit

Tappet outer diameter 26.959 –26.975 (1.0614 –1.0620)mm (in)STD

27.000 –27.021 (1.0630 –1.0638)mm (in)

STD

Cylinder head bore

DF40/DF50 “K3”(‘03) model 5

VALVE / VALVE GUIDE

24.6 (0.97)mm (in)

Tappet clearance

(Cold engine

condition)

mm (in)

Valve diameter

STD

STD mm (in)

mm (in)

STD

Limit mm (in)

0.045 –0.072 (0.0018 –0.0028)

mm (in)

STD

Limit 0.090 (0.0035)mm (in)

IN,EX mm (in)

STD 5.500 –5.512 (0.2165 –0.2170)

Item Unit Data

DF40T/40QH DF50T/50WT/50WQH

21.5 (0.85)mm (in)

0.18 –0.24 (0.007 –0.009)

0.020 –0.047 (0.0008 –0.0019)

0.070 (0.0028)

Valve guide to

valve stem

clearance

Valve guide inside

diameter

Valve seat

angle

30°, 45°

15°, 45°

IN,EX mm (in)

STD 11.0 (0.43)

Valve guide

protrusion

Valve stem

outside diameter

mm (in)

STD

STD mm (in)

5.465 –5.480 (0.2152 –0.2157)

5.440 –5.455 (0.2142 –0.2148)

IN,EX mm (in)

Limit 3.20 (0.126)

Valve stem end

length

Valve stem end

deflection

mm (in)

Limit

Limit mm (in)

0.14 (0.006)

0.18 (0.007)

IN,EX mm (in)

Limit 0.05 (0.002)

Valve stem runout

IN,EX mm (in)

Limit 0.08 (0.003)

Valve head radial

runout

Valve head

thickness

mm (in)

STD

Limit mm (in)

1.0 (0.04)

0.7 (0.03)

mm (in)

STD

Limit mm (in)

1.15 (0.045)

0.5 (0.02)

Valve seat

contact width

mm (in)

STD

STD mm (in)

1.80 –2.20 (0.071 –0.087)

1.65 –2.05 (0.065 –0.081)

Valve spring free

length

33.1 (1.30)mm (in)

STD

31.8 (1.25)mm (in)

Limit

Valve spring tension 97 –113 (9.7–11.3, 21.4–24.9) for 28.5 mm (1.12 in)N (kg, Ibs)

STD

89 (8.9, 19.6) for 28.5 mm (1.12 in)N (kg, Ibs)

Limit

Valve spring

squareness 2.0 (0.08)mm (in)

Limit

degree

6 DF40/DF50 “K3”(‘03) model

CYLINDER/PISTON/PISTON RING

0.060 (0.0024)mm (in)

Limit

Piston ring

end gap

mm (in) 0.10 –0.25 (0.004 –0.010)

Cylinder distortion

Piston to cylinder

clearance

STD

Limit mm (in) 0.70 (0.028)

1st

mm (in) 0.25 –0.40 (0.010 –0.016)

STD

Limit mm (in) 1.00 (0.039)

2nd

Item Unit Data

DF40T/40QH DF50T/50WT/50WQH

mm (in) 0.020 –0.040 (0.0008 –0.0016)

STD

Limit mm (in) 0.100 (0.0039)

71.000 –71.020 (2.7953 –2.7961)mm (in)

STD

Cylinder bore

50 (2.0) from cylinder top surfacemm (in)

Cylinder measuring position

70.970 –70.990 (2.7941 –2.7949)mm (in)

STD

Piston skirt diameter

19 (0.7) from piston skirt endmm (in)

Piston measuring position

0.100 (0.0039)mm (in)

Limit

Cylinder bore wear

Piston ring

free end gap

mm (in) Approx. 7.5 (0.30)

STD

Limit mm (in) 6.0 (0.24)

1st

mm (in) Approx. 11.0 (0.43)

STD

Limit mm (in) 8.8 (0.35)

2nd

Piston ring

groove width

mm (in) 1.01 –1.03 (0.040 –0.041)

1st

mm (in) 1.01 –1.03 (0.040 –0.041)

mm (in) 2.01 –2.03 (0.079 –0.080)

2nd

Oil

Piston ring to

groove

clearance

mm (in) 0.02 –0.06 (0.001 –0.002)

STD

Limit mm (in) 0.10 (0.004)

1st

mm (in) 0.02 –0.06 (0.001 –0.002)

STD

Limit mm (in) 0.10 (0.004)

2nd

Piston ring

thickness

mm (in) 0.97 –0.99 (0.038 –0.039)

STD

STD mm (in) 0.97 –0.99 (0.038 –0.039)

1st

2nd

Pin clearance in

piston pin hole

mm (in) 0.006 –0.018 (0.0002 –0.0007)

STD

Limit mm (in) 0.040 (0.0016)

Piston pin outside

diameter

mm (in) 17.996 –18.000 (0.7085 –0.7087)

STD

Limit mm (in) 17.980 (0.7079)

Piston pin hole

diameter

mm (in) 18.006 –18.014 (0.7089 –0.7092)

STD

Limit mm (in) 18.040 (0.7102)

Pin clearance in

conrod small end

mm (in) 0.003 –0.015 (0.0001 –0.0006)

STD

Limit mm (in) 0.050 (0.0020)

Conrod small end

bore mm (in) 18.003 –18.011 (0.7088 –0.7091)STD

STD

DF40/DF50 “K3”(‘03) model 7

Item Unit Data

DF40T/40QH DF50T/50WT/50WQH

CRANKSHAFT / CONROD

Conrod big end oil

clearance

0.020 –0.040 (0.0008 –0.0016)mm (in)STD

0.065 (0.0026)mm (in)Limit

Conrod small end

inside diameter 18.003 –18.011 (0.7088 –0.7091)mm (in)

STD

Conrod big end

inside diameter 41.000 –41.018 (1.6142 –1.6149)mm (in)

STD

Crank pin outside

diameter 37.982 –38.000 (1.4954 –1.4961)mm (in)

STD

Crank pin outside

diameter difference

(out of round and taper)

0.010 (0.0004)mm (in)

Limit

Conrod bearing

thickness 1.486 –1.502 (0.0585 –0.0591)mm (in)

STD

Conrod big end side

clearance

0.100 –0.250 (0.0039 –0.0098)mm (in)

STD

0.350 (0.0138)mm (in)

Limit

21.950 –22.000 (0.8642 –0.8661)mm (in)

STD

Conrod big end width

22.100 –22.200 (0.8700 –0.8740)mm (in)

STD

Crank pin width

Crankshaft journal

oil clearance

0.020 –0.040 (0.0008 –0.0016)mm (in)

STD

0.065 (0.0026)mm (in)

Limit

Crankshaft center

journal runout 0.04 (0.002)mm (in)

Limit

Crankcase bearing

holder inside diameter 49.000 –49.018 (1.9291 –1.9298)mm (in)

STD

Crankshaft journal

outside diameter 44.982 –45.000 (1.7709 –1.7717)mm (in)

STD

Crankshaft journal

outside diameter

difference

(out of round and taper)

0.010 (0.0004)mm (in)

Limit

Crankshaft thrust

play

0.11 –0.31 (0.004 –0.012)mm (in)

STD

0.35 (0.014)mm (in)

Limit

Crankshaft thrust

bearing thickness 2.470 –2.520 (0.0972 –0.0992)mm (in)

STD

Crankshaft bearing

thickness 1.999 –2.015 (0.0787 –0.0793)mm (in)

STD

LOWER UNIT

Design specification thickness for shim & washer

Pinion gear back-up shim 1.0 (0.04)mm (in)

Forward gear back-up shim 1.0 (0.04)mm (in)

Forward gear thrust washer 2.0 (0.08)mm (in)

Reverse gear thrust washer 2.0 (0.08)mm (in)

Reverse gear back-up shim 1.0 (0.04)mm (in)

8 DF40/DF50 “K3”(‘03) model

ELECTRICAL

ATDC 1°–BTDC 27°

Degrees at r/min

Ignition timing

6500r/min

Over revolution limiter

Item Unit Data

DF40T/40QH DF50T/50WT/50WQH

Ω at 20°C

CKP sensor resistance

Ω at 20°C

CMP sensor resistance

Ω at 20°C

Ignition coil resistance Primary

k Ω at 20°C

Secondary

Ω at 20°C

Battery charge coil resistance

Watt

Battery charge coil output (12V)

NGK

Standard spark plug Type

mm (in)

Gap 0.8 –0.9 (0.031 –0.035)

Fuse amp. rating Main fuse : 30

Ah (kC)

Recommended battery

capacity (12V) 70 (252) or larger

Ω at 20°C

Fuel injector resistance

Ω at 20°C

IAC valve resistance

k Ω at 25°C

IAT sensor/Cylinder temp. sensor

/ Ex-mani. temp. sensor

(Thermistor characteristic)

Ω at 20°C

ECM main relay resistance

Ω at 20°C

Starter motor relay resistance

1.8 –2.3

80 –120

3.5 –5.1

STARTER MOTOR

30Sec.

Max. continuous time of use

0.9kW

Motor output

17.0 (0.67)

mm (in)

STD

Brush length

10.0 (0.39)mm (in)

Limit

0.5 –0.8 (0.02 –0.03)mm (in)

STD

Commutator

undercut 0.2 (0.01)mm (in)

Limit

33.0 (1.30)mm (in)

STD

Commutator

outside diameter 32.0 (1.26)mm (in)

Limit

0.05 (0.002)mm (in)

STD

0.40 (0.016)mm (in)

Limit

Pinion to ring gear gap 3.0 –5.0 (0.12 –0.20)

STD mm (in)

Commutator outside

diameter difference

168 –252

——

1.9 –2.5

8.1 –11.1

DCPR6E

ATDC 1°–BTDC 24°

7000

0.56 –0.84

216

11.0 –16.5

21.5 –32.3

PTT MOTOR

9.8 (0.39)mm (in)

STD

Brush length

4.8 (0.19)mm (in)

Limit

22.0 (0.87)

mm (in)

STD

Commutator

outside diameter 21.0 (0.83)mm (in)

Limit

Ω at 20°C

PTT motor relay resistance 3.0 –4.5

DF40/DF50 “K3”(‘03) model 9

Tube color: GrayDome shape O-ring

14 mm

Tube color: Green

12 mm

12V

ECM main relay

1 2 3

ECM MAIN RELAY

!09930-99320 : Digital tester

"Tester range : ##

#(Continuity)

(1) Disconnect ECM main relay from wire.

(2) Check continuity between terminal 1and 2each time 12 V

is applied. Connect positive (+) side to terminal 4, and nega-

tive (–) side to terminal 3.

ECM main relay function :

12 V power Continuity

Applied Yes

Not applied No

Be careful not to touch 12 V power supply wires to each

other or with other terminals.

EXHAUST MANIFOLD TEMPERATURE SENSOR AND CYL-

INDER TEMPERATURE SENSOR

The shape of temperature sensor has been changed. from the

middle of 2002 year model.

The temperature sensor has been changed 2003 year model.

•Change of connector

•Elimination of O-ring

•Change of tube color

NOTE:

Exhaust manifold temperature sensor does not contact with cool-

ing water from 2003 year model.

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