Suzuki DF 40 User manual

99500-87J00-01E

This manual contains an introductory description on
SUZUKI Outboard motor DF40/50 and procedures
for the inspection, service and overhaul of its main
components.
General knowledge information is not included.
Please read the GENERAL INFORMATION sec-
tion to familiarize yourself with basic information
concerningthismotor.Readandreferto the other
sections in this manual for information regard-
ing proper inspection and service procedures.
This manual will help you better understand this out-
board motor so that you may provide your custom-
ers with optimum and quick service.
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE CONTROL SYSTEM
ELECTRICAL
FUEL SYSTEM
POWER UNIT
MID UNIT
POWERTRIM ANDTILT
LOWER UNIT
WIRE / HOSE ROUTING
Marine & Power Products Division
GROUP INDEX
A
Apprentice machanics or do-it-yourself me-
chanics that don’t have the proper tools and
equipment may not be able to properly per-
form 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
1
2
3
4
5
6
7
8
9
10
• This manual has been prepared using the lat-
est information available at the time of publi-
cation.
If a modification has been made since then,
differences may exist between the content of
this manual and the actual outboard motor.
• Illustrations in this manual are used to show
thebasic principlesofoperation and work pro-
cedures and may not represent the actual
outboard motor in exact detail.
• Thismanualis intended foruse bytechnicians
whoalreadypossessthe basic knowledgeand
skills to service SUZUKI outboard motors.
Persons without such knowledge and skills
should not attempt to service an outboard
engine by relying on this manual only.
Instead, please contact your nearby autho-
rized SUZUKI outboard motor dealer.
COPYRIGHT SUZUKI MOTOR CORPORATION 1998

HOW TO USE THIS MANUAL
TO LOCATEWHATYOU ARE
LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed on the previous page
in a GROUP INDEX. Select the section you wish
to reference.
3. Holding the manual as shown at the right will al-
lowyou to find the first page of the section easily.
4. The first page of each section lists a table of con-
tents to easily locate the item and page you need.
COMPONENT PARTS AND IMPORTANT ITEM ILLUSTRATIONS
Under the name of each system or unit, an exploded view is provided with work instructions and other
service information such as the tightening torque, lubrication and locking agent points.
Example :
1Flywheel bolt
2Washer
3Key
4Flywheel
5CKP sensor
6Screw
7CMP sensor
8Bolt
1
2
3
4
5
5
5
6
78
Crankshaft
@200 N.m
(20.0 kg-m, 145 lb.-ft.)
o
h
NOTE:
Clean flywheel and crankshaft mating
surfaces with cleaning solvent.

SYMBOL
Listed in the table below are the symbols indicating instructions and other important information neces-
sary 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.
Apply THREAD LOCK “1342”.
Apply THREAD LOCK SUPER
“1333B”.
Measure in DC voltage range.
Measure in resistance range.
Measure in continuity test range.
Use peak voltmeter
“Stevens CD-77”.
Use special tool.
Torque control required.
Data beside it indicates specified
torque.
Apply oil. Use engine oil unless
otherwise specified.
Apply SUZUKI OUTBOARD
MOTOR GEAR OIL.
ApplySUZUKISUPERGREASE“A”.
Apply SUZUKI WATER
RESISTANT GREASE.
Apply SUZUKI BOND “1104”.
Apply SUZUKI BOND “1207B”.
Apply SUZUKI SILICONE SEAL.
SYMBOL DEFINITION SYMBOL DEFINITION
@
o
j
v
l
a
b
k
h
g
s
t
r
z
q

GENERAL INFORMATION
1
WARNING/CAUTION/NOTE _________________________________ 1-1
GENERAL PRECAUTIONS _________________________________ 1-1
IDENTIFICATION NUMBER LOCATION _______________________ 1-3
FUEL AND OIL ___________________________________________ 1-3
GASOLINE RECOMMENDATION ................................................................. 1-3
ENGINE OIL ................................................................................................... 1-3
ENGINE BREAK-IN _______________________________________ 1-4
PROPELLERS ___________________________________________ 1-5
SPECIFICATIONS_________________________________________ 1-6
SERVICE DATA___________________________________________ 1-8
TIGHTENINGTORQUE ____________________________________ 1-15
SPECIALTOOLS _________________________________________ 1-17
MATERIALS REQUIRED ___________________________________ 1-20
CONTENTS

1-1 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully.To emphasize special information, the sym-
bol and the words WARNING, CAUTION and NOTE have special meanings.Pay special attention to the
messages highlighted by these signal words.
A
Indicates a potential hazard that could result in death or injury.
B
Indicates a potential hazard that could result in motor damage.
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
potential hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the
WARNING and CAUTION stated, you must also use good judgement and observe basic mechanical
safety principles.
GENERAL PRECAUTIONS
• Proper service and repair procedures are important for the safety of the service mechanic
and the safety and reliability of the outboard motor.
• To avoid eye injury,always wear protective goggles when filing metals,working on a grinder,
or doing other work, which could cause flying material particles.
• When 2 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 and on a boat, 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.
• 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.
• Oil can be hazardous. Children and pets may be harmed from contact with oil. 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 dishwashing 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.
• After servicing fuel, oil/engine cooling system and 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.
A

GENERAL INFORMATION 1-2
• If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their
equivalent.
• 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 when 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.
• Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending
with smaller diameter, Always tighten from inside to outside diagonally, to the specified
tightening torque.
• 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.
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 en-
sure 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 operation.
• To protect the environment, do not unlawfully dispose of used motor oil, other fluids, and
batteries.
• To protect the Earth’s natural resources, properly dispose of used motor parts.
B

1-3 GENERAL INFORMATION
IDENTIFICATION NUMBER LOCATION
MODEL PRE-FIX SERIAL NUMBER
The MODEL, PRE-FIX and SERIAL NUMBER of motor are
stamped on a plate attached to the clamp bracket.
Example
FUEL AND OIL
GASOLINE RECOMMENDATION
Suzuki highly recommends that you use alcohol - free un-
leaded gasoline with a minimum pump octane rating of 87
(R+M /2method)or 91(Researchmethod). However, blends
of unleaded gasoline and alcohol with equivalent octane con-
tent may be used.
Allowable maximum blend of a single additive (not combina-
tion) : 5% Methanol, 10% Ethanol, 15% MTBE
B
If leaded gasoline is used, engine damage may re-
sult.
ENGINE OIL
Use only oils that are rated SE, SF, SG, SH, or SJ under the
API (American Petroleum Institute) classification system.
The viscosity rating should be SAE 10W-40.
If an SAE 10W-40 motor oil is not available, select an alterna-
tive according to the chart at right.
MODEL
PRE-FIX SERIAL NUMBER
DF 50
05001F–XXXXXX
ENGINE SERIAL NUMBER
A second engine serial number plate is pressed into a boss
on the cylinder block .

GENERAL INFORMATION 1-4
ENGINE BREAK-IN
The first 10 hours are critically important to ensure correct
running of either a brand new motor or a motor that has been
reconditioned or rebuilt.How the motor is operated during this
time will have direct bearing on its life span and long-term
durability.
Break-in period : 10 hours
WARM-UP RECOMMENDATION
Allow sufficient idling time (more than 5 minutes) for the en-
gine to warm up after cold engine starting .
THROTTLE RECOMMENDATION
NOTE:
Avoid maintaining a constant engine speed for an extended
period at any time during the engine break-in by varying the
throttle position occasionally.
1. FIRST 2 HOURS
For first 15 minutes, operate the engine in-gear at idling
speed.
During the remaining 1 hour and 45 minutes, operate the
engine in-gear at less than 1/2 (half) throttle (3000 r/min).
NOTE:
The throttle may be briefly opened beyond the recommended
setting to plane the boat, but must be reduced to the recom-
mended setting immediately after planning.
2. NEXT 1 HOUR
Operate the engine in-gear at less than 3/4 (three-quar-
ter) throttle (4000 r/min).
3. LAST 7 HOURS
Operate the engine in-gear at desired engine speed.
However, do not operate continuously at full throttle for
more than 5 minutes.

1-5 GENERAL INFORMATION
PROPELLERS
An outboard motor is designed to develop its rated power
within a specified engine speed range.The maximum rated
power delivered by the DF40 / 50 T models is shown below.
Blade ×Diam. (in.) ×Pitch (in.)
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)
If the standard propeller fails to meet the above requirement,
use another pitch propeller to hold the engine speed within
the range specified above.
Propeller selection chart
Recommended full
throttle speed range DF40T 5200-5800 r / min
DF50T 5900-6500 r / min

GENERAL INFORMATION 1-6
SPECIFICATIONS
Item Unit Data
DF40T DF50T
DIMENSIONS &WEIGHT
Overall length (front to back) mm (in.) 756 (29.8)
Overall width (side to side) mm (in.) 382 (15.0)
Overall height S mm (in.) 1263 (49.7)
Lmm (in.) 1390 (54.7)
Weight
(without engine oil) Skg (Ib.) 106 (234)
Lkg (Ib.) 109 (240)
Transom height S mm (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±50)
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

1-7 GENERAL INFORMATION
Item Unit Data
DF40T DF50T
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)

GENERAL INFORMATION 1-8
SERVICE DATA
POWERHEAD
Recommended operating range r/min 5200 – 5800
Idle speed 850 ± 50 (in-gear: approx.850±50)
r/min
5900 – 6500
**Cylinder compression 1300 – 1600 (13 – 16, 185 – 228)kPa (kg/cm2. psi)
**Cylinder compression max.
difference between any two
cylinders 100 (1.0, 14)
kPa (kg/cm2. psi)
**Engine oil pressure 295 – 373 (3.0 – 3.8, 42 – 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 48 – 52 (126 – 134)°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 DF50T

1-9 GENERAL INFORMATION
Item Unit Data
DF40T DF50T
ENGINE OIL PUMP
0.31 (0.0122 in.)mm (in.)
Limit
Radial clearance
0.15 (0.0059 in.)mm (in.)Limit
Side 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)
IN
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)
EX
0.045 – 0.087 (0.0018 – 0.0034)
mm (in.)
Camshaft journal oil
clearance STD
Limit 0.12 (0.0047)mm (in.)
Camshaft
journal
(housing)
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.)
STDCylinder head bore

GENERAL INFORMATION 1-10
VALVE / VALVE GUIDE
24.6 (0.9685)mm (in.)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 DF50T
21.5 (0.8465)mm (in.)
EX
IN
EX
0.18 – 0.24 (0.007 – 0.009)
0.18 – 0.24 (0.007 – 0.009)
0.020 – 0.047 (0.0008 – 0.0019)
0.070 (0.0028)
IN
EX
Valve guide to
valve stem
clearance
Valve guide inside
diameter
Valve seat
angle IN
EX
30°, 45°
15°, 45°
IN,EX mm (in.)
STD 11 (0.4331)
Valve guide
protrusion
Valve stem
outside diameter mm (in.)
STD
STD mm (in.)
IN
EX
5.465 – 5.480 (0.2152 – 0.2157)
5.440 – 5.455 (0.2142 – 0.2148)
IN,EX mm (in.)
Limit 3.2 (0.1260)
Valve stem end
length
Valve stem end
deflection mm (in.)
Limit
Limit mm (in.)
IN
EX
0.14 (0.0055)
0.18 (0.0071)
IN,EX mm (in.)
Limit 0.05 (0.0020)
Valve stem runout
IN,EX mm (in.)
Limit 0.08 (0.0031)
Valve head radial
runout
Valve head
thickness mm (in.)
STD
Limit mm (in.)
IN 1.0 (0.0394)
0.7 (0.0276)
mm (in.)
STD
Limit mm (in.)
EX 1.15 (0.0453)
0.5 (0.0197)
Valve seat
contact width mm (in.)
STD
STD mm (in.)
IN
EX
1.80 – 2.20 (0.0709 – 0.0866)
1.65 – 2.05 (0.0650 – 0.0984)
Valve spring free
length 33.13 (1.3043)mm (in.)
STD
31.80 (1.2520)mm (in.)
Limit
Valve spring tension 95 – 111 (9.7–11.3, 21.4–24.9) for 28.5 mm (1.12 in.)N (kg, Ibs)
STD
88 (8.9, 19.6) for 28.5 mm (1.12 in.)N (kg, Ibs)
Limit
Valve spring
sequareness 2.0 (0.079)mm (in.)Limit

1-11 GENERAL INFORMATION
CYLINDER / PISTON / PISTON RING
0.06 (0.0024)mm (in.)Limit
Piston ring
end gap mm (in.) 0.10 – 0.25 (0.0039 – 0.0098)
Cylinder distortion
Piston to cylinder
clearance
STD
Limit mm (in.) 0.70 (0.0276)
1st
mm (in) 0.25 – 0.40 (0.0098 – 0.0157)
STD
Limit mm (in.) 1.00 (0.0394)
2nd
Item Unit Data
DF40T DF50T
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 (1.969) from cylinder top surfacemm (in.)
Cylinder measuring position
70.970 – 70.990 (2.7941 – 2.7949)mm (in.)
STD
Piston skirt diameter
19 (0.748) from piston skirt end.mm (in.)
Piston measuring position
0.10 (0.039)mm (in.)
Limit
Cylinder bore wear
Piston ring
free end gap mm (in.) Approx. 7.5 (0.2953)
STD
Limit mm (in.) 6 (0.2362)
1st
mm (in.) Approx. 11 (0.4330)
STD
Limit mm (in.) 8.8 (0.3465)
2nd
Piston ring
groove width mm (in.) 1.01 – 1.03 (0.0398 – 0.0406)
1st
mm (in.) 1.01 – 1.03 (0.0398 – 0.0406)
mm (in.) 1.51 – 1.53 (0.0594 – 0.0602)
2nd
Oil
Piston ring to
groove
clearance
mm (in.) 0.020 – 0.060 (0.0008 – 0.0024)
STD
Limit mm (in.) 0.10 (0.0039)
1st
mm (in.) 0.020 – 0.060 (0.0008 – 0.0024)
STD
Limit mm (in.) 0.10 (0.0039)
2nd
Piston ring
thickness mm (in.) 0.97 – 0.99 (0.0382 – 0.0390)
STD
STD mm (in.) 0.97 – 0.99 (0.0382 – 0.0390)
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.) 17.966 – 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.) 0.05 (0.002)
Conrod small end
bore mm (in.) 18.003 – 18.011 (0.7088 – 0.7091)STD
STD
STD
STD

GENERAL INFORMATION 1-12
Item Unit Data
DF40T DF50T
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.)
STDCrank 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 (0.0016)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)
0.01 (0.0004)mm (in.)
Limit
Crankshaft thrust
play 0.11 – 0.31 (0.0043 – 0.0122)mm (in.)STD
0.35 (0.0138)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

1-13 GENERAL INFORMATION
ELECTRICAL
BTDC 0° – BTDC 32°
Degrees at r/min
Ignition timing
6500r/min
Over revolution limiter
Item Unit Data
DF40T DF50T
W at 20°C
CKP sensor resistance
W at 20°C
CMP sensor resistance
W at 20°C
Ignition coil resistance Primary
k W at 20°C
Secondary
W at 20°C
Battery charge coil resistance
Watt
Battery charge coil output (12V)
NGK
Standard spark plug Type
mm (in.)
Gap 0.9 – 1.0 (0.035 – 0.039)
A
Fuse amp. rating Main fuse : 30
Fuel pump fuse : 15
Ah (kC)
Recommended battery
capacity (12V) 70 (252) or larger
W at 20°C
Fuel injector resistance
W at 20°C
IAC valve resistance
k W at 25°C
IAT sensor/Cylinder temp.sensor
/ Ex-mani.temp.sensor
(Thermistor characteristic) W at 20°C
ECM main relay resistance
W at 20°C
Starter motor relay resistance
W at 20°C
PTT motor relay resistance
1.8 – 2.3
80 – 120
3.5 – 5.1
3.0 – 4.5
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 (0.008)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
DCPR 6E
BTDC 0° – BTDC 25°
7000
0.56 – 0.84
216
11.0 – 16.5
21.5 – 32.3

GENERAL INFORMATION 1-14
SELF-DIAGNOSTIC SYSTEM INDICATION
When the abnormality occurs in a signal from sensor, switch etc., the “CHECK ENGINE” lamp on the
monitor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sound-
ing.
PRIORITY
* FAILED ITEM CODE LAMP FLASHING PATTERN FAIL-SAFE SYSTEM ACTIVE
1MAP sensor 1 3 – 4 on
off YES
2CKP sensor 4 – 2 on
off NO
3IAC valve/By-pass air
screw adjustment 3 – 1 on
off NO
4CMP sensor 2 – 4 on
off YES
5CTP switch 2 – 2 on
off NO
6Cylinder temp.sensor 1 – 4 on
off YES
7IAT sensor 2 – 3 on
off YES
8MAP sensor 2
(Sensor hose) 3 – 2 on
off NO
91 – 1 on
off NO
Rectifier & regulator
(Over-charging)
* If more than two items fail at once, the self-diagnostic indication appears according to priority order.
The indication repeats three times.
PTT MOTOR
9.8 (0.39)mm (in.)
STD
Brush length
4.8 (0.19)mm (in.)
Limit
mm (in.)STD
Commutator outside
diameter mm (in.)
Limit
10 1 – 5 on
off YES
Exhaust manifold temp.
sensor
22.0 (0.87)
21.0 (0.83)

1-15 GENERAL INFORMATION
TIGHTENINGTORQUE
Tightening Torque – Important Fasteners
ITEM THREAD
DIAMETER TIGHTENINGTORQUE
kg-mN .m Ib.-ft.
Cylinder head cover bolt 6 mm 10 1.0 7.2
Cylinder head bolt 10 mm
Crankcase bolt 8 mm 25 2.5 18.1
Conrod cap nut 8 mm 35 3.5 25.3
Camshaft housing bolt 10 1.0 7.2
Camshaft timing sprocket bolt 10 1.0 7.2
Timing chain guide bolt 10 1.0 7.2
11 1.1 7.9
8 mm 23 2.3 16.5
Oil pressure switch 13 1.3 9.5
Intake manifold fuel main gallery 6 mm 10 1.0 7.2
35 3.5 25.3
Low pressure fuel pump bolt 6 mm 10 1.0 7.0
Thermostat cover bolt 6 mm 10 1.0 7.0
Flywheel bolt 16 mm 200 20.0 145
Starter motor mounting bolt 8 mm 23 2.3 16.5
Engine oil filter 14 1.4 10.0
Engine oil drain plug 12 mm 13 1.3 9.5
Power unit mounting bolt/nut 8 mm 23 2.3 16.5
10 mm 50 5.0 36.0
Driveshaft housing bolt 10 mm 50 5.0 36.0
Upper mount nut 10 mm 40 4.0 30.0
Upper mount cover bolt 8 mm 23 2.3 16.6
Lower mount nut 12 mm 60 6.0 43.5
12 mm 40 4.0 29.0
Clamp bracket shaft nut 22 mm 43 4.3 31.0
Water pump case nut 6 mm 8 0.8 5.8
Gearcase bolt 8 mm 23 2.3 16.6
Propeller shaft bearing housing bolt 8 mm 17 1.7 12.3
Pinion nut 50 5.0 36.2
Propeller nut 18 mm 55 5.5 40.0
3-way joint bolt
Upper/lower plug
Front
Rear
10 mm 53 5.3 38.3
6 mm
59 6.0 43.4
Intake manifold bolt / nut