Suzuki DF200 User manual

PRE - PRODUCTION
ISSUE
1

GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE CONTROL SYSTEM 3
ENGINE ELECTRICAL 4
FUEL SYSTEM 5
POWER UNIT 6
MID UNIT 7
POWER TRIM AND TILT 8
LOWER UNIT
[Standard rotation (Right-hand) model] 9
LOWER UNIT
[Counter rotation (Left-hand) model] 10
WIRE/HOSE ROUTING 11
12
© COPYRIGHT SUZUKI MOTOR CORPORATION 2003 Marine & Power Products Division
FOREWORD
This manual contains an introductory description of
the SUZUKI DF200/225/250 Outboard motors and
procedures for inspection, service and overhaul of
their main components.
General knowledge information is not included.
Please read the GENERAL INFORMATION section
to familiarize yourself with basic information con-
cerning this motor. Read and refer to the other
sections in this manual for information regarding
proper inspection and service procedures.
This manual will help you better understand these
outboard motors, assisting you in providing your
customers with optimum and quick service.
!
NOTE:
This manual is compiled based on 2004 (K4) model.
• This manual has been prepared using the
latest information available at the time of
publication.
Differences may exist between the content of
this manual and the actual outboard motor.
• Illustrations in this manual are used to show
the basic principles of operation and work
procedures and may not represent the actual
outboard motor in exact detail.
• This manual is intended for use by techni-
cians who already possess the basic knowl-
edge and skills to service SUZUKI outboard
motors.
Persons without such knowledge and skills
should not attempt to service SUZUKI out-
board engines by relying on this manual only
and should contact an authorized SUZUKI
outboard motor dealer.
Apprentice mechanics or do-it-yourself
mechanics that don’t have the proper tools
and equipment may not be able to properly
perform the services described in this man-
ual.
Improper repair may result in injury to the
mechanic and may render the engine unsafe
for the boat operator and passengers.
2

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 needed for reference.
3. Holding the manual as shown at the right will allow you to
find the first page of the section easily.
4. The first page of each section contains a table of contents 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 ser-
vice information such as the tightening torque, lubrication and locking agent points.
Example:
5
4
3
2
7
7
6
6
1 118 N·m (11.8 kg-m, 85.3 lb-ft)
1. Flywheel bolt
2. Flywheel
3. Dowel pin
4. CKP sensor
5. Bolt
6. CMP sensor
7. Bolt
NOTE:
Clean flywheel and crankshaft
mating surfaces with cleaning
solvent.
3

SYMBOL
Listed in the table below are the symbols indicating instructions and other important information necessary
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.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply THREAD LOCK “1342”.
Apply oil. Use the engine oil unless oth-
erwise specified. Apply THREAD LOCK SUPER “1333B”.
Apply SUZUKI OUTBOARD MOTOR
GEAR OIL. Measure in DC voltage range.
Apply SUZUKI SUPER GREASE “A”. Measure in resistance range.
Apply SUZUKI WATER RESISTANT
GREASE. Measure in continuity test range.
Apply SUZUKI BOND “1104”. Use peak voltmeter “Stevens CD-77”.
Apply SUZUKI BOND “1207B”. Use special tool.
Apply SUZUKI SILICONE SEAL.
4

ABBREVIATIONS
Abbreviations used in this service manual are as follows:
BTDC : Before Top Dead Center
CKP : Crankshaft position
CMP : Camshaft position
CTP : Close Throttle position
DC : Direct Current
DOHC : Double Over Head Camshaft
ECM : Engine Control Module
EX (Ex.) : Exhaust
IAC : Idle Air Control
IAT : Intake Air Temperature
IN (In.) : Intake
MAP : Manifold absolute pressure
OCV : Oil control valve
PCV : Positive Crankcase Ventilation
PORT : Port
PTT : Power Trim & Tilt
SPS : Shift Position Sensor
STBD : Starboard
TPS : Throttle Position Sensor
VSV : Vacuum switching valve
VVT : Variable Valve Timing
5