Suzuki DF 50 User manual

99500-87J03-01E
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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
concerning this motor. Read and refer to 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
POWER TRIM AND TILT
LOWER UNIT
WIRE / HOSE ROUTING
DF40QH/DF50QH
DF40/DF50 “Y” (’00) MODEL
DF40/DF50(W) “K1” (’01)
MODEL
Marine & Power Products Division
GROUP INDEX
!
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
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•Thismanualhasbeenpreparedusingthelat-
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.
•Illustrationsinthismanualareusedtoshow
the basic principles of operation and work pro-
cedures and may not represent the actual
outboard motor in exact detail.
•Thismanualisintendedforusebytechnicians
who already possess the basic knowledge and
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 2002
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HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU 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-
low you 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 (1)
2Washer (1)
3Key (1)
4Flywheel (1)
5CKP sensor assy (1)
6Screw (6)
7CMP sensor (1)
8Bolt (1)
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78
Crankshaft
"200 N.m
(20.0 kg-m, 144.5 lb.-ft.)
#
$
NOTE:
Clean flywheel and crankshaft mating
surfaces with cleaning solvent.
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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.
To r q u e c o n t r o l r e q u i r e d .
Data beside it indicates specified
torque.
Apply oil. Use engine oil unless
otherwise specified.
Apply SUZUKI OUTBOARD
MOTOR GEAR OIL.
Apply SUZUKI SUPER GREASE “A”.
Apply SUZUKI WATER
RESISTANT GREASE.
Apply SUZUKI BOND “1104”.
Apply SUZUKI BOND “1207B”.
Apply SUZUKI SILICONE SEAL.
SYMBOL DEFINITION SYMBOL DEFINITION
"
#
%
&
'
(
)
*
$
+
,
-
.
/
0
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GENERAL INFORMATION
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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
TIGHTENING TORQUE _____________________________________ 1-15
SPECIAL TOOLS __________________________________________ 1-17
MATERIALS REQUIRED ____________________________________ 1-20
CONTENTS
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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.
!
Indicates a potential hazard that could result in death or injury.
"
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
•Properserviceandrepairproceduresareimportantforthesafetyoftheservicemechanic
and the safety and reliability of the outboard motor.
•Toavoideyeinjury,alwayswearprotectivegoggleswhenfilingmetals,workingonagrinder,
or doing other work, which could cause flying material particles.
•When2ormorepersonsworktogether,payattentiontothesafetyofeachother.
•Whenitisnecessarytoruntheoutboardmotorindoors,makesurethatexhaustgasis
vented outdoors.
•Whentestinganoutboardmotorinthewaterandonaboat,ensurethatthenecessary
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.
•Whenworkingwithtoxicorflammablematerials,makesurethattheareayouworkinis
well-ventilated and that you follow all of the material manufacturer’s instructions.
•Neverusegasolineasacleaningsolvent.
•Toavoidgettingburned,donottouchtheengine,engineoilorexhaustsystemduringor
shortly after engine operation.
•Oilcanbehazardous.Childrenandpetsmaybeharmedfromcontactwithoil.Keepnew
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.
•Carefullyadheretothebatteryhandlinginstructionslaidoutbythebatterysupplier.
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GENERAL INFORMATION 1-2
• If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their
equivalent.
•Whenremovingpartsthataretobereused,keepthemarrangedinanorderlymannerso
that they may be reinstalled in the proper order and orientation.
•Besuretousespecialtoolswheninstructed.
•Makesurethatallpartsusedinassemblyarecleanandalsolubricatedwhenspecified.
•Whenuseofacertaintypeoflubricant,bond,orsealantisspecified,besuretousethe
specified type.
•Whenremovingthebattery,disconnectthenegativecablefirstandthenthepositivecable.
When reconnecting the battery, connect the positive cable first and then the negative cable.
•Whenperformingservicetoelectricalparts,iftheserviceproceduresdonotrequireusing
battery power, disconnect the negative cable at the battery.
•Tightencylinderheadandcaseboltsandnuts,beginningwithlargerdiameterandending
with smaller diameter, Always tighten from inside to outside diagonally, to the specified
tightening torque.
•Wheneveryouremoveoilseals,gaskets,packing,O-rings,lockingwashers,lockingnuts,
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.
•Neverreuseacirclip.Wheninstallinganewcirclip,takecarenottoexpandtheendgap
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.
•Useatorquewrenchtotightenfastenerstothetorquevalueswhenspecified.
Remove grease or oil from screw / bolt threads unless a lubricant is specified.
•Afterassembly,checkpartsfortightnessandoperation.
•Toprotecttheenvironment,donotunlawfullydisposeofusedmotoroil,otherfluids,and
batteries.
•ToprotecttheEarth’snaturalresources,properlydisposeofusedmotorparts.
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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 / 2 method) or 91 (Research method). 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
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If leaded gasoline is used, engine damage may re-
sult. Use only unleaded gasoline.
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 .
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