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DF200
Suzuki DF200 Service Manual
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1-
4
G
ENERA
L IN
FORMAT
I
O
N
IDENTI
FICATION NUMBER LOCATION
MO
DEL, PRE-F
IX, SERIAL NU
MBER
The
MOD
EL,
PRE-F
IX and S
ERI
AL N
UM
BER of
mot
or ar
e
stam
ped
on a p
late a
ttache
d to the
cla
mp br
acket.
Exampl
e
ENG
INE
SERI
AL NUM
BER
A se
cond
eng
ine seri
al num
ber plat
e is pr
essed
into a
boss
on
the cyl
inder block.
MODEL
PRE-FIX
SERIAL NUMBER
DF 250
25001F
XXXXXX
1.
Serial number plate
1
9
8
10
Table of Contents
General Information 1
6
General Information
2
Periodic Maintenance
2
Engine Control System
2
Fuel System
2
Power Unit
2
Power Trim and Tilt
2
Component Parts and Item Illustrations
3
How to Use this Manual
3
Table of Contents
6
Warning/Caution/Note
7
General Precautions
7
Identification Number Location
9
Fuel and Oil
10
Gasoline Recommendation
10
Engine Oil
10
Engine Break-In
11
Warm-Up Recommendation
11
Throttle Recommendation
11
Propellers
12
Powerhead Direction of Rotation
13
Cylinder Number
13
Specifications
14
Service Data
18
Tightening Torque
26
Special Tools
28
Materials Required
32
Periodic Maintenance
33
Periodic Maintenance Schedule
34
Periodic Maintenance Chart
34
Maintenance and Tune-Up Procedures
35
Engine Oil/Engine Oil Filter
35
Gear Oil
38
Lubrication
39
Spark Plug
40
Tappet Clearance
41
Idle Speed
48
Ignition Timing
49
Fuel Line
50
Low Pressure Fuel Filter
51
High Pressure Fuel Filter
51
Pcv System
52
Low Pressure Fuel Pump Filter
53
Water Pump/Water Pump Impeller
53
Propeller/Nut/Cotter Pin
53
Bonding Wires
53
Anodes
54
Battery
55
Bolts and Nuts
57
Fuel Mixture Check (O2 Feedback)
57
Oil Pressure
58
Cylinder Compression
60
Engine Vacuum Check
61
Engine Control System
62
Engine Control System Structure
63
System Structure 1
63
System Structure 2
64
Components for System Control
66
Engine Control Module (Ecm)
66
Ecm Connector/Terminals Layout
67
Ecm Internal Structure
68
Location of Sensor and Switch
69
Sensor and Switch
71
Ignition System
78
Ignition Control System
79
Electronic Fuel Injection System
81
Fuel Injection Control System
81
Fuel Delivery System Components
83
High Pressure Fuel Pump Control System
86
Low Pressure Fuel Pump Control System
87
Evaporation Purge System
87
Air Intake Components
88
Idle Air Control System
89
Multi-Stage Induction
92
Outline
92
System Composition
92
System Operation
93
VVT (Variable Valve Timing) SYSTEM
94
Caution System
96
Over-Revolution Caution System
96
Low Oil Pressure Caution System
97
Overheat Caution
98
Low Battery Voltage Caution System
99
Self-Diagnostic System
100
Priority/Code/Pattern for Self-Diagnostic System Operation
100
Condition for Self-Diagnostic System Operation
102
Fail-Safe System
104
Pre-Programmed Value for Fail-Safe System
104
Operating Hour Indication System
105
Oil Change Reminder System
106
Start-In-Gear Protection System
107
O2 Feedback System
108
Inspection
109
Precaution on System Inspection
109
26-Pin & 34-Pin Test Cord
109
Inspection for Ecm Circuit Voltage
110
Inspection for Resistance
113
Component Inspections
114
Multi-Stage Induction
124
Removal/Installation
127
Flywheel
127
Ckp Sensor
129
Cmp Sensor
130
Iac Valve
130
Oil Pressure Switch
130
OCV (Oil Control Valve)
131
Throttle Control
132
Synchronizing Throttle Bodies
132
Throttle Control Cable
133
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Suzuki DF200 Specifications
General
Brand
Suzuki
Model
DF200
Category
Outboard Motor
Language
English
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