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DF 40
Suzuki DF 40 User Manual
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ENGINE CONTROL SYSTEM 3-2
Fuel tank
Primer bulb
Low pressure
fuel filter
Low pressure
fuel pump
Evaporation
hose
Fuel
vapor
separator
Fuel
pressure
regulator
Breather
hose
High
pressure
fuel
pump
High
pressure
fuel
filter
CMP
sensor
Delivery
gallery
Fuel injector
CTP switch
Intake
manifold
By-pass
air screw
Silencer
Throttle body
IA
T sensor
Neutral
switch
IAC valve
MAP sensor
CKP
sensor
Alternator
(Battery charge coil)
Rectifier &
regulator
Battery
Ignition
switch
ECM main relay
Engine control module
CKP
sensor
CKP sensor
*O
2
sensor
Exhaust
manifold
temp.
sensor
Ignition
coil
Cylinder
temp.
sensor
* :
O
2
Sensor must be installed when perf
or
ming “O
2
feedbac
k operation” only
.
SYSTEM STRUCTURE 2
56
58
Table of Contents
General Information 1
5
Component Parts and Important Item Illustrations
3
Table of Contents
5
Warning/Caution/Note
6
General Precautions
6
General Information
6
Identification Number Location
8
Fuel and Oil
8
Gasoline Recommendation
8
Engine Oil
8
Engine Break-In
9
Propellers
10
Specifications
11
Service Data
13
General Information
15
Starter Motor
18
Self-Diagnostic System Indication
19
Tightening Torque
20
Special Tools
22
Materials Required
25
Periodic Maintenance 2
26
Periodic Maintenance Schedule
27
Periodic Maintenance Chart
27
Maintenance and Tune-Up Procedures
28
Engine Oil / Engine Oil Filter
28
Engine Oil Change/Engine Oil Filterreplacement
29
Gear Oil
31
Lubrication
32
Spark Plug
33
Tappet Clearance
34
Idle Speed
40
Ignition Timing
41
Breather and Fuel Line
42
Low Pressure Fuel Filter
42
High Pressure Fuel Filter
43
Water Pump / Water Pump Impeller
43
Propeller / Nut / Cotter Pin
43
Anodes and Bonding Wires
44
Battery
45
Bolt and Nuts
46
Fuel Mixture Check (Ofeedback)
47
Oil Pressure
52
Cylinder Compression
54
Engine Control System
55
Engine Control System Structure
56
System Structure 1
56
System Structure 2
57
Wiring Diagram for Engine Control
58
Engine Control System
58
Components for System Control
59
Engine Control Module (Ecm)
59
Ecm Connectors / Terminals Layout
60
Ecm Internal Structure
61
Sensor and Switch
62
Ignition System
66
Ignition Control System
66
Electronic Fuel Injection System
68
Fuel Injection Control System
68
Fuel Delivery System Components
70
Fuel Pump Control System
73
Air Intake Components
74
Idle Air Control System Outline
75
Caution System
77
Over-Revolution Caution System
77
Low Oil Pressure Caution System
78
Overheat Caution
79
Electrical
80
Low Battery Voltage Caution System
80
Self-Diagnostic System
81
Priority / Code / Pattern for Self-Diagnostic System Operation
81
Condition for Self-Diagnostic System Operation
83
Fail-Safe System
84
Pre-Programmed Value for Fail-Safe System
84
Operating Hour Indication System
85
Start-In-Gear Protection System
86
O 2 Feedback System
87
Inspection
88
Precaution on System Inspection
88
Inspection for Ecm Circuit Voltage
88
Inspection for Resistance
90
Other Inspection
91
Troubleshooting
96
Fuel System
96
Removal / Installation
102
Flywheel / Ckp Sensor / Cmp Sensor
102
Oil Pressure Switch
105
Electrical
106
Battery Charging System
107
Outline
107
Removal / Installation
110
Electric Starter System
112
Outline
112
Troubleshooting
113
Inspection
114
Starting Motor
117
Monitor-Tachometer
123
Inspection
123
Fuel System
124
Precaution on Fuel System Service
125
General Precaution
125
Fuel Pressure Relief Procedure
126
Fuel Line
127
Removal / Installation
127
Fuel Leakage Check Procedure
127
Fuel Hose Connection
128
Fuel Pressure Inspection
129
Fuel Vapor Separator / High Pressure Fuel Pump
131
Removal / Installation
131
Disassembly
132
Inspection
133
Assembly
135
Fuel Injector
136
Inspection
136
Removal
136
Installation
137
Low Pressure Fuel Pump
138
Removal / Installation
138
Disassembly / Reassembly
139
Inspection
140
Fuel Tank
141
Disassembly / Reassembly
141
Inspection
142
Power Unit
143
Intake Manifold Assembly
144
Removal
144
Installation
145
Power Unit
146
Removal
146
Installation
150
Oil Pump / Case
153
Removal
153
Disassembly
153
Inspection
154
Measuring Pump Components
154
Assembly
155
Installation
155
Timing Chain / Tensioner
158
Removal
158
Inspection
160
Installation
161
Cylinder Head Assembly
164
Removal
164
Assembly
164
Disassembly
167
Inspection / Servicing
168
Reassembly
181
Cylinder / Crankshaft / Piston
183
Disassembly
183
Inspection / Servicing
186
Reassembly
200
Thermostat
207
Operation
208
Water Cooling System
208
Engine Lubrication System
209
Power Trim and Tilt
210
System Wiring Diagram
211
Service Procedure
212
Oil Level
212
Air Bleeding
212
Power Trim and Tilt Unit
213
Removal
213
Disassembly
214
Cleaning and Inspecting
216
Reassembly
218
Ptt Motor
220
Installation
224
Ptt Motor Relay
226
Ptt Switch
227
Operation
228
Components
228
Principles of Operation
229
Lower Unit
234
Removal & Disassembly
235
Pinion Bearing
239
Inspection
241
Propeller
241
Gearcase
241
Gear
242
Propeller Shaft Components
242
Propeller Shaft Bearing Housing
242
Shift Rod and Shift Cam
243
Water Pump and Related Items
243
Driveshaft Bearing Housing
244
Driveshaft
245
Assembly & Installation
246
Trim Tab
256
Lower Unit Gears-Shimming and Adjustment
257
Wiring Diagram
263
Fuel / Water Hose Routing
269
Df40150 "K5" (2005) Model .
273
Specifications (Df50Wtidf50Wqh)
274
Service Data
278
Tightening Torque
285
Flywheel MAGNETO and CRANKSHAFT
286
Over-Revolution Caution System
286
Safety Relay System
286
Battery Charging System
287
Electric Starter System
289
Assembly
303
Remote Control Box & Remote Control Wire
306
Cylinder Head
307
Upper Oil Seal Housing
307
Upper Mount
308
Lower Mount
309
Clamp Bracket Shaft
310
Ptt Motor Relay
311
Swivel Bracket Bush
311
Tiller Handle Assy
311
Driveshaftidriveshaft Bearing Housing
313
Gearcase Magnet
314
Shift Rod Guide
314
Water Pump Case
314
Propeller Shaft Bearing
315
Wiring Diagram
316
Df40/50 "K6" (2006) Model
326
Specifications (Df40T/Df40Qh/Df50T/Df50Th)
327
Specifications (Df50Wt/Df50Wqh)
329
Service Data
331
Periodic Maintenance Schedule
338
Ecm
339
Fuel Filter
339
Iac Hose
339
Intake Manifold
340
Piston
341
Water Pump Case under Gasket
341
Wiring Diagram
342
Fuel Hose Routing
345
Df40/50 "K7" (2007) Model
348
Specifications (Df40T/Df40Qh/Df50T/Df50Th)
349
Specifications (Df50Wt/Df50Wqh)
351
Service Data
353
Tightening Torque
360
Periodic Maintenance Schedule
361
Ecm
362
Silencer
362
Tiller Handle (Df40Qh, Df50Qh and Df50Wqh)
363
Clutch Dog Shifter and Return Spring
365
Clutch Shaft Arm and Clutch Shaft Side Arm
365
Detent Spring and Shift Cam
365
Engine Side Cover
366
Forward
370
General Information
372
Warning/Caution/Note
372
General Precautions
372
Specifications
374
Lower Unit
375
Service Data
376
Tightening Torque
382
Special Tools
384
Materials Required
387
Wiring Diagram
388
Engine Control System
389
Caution / Diagnostic System
389
Engine Speed Control During Shifting
390
Checking Engine Total Operating Hours
390
MID Unit
391
Tiller Handle
391
Removal
391
Disassembly
392
Assembly
395
Installation
396
Tilt Aid System
401
Removal
401
Inspection
402
Installation
403
Other manuals for Suzuki DF 40
Supplemental Service Manual
20 pages
4
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Suzuki DF 40 Specifications
General
Brand
Suzuki
Model
DF 40
Category
Outboard Motor
Language
English
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