Suzuki DF 40 User manual

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)
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 0.120 (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)
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)
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 (0.43)
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 3.20 (0.126)
Valve stem end
length
Valve stem end
deflection
mm (in)
Limit
Limit mm (in)
IN
EX
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)
IN
1.0 (0.04)
0.7 (0.03)
mm (in)
STD
Limit mm (in)
EX
1.15 (0.045)
0.5 (0.02)
Valve seat
contact width
mm (in)
STD
STD mm (in)
IN
EX
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
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
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)
A
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
4
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.

10 DF40/DF50 “K3”(‘03) model
Early Late
2002: Ê 12
2002: Ê 12
2003: Ê 9
2003: Ê 9
Hole for exhaust temperature sensor Hole for cylinder temperature sensor
CYLINDER BLOCK
Cylinder block has been changed because of the change of tem-
perature sensor.
BUZZER
Buzzer in the remote control box (side-mount-type) has been
changed in function and shape.
Buzzer has function for intermittent sound-
ing itself.
Buzzer has function for continuous sound-
ing only.
NOTE:
Buzzer sounding pattern when caution or the other system acti-
vates is the same as the pattern on 2002.

DF40/DF50 “K3”(‘03) model 11
Forward gear thrust washer
NEUTRAL SWITCH BRACKET
The neutral switch bracket has been changed to be secured with
two bolt from the middle of 2002 year model.
NOTE:
When install a late type neutral switch bracket to the early cylin-
der, secure the neutral switch bracket with one bolt. In this case
use the upper side bolt hole on the neutral switch bracket, and
apply Thread Lock 1342 to the bolt.
UNDER OIL SEAL HOUSING
Before installing under oil seal housing, apply grease to oil seal
lip, under oil seal housing and crankshaft.
%99000-25160 : Water Resistant Grease
FORWARD GEAR THRUST WASHER
Available thickness
2.0 mm and 2.2 mm →2.0 mm only
Early Late

12 DF40/DF50 “K3”(‘03) model
Early
Late
Early
Arrow mark Arrow mark
LateExhaust cam sprocket
EXHAUST CAM SHAFT
The shape of exhaust cam shaft and exhaust cam sprocket have
been changed from the middle of 2002 year model.

DF40/DF50 “K3”(‘03) model 13
FP
HIGH PRESSURE FUEL PUMP
FUEL INJECTOR
#1 #2 #3
#1 #2 #3
EX-MANI TEMP SENSOR
RECTIFIER & REGULATOR
IGNITION COILS
ECM MAIN RELAY
+
CMP SENSOR
CYLINDER TEMP SENSOR
MAP SENSOR
COMMUNICATION CONNECTOR
CAP
ALTERNATOR
CKP SENSOR
FUSE 30A
ENGINE CONTROL MODULE
STARTER MOTOR
M
CTP SWITCH
IAC VALVE
IAT SENSOR
BATTERY 12V 70AH
+–
UP
DN
B
B
BB
BB
3
5
4
2
1
4
7
6
PTT MOTOR
M
TRIM SENDER
BZ
IGNITION SWITCH
REMOTE CONTROL BOX
OFF
IG
START
FREE
PUSH
W-TUBE
Bl-TUBU
W-TUBU
PTT SWITCH
PTT SWITCH
MONITOR
TACHO-
METER
METER
TRIM
METER
METER ILLUMINATION SWITCH
Bl-TUBE
PTT SWITCH
PTT MOTOR RELAY UP PTT MOTOR RELAY DN STARTER MOTOR RELAY NEUTRAL SWITCH N ON F.R OFF
CAUTION BUZZER (OVERHEAT/OIL PRESSURE/ BATTERY VOLTAGE/DIAGNOSIS) BATTERY CHARGE COIL OIL PRESSURE SWITCH 1.0kgf/cm
2
or less ON
1
2
5
6 7
4 3
..........Optional oarts
UP
UP
DN
DN
B
G
W
Gr
Br
O
GND
STOP
BATT
IG
START
BUZZER
CANCEL
TURN PUSH
Gr
Gr
Gr
B/W
B/W
B/W
R
RRB
B
Gr
Gr
Gr
Br
Br
Br
Y/G
Y/G
Y/G
Y/G
Y/G
Br
Br
Y/G
Br
Gr
Gr
Gr O/G
O/G
O/G B/W
B/W
Gr
Gr
B/W
Gr
VVBB
W
B/W
B/W
W
B/W RR
W/B
W/B
B/W
YYY
Y Y Y
W
W W W
WW
W
WWW
R/B
R/B
R/BB/W
B/W
B/W
R/B
R/B
R/B
B/W
B/W
B/W
Gr
Gr
Gr
OR
OR
O/B
B/Y
B/Y
B/Y
R/W
R/W
R/W
Gr
Gr
Gr Gr
Gr
Gr Gr
Gr
Gr
OO
Bl
Bl
Bl
GG
B
B
YVY/W
Y/W
V/W
B/W
B/W
B/W
BB
Gr
Gr
Gr
BB
Y
O/Y
O/Y
Y
O/Y
B/G
B/G
B/G
R
B
B
B B
B BB
B
BB BB B
B
B
B
BB
WW
R
Y/G
Y/G
R
Y/G
Y/G
Y/G
Y/G Y/G
Y/G
Y/G
Lg/R
Lg/R
Lg/R
Gr
Gr
B/R
B/R
Gr
B/R
Lg/B
Lg/B
Lg/B
Bl/B
Bl/B
P
Bl/B
P
B/W
B/W
B/W
G/Y
G/Y
G/W
G/W
G/Y
G/W
O
Br
Br
Bl/R
Bl/R
Bl/W
Bl/W
O
Br
Bl/R
Bl/W
W
Y/B
Y/B
Gr
Gr
B
W
Y/B
Gr
B
Bl
Bl
Bl
R/B
R/B
Gr
Gr
B/G
B/G
Bl
Bl
W
Lg/R
Lg/R
G/Y
G/Y
G/W
G/W
Bl/R
Bl/R
B/R
B/R
B/W
B/W
O/G
O/G
B
B
O/B
O/B
R/W
R/W
O
V/W
V/W
P/B
P/B
O/Y
O/Y
Y
R
Lg/B
Lg/B
Bl/B
Bl/B
P
O
Y/B
Y/B
Bl/W
Bl/W
Br
Br
Lg/W
Lg/W
B
B
B/W
B/W
B/Y
B/Y
G
Bl
Bl
R/B
Gr
B/G
Bl
W
Lg/R
G/Y
G/W
Bl/R
B/R
B/W
O/G
B
B
O/B
R/W
O
V/W
P/B
O/Y
Y
R
Lg/B
Bl/B
P
O
Y/B
Bl/W
Br
Lg/W
B
B
B/W
B/Y
G
Bl
Lg/W
Lg/W
Lg/W
W
Gr
Gr
W
Gr
W/R
W/R
W/R
P/B
P/B
P/B
G
G
P
W/R
W/R
Lb
Lb
l
P
Lb
Lb
l
Bl
Bl
B
W
W
G B
W
P
Lb
Lb
l
P
Lb
Lb
l
P
Gr
Gr
P
P
Lg
Lg
Bl
Bl
Bl
Bl
Br
Br
O
Br
Br
Gr
Gr
Br
Br
Gr
Gr
Gr
Gr
BB
G
W
Gr
Gr
W
Lb
Lb
lLb
Lb
l
PP
B
OG/Y
G/Y
G/W
G/W
P
Gr
Gr
Gr
Gr
Gr
Gr
P
W
R
Lb
Lb
l B
Gr
Gr
Gr
Gr
Lb
Lb
l
P
W
Y
B R
Gr
Gr
Y
B B
Gr
Gr
Gr
Gr
Gr
Gr
B
B
B
R/G
R/G
B
R/G
R/G
B
Gr
Gr
B
Gr
Gr
B
Gr
Gr
B
R/G
R/G
B
Gr
Gr
B
Gr
Gr
B
R/G
R/G
B
R/G
R/G
B
B
R/G
R/G
B
R/G
R/G
R/G
R/G
R/G
R/G
P
W/R
Lbl
P
Lbl
W/R
W/R
W/R
Bl B
W
W
GB
W
P
Lbl
P
Lbl
P
Gr
P
PP
Lb
Lb
l
B
O
B
O
LblLb
Lb
lLbl
W
Y
Gr
Gr
B
W
Y
Gr
B
O
O
Br
Br
G
Bl
Bl
Br
G
Bl
P
Lg
O
B
O
B
P
Gr
Gr
P
Gr
O
B
O
B
Bl Bl
Br
O
Br
Gr
Br
GrGr
BB
G
W
GrW
LblLbl
PP
B
OG/Y
G/W
Bl/B
Bl/B
P
Bl/B
P
P
Gr
P
Gr
Gr
Or
Or
B
P
Gr
O
B
P
Gr
Gr
P
Lg
Gr Gr
P
W
R
Lbl B
Gr
Gr
Lbl
P
W
Y
B R
Gr
Y
BB
Gr Gr
Gr
B
BGr
Gr
Y
Gr
Y
BGr
Gr
Y
Gr
Y
R/G
B
R/G
B
Gr
B
Gr
B
Gr
B
R/G
B
Gr
B
Gr
B
R/G
B
R/G
B
B
R/G
B
R/G
R/GR/G
Or
Or
B
O
B
WIRING DIAGRAMS

14 DF40/DF50 “K3”(‘03) model
"QH" MODEL
Install holder cover to holder hook securely.
ECM main relay
Clamp
Exhaust manifold temp. sensor
Rectifier & regulator
Engine wiring harness
Electric parts holder cover
Starter motor sub cable
PTT motor cable
Starter motor relay
Battery cable
PTT relay plate
PTT motor relay (DOWN)
PTT motor relay (UP)
Communication connector / cap
30A Fuse
WIRE ROUTING

DF40/DF50 “K3”(‘03) model 15
MAP sensor
MAP sensor hose / Protector
Gas filter
3N·m (0.3 kg-m, 2.0 lb-ft)
Neutral switch
PTT switch lead connector
Fuel injector #3 Fuel injector #2
Fuel injector #1
Clamp
Clamp
Clamp
Clip
Fix injector lead wire.
Fix fuel pump lead wire and fuel hose.
Fix neutral switch lead wire.
Oil pressure switch

16 DF40/DF50 “K3”(‘03) model
Cylinder temp. sensor
Exhaust manifold temp. sensor
Electric parts holder cover
Electric parts holder
CKP sensor
Clamp
Clamp
Clamp
Clamp Clamp
Clamp
Rectifier & regulator
Starter motor
Battery charge coil
MAP sensor bracket MAP sensor
Clean thread of sensor and cylinder block with cleaning solvent, when installing sensor.
Apply engine oil to O-ring when installing sensor.
Fix lead wire not to contact with flywheel magneto.
Fix lead wire not to contact with flywheel magneto.
Fix lead wires not to contact with flywheel magneto.
Fix engine wiring harness not to contact with oil filler cap.
Fix engine wiring harness not to contact with hose crip.
After installing flywheel magneto and securing nut with specified torque, check air gap between CKP sensor and reluctor bars on flywheel magneto. Air gap : 0.75 mm (0.030 in)

DF40/DF50 “K3”(‘03) model 17
Starter motor
Starter motor sub cable
Grommet
IAT sensor
Engine wiring harness
Battery cable
IAC valve
CTP switch
Battery cable
Route battery cable on fuel hose.
Route engine wiring harness
on battery cable - .
Tighten bolt with PTT relay
ground wire, battery cable
ground wire and harness
ground wire.
Clamp
Clamp
Clamp
Clamp
CMP sensor
Ignition coil #3
Ignition coil #2
Ignition coil #1
Clip
Position clip tabs
inward (engine side)

Prepared by
Marine & Power Products Division
July, 2002
Manual No. 99501-87J20-01E
Printed in Japan
20

Printed in Japan
K3