Tools: Suzuki Outboard Shop Manual 9.9-70HP Four Stroke 1997-2000
Tools: Suzuki Outboard Shop Manual 9.9-70HP Four Stroke 1997-2000
Tools: Suzuki Outboard Shop Manual 9.9-70HP Four Stroke 1997-2000
Fuel System
Power Head
Gearcase
Manual Starter
Remote Control
Index
Wiring Diagrams
Page: I Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
Contents
QUICKREFEMNCEDATA ...............................................H
CHAMER ONE
GENEWLINFOMATION ................................................
...................................
1
Manual organization . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Lubficants 8
Notes. cautions and warning . . . . . . . . . . . . . . . . . . . . 1 Gasket sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . .2 Galvanic corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Protection from galvanic corrosion . . . . . . . . . . . . . . 13
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHAMER TWO
TOOLS AND TECHNIQUES ..............................................
Safety first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21................................
Service hints
21
28
Basic hand tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Specialtips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Test equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Mechanic's techniques . . . . . . . . . . . . . . . . . . . . . . . . 31
CHAMER THREE
TROUBLESHOOTING AND TESTING
Outboard engine identification . . . . . . . . . . . . . . . . . . 33
........................................33
Warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Troubleshooting test equipment . . . . . . . . . . . . . . . . . 35 Fuses and wire harness . . . . . . . . . . . . . . . . . . . . . . . .81
Troubleshooting preparation . . . . . . . . . . . . . . . . . . . 38 Wire harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Starting difficulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8 Powerhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Fuelsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
C h ~ g k system
g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Trim system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Electronic he1 injection . . . . . . . . . . . . . . . . . . . . . . 100
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CHAPTER FOUR
LUBRICATION. MAINTENANCE AND TUNEmUP .............................. 121
Before and after each use . . . . . . . . . . . . . . . . . . . . . 121 Gearcase maintenance . . . . . . . . . . . . . . . . . . . . . . . 139
Routine power head maintenance . . . . . . . . . . . . . . 126 Storage preparation . . . . . . . . . . . . . . . . . . . . . . . . . I41
Midsection maintenance . . . . . . . . . . . . . . . . . . . . . . 136 Tune-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
CHAPTER FIVE
SYNCHRONIZATION AND ADJUSTMENT
Valve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
...................................
........................
Idle speed adjustment
148
167
Throttle cable and linkage adjustment . . . . . . . . . . . 155 Choke solenoid and choke linkage . . . . . . . . . . . . . .169
Shift cable and linkage adjustment . . . . . . . . . . . . . .160 Dashpot adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 169
Carburetor synchronization Neutral-only start cable . . . . . . . . . . . . . . . . . . . . . . 170
(DF25 and DF30 models) . . . . . . . . . . . . . . . . . . . . 165 Trim position sender . . . . . . . . . . . . . . . . . . . . . . . . . 171
Pilot screw adjustment . . . . . . . . . . . . . . . . . . . . . . . 166 Trimtab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
CHAPTER SIX
FUELSYSTEM ....................................................... 175
Fuel system semice precautions . . . . . . . . . . . . . . . .175 ............. Carburetor removal and installation 186
Low pressure fuel pump . . . . . . . . . . . . . . . . . . . . . . 183 Carburetor overhaul . . . . . . . . . . . . . . . . . . . . . . . . . I87
Silencercover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . 192
CHAPTER SEVEN
ELECTRICAL AND IGNITION ............................................
Starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 ............................
Warning system
200
220
Charging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 222
Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
CHAPTER EIGHT
POWERHEAD ......................................................
......................
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
229
Cylinder block cleaning 266
Power head removal/instaIlatiodrepair . . . . . . . . . . 232 Cylinder block inspection and maintenance. . . . . . .268
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Cylinder block asssembly . . . . . . . . . . . . . . . . . . . . 276
Cylinder block component removal . . . . . . . . . . . . . 258 Break-in procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Cylinder block disassembly . . . . . . . . . . . . . . . . . . .262
CHAPTER NINE
GEARCASE .........................................................
...................
289
Gearcase shim selection . . . . . . . . . . . . . . . . . . . . . . 334 Gearcase shim adjustments 339
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...................................................
Manual starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Page: 4 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke .1997-2000 http://www.ReadManuals.Com
Quick Reference Data
ENGINE DATA
MODEL YEAR:
VIN NUMBER:
ENGINE SERIAL NUMBER:
CARBURETOR SERIAL NUMBER OR I.D. MARK:
Record the numbers here for reference.
Additional maintenancerequired
every 800 hours or 4 years Replace the timing belt.*
-
Model
-
Liters US Quarts 1
DF9.9, DF15
Oil change only 1.1
Oil and filter change 1.1 1.2
DF25, DF30
Oil change only 3.0 3.2
Oil and filter change 3.2 3.4
DF40, DF50
Oil change only 2.2 2.3
Oil and filter change 2.4 2.5
DF60, DF70
Oil change only 4.5 4.8
Oil and filter change 4.8 5.1
Page: 9 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
2 CHAPTER ONE
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GENERAL INFORMATION 3
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4 CHAPTER ONE
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GENERAL INFORMATION 5
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6 CHAPTER ONE
standards exist, but the most commonly used by are also designed to protrude above the metal
marine equipment manufacturers are American (round) or to be slightly recessed in the metal
standard and metric standard. The threads are cut (flat) (Figure 7).
differently as shown in Figure 5.
Most threads are cut so that the fastener must Bolts
be turned clockwise to tighten it. These are called
right-hand threads. Some fasteners have left- Commonly called bolts, the technical name
hand threads; they must be turned counterclock- for these fasteners is cap screw. They are nor-
wise to be tightened. Left-hand threads are used mally described by diameter, threads per inch
in locations where normal rotation of the equip- and length. For example, 1/4-20 x 1 indicates a
ment would tend to loosen a right-hand threaded bolt 114 in. in diameter with 20 threads per inch,
fastener. 1 in. long. The measurement across two flats on
the head of the bolt indicates the proper wrench
Machine Screws size to be used.
OPENINGS FOR
TURNING TOOLS
Slotted Phillips Allen Internal Torx External Torx
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GENERAL INFORMATION 7
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8 CHAPTER ONE
must have a hole in it; the nut or nut lock piece ciety of Automotive Engineers (SAE) in several
has projections that the cotter pin fits between. categories. Oil containers display these ratings
This type of nut is called a "Castellated nut." on the top or label (Figure 11).
Cotter pins should not be reused after removal. API oil grade is indicated by letters, oils for
gasoline engines are identified by an "S7'and oils
Snap Rings for diesel engines are identified by a "C." Most
Snap rings can be of an internal or external modern gasoline engines require SF or SG
design. They are used to retain items on shafts graded oil. Automotive and marine diesel en-
(external type) or within tubes (internal type). gines use CC or CD graded oil.
Snap rings can be reused if they are not distorted Viscosity is an indication of the oil's thick-
during removal. In some applications, snap rings ness, or resistance to flow. The SAE uses num-
of varying thickness can be selected to control bers to indicate viscosity; thin oils have low
the end play of parts assemblies. numbers and thick oils have high numbers. A
"W7'after the number indicates that the viscosity
testing was done at low temperature to simulate
LUBRICANTS
cold weather operation. Engine oils fall into the
Periodic lubrication ensures long service life 5W-20W and 20-50 range.
for any type of equipment. It is especially impor- Multi-grade oils (for example, 10W-40) are
tant to marine equipment because it is exposed less viscous (thinner) at low temperatures and
to salt or brackish water and other harsh environ- more viscous (thicker) at high temperatures. This
ments. The type of lubricant used is just as im- allows the oil to perform efficiently across a wide
portant as the lubrication service itself; although, range of engine operating temperatures.
in an emergency, the wrong type of lubricant is
better than none at all. The following paragraphs
describe the types of lubricants most often used
on marine equipment. Be sure to follow the
equipment manufacturer's recommendations for
lubricant types.
Generally, all liquid lubricants are called "oil."
They may be mineral-based (including petro-
leum bases), natural-based (vegetable and ani-
mal bases), synthetic-based or emulsions
(mixtures). "Grease" is an oil which is thickened
with a metallic "soap." The resulting material is
then usually enhanced with anticorrosion, anti-
oxidant and extreme pressure (EP) additives.
Grease is often classified by the type of thickener
added; lithium and calcium soap are commonly
used.
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GENERAL INFORMATION 9
Gear Oil
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10 CHAPTER ONE
Grease
RTV Sealant
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GENERAL INFORMATION 11
GALVANIC CORROSION
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12 CHAPTER ONE
by the process. The amount of electron flow becomes more severe as the difference in electri-
(and, therefore, the amount of corrosion) de- cal potential between the two metals increases.
pends on several factors:
In some cases, galvanic corrosion can occur
a. The types of metal involved. within a single piece of metal. Common brass is
b. The efficiency of the conductor. a mixture of zinc and copper, and, when im-
c. The strength of the electrolyte. mersed in an electrolyte, the zinc portion of the
mixture will corrode away as reaction occurs
Metals between the zinc and the copper particles.
+ Conductor
II
- Conductor
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GENERAL INFORMATION 13
Page: 21 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
14 CHAPTER ONE
Anodes must be used properly to be effective. corrosion could be occurring, it transmits this
Simply fastening pieces of zinc to your boat in information to the control box.
random locations won't do the job. The control box connects the boat's battery to
You must determine how much anode surface the anode. When the sensor signals the need, the
area is required to adequately protect the equip- control box applies positive battery voltage to
ment's surface area. A good starting point is the anode. Current from the battery flows from
provided by Military Specification MIL-A- the anode to all other metal parts of the boat, no
8 18001, which states that one square inch of new matter how noble or non-noble these parts may
anode will protect either: be. This battery current takes the place of any
a. 800 square inches of freshly painted steel. galvanic current flow.
b. 250 square inches of bare steel or bare Only a very small amount of battery current is
aluminum alloy. needed to counteract galvanic corrosion. Manu-
c. 100 square inches of copper or copper alloy. facturers estimate that it would take two or three
months of constant use to drain a typical marine
This rule is for a boat at rest. When underway,
battery, assuming the battery is never recharged.
more anode area is required to protect the same
An impressed current system is more expen-
equipment surface area.
sive to install than simple anodes but, consider-
The anode must be fastened so that it has good ing its low maintenance requirements and the
electrical contact with the metal to be protected. excellent protection it provides, the long-term
If possible. the anode can be attached directly to cost may actually be lower.
the other metal. If that is not possible, the entire
network of metal parts in the boat should be PROPELLERS
electrically bonded together so that all pieces are
protected. The propeller is the final link between the
Good quality anodes have inserts of some boat's drive system and the water. A perfectly
other metal around the fastener holes. Otherwise,
the anode could erode away around the fastener.
The anode can then become loose or even Fall
off, removing all protection.
Another Military Specification (MIL-A-
18001) defines the type of alloy preferred that
will corrode at a uniform rate without forming a
crust that could reduce its efficiency after a time.
Page: 22 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
maintained engine and hull are useless if the tip separates the leading edge from the trailing
propeller is the wrong type or has been allowed edge.
to deteriorate. Although propeller selection for a The leading edge is the edge of the blade
specific situation is beyond the scope of this nearest to the boat. During normal rotation, this
book, the following information on propeller is the area of the blade that first cuts through the
construction and design will allow you to discuss water.
the subject intelligently with your marine dealer. The trailing edge is the edge of the blade
farthest from the boat.
How a Propeller Works The blade face is the surface of the blade that
faces away from the boat. During normal rota-
As the curved blades of a propeller rotate tion, high pressure exists on this side of the blade.
through the water, a high-pressure area is created The blade back is the surface of the blade that
on one side of the blade and a low-pressure area faces toward the boat. During normal rotation,
exists on the other side of the blade (Figure 18). low pressure exists on this side of the blade.
The propeller moves toward the low-pressure The cup is a small curve or lip on the trailing
area, carrying the boat with it. edge of the blade.
The hub is the central portion of the propeller.
Propeller Parts It connects the blades to the propeller shaft (part
of the boat's drive system). On some drive sys-
Although a propeller may be a one-piece unit, tems, engine exhaust is routed through the hub;
it is made up of several different parts (Figure in this case, the hub is made up of an outer and
19). Variations in the design of these parts make an inner portion, connected by ribs.
different propellers suitable for different jobs.
The diffuser ring is used on through-hub ex-
The blade tip is the point on the blade farthest haust models to prevent exhaust gases from en-
from the center of the propeller hub. The blade tering the blade area.
O 19 Direction of
rotation
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16 CHAPTER ONE
Rake line
Page: 24
in. 20 in.
-
Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
GENERAL INFORMATION 17
Pitch is expressed by the theoretical distance ure 24). Progressive pitch starts low at the lead-
that the propeller would travel in one revolution. ing edge and increases toward to trailing edge.
In A, Figure 22, the propeller would travel 10 The propeller pitch specification is the average
inches in one revolution. I11 B, Figure 22, the of the pitch across the entire blade.
propeller would travel 20 inches in one revolu-
Blade rake is specified in degrees and is meas-
tion. This distance is only theoretical; during
ured along a line from the center of the hub to
actual operation, the propeller achieves about
the blade tip. A blade that is perpendicular to the
80% of its rated travel.
hub (A, Figure 25) has 0' of rake. A blade that
Propeller blades can be constructed with con- is angled from perpendicular (B, Figure 25) has
stant pitch (Figure 23) or progressive pitch (Fig- a rake expressed by its difference from perpen-
0" rake
^ 1 5 O rake
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18 CHAPTER ONE
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GENERAL INFORMATION
Page: 27 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
20 CHAPTER ONE
or selection, or blade damage can cause an un- air from entering the blade area (Figure 31). This
usual pressure drop on a small area of the blade plate is correctly called an "antiventilation
(Figure 30). Boiling can occur in this small area. plate," although you will often see it called an
As the water boils, air bubbles form. As the "anticavitation plate." Through hub exhaust sys-
boiling water passes to a higher pressure area of tems also have specially designed hubs to keep
the blade, the boiling stops and the bubbles col- exhaust gases from entering the blade area.
lapse. The collapsing bubbles release enough
energy to erode the surface of the blade.
This entire process of pressure drop, boiling and
bubble collapse is called "cavitation." The damage
caused by the collapsing bubbles is called a "cavi-
tation bum." It is important to remember that cavi-
tation is caused by a decrease in pressure, not an
increase in temperature.
Ventilation is not as con~plexa process as cavi-
tation. Ventilation refers to air entering the blade
area, either from above the surface of the water or
from a through-hub exhaust system. As the blades
meet the air, the propeller momentarily over-revs,
losing most of its thrust. An added complication is
that as the propeller over-revs, pressure on the blade
back decreases and massive cavitation can occur.
Most pieces of marine equipment have a plate
above the propeller area designed to keep surface
Page: 28 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
Tools an
This chapter describes the common tools re- 4. Use the proper size wrenches to avoid damage
quired for marine equipment repairs and trou- to fasteners and injury to yourself.
bleshooting. Techniques that will make your 5. When loosening a tight or stuck fastener, think
work easier and more effective are also de- of what would happen if the wrench should slip.
scribed. Some of the procedures in this book Protect yourself accordingly.
require special skills or expertise; in some cases, 6. Keep your work area clean, uncluttered and
you are better off entrusting the job to a dealer well lighted.
or qualified specialist. 7. Wear safety goggles during all operations
involving drilling, grinding or the use of a cold
chisel.
SAFETY FIRST 8. Never use worn tools.
Professional mechanics can work for years 9. Keep a Coast Guard approved fire extin-
and never suffer a serious injury. If you follow a guisher handy. Be sure it is rated for gasoline
few rules of common sense and safety, you too (Class B) and electrical (Class C) fires.
can enjoy many safe hours servicing your marine
equipment. If you ignore these rules, you can BASIC HAND TOOLS
hurt yourself or damage the equipment.
1. Never use gasoline as a cleaning solvent. A number of tools are required to maintain
2. Never smoke or use a torch near flammable marine equipment. You may already have some
liquids, such as cleaning solvent. If you are of these tools for home or car repairs. There are
working in your home garage, remember that also tools made especially for marine equipment
your home gas appliances have pilot lights. repairs; these you will have to purchase. In any
3. Never smoke or use a torch in an area where case, a wide variety of quality tools will make
batteries are being charged. Highly explosive repairs easier and more effective.
hydrogen gas is formed during the charging Keep your tools clean and in a tool box. Keep
process. them organized with the sockets and related
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22 CHAPTER TWO
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TOOLS AND TECHNIQUES 23
TOO
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24 CHAPTER TWO
Adjustable Wrenches
Socket Wrenches
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TOOLS AND TECHNIQUES 25
Torque Wrench
Impact Driver
Circlip Pliers
Hammers
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26 CHAPTER TWO
Feeler Gauge
TEST EQUIPMENT
Multimeter
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TOOLS AND TECHNIQUES 27
Tachometer/Dwell Meter
A portable tachometer is necessary for tuning.
See Figure 16. Ignition timing and carburetor
adjustments must be performed at the specified
idle speed. The best instrument for this purpose
is one with a low range of 0- 1000 or 0-2000 rpm
and a high range of 0-6000 rpm. Extended range
(0-6000 or 0-8000 rpm) instruments lack accu-
racy at lower speeds. The instrument should be
capable of detecting changes of 25 rpm on the
low range.
A dwell meter is often combined with a ta-
chometer. Dwell meters are used with breaker
point ignition systems to measure the amount of
time the points remain closed during engine
operation.
Compression Gauge
This tool (Figure 17) measures the amount of
pressure present in the engine's combustion
chamber during the compression stroke. This
indicates general engine condition. Compression
readings can be interpreted along with vacuum
gauge readings to pinpoint specific engine me-
chanical problems.
The easiest type to use has screw-in adapters
that fit into the spark plug holes. Press-in rubber-
tipped types are also available.
Page: 35 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
28 CHAPTER TWO
Vacuum Gauge
Hydrometer
SERVICE HINTS
Most of the service procedures covered in this
manual are straightforward and can be per-
formed by anyone reasonably handy with tools.
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TOOLS AND TECHNIQUES 29
It is suggested, however, that you consider your equipment required, it would be better to have a
own skills and toolbox carefully before attempt- qualified repair shop make the measurements for
ing any operation involving major disassembly you.
of the engine or gearcase.
Preparation for Disassembly
Some operations, for example, require the use
of a press. It would be wiser to have these per- Repairs go much faster and easier if the equip-
formed by a shop equipped for such work, rather ment is clean before you begin work. There are
than trying to do the job yourself with makeshift special cleaners, such as Gunk or Bel-Ray De-
equipment. Other procedures require precise greaser, for washing the engine and related parts.
measurements. Unless you have the skills and Just spray or brush on the cleaning solution, let
it stand, then rinse away with a garden hose.
Clean all oily or greasy parts with cleaning sol-
vent as you remove them.
WARNING
Never use gasoline as a cleaning agent.
It presents an extieme fire hazard. Be
sure to work in a well-ventilated areu
when iisini; cleaning .soh*ent. Keep a
Coast Guard approved fire extingui.v/~e/.,
rated for gasoline fires, handy in any
case.
Disassembly Precautions
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a bearing in a case, there is usually a tool de- Whenever a rotating part butts against a sta-
signed to separate them. Never use a screwdriver tionary part, look for a shim or washer. Use new
to pry apart parts with machined surfaces (such gaskets if there is any doubt about the condition
as cylinder heads and crankcases). You will mar of the old ones. Unless otherwise specified, a thin
the surfaces and end up with leaks. coat of oil on gaskets may help them seal effec-
Make diagrams (or take an instant picture) tively.
wherever similar-appearing parts are found. For Heavy grease can be used to hold small parts
example, head and crankcase bolts are often not in place if they tend to fall out during assembly.
the same length. You may think you can remem- However, keep grease and oil away from electri-
ber where everything came from, but mistakes cal components.
are costly. There is also the possibility you may High spots may be sanded off a piston with
be sidetracked and not return to work for days or sandpaper, but fine emery cloth and oil will do a
even weeks. In the interval, carefully laid out much more professional job.
parts may have been disturbed. Carbon can be removed from the cylinder
Cover all openings after removing parts to head, the piston crown and the exhaust port with
keep small parts, dirt or other contamination a dull screwdriver. Do not scratch either surface.
from entering. Wipe off the surface with a clean cloth when
Tag all similar internal parts for location and finished.
direction. All internal components should be re- The carburetor is best cleaned by disassem-
installed in the same location and direction from bling it and soaking the parts in a commercial
which removed. Record the number and thick- carburetor cleaner. Never soak gaskets and rub-
ness of any shims as they are removed. Small ber parts in these cleaners. Never use wire to
parts, such as bolts, can be identified by placing clean out jets and air passages; they are easily
them in plastic sandwich bags. Seal and label damaged. Use compressed air to blow out the
them with masking tape. carburetor after the float has been removed.
Wiring should be tagged with masking tape Take your time and do the job right. Do not
and marked as each wire is removed. Again, do forget that the break-in procedure on a newly
not rely on memory alone. rebuilt engine is the same as that of a new one.
Protect finished surfaces from physical dam- Use the break-in oil recommendations and fol-
age or corrosion. Keep gasoline off painted sur- low other instructions given in your owner's
faces. manual.
Page: 38 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
of thread locking compound. A screw or bolt lost designated. Many gaskets are designed to swell
from an engine cover or bearing retainer could when they come in contact with oil. Gasket
easily cause serious and expensive damage be- sealer will prevent the gaskets from swelling as
fore its loss is noticed. intended and can result in oil leaks. Authorized
When applying thread locking compound. use replacement gaskets are cut from material of the
a small amount. If too much is used, it can work precise thickness needed. Installation of a too
its way down the threads and stick parts together thick or too thin gasket in a critical area could
that were not meant to be stuck together. cause equipment damage.
Keep a tube of thread locking compound in
your tool box: when used properly, it is cheap
insurance. IC'S TECHNIQUES
2. Use a hammer-driven impact tool to remove
and install screws and bolts. These tools help emoving Frozen Fasteners
prevent the rounding off of bolt heads and screw
slots and ensure a tight installation.
3. When straightening the fold-over type lock- When a fastener rusts and cannot be removed,
washer, use a wide-blade chisel, such as an old several methods may be used to loosen it. First,
and dull wood chisel. Such a tool provides a apply penetrating oil, such as Liquid Wrench or
better purchase on the folded tab, making WD-40 (available at any hardware or auto sup-
straightening easier. ply store). Apply it liberally and allow it pene-
4. When installing the fold-over type lock- trate for 10-15 minutes. Tap the fastener several
washer, always use a new washer if possible. If times with a small hammer; do not hit it hard
a new washer is not available, always fold over enough to cause damage. Reapply the penetrat-
a part of the washer that has not been previously ing oil if necessary.
folded. Reusing the same fold may cause the
For frozen screws, apply penetrating oil as
washer to break, resulting in the loss of its lock-
described, then insert a screwdriver in the slot
ing ability and a loose piece of metal adrift in the
and tap the top of the screwdriver with a hammer.
engine. This loosens the rust so the screw can be re-
When folding the washer, start the fold with a moved in the normal way. If the screw head is
screwdriver and finish it with a pair of pliers. If too chewed up to use a screwdriver, grip the head
a punch is used to make the fold, the fold may be with locking pliers and twist the screw out.
too sharp, thereby increasing the chances of the
washer breaking under stress. Avoid applying heat unless specifically in-
These washers are relatively inexpensive and structed because it may melt, warp or remove the
it is suggested that you keep several of each size temper from parts.
in your tool box for repairs.
5. When replacing missing or broken fasteners
Remedying Stripped Threads
(bolts, nuts and screws), always use authorized
replacement parts. They are specially hardened
for each application. The wrong 50-cent bolt Occasionally, threads are stripped through
could easily cause serious and expensive dam- carelessness or impact damage. Often the threads
age. can be cleaned up by running a tap (for internal
6. When installing gaskets, always use author- threads on nuts) or die (for external threads on
ized replacement gaskets without sealer, unless bolts) through threads. See Figure 23.
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32 CHAPTER TWO
Removing Broken Screws or Bolts or cut a slot in it to fit a screwdriver. See Figure
24.
When the head breaks off a screw or bolt, If the head breaks off flush. use a screw ex-
several methods are available for removing the tractor. To do this, centerpunch the remaining
remaining portion. portion of the screw or bolt. Drill a small hole in
If a large portion of the remainder projects out, the screw and tap the extractor into the hole.
try gripping it with vise-grip pliers. If the pro- Back the screw out with a wrench on the extrac-
jecting portion is too small, file it to fit a wrench tor. See Figure 25.
Filed Slotted
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Chapter Three
Modem outboard engines are quite reliable when com- OUTBOARD ENGINE IDENTIFICATION
pared to earlier models. They provide inlpressive perfor-
mance and better fuel economy than those produced just a It is essential that the engine is correctly identified be-
few years ago. fore performing any testing, maintenance or repairs. Test
specifications and repair instructions may vary by model
As reliable as outboards have become, problems can year, optional equipment, serial number and other charac-
and eventually do occur. This chapter provides the infor- teristics. Use the serial/model number tag (Figure 1) to
mation and instructions to pinpoint the cause of most op- determine the following:
erational problems. 1. Seriallmodel number tag location.
2. Model name.
Follow the troubleshooting steps in this chapter to de-
termine which engine system is malfunctioning. Further 3. Power rating.
testing isolates defective or misadjusted components. 4. Model year.
5 . Engine configuration.
Test specifications and other useful information is pro- 6. Model indicator number.
vided in the tables located at the end of this chapter. 7. Unique serial number.
Before beginning any testing perform a quick visual in- NOTE
spection of the engine. Look for leaking fluid, discon- When ordering replacement parts, always
nected wires or damaged components. Refer to provide the Suzziki dealership with all the
Preliminmy Inspection in this chapter for a list of items to information listed on the serial/model num-
check and additional instructions. ber tag.
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34 CHAPTER THREE
Model Name
Power Rating
Model Year
Engine Configuration
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TROUBLESHOOTING AND TESTING 35
~ o d eindicator
i Unique serial
number number
Page: 43 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
ships. Some of the electrical tests described in this nianual
require a special test harness that is available from Suzuki.
WARNING
Electrical shock can result in severe injury'
or death. Use extreme caution when work-
ing with electrical meters and test leads.
Never allow the conductive metallic por-
tions of the test lead to contact any portion
of the body. Never work while standing in
water or with wet components. High volt-
ages may be present on any electrical com-
ponent or wires on the engine.
NOTE
Variations exist in the scale range capability
and available functions in various meters.
Always refer to the instructions provided
with the meter for specific instructions.
Multimeter
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37
the meter. Refer to the instructions that came with the me-
ter to measure such circuits.
Diodes act as electrical check valves within a circuit.
Diodes are used in the rectifierlregulator portion of the
charging system. Testing diodes requires measuring the
resistance then switching the test lead polarity. Typically
the resistance changes dramatically when the test lead po-
larity is switched..
NOTE
Due to differences in meter test lead polar-
ity, seemingly incorrect test results can re-
sult when testing diodes. Perform the
resistance testing with the test lead connec-
tion points reversed from the specification
before replacing the component. Correct
test results with the test leads reversed may
indicate that the diode is functioning prop-
e7dy
Amperage
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38 CHAPTER THREE
TROUBLESHOOTING PREPARATION
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form electrical testing when fuel or fuel
vapors are present.
NOTE
Models DF40 and DF50 utilize an ignition
coil integrated into the spark plug connec-
tor When performing a spark test on these
models, connect the spark gap tester to the
sparkplug end of the connector. On all other
models connect the spark gap tester to the
end of the sparkplug cap.
model and optional equipment. Review the owner's man- 1. Make a note of the spark plug connector locations and
ual for starting procedures. This section provides infor- lead routing prior to disconnecting them. Disconnect all
mation to help pinpoint the cause of difficult starting. spark plug connectors. Remove the spark plugs as de-
Topics covered include: scribed in Chapter Four.
1. Determining a fuel or ignition fault. 2. Remove the propeller (Chapter Nine).
2. Spark test. 3. Connect the ground lead of the spark gap tester (A,
3. Checking the fuel system. Figure 16) to a suitable engine ground such as the cylin-
der head bolt.
4. Connect a spark plug connector to the spark gap tester
Spark Test (B, Figure 16). On adjustable spark gap testers, adjust the
gap to approximately 6 mm (114 in.).
The first step in isolating a starting problem is to deter-
5. Connect all remaining spark plug leads to a suitable
mine whether the cause is fuel or ignition related.
engine ground (C, Figure 16). Shift the engine into
This section provides instructions for checking the NEUTRAL. Ensure the ignition switch or key is on.
spark at the spark plug connector. A spark gap tester is re-
6. Observe the spark gap tester while operating the elec-
quired for this test.
tric or manual starter. Correct ignition system operation
Refer to Checking the FuelSystem in this chapter ifade-
produces a strong blue spark as the engine cranks.
quate spark is present yet starting difficulty persists.
7. Repeat Steps 3-6 for the remaining cylinders.
I i 4 RNLVG 8. Install the propeller.
Electric shock can cause serious injury or. 9. Clean and install the spark plugs and connect the spark
death. High voltages are generated b y the
plug connectors to the correct spark plug.
ignition system. Never touch wires or wire
connections while running the engine or 10. Refer to Ignition System Troubleshooting in this
perfor/n//zg the test. Never perform ignition chapter if a no spark or weak spark condition is indicated
.s'~~.ste~n
testing in wet conditions. Never pet- on any of the cylinders.
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40 CHAPTER THREE
WARNING
Use extreme caution when working with the
fuel system. Fuel is extremely flamnzable
and i f ignited can result in serious injury or
death. Never smoke or allow sparks around
fuel or fuel vapors. Wipe up any spilled fuel
with a shop towel, then dispose of the shop
towel in a responsible manner. Check all stallation instructions are provided in Chapter Six. Inspect
fuel hoses, connections andfittings for leaks the fuel as follows:
after any fuel system repair. Correct all fuel
system leaks before returning the engine to 1. Disconnect and secure the negative battery cable so it
service. will not contact the battery terminal.
2A. On DF9.9-DF30 models perform the following:
NOTE Pull the drain hose (Figure 19) from the lower en-
Contact a local waste pickup service, auto- gine cover.
motive repair facility or marine dealership
to properly dispose the fuel. Direct the other end of the fuel into a container suit-
able for holding fuel.
Carefully open the bowl drain screw. Squeeze the
Inspecting the fuel primer bulb (Figure 20) a few times to fill the bowl.
Continue until an adequate fuel sample is obtained.
Float bowl drain hoses (Figure 17) on DF9.9, DF15
Securely close the bowl drain screw. Drain any re-
and DF25 models allow relatively easy draining of the
fuel in the float bowl. sidual fuel from the drain hose then pull the hose
from the drain fitting.
On models equipped with electronic fuel injection, a
dedicated fuel system drain is provided in the vapor sepa- On DF25 and DF30 models repeat these steps for
rator tank. Access to the fuel drain may require removal of the remaining two carburetors.
the intake manifold and other components. It is easier to 2B. On fuel injected models perform the following:
drain a sample of fuel from the hoses connected to the low a. Disconnect the hoses from fuel filter as described in
pressure fuel filter (Figure 18). Fuel filter removal and in- Chapter Six.
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TROUBLESHOOTING AND TESTING 41
FUEL SYSTEM
WARNING
Use extreme caution when working on the
fuel system. Fuel presents a seriousjire risk.
Never smoke or allow sparks to occur
around fuel orfuel vapors. Wipe up spilled
fuel with a shop towel and dispose of the
towel in a responsible manner. Check all
fuel hoses, connections andfittings for leaks
after anyfuel system repair. Correct anyfuel
system leakage before returning the engine
to service.
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42 CHAPTER THREE
1. Pickup adapter
2. Pickup screen
3. Gasket
4. Fuel level float
5. Primer bulb
6. Cap
7. Tank
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condition causing the leakage usually affects both con-
nectors.
Inspect the section of hose from the primer bulb to the
fuel tank connection. Tighten or replace hose clamps
when leakage is detected at hose connection points. Pump
the primer bulb until it firms up. A spongy feel or inability
to firm up the bulb indicates possible air leakage. The
leakage point is at the fuel tank connection, fuel hoses or
fuel tank pickup. First test the primer bulb as described in
this chapter. A faulty connection, fuel hose or fuel tank
pickup is indicated if the primer bulb tests correctly. Dis-
assemble and inspect these components as described in
Chapter Six.
NOTE
The engine must be run at full throttle for
several minutes to verify afaulty fuel tank or
fuel supply hose.
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Primer Bulb
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TROUBLESHOOTING AND TESTING 45
Fuel Pump
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46 AFTER THREE
NOTE
Shaking at various engine speeds
Always inspect all fuel filters before testing
the fuel pump.
1 . Improper carburetor adjustment or synchronization
2. Choke valve malfunction.
3. Plugged carburetor passages.
Carburetor 4. Improper float level adjustment.
5. Air leakage at the carburctor mount.
This section provides typical carburetor (Figure 32) re-
lated symptoms and possible causes. The possible causes Bogging or soggiizg on acceleration
and corrective action is further explained in the sections
that follow. 1. Improper carburetor adjustment or synchronization.
DF9.9 and DF15 models are equipped with one carbu- 2. Faulty accelerator pump.
retor, while DF25 and DF30 models have three. All other 3. Plugged carburetor passages.
models are equipped with EFI. 4. Improper float level adjustment.
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TROUBLESHOOTING AND TESTING 47
Flooding carburetor
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48 CHAPTER THREE
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TROUBLESHOOTING AND TESTING 49
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away as the switch is released. Turn the ignition
switch OFF. Shift the engine to NEUTRAL.
e. Perform a choke solenoid resistance test as de-
scribed in this section if incorrect choke valve oper-
ation is noted.
3C. On DF25 and DF30 models with tiller control check
the choke valve as follows:
a. Push in on the choke knob (Figure 41) to open fully
the choke valve.
b. The choke valve should be in the open position
(Figure 39).
c. Pull out on the choke knob to close fully the choke
valve.
d. The choke valve should be in the fully closed posi-
tion (Figure 40).
e. Replace missing, bent or broken linkages if incor-
rect choke valve operation is noted.
3D. On DF25 and DF30 models with remote control Positive lead
check the choke valve as follows: \
a. Place the control handle in the forward gear position
to prevent activation of the electric starter.
b. Place the ignition switch in the run position. Do not
place the switch in the start position.
c. Have an assistant repeatedly push in then release the
ignition switch while observing the choke valve
(Figure 39).
d. The choke valve should close fully (Figure 40) as ~ h o k solenoid
e
the switch is pushed in and fully open (Figure 39)
as the switch is released. Turn the ignition switch
OFF. Shift the engine to NEUTRAL.
e. Perform a choke solenoid resistance test as de-
scribed in this section if incorrect choke valve oper- is mounted to the top of the carburetor. On DF25 and
ation is noted. DF30 models the choke solenoid is mounted above and
4. On DF25 and DF30 models install the silencer cover as slightly behind the top carburetor. It is not necessary to re-
follows: move the choke solenoid for testing. Test the choke sole-
a. Align the silencer cover with the silencer lcarbure- noid resistance as follows:
tor mounting base. 1. Disconnect the negative battery cable. Disconnect
b. Ensure the ridges on the silencer cover fit into the both choke solenoid wires from the engine wire hamess.
groove on the mounting base then install all four
2. Calibrate a mutimeter to Rxl.
bolts (Figure 36). Securely tighten the bolts.
c. Install the manual starter as described in Chapter 3. Connect the meter test leads to the wires leading to the
Ten. Install the flywheel cover on electric start mod- solenoid (Figure 46).
els as described in Chapter Eight. 4. Compare the measured resistance with the specifica-
5. Install the spark plugs and leads. Connect the negative tion in Table 16.
battery cables. 5. Replace the solenoid if resistance is incorrect. If the re-
sistance is within specification and the solenoid does not
operate, test the ignition switch, wire harness, wire con-
Choke solenoid resistance test nector or fuse as described in this chapter.
This section provides instructions for testing the resis- 6. Connect the solenoid leads to the engine wire harness.
tance of the coil within the choke solenoid. This compo- Route the wires so they do not contact any moving com-
nent is used on remote control DF9.9-DF25 models. On ponents. Retain the wires with clamps if necessary.
DF9.9 and DF 15 models the choke solenoid (Figure 45) 7. Connect the negative battery cable.
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TROUBLESHOOTING AND TESTING 51
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52 CHAPTER THREE
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TROUBLESHOOTING AND TESTING 53
Battery
starter button
or ignition switch
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54 CHAPTER THREE
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TROUBLESHOOTING AND TESTING 55
Manifold temperature
Rectifierl
regulator
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56 CHAPTER THREE
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TROUBLESHOOTING AN 57
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control bracket. Trace the starter button wires from the
back of the switch to their respective connections to the
engine wire harness.
2. Disconnect the white or whitelred wire and brown wire
connectors from the engine wire harness.
3. Set the multimeter to R x l . Connect the positive meter
test lead to the white or whitelred wire leading to the but-
ton (Figure 62). Connect the negative meter test lead to
the brown wire.
4. Observe the meter reading while depressing then re-
leasing the starter button. The button shoul have continu-
ity when depressed and no continuity when released.
Repeat the test several times to test for intermittent faults.
5. Replace the button if incorrect operation is noted. Con-
nect the white or whitelred and brown wires to their re-
spective connections to the engine wire harness. Route the
wires to avoid interference.
6. Connect the negative battery cable.
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TROUBLESHOOTING AND TESTING 59
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60 CHAPTER THREE
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TROUBLESHOOTING AND T 61
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@ IGNITION SYSTE
DF9.9 AND DF15 MODELS
Stop swil
Ignition charge
coil 1
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TROUBLESHOOTING AND TESTING 63
System Operation
7. Clean the wire harness terminals. Carefully route the DF25 and DF30 Models
wires and reconnect them. Route the wires so they will not
contact any moving components. Carefully wrap the spi- The ignition system (Figure 71) is a solid state
ral wrap around the wires. condensor discharge system (CDI). The CDI unit deter-
8. On DF60 and DF70 models install the electrical com- mines ignition timing based on engine speed, which
ponent cover to the starboard side of the power head. makes it very efficient. The timing (static and dynamic) is
9. Reconnect the spark plug leads and the negative bat- not adjustable. The system is very reliable and mainte-
nance is limited to spark plug cleaning and replacement.
tery cable.
In most cases, problems are related to poor wire connec-
tions or a defective stop switch.
IGNITION SYSTEM This system generates ignition voltage with an ignition
charge coil. The CDI unit converts the alternating charge
This section provides a description of the various igni- coil current to direct current and stores it in a capacitor.
tion systems and test instructions for the ignition system The CDI unit determines engine speed and ignition timing
components. based on when the raised flywheel boss passes the two
Refer to the Troubleshooting Preparation section at the crankshaft position sensors (Figure 72). The CDI unit
beginning of this chapter and Table 3 at the end of the then determines the optimum ignition timing and releases
chapter before performing any test. Avoid unnecessary the stored capacitor current to the primary circuit of the
parts replacement and wasted effort by using systematic ignition coils (Figure 73). The current is increased in the
and logical troubleshooting procedures. Make sure that secondary coil circuit to fire the spark plugs.
the possibility of a poor connection or damaged wiring is The stop switch or ignition switch turns off the ignition
eliminated before replacing an ignition component. Refer system by sending a ground signal to the CDI unit.
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64 CHAPTER THREE
1 1 Flywheel
'I
Stop switch
CDI
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TROUBLESHOOTING AN 65
Crankshaft position
System relay sensor No. 3 Flywheel
/ /
Ignition
switch
\
Positive
battery Spark
terminal
Plug
No. 1
Spark
plug
No. 2
Spark
Plug
No.2
Ignition coil
/
No. 3
DF40 and DF50 Models the sensors. The ECM determines the optimum ignition
timing by using these signals and then interrupting the
The ignition system (Figure 74) is a fully transistorized current to the primary coil winding. This induces a high
direct ignition direct ignition system. The ECM deter- voltage in the secondary coil circuit to fire the spark plugs.
mines ignition timing based on engine speed, which When the ignition switch is turned off, the system relay
makes it very efficient. The timing (static and dynamic) is is de-energized and no current is available to the ignition
not adjustable. The system is very reliable and mainte- coil (Figure 75) or ECM.
nance is limited to spark plug cleaning and replacement.
In most cases, problems are related to poor wire connec-
tions or a defective stop circuit. DF60 and DF70 Models
System current is provided by the battery and is di-
rected to the ECM via the system relay and ignition The ignition system (Figure 76) is a fully transistorized
switch. A crankshaft position sensor (Figure 72) for each system. The ECM unit determines ignition timing based
cylinder signals the ECM as to engine speed and piston on engine speed, which makes it very efficient. The tim-
position based on when the raised flywheel boss passes ing (static and dynamic) is not adjustable. The system is
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66 CHAPTER THREE
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TROUBLESHOOTING AND TESTING 67
Camshaft
position
sensor
Positive
battery
terminal
\
Camshaft
'Spark
Plug
No. 1
'Spark
Plug
No. 4
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68 CHAPTER THREE
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SHOOTING AN 69
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70 CHAPTER THREE
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SHOOTING AN TING 71
4. Connect tlie meter test leads to the pulser coil wire ter-
minals (Figure 83) indicated in Table 7.
5. Compare the meter readings with the specification
provided in Table 7. Replace the pulser coil as described
in Chapter Seven if an incorrect reading is noted.
6. Connect the pulser coil wire connectors to the engine
wire harness. Route the wires to avoid interference.
7. Connect the spark plug leads and the negative battery
cable (if so equipped).
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72 CHAPTER THRE
A fault with the ignition coil generally causes no spark Primary coil winding test
at the affected cylinder. A partial short within the coil can
cause an ignition misfire. Generally this type of fault oc- 1. Disconnect the negative battery cable (if so equipped).
curs at higher engine speeds. A common cause of ignition Note the routing and connection points then disconncct
coil failure is due to an internal short. Internal shorts cause the ignition coil wires.
arcing within the coil housing that prevents a strong blue 2. Set the meter to the Rxl scale.
spark at the plug. A clicking noise emanating from the coil 3. Connect the meter test leads to the coil as indicated.
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LESHOOTING AND TESTING 73
-
Digtal Meter coil winding test
Secof~i/iwy
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cap (Figure 89). Connect the negative meter test
lead to the contact within the other spark plug cap.
5. Compare the results with the specification in Table 11.
Replace the ignition coil(s) as described in Chapter Seven
if an incorrect reading is noted.
6. On DF9.9, DF15 and DF25 models fully thread the
spark plug cap onto the end of the spark plug lead.
7. Connect the engine wire harness to the ignition coil
wires or terminals. Route the wires to avoid interference.
8. Connect the negative battery cable.
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TROUBLESHOOTING AND TESTING 75
Flywheel
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76 CHAPTER THREE
System Operation
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TROU HOOTING AN 77
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78 CHAPTER THREE
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black/white wire leads to the engine temper-
utzirp sensor. A violethhite and black/white
wire leads to the exhaust manifold tempera-
ture sensor. Verify the color of the connect-
ing wire to select the proper sensor.
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80 CHAPTER THREE
Warning Buzzer
WARNING
When performing a test ~isi17ga batten;
never make the final connection of a circuit
at the batten^ terminal. Arcing may occur
and ignite the explosive gasses that form
near the batten'.
This test requires a fully charged battery and jumper
leads. The warning buzzer is mounted within the control
box or behind the dash on remote control models. On tiller
control models the buzzer is mounted within the tiller con-
trol housing.
Access to both buzzer wire terminals is required for
testing. On tiller control models, remove the cover from
the tiller control housing as described in Chapter Eleven Pink
to access the buzzer wires. On remote control models, dis-
assemble the remote control enough to access the wires.
Remote control disassembly and assembly instructions
are provided in Chapter Twelve.
Connect the warning buzzer wires to the battery using
jumper leads as shown in Figure 99. Replace the warning
buzzer if it fails to emit a loud warning tone.
Warning Light
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TROUBLESHOOTING AND TESTING
Glass tube
Fuse holder
\
Fuse Testing
FUSES AND WIRE HARNESS
Aniultimeter is required for this test. Refer to the wiring
WARNING diagrams at the end of the manual to identify the fuse con-
Avoid the potential for fire and/or damaged nection points. Trace the indicated wire colors to the fuse.
engine components. Never install a fuse Test the fuse as follows:
with a higher amperage rating than the 1. Disconnect the negative battery cable. Remove the
original fuse. The wire harness may not fuse as follows:
have the capacity for a higher amperage
fuse. Refer to the wiring diagrams at the end a. On push in fuses, carefully pull the fuse (F'g I urc
of the manual to determine the fuse rating. 102) from the wire harness.
b. On glass tube fuses, pull the fiise holder (Figure
Blown fuses and faulty wire harness cause far more 103) from the mounting clamp. Pull the ends of the
electrical problems than failure of other electric compo- fuse holder to release the fuse.
nents. This section provides test and inspection instruc- 2. Set a multimeter to the Rxl scale. Connect the meter
tions for these components. test leads to each end or contact of the fuse. A continuity
Fuses are used on all electric start and battery charging reading indicates a good fuse.
models. Fuses help protect wires and electric components 3. If a blown fuse is found, thoroughly inspect the engine
from shorted or overloaded circuits. Blown fuses seldom wire harness and connections. Repair or replace faulty
occur during normal engine operation. Worn or damaged wires or connections before installing a new fuse.
Page: 89 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
4. Install the fuse then connect the negative battery cable.
Start the engine and operate the components powered by
the blown fuse. Arepeat failure of the fuse indicates a hid-
den short circuit along the circuit. Refer to the wiring dia-
grams at the end of the manual to identify the wires or
components connected to the fiise. Inspect or test all wir-
ing or components along the affected circuit.
5. If no wiring faults are found, check for radios or other Bent pin
electrical accessories wired into the circuit. The amperage
draw from these accessories and the engine instruments
niay exceed the fuse capacity. Provide an alternate con-
nection point for accessories to prevent potential fuse fail-
ure.
6. Connect the negative battery cable.
WIRE HARNESS
Terminal Inspection 2. Refer to the wiring diagrams at the end of the manual
to identify the wire connection points.
1. Disconnect the negative battery cable (if so equipped). 3A. On tiller control models, disconnect the tiller control
Remove and ground the spark leads. harness from the engine wire harness.
2. Refer to the wiring diagrams at the end of the manual 3B. On remote control models, disconnect the remote
to identify the wire connection points. Disconnect all wire control harness from the engine wire harness.
harness connectors from the electrical components.
3. Inspect the connectors for a bent pin (Figure 104). Pull 4. Note the wire routing and connection points then dis-
on the wires at the back of the connector to check for a connect all electric components from the engine wire har-
loose connector (Figure 105). Repair or replace the af- ness.
fected wire or harness if either of these conditions are 5. Set a multimeter to the R x 1 scale. Connect the meter
noted. test leads to each end of the selected wire color or circuit
4. Using a small pick or screwdriver, gently clean all cor- (Figure 106). The meter must indicate continuity. No
rosion or contaminants from the terminals. Work carefully continuity indicates a faulty wire or terminal.
and avoid damaging the terminals. Clean contaminants 6. With the meter test leads connected as described in
from the wire terminals using an electrical contact Step 5, bend, twist and manipulate the entire length of the
cleaner. suspect wire while observing the meter. A faulty wire is
indicated if intermittent no continuity readings are noted.
Using the meter, verify the faulty section of wire.
Wire Harness Testing
7. Repair or replace the wire if a constant or intennittent
Refer to the wiring diagrams at the end of the manual to fault is indicated. Carefully connect the wire harness to
identify wire harness connection points. the remote or tiller control harness and all electrical com-
1. Disconnect the negative battery cable (if so equipped). ponents. Ensure all connectors lock (Figure 107) to the
Remove and ground the spark leads. harness or electric components.
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G AND TESTING 83
Engine Noises
WARNING
Use extreme caution when working on or
around a running engine. Never wear loose
fitting clothing. Keep everyone away from
the ftj~~)lzeel,
drive belts and the propeller
shaft while the engine is running.
CAUTION
Ignoring suspicions noise may result in in-
creased damage to the power head.
Ticking noise
This section troubleshoots and tests the power head. A whirring noise that is most pronounced as the throttle
Areas covered include engine noises, lubrication system is decreased is usually caused by worn or damaged crank-
failure, detonation and preignition, engine seizure, valve shaft bearings. Be aware that a whirring noise can ema-
train failure, oil entering the combustion chamber and wa- nate from the flywheel. Noises can also transfer from the
ter entering the oil or combustion chamber. gearcase to the power head via the drive shaft.
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84 CHAPTER THREE
Knocking noise
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NG AND TESTING 85
Preignition
Detonation damage is the result of the heat and piessure Engine Seizure
in the combustion chamber becoming too great for the
fuel being used. Fuel normally burns at a controlled rate If the engine slowed down or came to an abrupt stop and
that causes the expanding gasses to drive the piston down. the starter is unable to turn the engine over, the engine
When conditions in the engine allow the heat and pressure may have seized. The engine may start after it cools and
to act too high, the fuel may explode violently These vio- then run rough at idle and lack power at higher speeds.
lent explosions in the combustion chamber cause serious Continued operation will only result in more extensive
damage to internal engine components. Carbon deposits. damage.
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86 CHAPTER THREE
CA UTION
Internal damage to the valves and pistons
can result from attempting to start the en-
gine with incorrect valve timing or a broken
timing belt.
Timing belt
(DF9.9, DF15, DF60 and DF70 models)
high operating hours. Worn valves guides usually accom-
A damaged timing belt (Figure 113) can result in an in- pany worn valves and seats (Figure 114). A compression
ability to start the engine, sluggish performance or a rough test will usually not detect worn valve guides unless they
running condition. A broken timing belt prevents cam- are worn to the point where they effect the valves sealing
shaft operation and causes a no start condition. ability. Disassembly and measurement is the only accu-
If the timing belt is sufficiently worn, it may allow the rate method to detect worn valve guides.
belt to jump over one or more of the teeth on the crank-
shaft pulley. This results in improper valve timing. Typi- Valves
cal symptoms include rough idle, poor performance and
backfiring. Check the valve timing as described in Chap- Corrosion or heavy carbon deposits can cause a valve
ter Five to determine if the belt has jumped. Replace the to stick open. Worn or damaged valves or valve contact
timing belt as described in Chapter Eight if inspection re- surfaces (Figure 114) prevent the valve from sealing
veals excessive wear orjumped teeth. To prevent potential properly. Either condition results in lost compression,
power head damage, Inspect the timing belt at the inter- rough running or backfiring. Backfiring or popping noises
vals listed in Chapter Four. coming from the intake or carburetor(s) indicates a prob-
lem with an intake valve. Likewise backfiring or other 1111-
Valve guides usual noise coming from the exhaust indicates a problem
with an exhaust valve.
Worn valve guides cause inconsistent or improper valve If detecting backfiring, try running the engine with one
to seat contact. The resulting poor sealing causes poor spark plug lead at a time grounded. If the backfire ceases
idle, backfiring and in some cases high oil consumption. when the spark is interrupted, a problem is indicated on
Worn valve guides usually occur only on an engine with that cylinder.
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LESHOOTING AND TESTING 87
Rocker arm
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CHAPTER THREE
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TROUBLESHOOTING AND T 89
Compression Test
CA UTION
Ensure the cratzkitg batten' is f~illlj charged
before performing a compression test.
Using a weak Lmtteiy may result in low com-
pression readings.
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90 CHAPTER TORE
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TROUBLESHOOTING AND TESTING 91
NOTE
Ifpossible, checkfor overheating under ac-
tual running conditions. When testing
smaller engines using a suitable test tank,
the pressurized flush test device may mask
problems with the water pump and other
cooling system components.
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equipped with and engine temperature sensor, hold the
stick to an area next to the spark plug opening. Try to
check the temperature during or immediately after an
overheat warning. Hold different temperature range sticks
to the engine to determine the temperature range the en-
gine is reaching. Stop the engine if the temperature ex-
ceeds 90' C (194' F) to avoid engine damage.
If the temperatures exceed 90" C (194' F), inspect or
test the thermostat as described in this section. The ther-
mostat is far easier to access than the water pressure relief
valve. Inspect the water pressure relief valve if overheat-
ing occurs primarily at higher engine speeds and a faulty
water pump and thermostat are ruled out. Remove the cyl-
inder head and exhaust cover as described in Chapter
Eight for water passage inspection if overheating persist
and no faults are found with the water pressure relief
valve. Water pressure relief valve, exhaust cover and ther-
mostat removal and installation instructions are in Chap-
ter Eight.
WARNING
To avoid serious injury or death, remove the
propeller before running the engine on a
flush test device. Disconnect the negative
battery cable and spark plug leads before
removing or installing the propeller.
CA UTION
Never run an outboard without providing
cooling water. Use either a test tank orflush 5. Closing temperature specifications arc not pro\ ided by
test device. the manufacture. Typically a thermostat should close
within 10' F of the opening temperature.
A fault with the thermostat can cause overheating or
prevent the engine from reaching normal operating tem- 6. Replace the thermostat if an incorrcet opening or clos-
perature. A thennometer, piece of string and a container of ing temperature is indicated.
water that can be heated are required for this test.
7. Install the thermostat as described in Chapter Eight.
1. Remove the thennostat as described in Chapter Eight.
Suspend the thennostat in a container of water (Figure
125).
2. Place a thermometer in the container and begin heating
the water. Continue to heat the water while observing the
thermostat for valve opening. Stop the test if the water be-
gins boiling before the thermostat opens. Problems with the gearcase can include water or lubri-
3. Record the temperature when thermostat just starts to cant leakage, a slipping propeller hub, failed internal com-
open. Stop heating the water and again observe the ther- ponents, noisy operation, or shifting difficulty. Thc keys
mostat as the water cools. Record the temperature when to preventing gearcase problems are to avoid contact with
the thermostat just starts to close. underwater objects, shift the engine at idle speed only and
4. Compare the opening temperature with the specifica- perform regular maintenance. Maintenance instructions
tion in Table 26. for the gearcase are provided in Chapter Four.
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TROUBLESHOOTING AND 3
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Squealing or a high pitched whine usually indicates
bearing problem or, in some cases, gear misalignment.
The only way to verify that a problem exists is to disas-
semble and inspect the gearcase components. Refer to
Chapter Nine for instructions.
Vibration in the engine can and often does originate in
the gearcase. In most all cases, the vibration is due to a
bent propeller shaft or damaged propeller. The propeller
may appear to be in perfect condition, yet be out of bal-
ance. The best way to solve propeller-caused vibration is
to have the propeller examined by a propeller shop. An-
other option is to try a different propeller. Have the pro-
peller balanced and trued if there is a significant reduction
in vibration.
Always check for a bent propeller shaft if vibration is
present. Check the propeller shaft following the instruc-
tions provided in Chapter Nine. Hitting an underwater ob-
ject(~)usually bends the propeller shaft. In many cases,
other damage occurs to the gearcase. Inspect the gearcase
lubricant as described in this section.
Never operate the engine if it vibrates severely. Vi-
brating components place added stress on the gears, bear-
ings and other components.
Shifting Difficulty
Pressure Testing
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TROUBLESHOOTING AND TESTING 95
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96 CHAPTER THREE
NOTE
Afault with the gas assist tilt system causes
a leak down or a loss of assist when tilting 5. Replace the hydraulic pump as described in Chapter
the engine. This system is non-serviceable.
Eleven.
Replace the system as described in Chapter
Eleven should a fault occur.
Leaks down from the full tilt position
Hydraulic Trim System Testing 1. Check the position of the manual relief valve.
2. Check the fluid level as described in Chapter Eleven,
Diagnose hydraulic trim problems by comparing the 3. Remove and inspect the manual relief valve as de-
symptoms in the following section with the possible scribed in Chapter Eleven.
causes listed under each symptom. 4. Have a professional replace all system seals and
O-rings.
5. Replace the hydraulic pump as described in Chapter
Will not move up or down Eleven if the symptoms persist
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TROUBLESHOOTING AND TESTING 97
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98 CHAPTER THFtEE
PTT switch
Remote control
relay
Electric trim
motor
Color Code
Starting B Black
relay W White
R Red
G Green
L Blue
P Pink
Gr Gray
Sb Sky blue
YIG YelIowlGreen
Battery
the up direction while observing the meter. Battery volt- be noted. If not, perform the relay continuity test as de-
age sl~ouldbe noted. If not, test the trim switches as de- scribed in this chapter.
scribed in this chapter. 8. If the test results are as specified, but the trim motor
5. Move the positive meter test lead to the blue (L) wire at fails to operate, check for damaged blue and green wires
the up relay. Note the meter reading while toggling the and terminals. If no faults are found with the wires, repair
trim switch in the up direction. Battery voltage should be or replace the electric trim motor as described in Chapter
noted. If not, perform the relay continuity test as described Eleven.
in this chapter.
6 . Connect the negative meter test lead to the black wire
terminal at the down relay and the positive test lead to the Relay continuity test
pink terminal at the relay. Toggle the trim switches in the
down direction wl~ileobserving the meter. Battery voltage This test requires a ~nultimeter,jumper leads and a fully
should be noted. If not, test the trim switches as described charged 12 volt battery.
in this chapter. 1. Disconnect the negative battery cable. Disconnect all
7. Move the positive meter test lead to the green wire on cables from the relays.
the down relay. Note the meter reading while toggling the 2. Set the n~ultiineterto the Rxl scale. Connect the meter
trim switch in the down direction. Batteiy voltage should to the relay terminals (Figure 138) as follows:
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OOTING AND TESTING 99
b. Connect the test leads to the A and B relay termi- 8. Reconnect all wires. Connect the negative battery ca-
nals. Continuity should be noted. bles
c. Connect the test leads to the B and C terminals.
Continuity should be noted.
Trim position sender
3. Connect the test leads to the C and D relay terminals.
Using jumper wires, connect the positive terminal of the NOTE
batteiy to the sky blue (sb) or pink relay wire (Figure Avoid attempting to repair damaged wire in-
138). Note the meter reading while connecting the black sulation on trim motor and trim position
relay wire to the negative battery terminal. Continuity sender wires. It is almost impossible to to-
should be noted. tullj seal worn, cracked or damaged wire
insulation. Even apin sized hole allows wa-
4. Repeat Steps 2 and 3 for the remaining relay. Replace ter into the component. Also note that in-
the relay if it does not function as specified. crectsed engine corrosion is likely [f
electrically live wires are in contact with
wutei:
Trim switch test
A faulty sender is generally the result of deteriorated or
The trim system is controlled by a three-position switch corroded wiring. Place the engine in the fiill tilt position
(Figure 139) nlo~mtedto the remote control, dash panel, and inspect the sensor wires for worn or damaged insula-
tiller handle or lower engine cover (Figure 136). tion. Replace the sender as described in Chapter Eleven if
Page: 107 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
defective wiring is noted. Adjust the trim position sender
as described in Chapter Five if the gauge fails to reach the
&ill up and down positions.
1. Remove the trim position sender as described in C l q -
1 Black
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TROUBLESHOOTING AND TEST 101
Primer bulb
Low pressure
- fuel filter-
\fl L?W pressure
Vapor separator
tank
Fuel
injector
\
Idle air
control motor
/
-Silencer
cover
manifold
Test proceduses for tlie low pressure fuel system are ex-
plained earlier in this chapter ~mderthe Fuel Syskwz sec-
[Ion.
Needle valve
Check for operation of tlie electric fuel pump as de-
scribed in this section ifthe engine refuses to stast. Follow
with t l x f~iel pressure test to determine if the
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102 APTER THREE
PVAW I N G
Use extreine caidou 1vhe1~working wit11the
.file[ system. Fuel cat7 spray O L ulider
~ high
pressure. A l u ~ ~ yuses required safe& g e w
Never smoke or perfoiw any test aroz117dcu7
ope17 jlmie 01. othel. source of igiiition. F L ~
at~d/orfuel vapor represelzt a serious fire
a i ~ de.xp1osive lzaza~~d.
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OOTING AND TESTING 103
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104 CHAPTER THREE
WARNING
Remove the propeller before riiiining the en-
gine to avoid injury Disconnect the spark
plug leads and negative battery cable before
removing and installing the propeller. Stay
clear of the propeller shaft while running an
outboard on a flush/test device.
CA UTION
Never run an outboard without providing
cooling water. Use either a test tank or
flush/test device. Use a test propeller to run
the engine in a test tank.
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LESHOOTTNG AND TESTING 105
@
PARATOR TANK
Fuel
inlet
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106 CHAPTER THREE
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4. Replace the injector if the n~easuredresistance exceeds
the specification in Table 20.
5. Align the tabs on the connector with the slot while con-
necting the harness to the injector. Repeat the resistance
test for the remaining injectors.
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108 CHAPTER THRE
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TROUBLESHOOTING AND TESTING 109
The ECM controls the idle speed using the idle air con-
trol valve. The IAC valve motor varies air flowing into a
dedicated passage in the intake manifold.
Symptoms of a faulty IAC valve include stalling when
the engine is shifted into gear, too slow or rough idle or
excessively high idle speed. The engine usually performs
correctly at higher speeds.
Check the operation of the motor by reading the diag-
nostic codes as described in Diagnostic System. If a trou-
ble code is present, test the resistance of the motor as
follows:
1. Disconnect the negative battery cable.
2. Refer to the wiring diagrams at the back of the manual
to identify the wire colors used for the IAC valve. Trace
4. Place the remote control handle in neutral. The switch the indicated wires to the IAC valve at the front and star-
should have continuity. board side of the intake manifold. Carefully disconnect
5. Place the remote control in the forward then reverse the engine wire harness from the IAC valve.
gear positions while observing the meter readings. The 3. Set the digital multimeter to the ohms scale indicated
switch should have no continuity with the engine shifted in Table 19.
to either forward or reverse. 4. Connect the meter test leads to the individual terminals
6. Replace the neutral switch as describe in Chapter of the idle air control motor. Replace the IAC valve
Seven if incorrect operation is indicated. (Chapter Six) if the measured resistance is not within the
7. Connect the engine wire harness to the neutral switch specification in Table 19.
harness connector. Route the wires to avoid interference. 5. Connect the engine wire harness to the IAC valve.
Install the lower engine covers. Connect the negative bat- Route the wires to avoid interference. Connect the nega-
tery cable. tive battery cable.
Starter does not energize Engine not in neutral gear Shift into neutral gear
Weak or discharged battery Fully charge and test the battery
Dirty or corroded battery Thoroughly clean battery terminals
termimals
Faulty neutral only start Test neutral only start switch
switch
Faulty electric starter switch Test electric starter switch
Faulty ignition switch Test ignition switch
Faulty starter relay Test starter relay
Loose or dirty wire connection Clean and tighten starter wire
connections
Faulty electric starter Repair the electric starter
(continued)
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110 CHAPTER THRE
Starter engages flywheel Weak or discharged battery Fully charge and test the battery
(flywheel rotates slowly) Dirty or corroded battery Thoroughly clean battery terminals
termimals
Loose or dirty wire connections Clean and tighten starter wire
connections
Engine is in gear Correct improper linkage
adjustment
Faulty electric starter Repair the electric starter
Internal power head damage Inspect power head for damage
Internal gearcase damage Inspect gearcase lubricant for debris
Electric starter engages Weak or discharged battery Fully charge and test the battery
(flywheel does not rotate) Dirty or corroded battery Thoroughly clean battery terminals
terminals
Loose or dirty wire connections Clean and tighten starter wire
connections
Engine is in gear Correct improper linkage adjustment
Water in the cylinder(s) Inspect spark plug(s) for water
contamination
Oil in the cylinder(s) Inspect spark plugs for oil
contamination
Damaged starter drive gear Inspect starter drive gear
Damaged flywheel gear teeth Inspect flywheel gear teeth
Faulty electric starter Repair the electric starter
Seized power head Inspect power head for damage
Seized gearcase Inspect gearcase lubricant fordebris
Improper valve timing or Check valve timing and adjustment
adjustment
Electric starter Dirty or dry starter drive gear Clean and lubricate starter drive
(noisy operation) gear
Damaged starter drive gear Inspect starter drive gear
teeth
Damaged or corroded flywheel Inspect flywheel drive gear teeth
gear
Loose starter mounting bolt(s) Tighten starter mounting bolt(s)
Worn or dry starter bushing(s) Repair electric starter
Rewind starter Worn or damaged drive pawl Replace the drive pawl
(does not engage flywheel) Broken or damaged friction Repair the friction spring
spring
Dry or binding rewind Repair the rewind starter
mechanism
Rewind starter Engine is in gear Shift engine into neutral
(engages the flywheel Misadjusted neutral only start Adjust the mechanism
but does not rotate) mechanism
Damaged neutral only start Repair the rewind starter
mechanism
Worn or damaged rewind Repair the rewind starter
mechanism
Frayed starter rope Replace the starter rope
Corroded or binding starter Repair the rewind starter
sheave
Water in the cylinders Inspect the spark plug(s) for water
contamination
Oil in the cylinders Inspect the spark plug(s) for oil
contamination
Improper valve timing or Check valve timing and adjustment
adjustment
seized or damaged power head Inspect power head for damage
Seized or damaged gearcase Inspect gearcase lubricant for
debris
(continued)
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TROUBLESHOOTING AND TESTING Ill
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CHAPTER THREE
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TROUBLESHOOTING AND TESTING 113
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CHAPTER THREE
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TROUBLESHOOTING AND TESTING 115
DF25, DF30
No. 1 Red Black 148-222*
No. 2 Redlwhite Whitelblack 148-222*
DF40, DF50
No. 1 Redlblack Blacklwhite 168-252*
No. 2 Whitelblack BlacWwhite 168-252*
No. 3 Redlwhite BlacWwhite 168-252*
DF60, DF70
No. 1 Redlblack Black 168-252*
No. 2 Whitelblack Black 168-252*
* Measured at 20' C (6E0F)
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116 CHAPTER THREE
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LESHOOTING AND TESTING 117
TABLE 15 RECTIFIERIREGULATOR
ode! Positive (+) test lead Negative (-) test lead Meter reading
DF9.9, DF15 Black White Infinity
(with rectifier) Black Yellow Continuity
Black Red Continuity
White Black Infinity
White Yellow Infinity
White Red Infinity
Yellow Black Infinity
Yellow White Continuity
Yellow Red Infinity
Red Black Infinity
Red White Continuity
Red Yellow Infinity
DF9.9, DF15, DF25, Black White Infinity
DF30 (with rectifier1 Black Yellow Infinity
regulator) Black Red Infinity
White Black 3000 ohms
White Yellow 2600 ohms
White Red 2800 ohms
Yellow Black 2500 ohms
Yellow White Infinity
Yellow Red Infinity
Red Black 2500 ohms
Red White Infinity
Red Yellow Infinity
Black White 9-14 ohms
Black Yellow 1 6-9 ohms
Black Yellow 2 6-9 ohms
Black Yellow 3 6-9 ohms
White Black Infinity
White Yellow 1 Infinity
White Yellow 2 Infinity
White Yellow 3 Infinity
Yellow 1 Black Infinity
Yellow 1 White 7-11 ohms
Yellow 1 Yellow 2 Infinity
Yellow 1 Yellow 3 Infinity
Yellow 2 Black Infinity
Yellow 2 White 8-13 ohms
Yellow 2 Yellow 1 infinity
Yellow 2 Yellow 3 Infinity
Yellow 3 Black Infinity
Yellow 3 White 7.5-1 1.5 ohms
Yellow 3 Yellow 1 Infinity
Yellow 3 Yellow 2 Infinity
Black White 5 ohms
Black Yellow 1 0.8 ohms
Black Yellow 2 0.8 ohms
Black Yellow 3 0.8 ohms
White Black 20-50 ohms
White Yellow 1 20-50 ohms
White Yellow 2 20-50 ohms
White Yellow 3 20-50 ohms
Yellow 1 Black 20-50 ohms
Yellow 1 White 0.8 ohms
Yellow 1 Yellow 2 20-50 ohms
Yellow 1 Yellow 3 20-50 ohms
Yellow 2 Black 20-50 ohms
Yellow 2 White 0.8 ohms
Yellow 2 Yellow 1 20-50 ohms
(continued)
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118 CHAPTER THREE
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TROUBLESHOOTING AND TESTING 119
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120 CHAPTER THREE
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Chapter four
This chapter covers lubrication maintenance and Pay particular attention to the items covered in Before
tune-up procedures. It is divided into the following sec- and After Each Use in this chapter. Frequent attention to
tions: these items may identify potential problems before signif-
1. Before and after each use. icant engine damage occurs.
2. Power head maintenance.
3. Midsection maintenance. BEFORE AND AFTER EACH USE
4. Gearcase maintenance.
5. Storage preparation and re-commissioning. Table 1 lists the checks, inspection and maintenance re-
quired before and after operating the outboard. Refer to
6. Submersion
the specific instructions provided in this section.
7. Corrosion prevention maintenance.
8. Tune-up.
Table 1 at the end of this chapter and the Quick Refer- Checking the Engine Oil Level and Condition
ence Date section at the front of the manual list the main-
CA UTION
tenance item and interval for all engine components and
Never start the engine with a low or high oil
systems. Always check and/or inspect the items listed in level. Low oil level or overfilling can result
Table 1 to help ensure safe operation and maximum en- in inadequate power head lubrication.
gine longevity. Tables 2-6 provide capacities and specifi-
cations. Always check the oil level before and after each use.
If maintenance is neglected, performance, reliability Accurate oil level measurements are only possible if the
and longevity are substantially reduced. engine is switched off for 30 minutes or more and the en-
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122 AFTER FOUR
Oil dipstick f
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MAINTENANCE, LUBRICATION AND TU 123
Low
level
level
line
line
Oil dipstick
WARNING
Use extreme caution if working with or
around fuel. Never smoke around fuel or
@ DF60 AND DF70 MOD
fuel vapors. Ensure no sparks,flame or igni-
tion source is present in the work area.
Flame or sparks can ignite fuel or fuel w-
p u s and result in fire or explosion.
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124 CHAPTER FOUR
els use bolts and nuts on both the upper and lower ends of
the clamp brackets. Ensure all mounting bolts are tight be-
fore operating the engine.
Propeller Inspection
CA UTION
Never operate the engine with significant
propeller damage. Damage to the propeller
can result in a significant decrease in per-
fornzance, increased wearfrom excessive vi-
bration, Z O I I ~ S handling
I ~ characteristics
and /or excessive engine speed.
NOTE
Inspect the cooling system forproper opera-
tion eveiy time the engine is run. A stream of
water exitingfrom the rear of the lower en-
gine cover indicates that the water pump is
operating. Never run the engine if it over- the engine switched off Careful!} remove
heats or i f the water stream is absent. the center plug and thread a common water
hose into the plug opening R u n f r e h u t e r
NOTE through the passages until the exiting water
DF60 and DF70 models are equipped with is clear
a freshwaterflush port. This port is located
on the rear port side of the lower engine
cover (Figure 11). It allows f o r j l ~ ~ s l ~ the
ing CA UTION
power head cooling passages on engines Never run the engine while using the fresh-
moored in the water. Use this port only with water flush port with the engine out o f the
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MAINTENANCE, LUBRICATION AND TUNE-UP 125
1 Gasket
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126 CHAPTER FOUR
Maintenance to the power head involves changing the DF9.9, DF15 AND
engine oil and filter, inspecting various power head com-
ponents and lubricating the throttle and shift linkage.
I DF25 MODELS
WARNING
Never use 2-stroke outboard engine oil in a
4-stroke outboard. Using the wrong type of
oil will cause sigiiificant engine wear and
possib(1)power head failure.
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MAINTENANCE, LUBRICATION AND TUNE-U 127
LOWER ENGINE
COVER REMOVAL
DF9.9 AND DF15 MODELS
1. Seal
2. Starboard cover
3. Screw
4. Clamp
5. Screw
6. Pin
7. Latch
8. Cotter pin
9. Washer
10. Port cover
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128 CHAPTER FOUR
@ LOWER ENGINE
COVER REMOVAL
DF25 AND DF30 MODELS
Bolts (4)
\
Port
cover
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MAINTENANCE, LUBRICATION AND TUNE-U 129
LOWER ENGINE
COVER REMOVAL
DF60 AND DF70 MODELS
1. Seal
2. Screw
3. Port cover
4. Cotter pin
5. Washer
6. Latch
7. Pin
8. Screw
9. Plug
10. Starboard cover
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130 CHAPTER FOUR
Oil filter
- oil filter
7. Thread the new filter onto the oil filter adapter until the
sealing washer just contacts the oil filter mounting surface
(Figure 25). Tighten the filter an additional 314 to 1 turn.
8. Reverse the removal procedure to install the cover
while noting the following:
a. Make sure there are no hoses, cables or other engine
components pinched between the engine covers.
b. Align the lower covers before installing the screws.
c. Securely tighten the cover screws or bolts.
9. Fill the engine with oil as described in this chapter.
10. Start the engine and check for leakage.
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MAINTENANCE. LUBRICATION AND TUNE-UP 131
Valve Adjustments
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problem can prevent potential damage to power head
components.
CA UTION
Use special insulated pliers to remove the
spark plug cap from the spark plugs. The
caps are easily perforated by the gripping
surfaces of standardpliers. A damaged cap
may cause an ignition misfire.
NOTE
Mark or make note of the cylinder for each
sparkphig andplug lead as they are removed.
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MAINTENANCE. LUBRICATION AND TUNE-UP 133
PREIGNITION
OVERHEATING
Identified by melted electrodes and
* Identified by a white or light gray in- possibly blistered insulator. Metallic
FUSED SPOT DEPOSIT sulator with small black, gray or
deposits on insulator indicate en-
Identified by melted or spotty depos- brown spots and with a burnt ap-
gine damage.
its resembling bubbles or blisters. pearance of electrodes.
Caused by wrong type of fuel, incor-
Caused by sudden acceleration. Can Caused by engine overheating, rect ignition timing or advance, too
be cleaned. wrong type of fuel, loose spark
hot a plug, burned valves or engine
plugs, too hot a plug or incorrect ig-
overheating. Replace the plug.
nition timing. Replace the plug.
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134 CHAPTER FOUR
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MAINTENANCE. LUBRICATION AND TUNE-UP 135
1. Fuel connector
2. Primer bulb
3. Fuel metering assembly
4 Fuel tank cap
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136 CHAPTER FOUR
Fastener Inspection
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MAINTENANCE, LUBRICATION AND TUNE-UP 137
CA UTION
The steering cable must be in the retracted
position before grease i s injected into the
cable grease fitting The cable can become
li~~d~~aulically
locked if grease is injected
with the cable extended. Refer to the cable
manufactures instructions for the type and
frequency of lubrication.
Anode Inspection
Page: 145 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
5. Cover the mounting bolt heads with a coating of
Suzuki silicone seal (part No. 99000-3 1120) as indicated
in Figure 45. Allow adequate time for curing of the seal-
ant before placing the engine in the water. Suzuki silicone seal
Anode I
CA UTION
Never paint or apply any coating to the sac-
rzficial anodes or anode mounting surfaces.
Anodes must be cleaned of allforeign mate-
rial to provide maximum corrosion protec-
tion.
Fastener Inspection
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MAINTENANCE, LUBRICATION AND TUNE-UP 139
CA UTION
Never use automotive gear lubricant in the
geatruse. It is not suitable for marine appli-
cations, and its use can lead to increased
wear and corrosion of internal components.
CA UTION
Ensure that the correct gemcase plugs are
removed when checking, or chatiging the
yarcase lubricant. Some models have a
flush plug (Figure 48) located on the same
side of fhe gearcase as the gearcase fill/level
plugs. The flush plug is used with a special
adctpter to flush contatt1it1a11tsfrom the
cooling system. On models so equipped, the
word FLUSH is cast into the gearcase lio~/s-
ing next to the plug.
CAUTION
Inspect the sealing washers anytime the
gearcase plugs are removed. Replace miss-
ing or damaged sealing washers to prevent
leakage.
(so) ~ e v e l ~ v e opening
nt Check the gearcase lubricant level and condition at the
intervals specified in Table 1. Refer to Gearcase Lzhri-
cant Replacement for the recommended gearcase lubri-
cant.
1. Position the engine in the upright position for at least
one hour before checking the lubricant.
2. Disconnect the negative battery cable.
3. Position a suitable container under the gearcase.
Slowly remove the fillldrain plug (Figure 49) and allow a
small sample (a teaspoon or less) to drain from the
gearcase. Quickly replace the fillldrain plug and tighten it
securely. Refer to Chapter Three if water or a milky ap-
GEARCASE MAINTENANCE pearance is noted in the fluid sample.
4. Rub a small amount of the fluid sample between your
Maintenance to the gearcase involves checking and finger and thumb. Refer to Chapter Three if the lubricant
changing the gearcase lubricant, lubricating the propeller feels gritty or if metal particles are present.
shaft, tightening the propeller nut, inspecting gearcase 5 . Slowly remove the levellvent plug (Figure 49). The
mounted anodes and checking for loose fasteners. Refer lubricant level should be even with the bottom of the
to Table 1for gearcase maintenance requirements and in- level/vent plug opening. Add lubricant into the fillldrain
tervals. plug opening (Figure 50) until fluid flows from the
Checking the gearcase lubricant at periodic intervals level/vent opening. Suspect a leak if more than loz.
may make it possible to detect potential gearcase prob- (291111) is required to fill the gearcase. Refer to Chapter
lems and correct the cause before more extensive damage Three if a leak is suspected. Install the levellvent then
occurs. Normal gearcase operation contaminates the ILI- drain/fill plugs. Securely tighten both plugs.
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140 CHAPTER FOUR
Propeller Shaft and Nut Lubrication I. Remove the anode or trim tab mounting bolt and care-
fully pry it from the mounting surface.
Lubricate the propeller shaft and tighten the propeller
2. Use a stiff brush to thoroughly clean the mounting
nut (Figure 51) at the intervals specified in Table 1. Rcg-
bolts, bolt holes and mountingsurfaces The surfaces
ular lubrication with marine grade all purpose grease will
must be cleaned until the surface is shiny. Do not apply
prevent corrosion and potential propeller shaft seizurc.
any paint or other material to the mounting surface.
Perform this maintenance at more frequent intervals ifop-
erating in salt, brackish or polluted water. 3 Use a stiff brush and file to clean all contaminants or
I. Remove the propeller as described in Chapter Nine. casting slag from the mounting surfaces of the anode or
2. Clean all corrosion and old grease from the propeller ti im tab. The anodc n~o~intingsurfaces must be clean and
shaft and splined section of the propeller. true to ensure a good ground connection and a flush lit to
3. Apply a generous amount grease to the propeller shaft the geaicase.
splines.
4. Install the propeller and tighten the propeller nut as de- 4. Install the anode or trim tab and nio~~ntingboll. Align
scribed in Chapter Nine. the trim tab reference marks. Securely tighten the mount-
ingbolt.
Anodes Inspection 5 . Cover the mounting bolt head with a coating of Suzuki
silicone seal (part No. 99000-3 1120) as indicated in Fig-
Clean and inspect the gearcase mounted anodc at the in- ure 45. Allow adequate time fur curing of the sealant be-
tervals listed in Table 1. Inspect the anodes more Ire- fore placing the engine in the water.
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MAINTENANCE, LUBRICATION AND TUNE-UP 141
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142 CHAPTER FOUR
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AINTENANCE, LUBRIC ION AND TUNE-U 143
NOTE
Due to manufacturing and design vuri-
unces, ignition timing may vaiy as much as
2-3' i f checked with different brands or
types of timing lights. I f incorrect timing is
indicated, check the ignition timing with u
different brand or type of timing light before
replacing the CDI unit.
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144 CHAPTER FOUR
DF25 and DF30 models require pilot screw adj~istment, rect starting and idle speed prior to running the engine un-
carburetor synchronization and idle speed adjustment. der actual running conditions. Connect a shop tachometer
DF40, DF50, DF60 and DF70 models are equipped then start the engine. Allow the engine to reach operating
with electronic fuel injection and require adjustment to temperature before advancing the throttle. Check the full
the air bypass screw. Have a Suzuki dealership analyze throttle engine speed with a normal passenger and fuel
the fuel mixture at two year intervals. load. Adjust the trim position on power trim models to
Perform all applicable fuel system adjustments as de- achieve the highest boat speed then note the tachometer
scribed in Chapter Five at the intervals specified in Table 1. reading. Record the maximum engine speed and refer to
Chapter Three to determine the correct engine operating
speed. Check the propeller for damage or correct pitch if
Test Run the maximum engine speed is below or above the recoin-
mended range. If the engine speed is too low, check the
The final step in a fame-up is the test run. Operate the fuel and ignition system for faults as described in Chapter
engine on a flushltest device or in a test tank to verify cor- Three.
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MAINTENANCE, LUBRICATION AND TUNE-UP 145
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146 CHAPTER FOUR
K PLUG SPECIFICATIONS
Model Recommended plug Spark plug gap
DF9.9, DF15 NGK DCPR6E 0.9-1.0 mm (0.035-0.039 in.)
DF25, DF30, DF40, DF50 NGK DCPR6E 0.8-0.9 mm (0.031-0.035 in.)
DF60, DF70 NGK BPR6ES 0.7-0.8 mm (0.028-0.031 in.)
Page: 154 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
Spark plug
DF9.9, DF15 18 13 -
DF25, DF30 18 13 -
DF40, DF50 18 13 -
DF60, DF70 28 21 -
Oil drain plug
II models 13 - 115
Refer to the QRD section for standard torque specifications.
Page: 155 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
Chapter Five
For an outboard motor to deliver maximum efficiency, 4. Standard torque specifications are listed in the Quick
performance and reliability, the ignition, valve train and Reference Data section at the front of the manual.
fuel systems must be correctly adjusted and synchronized.
On models equipped with multiple carburetors, the throt-
tle valves on all carburetors must be synchronized to open VALVE ADJUSTMENT
and close simultaneously. Perform the synchronization
and adjustment procedures after a tune-up or after replac- DF40 and DF50 models require a tappet retaining tool
ing any fuel or control system component that may effect (Suzuki part No. 09916-67010). Check andor adjust the
synchronization. valves with the power head at 20' C (68' F).
Adjust the shift cable and linkage if the gearcase is re-
moved or if incorrect shift operation is noted.
DF9.9 and DF15 Models
Check andlor adjust the valve clearance at the intervals
in Chapter Four and anytime a valve train component is
removed or replaced. 1. Disconnect the negative battery cable. Remove the
spark plugs and ground the spark plug leads.
This chapter provides complete synchronization and
adjustment instructions for all Suzuki 4-stroke outboards. 2. Remove the lower engine covers as described in Chap-
Tables 1-4 provide valve clearance, pilot screw, idle ter Four under Oil Filter Replacement.
speed and torque specifications. Table 1-4 are at the end 3A. On manual start models, remove the manual starter as
of this chapter. described in Chapter Ten.
Torque specifications are listed in Table 4. Use the stan- 3B. On electric start models, remove the flywheel cover as
dard torque specification for fasteners not listed in Table described in Chapter Eight.
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SYNCRONIZATION AND ADJUSTMENT 149
No. 1 exhaust
No. 1 intake
No. 2 intake
No. 2 exhaust
~aked camshaft
0
^
boss pulley
Locknut
Screw
Valve
clearance
I
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150 CHAPTER FIVE
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SYNCRONIZATION AND ADJUSTMENT 151
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152 CHAPTER FIVE
No. 1 No. 1
intake exhaust
No. 2 No. 2
intake exhaust
No. 3
intake No. 3
exhaust
Remove the cover from the cylinder head. Inspect the gas-
ket for damaged surfaces and replace as required.
7. Rotate the flywheel clockwise until the No. 1 camshaft
lobes (Figure 9) face out and directly opposite the valve
tappets (Figure 10).
8. Insert feeler gauges of various sizes between the tappet
shim and the camshaft lobe (Figure 10). The size that
passes between the shim and lobe with a slight drag indi- opening ~ a ~ pshim
et
cates the valve clearance. Record the valve clearance for
each valve.
9. Rotate the flywheel clockwise until the No. 3 camshaft
lobe tips (Figure 10) are facing out and directly opposite the tappet shim as described in Step 14. Determine the
the valve tappets. amount of change needed as follows:
10. Insert feeler gauges of various sizes between the tap- a. Valve clearance greater than the specificci-
pet shim and tlie camshaft lobe (Figure 10). The size that tion-Subtract the valve clearance specification
passes between the shim and lobe with a slight drag indi- (middle of the range) listed in Table 1 from the
cates the valve clearance. Record the valve clearance for measured clearance. Increase the shim thickness by
each valve. this amount.
1 1 Rotate the flywheel clockwise until the No. 2 cam- b. Valve clearance less than the specification-Sub-
shaft lobe tips (Figure 10) are facing out and directly op- tract the measured clearance from the valve clear-
posite the valve tappets. ance specification (middle of the range) listed in
12. Insert feeler gauges of various sizes between the tap- Table 1. Decrease the shim thickness by this
pet shim and the camshaft lobe (Figure 10). The size that amount.
passes between the shim and lobe with a slight drag indi- 14. Replace the tappet shim as follows:
cates tlie valve clearance. Record the valve clearance for a. Rotate the flywheel clockwise until the camshaft
each valve. lobe tip for the selected valve is opposite the tappet
13. Compare the clearances with the specifications listed (Figure 10). Carefully rotate the tappet within its
in Table 1. If incorrect valve clearance in noted, replace bore until the notch (Figure 11) is facing toward the
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SYNCRONIZATTON AND ADJUSTMENT 1%
Camshaft
Tappet retainer
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154 CHAPTER FIVE
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SYNCRONIZATION AND ADJUSTMENT 155
0.1-1.0 mm
(0.004-0.04 i
Tiller control
Throttle arm
(Figure 7) for both valves. The size that passes bctw een 18. Install a new gasket and the rocker arm cover. Tighten
the arm and stem with a slight drag indicates the valve the cover bolts in a crossing pattern to the specification in
clearance. Compare the clearance measured with the Table 4. Install the fuel pump as described in Chapter Six.
specification in Table 1. 19. Install the ignition coils as described in Chapter
10. Adjust the valve clearance as described in Stcp 7. Seven. Install the flywheel cover as described in Chapter
11. Rotate the flywheel clockwise until the No. 4 TDC Eight.
mark aligns with the raised boss on the cylinder head 20. Install the lower engine covers.
(Figure 16). 21. Install the spark plugs and leads. Connect the nega-
12. Measure the clearances of the No. 4 cylinder intake tive battery cablc. Start the engine and check for oil leak-
and exhaust valves (Figure 17). Insert feeler gauges of age at the rocker arm cover mating surfaces. Correct any
various sizes between the rocker arm and the valve stem oil leakage before returning the engine to service.
(Figure 7) for both valves. The size that passes between
the arm and stem with a slight drag indicates the valve
clearance. Compare the clearance measured with the THROTTLE CABLE AND
specification in Table 1. LINKAGE ADJUSTMENT
13. Adjust the valve clearance as described in Step 7.
This section provides the procedures to properly adjust
14. Rotate the flywheel clockwise until the No. 2 TDC
the throttle linkage and cables. Adjust the cables and link-
mark aligns with the raised boss on the cylinder head
age if disturbed or if improper adjustment is suspected of
(Figure 16).
causing engine malfunction.
15. Measure the clearances of the No. 2 cylinder intake
and exhaust valves (Figure 17). Insert feeler gauges of
various sizes between the rocker arm and the valve stem DF9.9 and DF15 Models
(Figure 7) for both valves. The size that passes between
the arm and stem with a slight drag indicates the valve 1. Disconnect the negative battery cable (if so equipped).
clearance. Compare the clearance measured with the Remove the spark plugs and connect the leads to an en-
specification in Table 1. gine ground. Place the controls in the idle and neutral po-
16. Adjust the valve clearance as described in Stcp 7. sition.
17. Rotate the flywheel clockwise until the No. 1 TDC 2. Carefully pry the remote or tiller control cablc connec-
mark aligns with the raised boss on the cylinder head tor (Figure 18) from the throttle a m . Pry the throttle link-
(Figure 16). age (Figure 19) from the throttle arm and throttle lever.
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156 CHAPTER FIVE
DF15 MODELS
0.1-1.0 mm
3. Rotate the idle speed screw (Figure 19) until a gap ex- ure 18). The specified gap is 0.1-1.0 mm (0.004-0.04 in.).
ist between the screw and the throttle shaft lever. If necessary, loosen the jam nut (Figure 18) and rotate the
4. Measure the throttle linkage at the points indicated in cable connectors until the gap is correct. Securely tighten
Figure 19. Loosen the jam nut and adjust the linkage as the jam nut and carefully snap the cable connector onto
required. Ensure the linkage connectors are orientated to the throttle arm connector.
allow installation to the throttle lever and throttle arm. Se- 8. Rotate the idle speed screw until it just contacts the
curely tighten the jam nut. Carefully snap the throttle link- throttle shaft lever (Figure 19). Turn the screw clockwise
age onto the throttle lever and throttle arm. one additional turn.
5. Move the throttle arm to the full throttle position (Fig- 9. Operate the throttle and shift control through their
ure 19) or until the throttle shaft lever contacts the stop on complete range. Correct the cause of any binding or im-
the carburetor. Use a feeler gauge to measure the gap be- proper operation before operating the engine.
tween the throttle arm and the stop. The specified gap is 10. Install the spark plugs and leads. Connect the nega-
0.1-1.0 mm (0.004-0.04 in.). If necessary, adjust the throt- tive battery cable (if so equipped). Adjust the idle speed as
tle linkage length to correct the gap. described in this chapter.
6. Place the throttle arm in the closed throttle position
(Figure 19). Fit the grooved portion of the throttle cable DF25 and DF30 Models
into the slot provided in the cable bracket (Figure 18).
Loosen the jam nut (Figure 18) and rotate the cable con- 1. Disconnect the negative battery cable (if so equipped).
nector until it fits over its connection to the throttle arm Remove the spark plugs and connect the leads to an en-
without disturbing previous adjustments. The flat side of gine ground. Place the controls in the idle and neutral po-
the cable connector must face the throttle arm and the con- sition.
nector must thread onto the cable a minimum of 8 mm 2. Carefully pry the throttle cam linkage (Figure 20 or
(0.3 14 in.). Figure 21) from the throttle arm and throttle cam (1 and 4.
7. Use a feeler gauge to measure the gap between the Figure 22). Measure the distance between the center of.
throttle lever and the stop provided on the carburetor (Fig- connector openings at each end of the linkage. The dis-
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SYNCRONIZATION AND ADJUST 157
0 DF25 AND D
/
Throttle cam linkage 240.5 mm (9.47 in.)
81 mm (3.19 in.)
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158 CHAPTER FIVE
1. Throttle cam
2. Roller
3. Throttle cables
4. Throttle arm
5. Cable bracket
6. Jam nuts
tance must be 81 mm (3.19 in.). If necessary, loosen the tance must be 140 n m (5.51 in.). If necessay. loosen the
jam nuts and evenly rotate the connectors to correct the jam nuts and evenly rotate the connectors to correct the dis-
distance. Ensure the connector threads evenly onto each tance. Ensure the connector threads evenly onto each end
end of the linkage and securely tighten the jam nuts. Care- of the linkage and securely tighten the jam nuts.
fully snap the throttle cam linkage onto the throttle cam 4. Place the tiller or remote control in the close throttle
and throttle arm connections (1 and 4, Figure 22). (idle) position. If the throttle cable adjustment is correct,
3A. On tiller control models, remove the locking pins and the mark on the throttle cam (1, Figure 22) will align with
disconnect the throttle limiter linkage (Figure 20) from the center of the roller (2). If necessary, adjust the cables
the throttle arm and shift linkage connections. Measure as follows:
the distance between the center of the connector openings a. On tiller control models, loosen all four jam nuts (6,
at each end of the linkage. The distance must be 240.5 inn1 Figure 22). Turn the jam nuts until the throttle cam
(9.47 in.). If necessary, loosen the jam nuts and evenly ro- mark aligns with the roller without excessive slack
tate the connectors to correct the distance. Ensure the con- in the cables (3, Figure 22). Securely tighten the
nector threads evenly onto each end of the linkage and jam nuts (6, Figure 22). Cycle the throttle several
securely tighten the jam nuts. Position the throttle limiter times from closed to full throttle and then recheck
linkage onto it connections to the throttle arm and shift for proper adjustment. Readjust the cables as neces-
linkage. Install the locking pins into the connections to re- sary to correct improper adjustment.
tain the linkage. b. On remote control models, remove the locking pin;
3B. On remote control models, carefully pry the throttle - ' I ure
then pull the remote control throttle cable (T'g
linkage (Figure 21) from the throttle am1 and throttle cable 21) from its connection to the throttle linkage.
lever connections. Measure the distance between the center Loosen the jam nut, then rotate the cable connector
of connector openings at each end of the linkage. The dis- until the throttle cam mark aligns with the roller.
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SYNCRONIZATION AND ADJUST 159
1. Cable bracket
2. Throttle cable
3. Shift cable
4. Jam nut
5. Cable connector
6. Jam nut
7. Shift arm post
8. Shift arm
9. Throttle arm
10. Throttle arm post
11. Throttle shaft lever
12. Throttle position switch
13. Shift linkage lever
14. Neutral switch plunger
15. Post
The flat side of the cable connector must face the 2. Remove the locking pin from the throttle arm post (10,
throttle arm. Ensure the cable end threads onto the Figure 23) and pull the throttle cable (2) away from the
threaded portion of the cable a minimum of 8 mm throttle arm (9).
(0.3 l 4 in.). tighten the jam nut. Connect 3. Rotate the throttle arm (9, Figure 23) until the throttk
the cable to the linkage and the lock- shaft lever (1 1) contacts and fully depresses the proti-usion
ing pin. Cycle the throttle several times from closed oll the throttle position switch (12).
to full throttle and make sure the throttle cam mark
aligns with the roller. Readjust the throttle cable as 4- h o s e n the Jam nut (4, Figure 23) and push in on the
reauired. cable connector (5) to remove slack from the cable. With
the throttle arm positioned as described in Step 3, rotate
5. Operate the throttle and shift control through their the cable connector (5, Figure 23) until it fits over the
complete range. Correct the cause of binding or improper throttle arm post (10). Adjust the cable to remove all slack
operation before operating the engine. without excessive preload. The flat side of the cable con-
6. Install the spark plugs and leads. Connect the negative nector must face the throttle arm and the connector must
battery cable (if so equipped). Adjust the idle speed and thread onto the cable a minimum of 8 mm (0.3 14 in.).
synchronize the carburetors as described in this chapter. 5. Securely tighten the jam nut. Install the cable to the
post and install the locking pin.
6. Cycle the controls from closed to full throttle several
DF40 and DF50 Models
times. Return the throttle to the closed position. Ensure
the throttle shaft lever (1 1, Figure 23) fully depresses the
1. Disconnect the negative battery cable. Remove the protrusion on the throttle position switch (12) without ex-
spark plugs and connect the leads to an engine ground. cessive cable preload. Readjust the cable if improper ad-
Place the controls in the idle and neutral position. justment or excessive cable preload is noted.
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160 CHAPTER FIVE
DF60 and DF70 Models 6. Cycle the controls from closed to full throttle several
times. Return the throttle to the closed position. Ensure
1. Disconnect the negative battery cable. Remove the the throttle ann lever fully depresses the protrusion on the
spark plugs and connect the leads to an engine ground. throttle position switch (1, Figure 24) without excessive
Place the controls in the idle and neutral position. cable preload. Readjust the cable if improper adjustment
2. Remove the locking pin from the throttle arm post (8, or excessive cable preload occurs.
Figure 24) and pull the throttle cable (4) away from the
throttle arm (12).
3. Rotate the throttle arm (12, Figure 24) until the throttle SHIFT CABLE AND
shaft lever (on the bottom of the throttle body) contacts LINKAGE ADJUSTMENT
and fully depresses the protrusion on the throttle position
switch (1). Adjust the shift cablellinkage anytime the gearcase or
4. Loosen the jam nut (6, Figure 24) and push in on the shift linkage is disturbed or if incorrect adjustment is sus-
cable connector (7) to remove slack from the cable. With pected of causing an engine malfunction. Refer to the in-
the throttle arm positioned as described in Step 3, rotate structions for the selected model.
the cable connector (7, Figure 24) until it fits over the
throttle arm post (8). Adjust the cable to remove all slack
without excessive preload. The flat side of the cable con- DF9.9 and DF15 Models
nector must face the throttle arm and the connector must
thread onto the cable a minimum of 8 mm (0.3 14 in.). 1 . Disconnect the negative battery cable (if so equipped).
5 . Securely tighten the jam nut. Install the cable to the Remove the spark plugs then connect the spark plug leads
post and install the locking pin. to a suitable engine ground.
Page: 168 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
2. Refer to Chapter Nine for instructions and remove the
propeller from the gearcase.
3. Place the shift selector or remote control lever in the
neutral position (Figure 25). Place a piece of tape on the
motor cover or remote control housing that is between the
shift selector or control lever and the cover or control
housing. Make marks that align with the shift selector.
4. Place the shift selector or control lever into the forward
position (Figure 25). Ensure that you feel the bump or
detent when the forward gear engages. Rotate the propel-
ler shaft counterclockwise as viewed from the rear to en-
gage the clutch to the forward gear. Place a piece of tape
on the motor cover between the shift selector or control le-
ver and the cover or control housing. Make marks that
align with the shift selector.
5. Place the shift selector or control lever into the reverse
position (Figure 25). Ensure that you feel the bump or
detent when the reverse gear engages. Rotate the propeller
shaft clockwise as viewed from the rear to engage the
clutch to the forward gear. Place a piece of tape on the mo-
tor cover or control housing between the shift selector or
lever and the cover or housing. Make marks that align
with the shift selector.
6. Place the shift selector in the neutral position (Figure
25). Measure the distance from the neutral-to-forward
position and neutral-to-reverse marks to determine the
amount of shift selector movement. The amount of move-
ment required to engage forward or reverse from neutral
must be equal. Perform Steps 7-10 if unequal selector
movement is noted.
7. Locate the lower-to-upper shift shaft connector on the
front edge of the drive shaft housing.
8. Using two wrenches, hold the connector and loosen
the jam nut (Figure 26). Rotate the shift connector (Fig-
ure 27) until equal shift selector movement occurs.
9. Ensure that the connector threads a minimum of four
threads onto the lower shift shaft. Securely tighten the jam
nut (Figure 26).
10. Check the shift selector for equal movement. Several
adjustments may be required before equal movement oc-
curs. Verify proper gear engagement and readjust as re-
quired.
11. On remote control models, place the remote control
lever in the neutral position. Loosen the jam nut and ro-
tate the cable connector until the cable aligns with its
mounting points 011 the cable bracket and shift linkage
with the neutral detent engaged. Ensure the connector
threads onto the cable a minimum of 8 mm (0.314 in.)
then securely tighten the jam nut. Attach the cable con-
nector to the shift linkage lever. Securely tighten all nuts,
bolts and screws.
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12. Refer to Chapter Nine for instructions then install the 11. Install the propeller. Connect the negative battery ca-
propeller. ble (if so equipped). Install the spark plugs and spark plug
13. Install the spark plugs and spark plug leads. Connect leads.
the negative battery cable (if so equipped). 12. Operate the engine and check for proper shift engage-
14. Operate the engine and check for proper shift engage- ment. Make any corrections before returning the engine to
ment. Make any corrections before returning the engine to service.
service.
Page: 170 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
8. Locate the lower-to-upper shift shaft connector on the wise as viewed from the rear to fully engage the clutch to
fi-ont edge of the drive shaft housing. the reverse gear. Place a piece of tape on the power head
9. Using two wrenches, hold the connector and loosen the that is directly in line with the shift linkage lever. Make a
jam nut (Figure 26). Rotate the shift connector (Figure mark that aligns with the shift linkage lever when in re-
27) until equal shift selector movement occurs. verse.
10. Thread the connector onto the lower shift shaft a min- 6. Place the shift linkage lever (13, Figure 23) into neu-
imum of 6 threads, Securely tighten the jam nut (Figure tral. Measure the distance from the neutral-to-forward
26). and neutral-to-reverse marks to determine the amount of
1I. Check the shift linkage lever for equal movement. shift selector movement. The amount of movenlent re-
Several adjustments may be required before equal move- q~iiredto engage forward or reverse fi-om neutral must be
ment occurs. Verify proper gear engagement as indicated equal. Perform Steps 7-10 if unequal lever movement is
in Steps 4-6 and readjust as required. noted.
12. Place the shift linkage lever (Figure 21) in the neutral 7. Locate the lower-to-upper shift shaft connector on the
position. Rotate the propeller shaft to v e r i neutral
~ gear. front edge of the drive shaft housing.
13. Place the remote control lever in neutral gear. To re- 8. Loosen the jam nut (Figure 26) and rotate the shift
move excessive slack, push in lightly on the shift cable connector (Figure 2'7) until equal shift selector movement
during adjustn~ents.Loosen the jam nut and rotate the ca- is achieved.
ble connector until it aligns with its connection to the shift 9. Thread the connector onto the lower shift shaft a mini-
linkage. Ensure the cable end threads onto the shift cable a mum of 6 threads. Securely tighten the jam nut (Figure
minimum of 8 nlm (0.3 14 in.) then securely tighten the 26).
jam nut. Install the shift cable to the shift linkage. Se- 10. Check the shift linkage lever for equal movement.
curely tighten all fasteners. Several adjustments may be required before equal move-
14. Install the propeller. Connect the negative batte~yca- ment occurs. Verify proper gear engagement and readjust
ble (if so equipped). Install the spark plugs and spark plug as required.
leads. 11. Place the shift linkage lever (Figure 21) in neutral.
15. Operate the engine and check for proper shift engage- Rotate the propeller shaft to verify neutral gear. Install the
ment. Make any corrections before returning the engine to linkage to the post (1 5, Figure 23) of the shift linkage lc-
service. Lrer (13). Slip the locking pin into the hole in the post.
12. Remove the locking pin and pull the shift cable con-
nector from the shift arm post (7, Figure 23).
13. Inspect the alignment of the tip on shift arm (8, Fig-
I . Remove the spark plugs and ground the spark plug ure 23) to the neutral switch plunger (14). The tip on the
leads. Disconnect the negative battery cable. shift lever must align with the plunger of the switch. Cor-
2. Remove the propeller from the gearcase. Remove the rect misalignment as follows:
locking pin and carefi~llypull the shift linkage from the a. Remove the locking pin and pull the linkage fiom
post (15, Figure 23) on the shift linkage lever (13). the shift lever post (1 5, Figure 23).
3. Move the shift linkage lever (13, Figure 23) toward b. Loosen the jam nut at the lever end of the linkage.
the front and rear of the engine to locate the neutral detent. Rotate the linkage connector until the lever and
The propeller shaft rotates freely in both directions in neu- plunger align.
tral gear. Place a piece of tape on the power head that is di- c. Ensure the linkage connector threads onto the link-
rectly in line with the shift linkage lever. Make a mark that age a minimum of 8 mm (0.314 in.). Securely
aligns with the shift linkage lever when in neutral. tighten the jam nut.
4. Move the shift linkage lever toward the front of the en- d. Install the linkage to the post and install the locking
gine until the bump or detent is felt when the forward gear pin. Verify correct adjustment.
engages. Rotate the propeller shaft counterclockwise as 14. Place the remote control lever or tiller mounted shift
viewed from the rear to engage the clutch to the forward selector in neutral. To remove excessive slack, push in
gear. Place a piece of tape on the power head that is di- lightly on the shift cable during adjustment. Loosen the
rectly in line with the shift linkage lever. Make a mark that jam nut (6, Figure 23) and rotate the cable connector until
aligns 11ith the shift linkage lever when in forward. it aligns with its post (7) on the shift arm. Ensure the cable
5. Move the shift linkage lever (13, Figure 23) toward end threads onto the shift cable a minimum of 8 min
the rear of the engine until the bump or detent is felt when (0.3 14 in.). Securely tighten the jam nut. Install the shift
the reverse gear engages. Rotate the propeller shaft clock- cable to the shift arm and install the locking pin. Verify
Page: 171 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http:llwww.ReadManuals.Com
correct alignment of the shift lever and neutral switch. Re-
adjust the sliift cable as necessasy. Securely tighten all
fasteners. Synchronizer
15. Install the propeller. Connect the negative battesy ca-
ble (if so equipped). Install the spark plugs and spark plug
leads.
16. Operate the engine and check for proper shift engage-
ment. Verify proper operation of the net~tralswitch. The
engine n i ~ ~not
s t start if in gear. Make any cossections be-
fore returning the engine to service.
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ATION AND AD 165
11. Operate the engine and check for proper shift engage- I . Remove the starboard side lower engine cover as de-
ment. Verify proper operation of the neutral switch. The scribed in Chapter FOLISunder Oil Filter Replacemei~t.
engine must not stast if in gear. Make any corrections be- Connect the shop tachometer following the manufac-
fore returning the engine to service. turer's instructions.
2. Remove the plug (6, Figure 29) from the No. 3 intake
sunner. Thread one of the adapters (Figure 28) hlly into
TOR SYNCHRONIZATION the plug opening. Connect the No. 3 hose of the synchro-
(DF 25 AND DF30 MODELS) nizer (Figure 30) to the adapter.
3. Start the engine and allow it to reach nosmal operating
Use an accurate shop tachometer and a carburetor syn- tenlperature. With the engine in neutral, adjust the idle
cllronizer (Figure 28). Purchase the syncl~ronizerfrom a speed with the idle speed screw (1, Figure 29) to 1000
tool supplier or Suzuki dealership (part No, rpm.
099 13- 13 12 1). The adapters (Figure 28) connect the syn- 4. Calibrate the synchronizer as follows:
chsonizer hoses to the intake manifold. These adapters are a. Hold the synchronizer in the vertical position and
included with the Suzuki offered syncllronizer. Obtain note the position of the floating steel ball (Figure
suitable adapters to prevent damage to the threaded open- 31). Rotate the No. 3 adjusting screw (Figure 30)
ings if using a different type of synchronizer. To ensure until the steel ball floats h a l h a y up the tube as indi-
the smoothest engine operation, synchronize the carbure- cated in Figure 31.
tors with the boat in the water or with the engine mounted b. Disconnect the No. 3 hose (Figure 30) from the
in a suitable test tank. adapter and connect the No. 2 hose to the adapter on
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166 CHAPTER FIVE
hose
Steel
ball
screw
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SYNCRONIZATIQN AND ADJUSTMENT 167
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168 CHAPTER FIVE
OF INTAKE MANIFOLD
DF40 AND DF50 MODELS
1. Install a shop tachometer following the manufacturer's 1. Install a shop tachometer following the manufacturer's
instructions. Start the engine and allow it to reach normal instructions. Start the engine and allow it to reach normal
operating temperature. operating temperature. Adjust the idle speed with the en-
2. Place the throttle control in the idle position. Shift the gine in neutral gear.
engine into forward gear. Allow a few minutes for the idle 2. Place the throttle control in the idle position. Using
to stabilize. locking pliers, pinch the hose connecting the throttle body
3. Refer to Table 3 to determine the correct idle speed. to the idle air control valver closed (Figure 35).
Note the idle speed on the tachometer. Rotate the idle 3. Remove the rubber plug from the idle speed screw
speed screw (1, Figure 29) until the idle speed is correct. opening (Figure 36). Slowly turn the idle speed screw un-
4. Have an assistant advance the throttle to 2000 rpm, til the idle speed reaches 800 rpm.
then quickly return the throttle to idle. Allow a few min- 4. Have an assistant advance the throttle to 2000 rpm.
utes for the idle to stabilize then note the idle speed. Read- then slowly return the throttle to idle. Allow a Sew minutes
just the idle speed as necessary. for the idle to stabilize then note the idle speed. Readjust
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SYNCRONIZATION AND ADJUST 169
the idle speed as necessary. Press the rubber plug into the
idle speed screw opening.
5. Remove the locking pliers from the hose. Have an as-
sistant shift the engine into forward gear. Note and record
the idle speed. Compare the idle speed with the specifica-
tion listed in Table 3. Test the idle air control valve if the
Idle speed screw
idle speed is incorrect.
6. Shift the engine to neutral. Switch the engine off and
remove the tachometer.
DASHPOT ADJUSTMENT
Idle air control valve Idle speed screw
A dashpot is used on DF25 and DF30 models. Adjust
the dashpot if the engine stalls upon deceleration. Im-
proper adjustment may cause a high idle speed that cannot
be corrected by adjusting the idle speed screw. Use a shop
Page: 177 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
tachometer for this adjustment. Adjust the dashpot with
the engine in neutral. Adjust the dashpot as follows:
1. Connect a shop tachometer to the engine following the
manufacturer's instructions. Start the engine and allow it
to reach normal operating temperature.
2. Move the throttle lever until the engine reaches ap-
proximately 3000 rpm. Observe the tachometer while
quickly returning the throttle to the idle position. Correct
dashpot adjustment causes the engine speed to hold at ap-
proximately 1500 spm for a few seconds before slowly
falling to normal idle speed (Table 3).
3. Adjust the dashpot holding speed as follows.
a. On manual start models, remove the manual stai ter
as described in Chapter Ten.
b. On electric start models, remove the flywheel cover
as described in Chapter Eight.
c. Locate the dashpot on the port side of the top carbu-
retor. Loosen the nut (Figure 38) on the dashpot
mount.
d. Rotate the dashpot counterclockwise on the mount 4. Shift the engine into forward gear and attempt to oper-
to raise the holding speed. Rotate the dashpot clock- ate the manual starter. Repeat this check with the engine in
wise to lower the holding speed. Repeat Steps 2 and reverse gear. Correct operation prevents the starter from
3 until correct operation occurs. Securely tighten operating with the engine in gear. Repair the manual
the nut. starter as described in Chapter Ten if incorrect operation
e. Install the rewind starter or flywheel cover. Repeat occurs.
Step 2 to check for correct operation. Perform addi-
5. Install the spark plugs and leads. Connect the negative
tional adjustment as necessary.
battery cable (if so equipped).
4. Switch the engine off and remove the tachometer.
Adjust the neutral-only start cable after installation of 1. Remove the spark plugs and ground the leads. Discon-
the manual starter and if incorrect operation of the mecha- nect the negative battery cable (if so equipped).
nism occurs. Refer to the instructions for the selected 2. Shift the engine into neutral. Locate the mark (Figure
model. 40) on the manual starter housing. The center of the cam
(Figure 40) should align with the mark.
3. Adjust the cable as follows:
DF9.9 and DF15 Models
a. Follow the neutral only start cable to the cable
1. Remove the spark plugs and ground the leads. Discon- bracket on the starboard side of the power head
nect the negative battery cable (if so equipped). (Figure 40).
2. Shift the engine into neutral gear. Locate the mark b. Loosen both adjusting nuts (Figure 40). Hold the
(Figure 39) on the manual starter housing. The slot on the cable from rotating and turn the lower adjusting
stopper lever (Figure 39) should align with the mark. nut until the cam and mark align as described in
3. Adjust the cable as follows: Step 2.
a. Follow the neutral only start cable to the cable c. Securely tighten the upper then lower adjusting
bracket just above the shift linkage. nuts. Check the adjustment and correct if neces-
b. Loosen both jam nuts (Figure 39) and rotate the ad- sary.
justing nut until the mark and slot align as described 4. Shift the engine into forward gear and attempt to oper-
in Step 2. ate the manual starter. Repeat this check with the engine in
c. Securely tighten the jam nuts. Check the adjustment reverse gear. Correct operation prevents the starter from
and correct if necessary. operating with the engine in gear. Repair the manual
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SYNCRONIZATION AND ADJUSTMENT 171
Stopper lever
Cable
Cable bracket
Mar
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172 CHAPTER FIVE
move the block and position the engine in the fully down
position. TRIM TAB ADJUSTMENT
3. Access the sender from the gap between the clamp
bracket and swivel bracket with small screwdrivers (Fig-
ure 42).
4. Move the sender slightly within its adjusting slot until
the correct reading occurs on the gauge.
5. Raise the engine to access the screws and block the en-
gine. Securely tighten the sender retaining screws (Figure
41).
6. Remove the blocks, then operate the trim to the up and
down limits to check for proper gauge operation. Readjust
as required.
Starboard ' I
TRIM TAB
Excessive steering torque causes the engine to pull or a. Pulls to theport side-Move the trailing edge of the
steer easier to one side. Trim tab adjustment can reduce or trim tab to the port side.
eliminate steering torque. Determine the direction of pull b. Pulls to the starboardside -Move the trailing edge
(Figure 43) and adjust the trim tab as follows: to the starboard side.
4. Securely tighten the trim tab bolt. Slowly rotate the
1. Shift the engine into neutral gear. Disconnect the nega-
propeller to ensure it does not contact the trim tab. Contact
tive battery cable (if so equipped). Remove the spark
indicates an incorrect or improperly installed trim tab. Re-
plugs and ground the leads.
place the trim tab as needed.
2. Locate the trim tab just above the propeller. Loosen but 5. Install the spark plugs and leads. Connect the negative
do not remove the bolt located in the middle of the trim tab battery cable (if so equipped).
body. 6. Operate the engine and check for excess steering
3. Adjust the trim tab as follows: torque. Readjust as necessary.
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SYNCRONIZATION AND ADJUSTMENT 173
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Chapter Six
Fuel System
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176 CHAPTER SIX
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FUEL SYSTEM 177
1. Quick connector
2. Low pressure fuel filter
3. Fuel pump
4. Bottom carburetor
5. Middle carburetor
1. Quick connector
6. Top carburetor
2. Low pressure fuel filter 7. Bowl drain hoses
3. Fuel pump
4. Bowl drain hose
5. Carburetor
blunt tip scraper. Never scrape away any material other This section provides removal and installation instruc-
than the gaskets from the component. Use a stiff cleaning tions for the low pressure fuel filter. Refer to Electronic
brush and solvent to remove deposits from the carburetor Fuel Injection in this chapter to replace the high pressure
bowl. Do not use a wire brush as delicate sealing surfaces fuel filter. DF9.9 and DF15 n~odelsuse an in-line type fuel
can quickly become damaged. Blow out all passages and filter (Figure 3). All other models use a canister fuel filter
orifices with compressed air (Figure 2). A piece of straw (Figure 4). Both types are non-serviceable and must be
from a broom works well to clean out small passages. replaced if contaminated. Refer to Figures 5-8 to assist
Never use stiff wire for this purpose as the wire may en- with fuel hose connection points,
large the size of the passage, possibly altering the carbure-
1. Disconncct the negative battery cable (if so equipped).
tor calibration. Allow the component to soak in the
solvent for several hours if the deposits are particularly 2A. On DF9.9, DF 15, DF25 and DF30 models, discon-
difficult to remove. nect the remote fuel tank hose from the engine.
One small particle left in the carburetor can cause a seri- 2B. On all other models, trace the fuel tank hose to locate
ous malfunction. Never compromise the cleaning process. the engine fuel hose coupling. Remove the clamps and
Continue to clean until all deposits and debris are re- carefully disconnect the fuel supply hose.
moved. 3. Locate the fuel filter for the selected model.
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178 CHAPTER SIX
1. Supply hose
2. Low pressure filter
3. Pump
4. Pressure regulator
5. Vapor separator tank
6. High pressure filter
7. No. 1 injector
8. No. 2 injector
9. No. 3 injector
10. Idle air control valve
a. On DF9.9 and DF15 models, trace the fuel connec- 7. Position the new filter on the power head with the fit-
tor hose to the fuel filter (Figure 3) on the lower tings orientated as noted prior to removal. Install and se-
port side of the power head. curely tighten the filter mounting fasteners (if used).
b. On DF25, DF30, DF40 and DF50 models, trace the 8. Slide the inlet and outlet hoses fully onto their fittings.
fuel supply hose to the fuel filter located directly be- Install the fuel hose clamps over the hose and fittings.
low the fuel pump on the lower starboard side of the 9. Observe the fuel hose fittings for fuel leakage and
cylinder head. squeeze the primer bulb. Correct any fuel leaks before op-
erating the engine. Clean up any spilled fuel.
c. On DF60 and DF70 models, the filter is located on
10. Connect the negative battery cable (if so equipped).
the lower front and port side of the power head.
4. Cut and discard the plastic tie clamps used on some
hoses. Remove the spring type hose clamps. Fuel Hoses, Fittings and Connectors
5. Position a container or clean shop towel below the fuel NOTE
filter. Note the orientation of the fuel hose fittings before The fuel pressure regulator is mounted
removing the filter. Carefully pull the hoses from the fuel within the vapor separator tank on 1999-011
filter fittings. Manipulate the hose carefully to avoid DF60 and DF70 models, On earlier models
bending or breaking the fuel hose fittings. Replace hoses the regulator is mounted to the bottom of the
that are hard or brittle. If it is necessary to cut the hose, use fuel rail. Thefuel hose routing is very simi-
care to avoid damaging the fuel hose fitting. Inspect all lar to DF40 and DF50 models. DF60 and
spring clamps for corrosion or lack of spring tension. Re- DF70 models use four fuel injectors and a
separate fuel rail.
place any faulty or questionable hose clamps.
6. Remove the fasteners (if used) that retain the filter to Refer to Figures 5-8 for correct hose connections and
power head. Pull the filter from the power head. routing. Use only Suzuki replacement hoses that meet US
Page: 186 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
FUEL SYSTE 179
Coast Guard requirements for marine applications. Never Refer to Fuel Injection if working with the high prcs-
install a fuel hose that is smaller in diameter than the origi- sure fuel hoses on EFI models.
nal hose. Replace both ends of quick connector type clamps if ei-
Inspect all fuel hoses, and replace hoses that feel sticky, ther side leaks. If replacing the quick connector on the fuel
spongy, are hard and brittle or have surface cracks. Re- tank hose end, position the connector over a container
place hoses that have splits on the ends. Do not simply cut suitable for holding fuel. Remove and discard the hose
off the split end and reattach the hose. The hose will likely clamp. Pull the fuel hose from the connector. Slide the
split again and lead to a potentially dangerous fuel leak. hose onto the new connector. Install a new hose clamp
To avoid hose failure or interference with other compo- onto the hose and tighten it securely.
nents, never cut the replacement hose shorter or longer When replacing the clamp at the engine end, locate the
than the original. When one fuel hose on the engine re- screw that retains the clamp to the engine cover. Remove
quires replacement, others are likely to have similar de- the screw and move the disconnected hose end over a con-
fects. Replace all fuel hoses on the engine to ensure a tainer suitable for holding fuel. Remove and discard the
reliable repair. hose clamp. Slide the fuel hose fully onto the new connec-
Connectors used on fuel hoses include the quick con- tor. Install a new fuel hose clamp and tighten it securely.
nector (Figure 9), spring type hose clamp (Figure 10) and Place the connector into position and install the retaining
plastic locking tie clamp (Figure 11).Use the same size screw. Tighten it securely.
and type of clamp that was originally on the engine. To en- The plastic locking tie clamps must be cut to be rc-
sure the correct clamp is used, replace it with the correct moved. Some plastic locking tie clamps are not suitable
Suzuki part number. for marine applications and may fail. Use only the Suzulii
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180 CHAPTER SIX
Fuel Tank
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UEL SYSTE
1. Quick connector
2. Clamp
3. Clamp
4. Primer bulb
5. Clamp
6. Clamp
7. Quick connector
8. Quick connector
9. Gasket
10. Cover
11. Gasket
12. Window
13. Gasket
14. Pickup assembly
15. Screw
16. Float
17. Clip
18. Gasket
19. Fuel tank
20. Seal
21. Seal cap
?A. On steel fuel tanks check for free movement of the Empty the solvent, then dry the tank dry with compressed
float arm on the fuel pickup assembly (14, Figure 12). Re- air.
place the assembly if binding cannot be corrected by 7. Inspect the internal and external tank surfaces. Note
bending the float arm into the correct position. the presence of rusted or corroded surfaces or debris. Re-
3B. On plastic fuel tanks check for free vertical movement place the tank if internal or external corrosion or damage
of the float on the fuel cap (5, Figure 13). Replace the cap is present. Replace the tank if fuel leakage is noted. Re-
assembly if binding occurs. peat Step 6 if residual deposits or debris remain in the
tank.
4. Inspect the float. Replace the float if any physical dam-
age is noted or it appears to be saturated with fuel. 8. Assembly is the reverse of disassembly, noting the fol-
lowing:
5. Remove and inspect the fuel screen from the bottom of
the pickup tube. Inspect the screen for damage or block- a. Clean all debris or contaminants from the
age. Clean or replace this screen as required. adapter-to-fuel tank gasket surfaces.
6. Add a small amount of solvent to the fuel tank. Block b. Install a new gasket (18, Figure 12) between the
the fuel metering assembly opening (steel tank) or pickup pickup assembly (14) and the fuel tank (19).
tube opening (plastic tank) with a shop towel. Install the c. Install a new O-ring (10, Figure 13) between the
fuel tank cap. Shake or agitate the tank for a few minutes. pickup tube (8) and the tank (1 1).
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182 CHAPTER SIX
1. Supply hose
2. Quick connector
3. Clamp
4. Primer bulb
5. Fuel cap
6. Seal
7. Quick connector
8. Pickup tube
9. Screen
10. O-ring
11. Tank
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FUEL SYSTEM 183
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a. On DF60 and DF70 models apply oil to tlie push rod
surfaces and carefully slide it into the mounting
bore.
b. Apply a coating or oil and install a new O-ring (10,
Figure 16) to the fuel pump.
c. Tighten the fuel pump mounting bolts to the specifi-
cation provided in Table 3.
d. Gently squeeze the primer bulb while checking for
fuel leakage. Correct any fuel leaks before returning
the engine to service.
Repair
CA UTION
Do not apply gasket sealing compound to using a suitable solvent. Dry all components with ~0111-
any fuel pump component. Small particles pressed air.
of compound may break free and blockfuel 7. Inspect the surfaces of the fuel cover, body and base ( 1,
system passages. 3, 1 1, Figure 16) with a straight edge. Inspect gasket sur-
faces for scratches, voids or any irregularities. Inspect the
1. Remove the fuel pump as described in this section. fuel pump body for cracks. Replace warped 01- damaged
2. Mark the orientation of the front and back fuel pump components.
covers relative to the fuel pump body. Remove the screws 8. Inspect the fuel pump check valves for bent, cracked or
(6, Figure 16) from the fuel pump. corroded surfaces. Replace the fuel pump body if defects
3. Carefully pry the outer cover (1, Figure 16) from the are noted with the check valves.
fuel pump body (3). Avoid damaging the gasket surface.
9. Align the slotted portion of the plunger (,4. Figure 16)
4. Remove the diaphragm (2, Figure 16) from the outer with the hole in the piston (7) and the slot in the mounting
cover (1) or pump body (3). Carefully pry the fuel pump base. Push in on the plunger and piston (4 and 7. Figure
body (3, Figure 16) from the pump mounting base (1 1). 16) to compress the springs (5 and 9).
5. Push the plunger (4, Figure 16) in until the spring (5) is
10. Install the pin through the openings. Rotate the
fully compressed. Rotate the plunger on the pump mount-
plunger 90Âto position the pin away from the slot in the
ing base until the pin (8, Figure 16) aligns with the slot in
mounting base. Release the plunger and piston.
the mounting base. Maintain pressure on the plunger
6. Use a small screwdriver to push the pin from the 11. Install new gaskets and diaphragms. Use the screw
pump mounting base and plunger. Release the pressure hole locations in tlie gaskets and diaphragms for proper
and lift the plunger and spring (4 and 5, Figure 16) from orientation. All gaskets and diaphragms must be orien-
the mounting base. Pull the piston and spring (7 and 9, tated as indicated in Figure 16.
Figure 16) from the mounting base. Clean the fuel pump 12. Align the marks made in Step 2.
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FUEL SYSTE 185
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186 CHAPTER SIX
7. Remove the gasket material from the rear carburetor 6. Install the flywheel cover as described in Chapter
mounting plate and intake manifold. Use a suitable sol- Eight.
vent to clean the silencer cover and carburetor mounting 7. Connect the negative battery cable.
surfaces.
8. Installation is the reverse of removal. Note the follow-
CARBURETOR
ing:
REMOVAL AND INSTALLATION
a. Install new gaskets to the intake manifold mating
surface. This section provides removal, repair and installation
b. Tighten all fasteners to the specification listed in instruction for the carb~iretor(s).Refer to Figure 5 and
Table 3. Figure 6 to assist with fuel hose connection points. Note
c. Gently squeeze the primer bulb and check for fuel the routing and connection points for all hoses prior to dis-
leakage. Correct any fuel leaks before returning the connecting them. Have a shop towel and a suitable con-
engine to service. tainer handy as fuel will likely spill from the disconnected
hoses. Inspect all fuel hoses for defects. Replace brittle,
leaking, or weathered hoses.
DF40 and DF50 Models
1. Disconnect the negative battery cable (if so equipped). DF9.9 and DF15 Models
2. Remove the flywheel cover as described in Chapter
Eight. Disconnect the breather hose from the silencer 1. Remove the silencer cover as described in this chapter.
cover. 2. Disconnect the fuel hose connecting the fuel pump to
3. Refer to the wiring diagrams at the back of the manual the carburetor(s). Drain residual fuel from the hose.
to identify the wire color used for the air temperature sen- 3. Direct the carburetor drain hose into a suitable con-
sor. Disconnect the wire connector from the air tempera- tainer. Open the drain screw and drain the fuel from the
ture sensor. float bowl. Close the drain screw.
4. Carefully pry the throttle linkage from the port side of
4. Pull the silencer cover away from the throttle body.
the carburetor. Disconnect the choke linkage from the top
Wipe the cover clean with a shop towel and suitable sol-
of the carburetor.
vent.
5. Lift the carburetor from the intake manifold. Carefully
5. Align the cover and throttle body openings. Push the
scrape the gasket material from the carburetor and intake
cover onto the throttle body. Clean the terminals and at-
manifold surfaces. Repair the carburetor as described in
tach tlie connector to the air temperature sensor. Connect
this chapter.
the breather hose to the silencer cover.
6. Installation is the reverse on ren~oval.Note the follow-
6. Install the flywheel cover as described in Chapter
ing:
Eight.
a. Install a new carburetor mounting gasket.
7. Connect the negative battery cable. b. Tighten the carburetor and silencer mounting bolts
to the specification listed in Table 3.
DF60 and DF70 Models c. Inspect fuel hose clamps for defects and replace if
defective.
1. Disconnect the negative battery cable (if so equipped). d. Push the fuel pump hose fully over the carburetor
2. Remove the flywheel cover as described in Chapter hose fitting and secure with a clamp.
Eight. Disconnect the breather hose from the silencer e. Gently squeeze the primer bulb while checking for
cover. fuel leakage. Correct any fuel leaks before returning
3. Remove the bolt securing the silencer cover to the in- the engine to service.
take manifold.
4. Pull tlie silencer cover away from the throttle body. DF25 and DF30 models
Wipe the cover clean with a shop towel and suitable sol-
vent. 1. Remove the silencer cover as described in this chapter.
5. Align the cover and throttle body openings. Push the Carefully pry the throttle and choke linkage from the car-
cover onto the throttle body. Install the bolt into the cover buretors.
and intake manifold. Securely tighten the bolt. Connect 2. Remove the six nuts and lift the front mounting plate
the breather hose to the silencer cover. and supports from the carburetors.
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FUEL SYSTE 187
CA UTION
Never use steel wire to clean carburetor
passages. Material can be removed from the
inner diameter of the orifice, disturbing the
fuel calibration. Carburetor replacement
may be required ifpassages are damaged
during the cleaning process.
NOTE
Never compromise the cleaningprocess for
the carhiiretor(s). Residual debris or depos-
its in the carburetor may break free at a
3. Disconnect the fuel supply hose from each carburetor. later time and block passages. Use com-
Mark the carburetor mounting location and lift them from pressed air and blow through all passages
to ensure they are completely clear.
the rear mounting plate.
4. Remove the insulator and both mounting gaskets from CAUTION
each pair of carburetor mounting studs. Carefully scrape L 4 / ~ t ~ qreplace
~.s damaged carburetor fuel
the gasket material from the mating surfaces. Repair the jets Seemingly insignificant damage to ale1
carburetors as described in this chapter. can have a profound effect on fuel delivery
5. Installation is the reverse of removal. Note the follow- Adverse effects to engine performance and
ing: durability can result from using damaged
carburetor fuel jets
a. Install new carburetor mounting gaskets.
b. Tighten the carburetor mounting nuts to the specifi- CA UTION
cation listed in Table 3. Later models are equipped with a tamper re-
c. Inspect fuel hose clamps for defects and replace if sistunt cover over the pilot adjusting screw.
defective. Do not remove the cover or tamper with the
screw adjustments on these models. 1m-
d. Push the fuel pump hose fully over the carburetor proper engine operation and/or increased
hosc fittings and secure them with a clamp. exhaust emissions can result from an im-
e. Synchronize and adjust the carburetors as described properly adjusted pilot screw.
in Chapter Five.
I. Drain the fuel from the carburetor and inspect it for
contaminants. Inspect the entire fuel system if the pres-
CARBURETOR OVERHAUL ence of water or other debris is noted. Failure to correct
the cause of contamination may cause the symptoms to re-
To ensure success when rebuilding carburetors, always occur after the carburetor is rebuilt.
work in a clean environment. Mark all hosc connections 2. Disassemble the carburetor as described in this section.
during removal and refer to the illustrations to ensure cor- If jet removal is difficult, soak the carburetor in solvent
rect hose routing and orientation. On multiple-carburetor first. Do not use excessive force to remove the jets. If a jet
engines, repair one carburetor at a time. Some models cannot be removed without damaging in, clean the carbure-
have fuel and air jet sizes calibrated to the cylinder in tor without removing the jet. Replace damaged jets.
which they supply fuel. Always perform all applicable 3. Use a suitable solvent and clean all deposits fro111 the
carburetor and linkage adjustments as described in Chap- carburetor passages, fuel jets, orifices and float bowl. Use
ter Five. compressed air and blow through the passages.
4. Place all components on a clean surface. Arrange the
CA UTION
components consistent with the illustrations in this sec-
Make certain that all fueljets are instolled
into the correct location in the carburetor. tion.
Improper,fuel calibration will result if fuel 5 . Inspect the sealing surface of the fuel inlet valve (nee-
jets are installed incorrectly or it~stalledin dle) (Figure 22) for damage. Inspect the valve seat for pit-
the wrong location. Improper engine operci- ting, worn or irregular surfaces. Replace worn or damaged
tion or, i11 some cases, severe power head components.
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188 CHAPTER SIX
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FUEL SYSTE 189
CARBURETOR COMPONENTS
DF9.9 AND DFI 5 MODELS
1. Spring
2. Idle speed screw
3. Pilot jet
4. Pilot screw
5. Spring
6. Accelerator pump screw
7. Spring
8. Seat
9. Inlet needle
10. Clamp
11. Screw
12. Cap
13. Cap
14. Boot
15. Retainer
16. Pump shaft
17. O-ring
18. Spring
19. Screw
20. Fuel hose
21. Float bowl
22. Bowl drain screw
23. Float
24. Gasket
25. Main nozzle
26. Main jet
27. Carburetor casting
28. Float pin
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190 CHAPTER SIX
13. Install the spring (18, Figure 26) and a new O-ring
(17) into the accelerator pump bore. Thread the retainer
and pump shaft (15 and 16) fully into the pump bore. Slip
the boot (14) onto the pump shaft and retainer. Push the
cap (13) onto the pump shaft.
14. Install a new gasket (24, Figure 26) onto the carbure-
tor and carefully position the float bowl onto the carbure-
tor. Install and securely tighten the bowl retaining screws
(19). Install and securely tighten the bowl drain screw
(22).
15. Turn the accelerator pump screw (6, Figure 26) to
achieve a gap of 0.1-0.5 mm (0.004-0.020 in.) between
the pump lever and cap (13).
16. Ifremoved, install the pilot screw and spring (4 and 5,
Figure 26). Adjust the pilot screw as described in Chapter
Five.
7 . Install and securely tighten the pilot jet (3, Figure
26). Install the idle speed screw and spring (2 and 1). In-
stall the carburetor as described in this chapter.
9. Clean all surfaces and passages completely. Inspect all
components for cracked or worn areas and replace them as
DF25 and DF30 Models
required.
Refer to Figure 29. 10. Install the O-ring and seat (25 and 24, Figure 29) into
the carburetor. Retain the seat with the damp and screw
I. Remove the bowl drain screw (33, Figure 29) and
(22 and 2 1). Securely tighten the screw.
drain any residual fuel from the carburetor.
2. Remove the four screws (35, Figure 29) and remove I I Thread the main nozzle (26, Figure 29) securely into
the float bowl (34) from the carburetor. Remove and dis- the carburetor. Thread the main fuel jet (3 1) securely into
card the gasket (30). the carburetor casting. Place the O-ring and cap (27 and
28) onto the exposed end of the main nozzle with the pro-
3. Carefully pull the float pin (19, Figure 29) from its
trusion facing in.
mounting bosses and lift the float (20) from the carbure-
tor. 12. Place the needle valve into the seat with the pointed
tip facing the seat. Install the float and pin onto the carbu-
4. Lift the inlet needle (23, Figure 29) from the seat (24).
retor. Install the inlet needle (23, Figure 29) into the seat
Remove the screw and clamp (2 1 and 22) from the carbu-
(24) with the pointed end facing in. Place the float (20)
retor. Use needle nose pliers to pull the seat (24) from the
onto the inlet needle and install the float pin (19).
carburetor. Remove the O-ring (25) from the seat.
5. Pull the cap and O-ring (28 and 27, Figure 29) from 13. Adjust the float height as follows:
the main nozzle (26). Unthread the main jet (3 1) from the a. With the float gently resting on the needle valve and
carburetor casting. Use a properly sized screwdriver and pivot pin, measure the float height at the points indi-
avoid using excessive force to remove the main nozzle cated in Figure 27.
(26) from the carburetor. b. Compare the measurement with the float height
6. Remove the pilot jet (3, Figure 29). Remove the pilot specification listed in Table 2.
screw and spring (4 and 5). Do not remove the screw on c. Remove the float and carefully bend the float arm
models with a tamper resistant cover. Remove the idle tab (Figure 28) to change the float height. Repeat
speed screw and spring (1 and 2). this step until the float height measurement is cor-
7. Remove the cap and boot (13 and 14, Figure 29) from rect.
the accelerator pump shaft (17). Unthread the pump re- 14. Install the spring (18, Figure 29) and a new O-ring
tainer (15) and lift the pump shaft (17), and spring (18) (16) into the accelerator pump bore. Thread the retainer
from the float bowl. Remove and discard the O-ring (16). and pump shaft (15 and 17) fully into the pump bore. Slip
8. Remove the main air jet (29, Figure 29) from the car- the boot (14) onto the pump shaft and retainer. Push the
buretor throat. cap (1 3) onto the pump shaft.
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FUEL SYSTEM 191
CARBURETOR COMPONENTS
DF25 AND DF30 MODELS
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192 CHAPTER SIX
THROTTLE BODY
1. Pivot bolt
2. Cable pivot pin
3. Connector
4. Jam nut
5. Linkage
6. Gasket
7. Throttle body
8. Washer
9. Throttle lever
10. Bushing
11. Washer
12. Bolt
15. Install a new gasket (30, Figure 29) onto the carbure- take all steps necessary to prevent contami-
tor and carefully position the float bowl onto the carbure- nation.
tor. Install and securely tighten the bowl retaining screws
(35). Install and securely tighten the bowl drain screw Relieving the System Pressure
(33).
16. Turn the accelerator pump screw (10, Figure 29) to 1. Disconnect the negative battery cable.
achieve a gap of 0.1-0.5 mm (0.004-0.020 in.) between 2A. On DF40 and DF50 models disconnect the harness
the pump lever and cap (1 3). connector from the three ignition coils.
17. If removed, install the pilot screw and spring (4 and 5 , 2B. On all other models disconnect and ground the spark
Figure 29). Adjust the pilot screw as described in Chapter plug leads.
Five. Install and securely tighten the pilot jet (3). Install 3. Operate the electric starter 10 times in 3 second inter-
the idle speed screw and spring (1 and 2). vals to relieve the fuel system pressure.
18. Install the carburetor as described in this chapter. 4. Reconnect the coil or spark plug lead(s) after complet-
ing the repair. Connect the negative battery cable.
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FUEL SYSTE
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194 CHAPTER SIX
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UEL SYSTEM 195
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3. Place a small container suitable for holding file1 under
the fuel pressure regulator (6, Figure 34).
4. Loosen the clamp (7, Figure 34) and carefidly pull the FUEL RAIL, INJ
hose (1 1) from the regulator. Drain residual fuel from the RESSURE REGULATOR
hose.
5, Loosen the screws and pull the regulator awdy from
the fuel rail (4, Figure 34). Remove the screws and the
regulator after all fuel has drained from the rail. Remove
the O-ring from the regulator fitting.
6 , Clean the regulator to fuel rail mating surfaces with a
quick drying solvent and lint free towels.
7 . Installation is the reverse of removal. Note the follow-
ing:
a. Install a new O-ring onto the regtdator fitting.
b. Apply fuel to the regulator O-ring prior to installa-
tion.
c. Tighten the regulator retaining screws to the speci-
fication listed in Table 3.
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FUEL SYSTEM 197
System Relay
1. Relieve the system pressure as described in this chap- Removal, testing and installation instructions for this
ter. Disconnect the negative battety cable. component are covered in Chapter Three.
2. Remove the Iowcr engine covers as described in Chap-
ter Four. Idle Air Control (IAC) Valve
3. Use compressed air to remove all dcbris from the in-
jectors and intake manifold. 1. Remove the silencer cover as described in this chapter.
4. Push in on the retaining clip and carefully pull the con- 2. Refer to the wire diagrams at the back of the manual
nector from the injectors. and located the IAC valve as follows:
5. Loosen the clamps and remove both hoses (I I and 13, a. On DF40 and DFS0 models the valve is ino~~nted to
Figure 34) from the f ~ ~rail.
el the starboard side of the throttle body.
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198 CHAPTER SIX
b. On DF60 and DF70 models the valve is mounted to 5. Clean the sensor and cover or throttle body niating sur-
the intake manifold and just above the throttle body. faces.
3. Note the routing and connection points and carefidly 6. Installation is the reverse of removal. Note the follow-
disconnect the hoses and wires fi-om the valve. ing:
4A. On DF40 and DF50 inodels remove the screws and a. Securely tighten the mounting screws.
pull the valve and bracket from the power head. b. Route the wires to avoid iilterference.
4B. On DF60 and DF70 inodels remove the screws and re-
tainer. Pull the valve, flange and lubber gasket from the Cylinder and Exhaust Manifold
intake inanifold or valve. Temperature Sensors
5. Use a suitable solvent to clean the mating surfaces.
Removal and installation of these sensors is in Chapter
6. Installation is the reverse of removal. Note tlie follow-
ing: Seven
a. Sec~irelytighten the mounting screws.
b. Ensure all hose and wires are connected and routed Manifold Absolute Pressure (MAP) Sensor
to avoid interference
1. Discoimect the negative battesy cable.
2. Refer to the wire diagrams at the back of the manual
Engine Control Module (ECM) and located the MAP sensor as follows:
a. On DF40 and DF50 models the sensor is m o ~ ~ n t e d
ECM removal and installation is in Chapter Seven to the top of the intake manifold on the port side of
the power head.
b. On DF60 and DF70 models tlie sensor is mounted
Intake Air Temperature (IAT) Sensor to the fsont and post side of the power head above
the throttle body.
1. Disconnect the negative batte~ycable. 3. Note the routing and connection points and caref~illy
2. Refer to the wire diagrams at the back of the ii~anual disconnect the engine wire harness and hoses fsom the
and locate the IAT sensor as follows: sensor.
a. On DF40 and DF50 models the sensor is iiiounted 4. Carefully remove the mo~mtingscrews and the sensor
the bottom starboard side of the silencer cover. from the intake manifold or power head.
b. On DF60 and DF70 models the sensor is mo~mtcd 5. Clean the sensor and power head or manifold mating
to the top side of the throttle body. surfaces.
3. Note the routing and connection points and carefiilly 6. Installation is the reverse of removal. Note the follow-
disconnect the engine wire harness from the sensor. mg:
4. Caref~illyrcinove the mounting screws and the sensor a. Securely tighten the mounting screws.
froin the cover or throttle body. b. Route tlie wires to avoid interference.
I (continued)
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FUEL SYSTEM
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Chapter Seven
This chapter provides removal and installation instruc- inspection does not detennine the problem2test the start-
tions for electrical and ignition system conlponents. In ad- i ~ i gsystem as described in Chapter Three.
dition, battery maintenance and testing instr~~ctions are
provided in this chapter.
Starter Relay
Specifications for the electrical system arc provided in
Tables 1-5 at the end of this Chapter. Usc the standard This section covers removal and installation of the
tightening torque for fasteners not listed in Table 5. Stan- starter relay (Figure 1). When necessaly for access, re-
dard torque specifications are listed in the Quick Refer- move the electrical component cover (Figure 2) from the
ence Data section at the front of the manual. power head.
1. Disconnect the negative battery cable.
2. Remove the mounting screw (Figure 1) and lift the
STARTING SYSTEM bracket with the starter relay from the power head.
3. Disconncct the yellowlgreen wire terminal from the
The starter motor is capable of prod~~cing very high starter button or engine wire harness. Remove the n~its
torque, but only for a brief time, due to rapid heat b u i l d ~ ~ p . and washers (Figure 1) then lift the whitelred, battery and
To prevent overheating, never operate the starter motor electric starter wires from the starter relay. P ~ dthe
l starter
contin~~ously for more than 10 seconds. Allow the motor relay from the arms of the bracket.
to cool for at least two minutes before further operation. 4. Installation is the reverse of removal, while noting the
If the starter motor does not crank the engine, check the following:
battely and all related wiring for loose or corroded con- a. Enstire all wire terminals are positioned to prevent
nections, shorted or open circuits or other defects. If this contact with each other or with other engine con~po-
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ELECTRICAL AND IGNITION 201
STARTER RELAY
(TYPICAL)
Blue
screw
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202 CHAPTER SEVEN
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ELECTRICAL AND IGNITION
@ Switch
Ground wire
(not used on
all models)
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204 CHAPTER SEVEN
Starter Motor
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ELECTRICAL AND IGNITION 205
ELECTRIC STARTER
(ALL MODELS)
1. Locking clip
2. Stopper
3. Spring
4. Pinion drive
5. Bushing
6. Upper cover
7. Washer
8. Washer
9. Washer
10. Helical splines
11. Armature
12. Bearing surface
13. Thrust washer(s)
14. Nut
15. Lockwasher
16. Nut
17. Lockwasher
18. Washer
19. Nut
20. Insulator
21. Throughbolt
22. Lockwasher
23. Washer
24. Lower cover
25. Brush spring
26. Brush plate
27. Brush
28. Screw
29. Frame
d. Place the insulator over the starter to relay cable ter- CA UTION
minal. Never drop or strike theframe of the starter
e. Check for proper starter and neutral-only start motor. The permanent magnets can crack or
switch operation. break, resulting i12starter nzoto~*failure
NOTE
Replace all O-rings, seals and gaskets ifre- Starter Motor Disassembly
moved or disturbed. Apply weather-strip
adhesive to the mating surfaces of all termi- This section provides complete starter disassembly,
nal insulators-to-starter housings on as- component inspection and assembly instructions. Refer to
sembly. Figure 10.
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206 CHAPTER SEVEN
Reference
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ELECTRICAL AND IGNITION 207
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208 CHAPTER SEVEN
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ELECTRICAL AND IGNITION 209
the large terminal and insulator fit properly into the open-
ing in the lower cover.
2. Fabricate a brush-retaining tool to assist with the asma-
hire installation. Bend a stiff piece of thin rod into a U
shape and position it between the brushes as shown in
Figure 26.
3. Place the thrust washer, if so equipped, onto the lower
end of the armature shaft. Install the armature into the
bushing in the lower cover, then carefully remove the tool.
If possible, install the armature without using a tool.
Manually hold the bsushes away and carefully slide the ar-
mature into the cover. Release the brushes and inspect
them for damage before proceeding (Figure 27).
4. Wipe a small amount of Suzuki water-resistant grease
onto the upper cover bushing. While holding the armature
Starter Motor Assembly firmly in position in the lower cover install the frame as-
sembly over the armature. Align the marks (Figure 12)
and/or anti-rotation structures (Figure 28). Install the
Apply a light coat of Suzuki water-resistant grease to all thrust washers (7-9, Figure 10) over the upper end of the
bushing contact surfaces and the pinion drive end of the armature shaft in exactly the same orientation as removed.
armature. Do not apply grease to the brushes or near the 5. Without pulling the armature from the frame or lower
brush contact surfaces. cover, place the upper cover over the armature shaft and
1. Align the marks and install the brush plate into the onto the frame. Align the mark on the upper cover with the
lower starter cover. Tighten all fasteners securely. Ensure mark on the frame (Figure 12).
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10 CHAPTER SEVEN
CHARGING SYSTEM
Rectifier
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CTRICAL AND IGNITION 211
RECTIFIERIREGULATOR
D DF15 MODELS (TYPICAL)
Rectifierlregulator
Batterylignition
To engine wire
mounting base
s./J ~ o u n t i n gbolt
The battery charge coil and ignition charge coils are in-
~ o u n t i n gscrew tegrated into a single component on all models except
DF9.9 and DF 15 models.
Prior to removal, make a sketch or a photograph of the
wire routing for reference during installation. During in-
stallation, route all wires to prevent interference with
5. Clean, inspect and repair, if necessary, the threads in moving parts.
the power head. Clean all corrosion from the mounting lo-
cation. CA UTION
It may be necessary to use an impact driver
6. Carefully route the rectifier/regulator unit wires and to remove the battery charge and ignition
position the rectifier to the power head. Install and se- charge coil mounting screws. Work care-
curely tighten the mounting bolts, mounting screw and fi1ll.v and avoid using excessive force that
black wire terminal. Route and connect the black wire ter- may damage the cylinder block.
minal to its connection point.
NOTE
7. Connect the remaining leads to the engine wire harness The batteiy charge and ignition charge coils
andlor battery charge coil. appear almost identical on most models.
8. Connect the negative battery cable. Check for proper Use the wire colors and illustrations to
charging and ignition system operation immediately after identify the proper component.
starting the engine.
1. Disconnect the negative battery cable.
2. Remove the flywheel as described in Chapter Eight.
3. Disconnect the battery charge coil from the recti-
Battery Charge Coil fierlregulator, CDI unit andlor engine wire harness. Refer
to the wiring diagrams at the end of the manual to assist
Removal and installation instructions are similar for all with wire connection points.
models. Refer to Figure 33 for DF9.9 and DF15 models. 4. Mark the orientation of the charge coil relative to the
Figure 34 for DF25 and DF30 models, Figure 35 for mounting base. Remove the mounting screws and remove
DF40 and DF50 models and Figure 36 for DF60 and the coil. Carefully guide the coil wires during removal to
DF70 models. prevent damage.
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212 CHAPTER SEVEN
1. Flywheel bolt
2. Washer
3. Key
4. Flywheel
5. Screw
6. Crankshaft position (CKP)
sensor
7. Screw
8. Batterylignition charge
coil
9. Screw
10. Crankshaft taper
11. Crankshaft position (CKP)
sensor
12. Connector
13. Clamp
14. Bolt
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ELECTRICAL AND IGNITION 213
1. Flywheel bolt
2. Washer
3. Key
4. Flywheel
5. Batterylignition charge
coil
6. Screw
7. Crankshaft position (CKP)
sensor
8. Crankshaft position (CKP)
sensor
9. Screw
10. Crankshaft
1I. Crankshaft position (CKP)
sensor
12. Connector
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5. Clean the battery charge coil rno~~nting location, the
threads or the mounting screws.
6. To install the coil, carefdy route the wires and lower
the battery charge coil onto the mounting base. Make cer-
tain the coil is h l l y seated onto the ino~mtingbase.
7A. On DF9.9 and DF15 models route the charge coil I. Disco~mectthe negative batte~ycable (if so equipped).
wires into the grooves (15, Figure 33) provided 011 the 2. Remove the flywheel as described in Chapter Eight.
mounting base. 3. Refes to the wiring diagrams at the end of the n~anual
7B. On DF25 and DF30 models bend the clamp (13, Fig- to assist with wire connection points. Disconnect the igni-
ure 34) over the charge coil harness to secure the wiring. tion chai-ge coil wires as follows:
8. Apply S~izukithread lock (part No. 99000-32050) to a. On DF9.9 and DF15 models trace the wires fsom
the h+eadsand install the coil mou~itingscrews. Securely the ignition charge coil (7, Figure 33) to tlleir con-
tighten the screws. nection to the CDI unit hamess. Disconnect the
9. Connect the batte~ycharge coil wires to the rectifier or wires.
rectifierlreg~~lator har~iessand engine wire Ilarness. Se- b. On DF25 and DF30 models trace the wires from the
cure the black wire terminal to the engine gro~mdor its combination ignition and batte~ycharge coil (8,
wire harness connection point. Figure 34) to the connections to the reclifier/regu-
lator and CDI unit. Disconnect the wises.
10. 111staIl the flywheel as described in Chapter Eight.
Connect any remaining wires to their terminals on the c. On DF40 and DF50 models carefully unpl~lgthe
main engine wire hamess or ignition components. connector (I 2, Figure 35) from the e ~ ~ g i wire
n e har-
ness.
11. Connect the negative battery cable. Check for proper
d. On DF60 and DF70 models caref~lllyunp1~1gthe
cliarging and ignition system operation following the in-
connector (7, Figure 36) fi-om the engine wire har-
stniction provided in Chapter Three.
ness.
4. Mark the orientation of the cl~argecoil relative to the
IGNITION SYSTEM inoui~tingbase. Remove the mounting screws and the coil.
Casef~~lly g ~ ~ i the
d e coil wires during removal to pi-event
This section provides i~istr~ictions
for removing all igni- damage.
tion system components. 5. Clean the coil mo~mtinglocation, the threads or the
mounting screws.
6. To install tlie coil, severse the ren~ovalsequence, case-
Ignition Charge Coil fully route the wires and lower the coil onto the mo~mting
base. F~dlyseat the coil onto the mounting base and note
Ren~ovaland installation are similar for all models. Re- the following:
fer to Figure 33 for DF9.9 and DFl5 models, Figure 34 a. On DF9.9 and DF15 models route the coil wires
for DF25 and DF30 models, Figure 35 for DF40 and into the grooves (15, Figure 33) provided on the
DF50 models and Figure 36 for DF60 and DF70 models. mo~mtingbase.
The ignition charge and battery charge coils are inte- b. On DF25 and DF30 models bend the clamp (13.
grated into a single component on all models except Figure 34) over the charge coil hasness to secure
DF9.9 and DF 15 models. the wiring.
Prior to removal, make a sketch or a pliotograpl~of the c. Apply S L I Z LThread
I ~ ~ lock (part No. 99000-32050)
wire ro~itingfor rcfesence during installation. D ~ ~ r i nin-
g to tlie tl~seaclsand i~~stall
the coil mounting screws.
stallation, route all wires to prevent interference with Seci~relytighten the screws.
moving pasts.
Pulser Coil
CAUTION
It may be izecessaqj to use a11 iv~pactd ~ i v e r (DF9.9 and QF15 Models)
to reinove the battety charge m d ig~zitim
charge coil inowiting screws. Work care- Use a feelcr gaugc to set tlie pulses coil to flywheel a x
frilly and avoid usiizg excessive force that gap aftu flywheel 01 pulses c011 ~ c p l a c c ~ n c ~ ~ t .
may damage the cylinder bloclc. 1. Disconnect tlic negatlve batteiy cable (IFso equipped).
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TRICAL AND IGNITION 215
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216 CHAPTER SEVEN
Harness connection
Clamp Clamp
Clamp
Hose retainers
Clamp
a. Apply Suzuki Thseadlock (past No. 99000-32050) DF40 and DF50 models
to the mounting screws. Securely tighten the
screws. Retain the wires by bending the clamp(s)
The CMP sensor (Figure 38) is mounted on the rocker
over them (if applicable).
arm cover. Air gap adjustment is not required on ti~ese
b. Route all wires to prevent interference with moving
models.
components. Plug the sensor harness connector to
the CDI unit, ECM or engine wire harness. 1. Disconnect the negative battery cable.
c. On DF60 and DF70 models install and adjust the
2. Carefully bend the clamp away from the sensor wire
CMP sensor as described in this chapter.
and unplug the connector from the sensor.
d. Install the flywheel as described in Chapter Eight.
Slowly rotate the flywheel to check for interference 3. Remove the bolt (Figure 38) then lift the sensor and
between the sensors and the flywheel. Check for an clamp from the rocker a m cover.
improperly installed sensor or flywheel if interfer- 4. Use suitable solvent to clean all contaminants from the
ence occurs. sensor and it mo~mtingsurface.
e. Check for proper ignition system operation as de-
scribed in Chapter Three. 5. Place the tip of the sensor into the opening and seat the
sensor against the rocker arm cover. Install the bolt and
clamp. Securely tighten the bolt.
Camshaft Position (CMP) Sensor
6. Clean the teminals and plug the wire l~arnessconnec-
Prior to removal, make a sketch or a pl~otograpl~ of the tor onto the sensor. Retain the wire hasness with the clamp
wire r o ~ ~ t i nfor
g reference during installation. D~iringin- as indicated in Figure 38.
stallation, route all wires to prevent interference with
7. Connect the negative battery cable.
moving parts. Use a feeler gauge to set thc air gap on
DF60 and DF70 models. Refer to the instructions for the 8. Check for proper ignition system operation as de-
selccted model. scribed in Chapter Three.
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ELECTRICAL AND IGNITION 217
Lanyard Switch
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21 8 CHAPTER SEVEN
Ignition Coil
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ELECTRICAL AND IGNITION 21 9
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220 CHAPTER SEVEN
WARNING SYSTEM
This section provides removal and installation instruc- On DF60 and DF70 models, the switch is mounted on
tions for the oil pressure switch, engine and manifold tem- the starboard side of the power head. Remoi e the electric
perature sensor, oil pressureloverheat warning light and component and engine control module to access the
warning buzzer. Refer to the instructions for the selected switch.
component.
1. Disconnect the negative battery cable (if so equipped).
2. Disconnect wire from the oil pressure switch. Thread
Oil Pressure Switch
the switch from the cylinder block. Carefully clean all
The mounting location for the oil pressure switch (Fig- sealant residue from the switch threads. Prevent contami-
ure 46) varies by model. Refer to the wiring diagrams at nants from entering the passages.
the end of the manual to identify the wire color connected 3. Wrap a layer of Teflon sealing tape (Figure 47) around
to the switch. the threads of the switch. Thread the switch into the open-
On DF9.9 and DF15 models, the switch is mounted on ing by hand then tighten the switch to the specification
the upper port side of the power head and directly above listed in Table 5.
the CDI unit.
4. Connect the pink, blue or bluelyellow wire to the
On DF25 and DF30 models, the switch is mounted on
switch. Install the spark plugs and leads. Connect the neg-
the lower front side of the power head and directly in line
ative battery cable. Route the wire to avoid interference
with the warning light.
with moving components.
On DF40 and DF50 models, the switch is mounted to
the upper port side of the power head and just below the 5. Start the engine and immediately check for oil leakage.
flywheel. Correct oil leakage before operating the engine.
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ELECTRICAL AND IGNITION 22 1
L I
Warning Light
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222 CHAPTER SEVEN
BATTERY MAINTENANCE
Cable Connections
Battery Mounting Requirements
Insufficient or dirty cable connections cause many
problems in marine applications. Use cable connectors Make sure the battery is securely mounted in the boat to
that are securely crimped or molded to the cable. Avoid avoid a dangerous acid spill or electrical arcing that can
the use of temporary or emergency clamps for normal us- cause a fire. The most common types of battery mounting
age. They are prone to corrosion and do not meet U.S. include the bracket mounted to the floor of the boat and
Coast Guard requirements for terminal connections. the support across the top of the battery (Figure 51 ). The
Use a cover on the positive terminal post (Figure 51). other common type of battery mounting is the battery case
They are available at marine dealerships. and cover that encloses the battery and secures i t to the
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ELECTRICAL AND IGNITION 223
Warm water
Battery Case
Maximum
Post electrolyte level
Electrolyte Level
WARNING
Use care when lifting or transporting the
battery. With age, the c a n y strap can be-
come weak or brittle and break. I f the bat-
teiy is dropped, the case may break and
boat structure (Figure 52). When properly installed, ei- release a dangerous acid solution.
ther of these provide secure mounting and protection for
the terminals. CA UTION
Mount the battery in a location that allows easy access Never allow the water and baking soda so-
for maintenance. Ensure that the battery terminals are not lution to enter the batteiy solution through
able to contact any component in the mounting area. The the vent caps; it can neutralize the acid and
rigorous marine usage can cause considerable shifting of damage the batten'.
the battery.
CA UTION
M2RNING Never overfill the battety The electrolyte
When mounting a battery in a boat con- may expand with the heat created from
structed of aluminum, mount the batter}' se- charging and overflow jkom the battery.
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224 CHAPTER SEVEN
Battery post
\ / cleaning tool
a' / Battery
cable
Battery Terminals
r
Rotate the tool on the post until the post is clean. Avoid re-
moving too much material from the post or the terminal Float
may not attach securely to it.
Use the other end of the tool to clean the cable end ter-
minal (Figure 56). Clean flat spade-type connectors and Electrolyte must be
the attaching nuts with the wire brush end of the tool. 3/16 in. above pla
Apply a coat of diaelectric grease, petroleum jelly or
other corrosion prevention compound to the battery post
and cable terminal. Tighten the fasteners securely. Avoid
using excessive force when tightening these terminals.
The battery and terminals can sustain considerable dam-
age if excessive force is applied.
Battery Testing
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ELECTRICAL AND IGNITION 225
NEEDS FULLY
DEAD CHARGING CHARGED
VOLTMETER
NOTE
Add 0.004O to the reading for every 10'
above 25' C (80°Fifthe hydrometer i s not
a temperature compensating model. Siib-
tract 0.004Ofrom the reading for eve? 10'
below 2.5' (80' F).
NOTE
4 n inaccurate reading can result i f the spe-
cific gravity is checked immediately after
adding water to the battety. To ensure accu-
racy, charge the battery at a high rate for
15-20 minutes prior to testing.
Weight
Cranking Voltage Test
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226 CHAPTER SEVEN
Battery Charging
WARNING
Batteries produce explosive hydrogen gas. Discharged
Charge the battery in a well-ventilated area. battery
Wear protective eye wear and suitable
gloves when working around batteries.
Never smoke or allow any source of ignition
in the area where batteries are stored or charging process to begin without first charging at the
charged. Never allow noninsulated compo- high rate.
nents to contact the battery terminals, as Check the specific gravity often and halt the charging
arcing can occur and ignite the hydrogen process when the battery is fully charged. Severely dis-
gas. charged batteries may require as long as 8 hours to re-
charge. Check the temperature of the electrolyte during
WARNING
the charging process. Halt the charging process if the elec-
Use extreme caution when connecting any
wires to the battery terminals. Avoid making trolyte temperature reaches or exceeds 53' C (125' F).
the last connection at the batten' terminal.
Explosive hydrogen gas in and around the
battety may ignite and lead to an explosion. Jump Starting
Always remove the battery from the boat to charge it. Jump starting provides the capability of starting an en-
Because most boats provide limited ventilation, the ex- gine that has a severely discharged battery. Jump starting
plosive gasses the battery gives out may remain in the area can be dangerous if correct instructions are not followed.
for a fair amount of time. The gasses may also cause ac- Never attempt to jump start a frozen battery. Always
celerated corrosion of components in the battery compart- check and correct the electrolyte level in each battery be-
ment. Removing the battery also allows for inspection of fore making any connection. A significant risk of explo-
the case for damage and cleaning and maintenance of the sion exists if the electrolyte level is at or below the top of
battery terminals. the plates. Always use a good pair of jumper cables with
Make the connections to the battery hefore plugging in clean connector clamps. Keep all clamps totally separated
or switching on the charger to avoid arcing at the termi- from any metallic or conductive material. Never allow the
nals. Connect the battery charger cables to the proper ter- clamps to contact other clamps.
minals on the battery. Plug the charger into its power
1. Connect a jumper cable to the positive terminal of the
supply and select the 12-volt battery setting.
discharged battery (1, Figure 60).
Charging the battery at a slow rate (lower amperage) re-
sults in a more sufficient charge and helps prolong the life 2. Connect the other end of the same jumper cable to ihe
of the battery. With a severely discharged battery, it may positive terminal of the fully charged battery (2, Figure
be necessary to charge the battery at a highcr amperage 60).
rate for a few minutes befoie starting the lower rate 3. Connect the second jumper cable to the negative termi-
charge. A severely discharged battery will not allow the nal of the fully charged battery (3, Figure 60).
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ELECTRICAL AND IGNITION 227
(continued)
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228 CHAPTER SEVEN
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Chapter Eight
Power Head
This chapter provides removal and installation instruc- dard torque specifications are located in the Quick Refer-
tions for the power head and flywheel. Complete power ence Data section at the front of the manual. Tables 2-12
head repair instructions are also included. Removal and provide service specifications for the power head. Tables
installation instructions for the water jackets, exhaust 1-12 are located at the end of this chapter.
covers, thermostats and water pressure relief valve are in-
cluded in the cylinder block section of this chapter.
FLYWHEEL
Since this chapter covers a large range of power heads,
engines with similar service procedures are grouped to- This section provides removal and installation instruc-
gether. The components shown are generally from the tion for the flywheel and flywheel cover. If the power
most common models. While it is possible that the com- head has been removed before the flywheel, bolt the
ponents shown in the illustrations may not be identical to power head to a sturdy workbench before attempting to
those being serviced, the step-by-step instructions cover remove the flywheel. Use the mounting bolt holes or
every model in this manual. mounting studs at the base of the power head to attach the
Table 1 provides torque specifications. Use the stan- power head to the workbench. Ensure that at least four
dard specification for fasteners not listed in Table 1. Stan- bolts are attached to the workbench surface.
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230 AFTER EIGHT
Flywheel Cover
2A. On DF9.9 and DF15 models remove the two bolts lo-
cated to the rear of the flywheel (Figure I), along with the
bolts on the port and starboard side of the flywheel.
2B. On DF25 and DF30 models remove the bolt from the
front side of the flywheel cover and the two bolts on the
rear port and starboard side of the flywheel cover.
2C. On DF40 and DF50 models remove the two bolts
from the front and front starboard side of the flywheel
cover. Remove the bolt located at the rear of the flywheel
cover.
2D. On DF60 and DF70 models remove the single screw
(Figure 2) from the front side of the flywheel cover. Care-
fully pry the cover loose from the grommets at the rear of
the cover.
3. Carefully lift the cover from the power head. Use com-
pressed air to remove belt material and other debris from
the power head and cover.
4. Installation is the reverse of removal. Note the follow-
ing:
a. Install all bushings, grommets and spacers upon as-
sembly.
b. Check for interference between the cover and mov-
ing engine components. Correct improper installa-
tion or replace missing components (bushings,
grommets, spacers) if interference occurs.
c. Securely tighten all fasteners.
d. Correct interference between the cover and other
components as soon the engine is started.
Flywheel
CA UTION
Use o* the appropriate tools and proce-
dures to remove the flywheel. Never strike
the flywheel with a hard object; the magnets
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may break and result in poor ignition system
performance or potentially damage other'
engine components.
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232 CHAPTER EIGHT
POWER HEAD
REMOVAL/INSTALLATION/REPAIR
WARNING
The power head may abruptly separate from
the inidsection during removal and drop
from the hoist and/or strike other objects.
Avoid using excessive force when lifting the
power head. Use ply bars to separate the
power head from its mounting surface be-
fore lifting it with an overhead hoist.
CA UTION
Lift the power head slowly and maintain
support to lift the power head straight off
the midsection The drive shaft and other NOTE
components may be damaged i f the power A complete power head can we@ several
head is lifted or lowered at an angle hundred pounds. Obtain the proper lifting
equipment before attempting to remove the
CA UTION power head. Large engines (25 hp and
Check for overlooked jasfeners before at- greater) generally require an overhead
tempting to pn' the power head from the hoist to safely lift the power head.
n~idsectionCorrosion may prevent easy re-
moval of thepower head Applypenetrating
oil to the matingsurface and allow it to soak Ensure that the workbench is of appropriate size and
in for a few hours before atternpti~~gpower strength to accommodate the power head..
head removal To prevent damage to the
mounting surfaces, avoid tmng any sharp Use a power head workstand and holding fixture (Fig-
object to pry the components apart ure 8). Using these supports greatly reduces the chance of
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POWER HEAD 233
NOTE
Take photographs and make notes o f all
hose, cable' and wire connections before be-
ginning to remove the power head. Mark all
hoses, wires and cables with u permanent
marker and tags before disconnection. In
many cases, these hoses, cables and wires
are much more accessible after the power
head is lifiedfrom the mounting surfaces.
Removal
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234 CHAPTER EIGHT
7A. On DF9.9 and DF15 models remove the four bolts lo-
cated on each side of the midsection-to-power head mat-
ing surface (Figure 12).
7B. On DF25 and DF30 models remove the six bolts lo-
cated on the starboard side of the midsection-to-power
head mating surface. Seven bolts are located on the port
side mating surface.
7C. On DF40 and DF50 models remove the four bolts and
one nut located on the starboard side of the
midsection-to-power head mating surface (Figure 13).
Four bolts are located on the port side mating surface
(Figure 14).
7D. On DF60 and DF70 models remove the four bolts lo-
cated on the starboard side of the midsection-to-power
head mating surface (Figure 14). Six bolts are located on
the port side mating surface.
8. Remove the oil dipstick from the power head.
9. Inspect the power head for cables, wires or hoses that
may interfere with removal.
10. Work carefully to avoid damaging the mounting sur-
faces. Carefully pry the power head loose from the power
head adapter or drive shaft housing (Figure 15). Check
for overlooked mounting bolts or nuts if the power head
cannot be separated from the midsection.
1 1 The power head assembly for DF9.9 and DF I5 mod-
els is relatively light and can be easily lifted with some as-
sistance. Other models require an overhead lift for
removal. Attach the lift to the power head as follows:
a. 011 DF25, DF30, DF40 and DF50 models attach the
overhead lift to the lifting hook mounted to the top
of the cylinder block (Figure 16).
b. On DF60 and DF70 models remove the mounting
bolt for the timing belt tensioner. Install a power
head lifting hook (Suzuki part No. 1 129 1-91850) to
the power head using the tensioner bolt opening
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POWER HEAD 235
Alignment pin
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236 CHAPTER EIG
Installation
Work carefully to ensure that hoses, wires, and linkage @ Groove camshaft
are clear before lowering the power head into position.
n
CA UTION
DF25, DF30, DF60 and DF70 models uti-
lize an oil pump mounted to the bottom side
of the power head adapter. Align the oil
pump shaft to the camshaft slot (Figure 20)
while mating the power head to the
midsection. The oil pump and/or camshaft
will be damaged i f the power head is in-
stalled with these components misaligned.
Page: 244 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
However, it is a good practice to replace all piston rings,
seals, rod bolts, gaskets and piston pin lockrings during
assembly. The cost of these components is small com-
pared to the damage they can potentially cause if they fail.
If bearings must be reused, make certain that they remain
in the same location from which they were removed. Pis-
ton rings must be replaced and cylinder bores honed any
time a piston is removed from its cylinder bore. Procure
these and other major components (pistons, crankshaft,
cylinder block) before beginning the repair.
Nut Make notes, drawings and photographs of all externally
mounted power head components before beginning
power head disassembly. Although illustrations are pro-
a
vided throughout this manual, the time taken to make
notes, drawings and photographs aids the assembly pro-
Raised boss
cess. Correct hose and wire routing are important for
proper engine operation. An incorrectly routed hose or
wire may interfere with linkage movement, resulting in a
dangerous lack of throttle control. Hoses or wires may
chafe and short or leak if allowed to contact sharp or mov-
ing parts. Other components (such as fuel pumps) can be
mounted in two or more positions. Note the up and for-
ward direction before removing any component. If possi-
ble, remove a section of components that share common
wires or hoses. This reduces the time to disassen~bleand
assemble the power head and reduces the chance of im-
proper connections during assembly.
Use muffin tins or egg cartons to organize the fasteners
as they are removed. Mark their location on the power
head.
Never reuse corroded or damaged fasteners. Replace
self-locking type fasteners with new ones. Connecting rod
bolts or nuts must be replaced once removed.
Crankshaft pulley
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238 CHAPTER EIGHT
Locknut
@ DF6O AND DF'70 MODEL
Screw
Valve
clearance
Camshaft pulley
shaft pulley mark (Figure 21) aligns with the raised boss
on the cylinder head.
3. Make a reference mark on the top of the timing belt in
the direction of rotation. Pull up on the timing belt to re-
move it from the crankshaft pulley. Slip the belt from the
crankshaft pulley.
4. Use compressed air to remove belt material and other
contaminants from the crankshaft and camshaft pulleys.
Inspect the timing belt for worn or damaged surfaces as
described in Chapter Four.
5. Make sure the engine is still at TDC. If not, rotate the
camshaft pulley to align the marks as follows:
a. Remove the rocker arm cover as described in Chap-
ter Four.
b. Loosen the lock nuts and fully loosen the valve ad-
crankshaft
justment screws (Figure 22). pulley
c. Adjust the valves as described in Chapter Five after
the belt is reinstalled.
6. Align the timing belt teeth with the teeth of the crank-
shaft pulley and install the belt around the pulley. If the
original belt is being used, make sure the belt is installed camshaft pulley aligns with the raised boss on the cylinder
so it rotates in the same direction head.
7. Align the timing belt teeth with the camshaft pulley
teeth. Do not rotate either pulley while pushing the timing 3. Loosen (do not remove) the two bolts (Figure 23) se-
belt onto the camshaft pulley. curing the tensioner to the cylinder block. Note the orien-
8. Install the flywheel as described in this chapter. Adjust tation of the arrow mark on the side of the timing belt. Pull
the valve clearance as described in Chapter Five. up on the timing belt to remove it from the camshaft pul-
ley. Slip the belt from the crankshaft pulley.
4. Use compressed air to remove belt material and other
DF60 and DF70 models
contaminants from the crankshaft and camshaft pulleys.
Inspect the timing belt for worn or damaged surfaces as
1. Remove the flywheel as described in this chapter.
described in Chapter Four.
2. Rotate the crankshaft the pulley (Figure 23) clockwise
until the mark on pulley aligns with the raised boss on the 5. Make sure the engine is still at TDC. If not, rotate the
cylinder block and the No. 1 cylinder TDC mark on the camshaft pulley to align the marks as follows:
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POWER HEAD 239
Aligning pin
Timing Chain Removal and Installation
(DF25, DF30, DF40 and DF50 Models)
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240 CHAPTER EIGHT
1. Timing chain
2. Tension adjuster
3. Chain tensioner
4. Crankshaft sprocket
5. Chain guide bracket
6. Chain guide bracket
7. Camshaft
8. Camshaft sprocket
9. Pivot bolt
Page: 248 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
OWER HEAD 24 1
in the cylinder block. Install the bolts into the brackets and 19. Rotate the crankshaft two revolutions and verify that
securely tighten them. the camshaft and crankshaft timing marks align as de-
scribed in Step 4. Correct improper timing as needed.
15. Position the chain tensioner in contact with the timing 20. Apply water resistant grease to the seal lip. Place the
chain as indicated in Figure 26. Install the spacer and new seal into the housing with the lip side facing the
pivot bolt (9, Figure 26). Securely tighten the bolt. crankshaft side of the housing. Press the seal fully into the
16. Move the latch (Figure 27) away from the notched bore with a seal driver or socket that is slightly smaller
side of the plunger. Push the plunger fully into the tension than the inside diameter of the housing bore.
adjuster body. Insert a straightened paper clip into the hole 21. Slide the seal lip over the crankshaft and seat the
in the latch and body to retain the plunger. lower seal housing to the cylinder block. Install and se-
curely tighten the housing mounting bolts (Figure 24).
17. Place the tension adjuster (2, Figure 26) onto the cyl- 22. Adjust the valves as described in Chapter Four.
inder block. Ensure the plunger contacts the chain
tensioner. Apply Suzuki thread lock (part No.
99000-32050) to the threads and install the tension ad- DF40 and DF50 models
juster bolts. Tighten the bolts to the specification listed in
1. Remove the power head as described in this chapter.
Table 1.
2. Remove the oil pump housing as described in this
18. Remove the paper clip from the tension adjuster. Coat chapter.
the timing chain and all related components with engine 3. Rotate the crankshaft until the mark on the crankshaft
oil. (9, Figure 28) aligns with the raised boss (10) on the cyl-
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CHAPTER EIGHT
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POWER HEAD 243
Oil Pump
1. Remove the four Allen bolts and carefully pull the oil
pump from the bottom of the cylinder head (Figure 31).
2. Wipe all contaminants from the oil pump to cylinder
head mating surfaces. Rotate the exposed shaft of the oil
pump and check for binding, roughness or looseness of
the shaft. Replace the oil pump if these conditions are
noted.
3. Lubricate the exposed shaft ends of the oil pump and
camshaft with engine oil. Rotate the oil pump shaft to
align the pin on the shaft with the slot on the camshaft
(Figure 31).
4. Align the oil pump shaft to the camshaft while install-
Oil cover ing the pump to the cylinder head. Rotate the pump
slightly as needed to align the shafts. The pump mates to
the cylinder head as the shafts align.
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5. Install the four Allen bolts and tighten them to the
specification in Table 1.
1. Remove the two bolts and lift the lower seal housing rotor
from the bottom of the cylinder block (Figure 24). With-
out damaging the seal bore, carefully pry the oil seal from
the housing.
2. Remove the seven bolts and carefully pry the oil pump
cover (Figure 32) from the bottom of the power head.
3. Remove the six screws and carefully lift the oil pump
cover (Figure 32) from the oil pump housing. Lift the in-
ner and outer rotor (Figure 33) from the oil pump hous-
ing.
4. Use a suitable solvent to clean all removed compo-
nents. Inspect the rotors and the oil pump housing for
worn, discolored or damaged surfaces. Replace all sus-
pect components.
5. Place the inner and outer rotor into the oil pump hous-
ing as indicated in Figure 33. Measure the clearance be-
tween the outer rotor and the oil pump housing (Figure
34). Replace the outer rotor and the oil pump housing if
the clearance exceeds 0.3 1 m m (0.012 in.).
6. Measure the oil pump side clearance as follows:
a. Place a straightedge on the oil pump housing (Fig-
ure 35). Ensure the straightedge spans the housing
and both rotors.
b. Hold down on the straightedge and with a feeler
gauge measure the clearance between the straight-
edge and the outer rotor.
c. Replace the outer rotor and the oil pump housing if
the clearance exceeds 0.15 mm (0.005 in.).
7. Apply engine oil to the inner and outer rotors. Install
the oil pump cover to the housing. Install and securely
tighten the six screws. Reach into the opening and rotate
the inner rotor. The oil pump must turn smoothly. Check
the installation if binding or roughness is noted.
8, Apply a bead of Suzuki bond (part No. 99000-3 1140)
to the housing and power head mating surfaces (Figure
32).
9. Align the pins while installing the oil pump housing to 11. Slide the seal lip over the crankshaft and seat the
the power head. Rotate the crankshaft to align it with the lower seal housing to the cylinder block. Install and sc-
drive surfaces for the oil pump. The housing seats to the curely tighten the housing mounting bolts (Figure 24).
power head as the surfaces align. Install and tighten the
seven bolts that retain the housing to the power head. CYLINDER HEAD
10. Apply water resistant grease to the seal lip. Place the
new seal into the housing with the lip side facing the This section provides removal, disassembly and assem-
crankshaft side of the housing. Press the seal fully into the bly instructions for the cylinder head. Component mea-
bore with a seal driver or socket that is slightly smaller surement requires precision measuring devices (Figure
than the inside diameter of the housing bore. 36). Have a reputable machine shop perform, the required
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POWER HEAD 245
Page: 253 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
sequence to two-thirds the torque. Tighten the bolts a third
time to the torque specification.
8. Align the marks and install the timing chain as de-
scribed in this chapter. Install the intake manifold and car-
buretors as described in Chapter Six. Adjust the valves
after power head installation as described in Chapter Five.
Page: 254 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
12. Align the marks and install the timing chain as de-
scribed in this chapter. Install the intake manifold as dc-
scribed in Chapter Six. Adjust the valves after power head
installation as described in Chapter Five.
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248 CHAPTER EIGHT
Port
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POWER HEAD 249
Keepers
stem with engine oil and slide it into the valve guide. Seat
the valve against the seat.
11. Place the spring base, valve spring and spring cap
(Figure 45) onto the cylinder head. Install the valve
spring compressor over the valve and the spring cap as in-
dicated in Figure 44.
12. Compress the spring enough to fully expose the
keeper groove on the valve stem (Figure 47). Place the
keepers onto the valve stem as shown in Figure 47. Hold
the keepers in position and slowly loosen the compressor.
Inspect the keepers for proper position. Remove the valve
if the keepers are not seated within the spring caps. Install
the remaining valves, springs, caps and keepers.
13. Apply engine oil to the surfaces and carefully slide
the camshaft into the cylinder head.
14. Apply engine oil to the rocker arm shaft. Place the
four rocker arms, two plain washers, three wave washers
and the spring in position while sliding the rocker arm
shaft into the cylinder head. The threaded side of the
rocker arm shaft must face the bottom side of the cylinder
head.
15. Install the oil pump as described in this chapter. Place
the key (Figure 43) into the groove on the camshaft.
pressor enough to remove the keepers (Figure 45) from Align the groove in the camshaft pulley with the key
the valve stem. while sliding the pulley onto the camshaft.
16. Install the washer and bolt (Figure 43) into the cam-
8. Slowly loosen the valve spring compressor. Pull the shaft and pulley. Install an adjustable wrench to the hex
valve from the cylinder head. Lift the spring cap, valve shaped boss of the camshaft pulley to prevent rotation.
spring and spring base from the cylinder head. Tighten the camshaft pulley bolt to the specification listed
9. Mark each component as removed. Remove the re- in Table 1.
maining valves. Carefully pry the seal (Figure 45) from
the valve guide. Inspect and measure the cylinder head
DF25 andDFSO models
components as described in this chapter.
10. Lubricate the seal with engine oil and carefully press 1. Remove the four bolts and the camshaft cover from the
it onto the valve guide (Figure 46). Lubricate the valve top side of the cylinder head. Remove the gasket.
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250 CHAPTER EIGHT
2. Remove the eight bolts and lift the rocker arm shafts
and retainers from the cylinder head. Mark the rocker
arms and springs to identify the mounting locations as
they are removed from the shafts.
3. Locate the two Phillips screws within the camshaft
cover opening. Remove the screws and carefully pull the
camshaft and thrust plate from the cylinder head. Intake rocker arm shaft
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DF60 and DF70 models
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252 CHAPTER EIGHT
Inspection
Cylinder head
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POWER HEAD 253
Cam height
Cam height 1
Cam
Camshaft
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254 CHAPTER EIGH
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POWER HEAD 255
Valves components
Inspect the valve face (Figure 63) and valve seats (Fig-
ure 64) for pitting, cracked, corroded or damaged sur-
faces. Inspect the valve stem (Figure 63) for wo1-n or
damaged surfaces. Measurement and repairs to valves,
valve seats and guides requires specialized equipment
(Figure 65) and experience in its use. Have a machine
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256 CHAPTER EIGHT
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POWER HEAD 257
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258 CHAPTER EIGHT
CYLINDER BLOCK
COMPONENT REMOVAL
WARNING
Wear safety glasses when removing or in-
stalling theflywheel or other components of
the engine. Never use a hammer or other
tools without wearing safety glasses.
Page: 266 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
POWER HEAD 259
Water Pressure Relief Valve 1. Locate the cover on the rear port side of the power
(DF60 and DF70) head. Loosen the eight bolts it the reverse of the tightening
sequence cast into the cover.
The water pressure relief valve is located beneath a 2. Carefully pry the cover from the cylinder block. Re-
cover (Figure 76) on the upper starboard side of the cylin- move all gasket material from the cover and cylinder
der block and just forward of the exhaust manifold. block.
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260 CHAPTER EIGHT
1. Stud
-14 2. ~ u t
3. Bolt
4. Bolt
5. Anode cover
6. Gasket
7. Anode
8. Bolt
9. Plug
10. Gasket
11. Bolt
12. Cover
3. Thoroughly clean all debris from the cooling passages. 4. Remove the two bolts (4, Figure 79) and pull the an-
4. Place a new gasket on the cover. Seat the cover to the ode cover (5) and gasket from the cover ( 1 2).
cylinder head. Install the eight bolts and tighten them to 5. Inspect the anode (7, Figure 79) for deep pitting or
the specification in Table 1. corrosion. Remove the screw (8, Figure 79) and replace
the anode as needed.
6. Thoroughly clean the cover-to-cylinder block mating
DF60 and DF70 models surfaces. Use a thread chaser to clean corrosion from the
bolts.
7. Install the nine plugs (13, Figure 79) into the corre-
1 Disconnect the water stream hose from the fitting on
sponding openings in the cover. Place a new gasket ( 14,
the bottom of the cover (12, Figure 79). Gradually loosen
Figure 79) onto the cover. Slide the cover over the studs
the eight bolts and four nuts in the reverse of the tighten-
and seat it against the cylinder block. Install the bolts and
ing sequence.
nuts and tighten them in sequence to the specification in
2. Carefully pry the cover from the cylinder block. Re- Table 1.
move all the gasket material (14, Figure 79) from the 8. Install the gasket and plug (9, Figure 79). Place a new
cover and cylinder block. gasket on the anode cover (5, Figure 79) and install it into
3. Remove the plug and gasket (9 and 10, Figure 79) the cover (12). Securely tighten the bolts.
from the cover. Pull the nine plugs (13, Figure 79) from 9. Connect the water stream hose to the fitting on the bol-
the openings in the cover. tom of the cover. Secure the hose with the clamp.
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OWER HEAD 26
Crankshaft adapter
AND DF15 MODEL
Nut
Lockwasher
Lower pulley
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262 CHAPTER EIGHT
NOTE
CYLINDER BLOCK DISASSEMBLY Keep components organized @ cylinder as
they are removed. Use an ink marker that
Remove the flywheel and cylinder head as described in can withstand solvent cleaning or a scratch
this chapter. Remove all fuel, electrical and ignition sys- awl.
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JENCE
Crankcase Cover
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264 CHAPTER EIGHT
0 PRWNG CRANKCASE
COVER FROM BLOCK
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POWER HEAD 265
Crankshaft
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266 CHAPTER EIGHT
CA UTION
Avoid using excessive force when removing
the crankslmft from the cylinder block. The
use of excessiveforce may dislodge or dam-
age the main bearings or cause damage to
the cylinder block or other components.
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OWER HEAD 267
CA UTION
Never use a wire brz~d1to remove gasket
material, carbon or other deposits from the
power head components. Delicate surfaces
are damaged quickly by a wire brush Also
metallic particles may become embedded in
the suyfaces.
Pistons
CA UTION
Never use a wire brush to remove carbon
from the piston. Small steel particles may
become embedded into the piston surface.
These small particles glow when hot and
promote pre-ignition or detonation damage
to the piston.
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268 CHAPTER EIGHT
NOTE
Some minor surface corrosion, glaze-like
deposits or minor scratches may be cleaned
up with crocus cloth or 320-grit
carb~wt~ndz/tn. Polish the surfaces only
enough to remove the deposits. Excessive
use can remove a considerable amount of
materialfrom the surfaces.
' A \
Feeler gauge
CYLINDER BLOCK
INSPECTION AND MEASUREMENT
Cylinder Block
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4. Thoroughly clean the cylinder head with hot soapy wa-
ter and dry with compressed air.
5. Have a machine shop perform this operation if a
surface plate is not available.
Cylinder Bores
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270 CHAPTER EIGHT
Crankshaft
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POWER HEAD 271
Piston
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272 CHAPTER EIGHT
Piston Rings
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POWER HEAD 273
Cylinder
block
Connecting Rods
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274 CHAPTER EIGHT
2. Place the rod cap onto the rod and align the reference
marks (Figure 122). Do not install the bearings. Install
and securely tighten the rod bolts or nuts. Measure the
crankpin end bore diameter.
3. Measure the width of the connecting rod at the
crankpin end.
4. Compare the measurements with the specifications in
Table 11. Replace the rod if any of the measurements ex-
ceeds the specification.
Thrust Bearings
place the thmst bearing if any defects occur. Measure the Upper bearing code
thickness of the thrust bearing. Replace any thrust bearing
with a measurement less than the minimum specification
in Table 10.
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OWER HEAD 275
Bearing Selection
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276 CHAPTER EIGHT
Crankshaft Installation
Coat the piston pin and piston pin bore with engine oil
prior to assembly. Select an appropriately sized section of
Page: 284 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
(133) ND GAP POSITION
DF25-DF70 MODELS
Up or 0 marking
Second ring gap
-k,
4. Refer to the instructions supplied with the new rings to
properly locate the ring to the piston. Marks on the rings
face up. Measure the ring thickness if necessary to iden-
Lower oil tify the top and second rings. Ring thickness specifica-
tions are in Table 9.
CA UTION
Use care while spreading the rings for in-
stallation onto the piston. Spread the gap
Second ring gap ends only enough to allow the rings to slide
over the piston. The rings usually break or
crack i f spread too much during installa-
tion.
tubing to use as an installation tool. The tubing must have 5. Use a ring expanding tool to expand the rings enough
a diameter slightly smaller than the diameter of the piston to clear the piston and carefully slide them into their
pin. Refer to Table 8 for piston pin diameter specifica- groove. Install and oil ring rail (thinner ring) to the top and
tions. bottom side of the spacer (thicker ring).
1. Position the connecting rod within the piston pin bore 6. Position the ring gaps relative to the up side of the pis-
area at the bottom of the piston. Ensure the marks on the ton as follows:
connecting rod face the same direction as the up mark on a. On DF9.9 and DF15 models position the ring gaps
the piston. and indicated in Figure 132.
2. Use the installation tool to push the piston pin into the b. On all other models position the ring gaps as indi-
pin bore of the piston and connecting rod. cated in Figure 133.
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278 CHAPTER EIGHT
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POWER HEAD 279
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a. On DF9.9 and DF15 models use Suzuki bond and ignition system components as described in the ap-
1207B (part No. 99104-3 1 140). propriate chapter. Install the cylinder head and flywheel
b. On all other models use Suzuki bond 1104 (part No. as described in this chapter. On DF9.9 and DPI 5 models,
99000-3 1030). install the oil pressure relief valve and hose to the power
4. Make sure that the alignment pins fit into the recess head
while placing the crankcase cover onto the cylinder block.
Align the seals and thrust rings with their respective BREAK-IN PROCEDURE
grooves in the crankcase cover. Press down lightly on the
crankcase cover to seat the crankcase cover on the cylin- During the first few hours of running, many of the com-
der block. ponents of the engine need to avoid continuous full load.
5. Install the crankcase cover attaching bolts and tighten To ensure a reliable and durable repair, perform the
them finger-tight. Do not use any wrench or socket at this break-in any time internal power head components are re-
time. Ensure the cylinder block and crankcase cover are in placed.
contact prior to tightening the bolts. Increased oil consumption is a normal occurrence dur-
6. Slowly rotate the crankshaft and note any tight spots, ing the break-in period. Oil consumption decreases as the
binding or roughness. Remove the cover and inspect the piston rings seat to the cylinder walls.
bearing, seal and thrust ring installation if binding or Check for and correct fuel, water and oil leakage imme-
roughness occurs. The surface must be cleaned and a new diately after starting the engine. Check the tightness of all
coating of Suzuki bond applied if the cover is removed. external fasteners after completing the break-in inslruc-
Ensure that the cylinder block and crankcase cover mating tions.
surfaces are in direct contact. The break-in period spans the first ten hours of opera-
7. Tighten the crankcase bolts in sequence to the specifi- tion. To enhance break-in, vary the engine speed during
cation in Table 1. Refer to Crankcase Removal in this the initial ten hours. Always allow the engine to reach op-
chapter to determine the tightening sequence for the cover erating temperature before advancing the throttle. Never
bolts. exceed the maximum recommended engine speed during
the break-in period.
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POWER HEAD 281
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282 CHAPTER EIGHT
Page: 290 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
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POWER HEAD 285
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286 CHAPTER EIGHT
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POWER HEAD 287
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288 CHAPTER EIGHT
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Chapter Nine
This chapter provides complete gearcase removal, dis- used to accomplish the precise alignment required. The
assembly, inspection, assembly and installation instruc- shims are typically located next to the bearing that sup-
tions. ports the gears and shafts. Shim selection operations in-
A number of special tools are required to remove, posi- volve using special tools, gauges and meters to measure
tion and install many of the components within the and determine the required shim thickness. Never com-
gearcase. The use of makeshift tools may result in damage promise this important step. The durability of the gearcase
to the housing or internal components of the gearcase. is substantially reduced if the gears are positioned im-
Suzuki part numbers for these tools are included in the re- properly. Shim selection procedures must be performed if
pair instructions. replacing gears, bearings, shafts or the housing. Refer to
Shim Selection in this chapter for instructions.
Tables 1-3 at the end of this chapter provide torque and
gearcase specifications. Use the standard torque specifi- Failure of the gearcase is usually the result of impact
cation listed in the Quick Reference Data for fasteners not with underwater objects or lack of gearcase maintenance.
listed. Proper maintenance is essential for proper gearcase oper-
The gears (Figure 1) must be precisely aligned to pro- ation and durability. Gearcase maintenance instructions
vide durability and quiet operation. Shims (Figure 2) are are in Chapter Four.
Page: 297 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
290 CHAPTER NINE
Drive shaft
(clockwise)
(clockwise)
Have a marine repair shop perform the repairs if the re- REVERSE Drive shaft
quired tools or experience is not available. An improper (clockwise)
repair can result in extensive damage to the gearcase.
Gearcase Operation
Page: 298 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
the dogs on the rear-mounted gear. This provides the
counterclockwise propeller shaft rotation necessary for
OPELLER reverse thrust.
ON AND REMOVAL
Propeller
CAUTION
1. Thrust washer The outboard may be equipped with a
2. Propeller Suziikipropeller or onejrom an aftermarket
3. Splined washer
manufbcturer. Because of this, the attaching
4. Plain washer
5. Castellated nut
hardware may differ from the illustrations.
6. Cotter pin Contact a propeller repair shop or marine
deale1d;ip for parts and information on
other brands ofpropellers.
CAUTION
Use light force, i f necessary, to remove the
propeller jrom the propeller shaft. The use
of excessive force will result in damage to
the propeller, propeller shaft and, possibly,
infernal components o f the gem-case. Have
ci marine repair shop or propeller repair
shop remove the propeller if the propeller
can not be removed by normal means.
Removal
Page: 299 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
the plain and splined washer (4 and 5, Figure 4) from the
propeller shaft.
4. Pull the propeller from the propeller shaft (Figure 6).
If necessary, use a block of wood as a cushion and care-
fully drive the propeller from the shaft.
5. Note the orientation and remove the thrust washer
(Figure 7) from the propeller shaft. If necessary, lightly
tap the washer to free it from the propeller shaft.
6. Clean the propeller shaft. Inspect the propeller shaft
for twisted splines or excessively worn areas. Rotate the
propeller shaft while looking for any shaft deflection. Re-
move and replace the propeller shaft if excessively worn
areas, twisted splines or a bent shaft is noted. Refer to
gearcase disassembly in this chapter for disassembly in-
structions.
Installation
Page: 300 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
GEARCASE 293
CA UTION
Work carefully when installing the upper
end of the drive shaft into the crankshaft
The lower seal on the crankshaft may be dis-
lodged or damaged by the drive shajt Never
force the drive shaft into the crankshaft Ro-
tate the drive shaft clocl~vzseas viewed from
the top to align the drive shaft and crank-
shaft splines
NOTE
Use caution if using a p ~ bar
y to separate
the gearcase from the drive shaft housing.
Ensure all fasteners are removed before at-
tempting to piy the gearcase from the drive
shaft housing. Use a blunt tip pry bar and
locate a pry point near the front and rear
mating surfaces. Apply moderate heat to the
gearcase and drive shajt housing mating
surfaces ifcorrosion prevents easy removal.
Removal
(DF9.9-DF50 models)
CA UTION
Never rotate the propeller shaft to align the
drive shaft to the crankshaft. The water
pump impeller can suffer damage that leads
to engine overheating.
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294 CHAPTER NINE
Installation
(DF9.9-DF50 models)
Page: 302 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
housing mating surfaces parallel and align the mounting
bolt holes in the gearcase with their respective holes in the
drive shaft housing. Also note the following:
a. Ensure the water tube in the drive shaft housing
aligns with the water tube sealing grommet on the
water pump.
b. Align the lower shift shaft and the upper shift shaft
while installing the gearcase. Do not install the con-
nector pin at this time.
c. Slide the speedometer hose onto the gearcase fitting
and secure with a plastic locking type clamp.
6. The gearcase mates to the drive shaft housing if the
drive shaft and crankshaft splines align. If the housings do
not mate, lower the gearcase slightly. Rotate the drive
shaft clockwise, as viewed from the top, until the drive
shaft splines engage the crankshaft splines. When prop-
erly aligned, the gearcase slips into position.
7. Hold the gearcase in position and thread the mounting
bolts into the gearcase and drive shaft housing. Tighten
the bolts to the specification in Table 1.
8. Install the connector pin into its openings in the upper
and lower shift shaft. Install a new cotter pin into the hole
in the connector pin. Bend over the ends of the cotter pin.
9. Align the marks and install the trim tab to the gearcase.
Install and securely tighten the trim tab bolt.
10. Refer to Chapter Five to adjust the shift linkage. Re-
fer to Chapter Four on filling the gearcase with the re-
quired lubricant. Check for proper cooling system
operation immediately after starting the engine.
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296 CHAPTER NINE
1. Bushing
2. Grommet
3. Drive key
4. Grommet
5. Screw
6. Water tube
7. Grommet
8. Gasket
9. Seal
10. Water pump base
11. Drain tube
12. Gasket
13. Wear plate
14. Alignment pin
15. Impeller
16. Water pump body
17. Bolt
water pump base (10, Figure 15). Slip the body over the
drive shaft and remove it from the gearcase (Figure 17).
4A. If the impeller remains in the water pump body (Fig-
ure 18), pry it out with a blunt tip pry bar.
-?B.If the impeller remains on the drive shaft, gently pry it
up with a blunt tip pry bar. Lift the impeller up and over
the drive shaft (Figure 19).
5 . Remove the drive key (Figure 20) from the drive shaft.
Use an aerosol parts cleaner to thoroughly clean the ex-
posed section of the drive shaft. Remove the gasket and
wear plate (1 2 and 13, Figure 15) from the water pump
base.
6. Remove the water pump base if it must be removed for
further gearcase disassembly or seal replacement as fol-
lows:
a. Use two pry bars to carefully pry the water pump b. Remove the screw (5, Figure 15) and lift the watcr
base ( 10, Figure 15) from the gearcase. Remove the tube and grommets from the gearcase.
gasket (8, Figure 15). Remove the alignment pin c. Note the direction of the seal lip (9, Figure 15) rela-
(14, Figure 15) from the base. tive to the water pump base. Use a blunt tip pry bar
Page: 304 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
to carefully pry the seal from the base. Do not allow
the pry bar tip to contact the seal bore.
d. Clean the water pump base, tube and grommets in
solvent.
7. Inspect the water pump components as described in
9
this section.
8. Assemble and install the water pump base as follows:
a. Position the new seal (9, Figure 15) into the water
pump base (10) with the seal lip facing out. Use an
appropriately sized socket or section of tubing to
carefully push the seal fully into the bore.
b. Lubricate the grommet (4 and 7, Figure 15) SLN-
faces with Suzuki water resistant grease (part No.
99000-25 160) and carefully position them onto the
water tube (6).
c. Attach the water tube and grommets to the water
pump base. Install and securely tighten the screw (5,
Figure 15).
d. Position a new gasket (8, Figure 15) onto the water
pump base. Apply a generous bead of grease to the
seal (9, Figure 15).
e. Slide the water pump base over the drive shaft.
Align the water tube and grommet (6 and 7, Figure
15) while seating the base against the gearcase.
Push the alignment pin (14, Figure 15) into the
opening in the base.
9. Align the gasket and wear plate (12 and 13, Figure 15)
with the alignment pin (14) while seating them on the wa-
ter pump base.
10. Apply grease to the drive key surfacc and install it
into the drive shaft slot (Figure 20). Lubricate the bore of
the impeller with grease and slide it onto the drive shaft.
Align the impeller with the drive key and seat it against
the wear plate.
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298 CHAPTER NINE
1. Grommet
2. Water pump body
3. Bolt and washer
4. Impeller
5. Drive key
6. Nut
7. Washer
8. Wear plate
9. Gasket
10. Drive shaft bearing
and seal housing
11. Seals
12. Bearing race
13. O-ring
14. Alignment pin
15. Gearcase mounting
bolt
11. Apply a coat of grease to the inner surfaces of the wa- 1. Refer to Gearcase in this chapter and remove the
ter pump body (16, Figure 15) and slide it onto the drive gearcase from the engine.
shaft until it just contacts the water pump impeller (15). 2. Carefully pry the sealing grommet (1, Figure 21) from
12. Align the water pump body with the base. Lightly the water pump body (2).
push down on the water pump body while rotating the 3. Remove the four nuts and washers from the water
drive shaft clockwise as viewed from the top. Continue pump body (Figure 22). Use two pry bars to carefi~llypry
until the impeller fully enters the water pump body. the water pump body free from the drive shaft bearing and
13. Install the four water pump bolts (17, Figure 15). seal housing. (10, Figure 21). Slip the body over the drive
Tighten the bolts evenly to the specification in Table 1. shaft and remove it from the gearcase (Figure 17).
14. Apply grease to the surfaces and install the bushing 4A. If the impeller remains in the water pump body (Fig-
and grommet (1 and 2, Figure 15) onto the water pump ure 18), pry it out with a blunt tip pry bar.
body. 4B. Ifthe impeller remains on the drive shaft, gently pry it
15. Install the gearcase as described in this chapter. up with a blunt tip pry bar. Lift the impeller up and over
the drive shaft (Figure 19).
DF25 and DF30 models 5. Remove the drive key (Figure 20) from the drive shaft.
Lift the wear plate and gasket (8 and 9, Figure 21) from
Refer to Figure 21 the seal and bearing housing (10). Thoroughly clean the
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GEARCASE 299
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300 CHAPTER NINE
1. Seal
2. Grommet
3. Water pump body
4. Impeller
5. Wear plate
6. Bearing and seal
seal housing
7. Stud
8. Drive shaft seals
9. Bearing
10. Alignment pin
11. Gearcase housing
12. Gearcase mounting
bolt
13. Water inlet
14. Screw
15. Alignment pin
16. O-ring
17. Stud
18. Gasket
19. Drive key
20. Washer
21. Nut
10. Apply grease to the drive key surfaces and install it DF40 and DFSO models
into the drive shaft slot (Figure 20). Lubricate the bore of
the impeller with grease and slide it onto the drive shaft. Refer to Figure 25.
Align the impeller with the drive key and seat it against 1. Refer to Gearcase in this chapter and remove the
the wear plate.
gearcase from the engine.
1 1. Apply a coat of grease to the inner surfaces of the wa-
2. Carefully pry the sealing grommet (2, Figure 25) and
ter pump body (2, Figure 21) and slide it onto the drive
seal (1) from the water pump body (3).
shaft until it just contacts the water pump impeller (4).
12. Align the water pump body with the base. Lightly 3. Remove the four nuts and washers from the water
push down on the water pump body while rotating the pump body (Figure 22). Use two pry bars to carefully pry
drive shaft clockwise as viewed from the top. Continue the water pump body free from the drive shaft bearing and
until the impeller fully enters the water pump body. seal housing. (6, Figure 25). Slip the body over the drive
13. Install the four nuts and washers (6 and 7, Figure 21). shaft and remove it from the gearcase (Figure 17).
Tighten the nuts evenly to the specification listed in Table 4A. If the impeller remains in the water pump body (Fig-
1. ure la), pry it out with a blunt tip pry bar.
14. Apply grease to the surfaces and install the grommet 4B. If the impeller remains on the drive shaft, gently pry it
(1. Figure 21) onto the water pump body. up with a blunt tip pry bar. Lift the impeller up and over
15. Install the gearcase as described in this chapter. the drive shaft (Figure 19).
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GEARCASE 30 1
PUMP COMPONENTS
AND DF70 MODELS
5. Remove the drive key (Figure 20) from the drive shaft. seat the seal in the bore. Apply water resistant grease to
Lift the wear plate and gasket (5 and 18, Figure 25) from the lip surfaces of the seal.
the seal and bearing housing (6). Thoroughly clean the ex- 11. Apply a coat of grease to the inner surfaces of the wa-
posed section of the drive shaft with an aerosol parts ter pump body (3, Figure 25) and slide it onto the drive
cleaner. shaft until it just contacts the water pump impeller (4).
6. Remove the bearing and seal housing if it must be re- 12. Align the water pump body with the base. Lightly
moved for further gearcase disassembly or seal replace- push down on the water pump body while rotating the
merit. All shafts, gears and bearings must be removed to drive shaft clockwise as viewed from the top. Continue
remove the bearing and seal housing. Refer to Gearcase until the impeller fully enters the water pump body.
Repair in this chapter for procedures. 13. Install the four nuts and washers (20 and 2 1, Figure
7. Inspect the water pump components as described in 25). Tighten the nuts evenly to the specification in Table
this section. 1.
8. Install the gasket and wear plate (1 8 and 5, Figure 25) 14. Apply grease to the surfaces and install the grommet
onto the housing (6). (2, Figure 25) onto the water pump body.
9. Apply grease to the drive key surfaces and install it 15. Install the gearcase as described in this chapter.
into the drive shaft slot (Figure 20). Lubricate the bore of
the impeller with grease and slide it onto the drive shaft.
Align the impeller with the drive key and seat it against DF60 and DF70 models
the wear plate.
10. Install the new seal (1, Figure 25) into the drive shaft Refer to Figure 26.
bore of the water pump body with the seal lip facing out. 1. Refer to Gearcase in this chapter and remove the
Use an appropriately sized socket or section of tubing to gearcase from the engine.
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302 CHAPTER NINE
1 . Inspect the impeller (Figure 27) for brittle, missing or 5. Inspect the wear plate (Figure 29) for a warped sus-
burned vanes. Squeeze the vanes toward the hub and re- face, wear grooves, melted plastic or other damaged ar-
lease them. Thc vanes should spring back to the extended eas. Replace the wear plate if a groove is worn in the plate
position. Replace the impeller if damaged, burned, brittle or any other defects are noted.
Page: 310 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
GEARCASE 303
1. Remove the nut and washer (3 and 4, Figure 30) and 4. Remove the propeller shaft, thrust washer, reverse gear
lift the shift shaft assembly from the gearcase. Make refer- and shim (30-33, Figure 31) from the bearing carrier.
Page: 311 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
304 CHAPTER NINE
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GEARCASE 305
GEARCASE COMPONENTS
DF9.9 AND DF15 MODELS
Page: 313 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
306 CHAPTER NINE
.-/-Â¥ Slidehammer
1. Remove the snap ring (10, Figure 31) from the drive
shaft bore.
2. Carefully lift the drive shaft (2, Figure 31) and bearing
(2) from the gearcase.
3. Remove the bearing (2, Figure 31) from the drive shaft I Reverse gear bearing
only if it must be replaced. Refer to Gearcase Component
Inspection in this chapter to determine the need for re-
placenlent. Remove the bearing as follows:
a. Remove the circlip (1, Figure 31) from the drive
shaft.
- /mb
Slide hammer
Page: 314 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
GEARCASE 307
Drive shaft bearing e. Use a block ofwood to protect the splined end of the
drive shaft and carefully drive the shaft from the
Bearing separator bearing.
f. Remove the circlip (4, Figure 31) from the drive
shaft.
Page: 315 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
Gear and bearing removal
Page: 316 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
proper seating. The snap ring retains the shaft into the
gearcase.
1. Slip the shift cam (1 5 , Figure 30) onto the lower end of
the shift shaft (8). Align the reference mark made prior to
removal. Insert the pin (14, Figure 30) into the hole in the
shift cam. Align the pin with the hole in the shift shaft.
Using a punch, carefully drive the pin into the cam and
shaft until centered.
2. Slide the washer over the top of the shift shaft. Lubri-
cate the surfaces with gearcase lubricant and install the
new O-rings (1 1 and 12, Figure 30) onto the bushing (1 0).
Page: 317 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
310 AFTER NINE
Page: 318 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
GEARCASE 311
1. Shift shaft
2. Pin
3. Boot
4. Retainer
5. Screw
6. Bushing
7. O-ring
8. O-ring
9. Magnet
10. Spacer
11. Shift cam
12. Spacer
13. Spring
14. Detent ball
15. Alignment pin
16. Gearcase mounting
bolt and washer
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312 CHAPTER NINE
Page: 320 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
1, Remove the water pump components and the drive
shaft bearing and seal housing as described in this chapter
under Water Pump Service.
2. Remove the screw (5, Figure 47) from the port side of
the gearcase. The screw opening aligns with the shift shaft
bore.
3. Lift the shift shaft retainer (4, Figure 47) from the
gearcase. Lift the shift shaft from the gearcase.
4. Remove the shift cam only if it must be replaced. Refer
to Gearcase Component Iiwpection in this chapter to de-
tennine the need for replacement. Remove the cam as fol-
lows:
a. Make reference marks on the shift shaft and shift
cam prior to removing the cam.
1. Drive shaft 26. Thrust washer
2. Spacer 27. Reverse gear b. Use a pin punch to drive the pin (2, Figure 47) from
3. Spring 28. Shim the shift shaft (1) and shift cam (1 1).
4. Spacer 29. O-ring c. Careftdly pull the shift cam, spacer and magnet
5. Tab spacer 30. Reverse gear (9-1 1, Figure 47) from the shift shaft.
6. Collar bearing
7. Spring retainer 31. Bolt and washer d. Transfer the reference mark to the replacement cam.
8. Snap ring 32. Thrust washer 5. Slide the bushing and boot (6 and 3, Figure 47) from
9. Shim 33. Propeller the shift shaft. Remove the O-rings (7 and 8, Figure 47)
10. Pinion gear 34. Splined washer
35. Plain washer
from the bushing.
1 I. Lower drive shaft
bearing 36. Propeller nut 6. Check the fit of the pin to the shift shaft and cam. Re-
12. Pinion nut 37. Cotter pin place the pin if a loose fit occurs. Replace the cam andlor
13. Sealing washer 38. Propeller shaft shaft if a loose fit occurs with a new pin.
14. Levellvent plug seals
15. Levellvent plug 39. Needle bearing 7. Inspect the boot for torn, cracked or suspect surfaces.
16. Sealing washer 40. Bearing carrier Replace the boot if any defects are noted.
17. Housing 41. Propeller shaft
18. Fillldrain plug 42. Spring
19. Sealing washer 43. Spring Bearing carrier removal and disassernb@
20. Forward gear 44. Cross pin
bearing 45. Clutch 1. Remove both carrier mounting bolts and washers (Fig-
21. Water screen 46. Cross pin connector
22. Bolt and washer 47. Thrust washer ure 32).
23. Trim tab 48. Forward gear 2. Thread the adapter (Suzuki part No. 09950-59310)
24. Water screen 49. Shim onto the end of the propeller shaft (Figure 33).
25. Screw 50. Cam follower 3. Thread the slide hammer into the adapter. Use ~110~3
strokes to pull the carrier slightly away from the gearcase.
Remove the slide hammer and adapter. Grasp the end of
propeller shaft and pull the carrier from the gearcase (Fig-
ure 34). Ren~ovcthe O-ring (29, Figure 48) from the car-
rier. If necessary to ease removal of the bearing carrier,
use a torch to apply heat to the gearcase near the gearcase
to carrier mating surfaces.
CA UTIOI?
When using heat, make sure to keep the
flame away,fiom the seals or O-rings. Never
heat the Iiotising to the point that the finish
is burned. Contiizuully inove the flame
uro~iizdthe mating surface to apply even
heating. Excessive use ofheat can distort 01-
melt the gearcase.
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314 CHAPTER NINE
4. Pull the propeller shaft (41, Figure 48) from the car-
rier. Place the bearing carrier on a sturdy work surface
with the gear side up. Lift the thrust washer, reverse gear
and shim (26-28, Figure 48) from the bearing carrier.
5, Remove the reverse gear bearing (30, Figure 48) only
if it must be replaced. Refer to Gearcase Coinponent In-
spection in this chapter to determine the need for replace-
ment. Remove the bearing as follows:
a. Clamp the bearing carrier into a vice equipped with
soft jaws.
b, Engage the jaws of a slide hammer into the bearing
as indicated in Figure 35.
c. Use short hammer strokes to remove the bearing.
6. Engage the jaws of a slide hammer to the propeller
shaft seals as indicated in Figure 36. Use short hammer
strokes to remove the seals from the carrier,
7. Remove the needle bearing (39, Figure 48) only if it
must be replaced. Remove the bearing as follows: ponent Inspection in this chapter to determine the need for
a. Select an appropriately sized socket or section of replacement. Remove the bearing as follows.
tubing for use as a bearing installation tool. The tool a, Position a bearing separator onto the open jaws of a
must be large enough in diameter to contact the vice as indicated in Figure 37.
bearing cage yet not contact the bearing carrier dur- b. Open the separator enough to allow the shaft to just
ing removal. slide through.
b. Place the bearing carrier on a sturdy work surface c. Slide the drive shaft into the separator with the pin-
with the seal bore facing down. ion gear side facing down. Rest the drive shaft bear-
c. Hold the tool in firn~contact with the bearing and ing against the separator.
lightly tap on the tool (Figure 49). Continue until d. Use a block of wood to protect the splined end of the
the bearing is free from the carrier. drive shaft and carehlly drive the shaft from the
8. Clean corrosion and other contaminants from the car- bearing.
rier with a soft bristle brush.
9. Inspect the carrier for cracked, pitted or damaged sur-
faces. Replace the carrier if defects are noted. Propeller shaji disassetnbly
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Shzj2 shaft asseinbb and installation
Page: 323 Suzoki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
seated (Figure 43). Place the tapered roller bearing into 2. Place the cross pin connector (46, Figure 48) into the
the race. opening and seat it against the spring. Insert the cam fol-
5 . Place the thrust washer (26, Figure 48) onto the hub of lower into the opening with the s~nallerdianietcr side Sac-
the gear. P~lshthe gear and shim into the bore of the bear- ing out (Figure 39).
ing until firmly seated. 3. Slide the clutch over the propeller shaj3 with the F
~ s t (9, Figure 48) onto the hub of
6. Place the t l ~ r ~washer mark facing the forward gear side of the shaft (Figure 44).
the pinion gear. Ensure the splined bore of the pinion gear, 4. Align the cross pin opening in the cl~1tc11with thc slot
bearing, spacers and shims align with the drive shaft bore in the propeller shaft (Figure 45). Remove and reposition
while installing them into the housing. Enstire the pinion the cl~~tcli
as needed.
gear teeth mesh with the forward gear teeth. 5. Push in and rotate tlie cam follower (50, Figure 48) to
align the hole in the cross pin connector (Figure 45) with
the cross pin hole in the cl~ttch.Push tlie cross pin (44>
Drive slzaji assembly and installation Figure 48) through both holes and release tlic cam fol-
lower.
I. Select a section of tubing for use as a drive shaft bear- 6. Ensure the ends of the cross pin are f l ~ ~ swith
l i the
ing installation tool. The inner diameter of tlie t~ibingmust clutch s~irfaces.Carefully wind the spring onto the c1~1tch
be slightly larger than the drive shaft. Clamp the pinion (Figure 38). Ensure the spring spans both ends of [lie
gear end of the drive shaft into a vice equipped with soft cross pin. Reposition the spring as needed.
jaws. 7. Apply grease to the surfaces and install the t h r ~ s t
2. Slide the drive shaft bearing (I, Figure 48) over the washer (26, Figure 48) onto the forward gear side of the
upper end of the drive shaft with the tapered side facing propeller shaft.
away from the pinion gear end. 8. Install the propeller shaft assenibly along with thc
3. Slide tlie installation tool over the drive shaft and seat bearing carrier as described in this chapter.
it against the bearing. Carehlly tap on the upper end of the
tool until the bearing seats against the step on the shaft,
Bearing carrier asse~nblyand installation
4. Slide the spacer (2, Figure 48) over the pinion end of
the drive shaft and seat it against the bearing. I. Place the needle bearing (39, Figure 48) into the bore
5. Slide the spring (3, Figure 48) and collar (6) over the opening with the number side facing out. Use the bearing
pinion end of the drive shaft. removal tool to carefi~llydrive the bearing into tl~ccarrier.
6. Install the spacer then tab washer (4 and 5, Figure 48) Seat the bearing against the step at the bottom oSthe bore.
over the drive shaft. Align the protrusion on the tab 2. Select an appropriately sized socket or section of tub-
washer with the slot at the bottom of the collar. Place the ing for use as a seal installation tool. The tool niust be of a
spring retainer (7, Figure 48) onto the bottom end of the diameter large enough to contact near the outer circumfer-
collar. ence of the seal yet not contact the seal bore d~lringinstal-
7. Install the drive shaft bearing into the bearing and seal lation.
h o ~ ~ s i n gInstall
. the bearing and seal liousing to the 3. Place one of the seals into the bore in the propeller side
gearcase as described in this chapter under Water Pzmp of the carrier with the lip side facing out. Slowly drive the
Service. seal into the bore until tlie seal surface is just below the
8. Apply Suzuki thread lock (part N0.99000-32050) to bore opening.
the threads of the drive shaft and pinion nut (12, Figure 4. Place the remaining seal into the bore with the lip side
48). Thread tlie pinion nut onto the drive shaft. facing out. Slowly drive the seal into the bore ~mtilit con-
9. Engage the splined adapter (Suz~iki part No. tacts the inner seal.
09921 -295 10) onto the upper end of the drive shaft (Fig- 5. Carefully drive both seals into the bore until the inner
ure 50). Hold the pinion nut (12, Figure 48) with a seal f~illyseats in the bore. Apply a bead of S L I Z Lwater
I~~
breaker bar and socket. Tighten the pinion nut to the speci- resistant grease (part No. 99000-25 160) to the lips ofboth
fication in Table 1. seals.
6. Install the reverse gear bearing as follotvs:
a. Select an appropriately sized socket or section of
Propeller shaft assentbly and itzstallatiofz tubing for use as a bearing installation tool. Tlic tool
must be of a diameter to contact the outer race of the
1. Insert the spring (42, Figure 48) into the opening in the bearing yet not contact the bearing bore during in-
f o ~ ~ v a side
r d of the propeller shaft. stallation.
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GEARCASE 317
b. L~~bricate the bearing with gearcase lubricant. Posi- to the gearcase near the gearcase to cassier inating siir-
tion the bearing Into the bore opening with the nuin- faces.
ber stamped side facing OLI~. Place the seal side of
the bearmg carrier down on a sturdy work surface. CA UTION
c. Hold the installation tool firmly against the bearing FViien using lleat, mzke suw to /cwp tile
flun~eu w ~ ~ j ~lhe ~ oseals
n ? or O-rings. N e ~ ~ e r
and tap the bearing into the bore (Figure 46). The
heat the I I O U S ~ I Zto~ the point that the fii~ish
bearing must seat against the step within the bore. is bui-ned. Cotiti~~uallv wove the f l u m
7. Position the shini (28, Figure 48) onto the hub of the aromd the m a t i ~ ~surface g to uppl~,even
reverse gear (27). Lubricate the reverse gear with heating. Excess~veuse oflleat can distort or
gearcase lubricant. Slide the reverse gear hub into the bore melt the gearcase.
of thc reverse gear bearing until seated against the shim
and bearmg (28 and 30, Figure 48). 4. Pull the propeller shaft (25, Figure 51) from the car-
8. Lubricate the O-ring (29, Figure 48) with water resis- rier. Lift the thrust washer, reverse gear and sliin~(32-34,
tant grease and posit~onit onto the groove of tlie bearing Figure 51) fro111the bearing cassier.
camer. Lubricate the surfaces with grease and slide the 5. Reinove the reverse gear bearing (30, Figure 51) only
t h r ~ ~washer
st (26, Figure 48) onto the rear side of the pro- if it must be replaced. Refer to Gearcase Con1p017ent111-
peller shaft. Seat the washer against the step near tlie spection in this chapter to determine the need for replace-
clutch. ment. Remove the bearing as follows:
9. Carefully slide the propeller shaft (splined section a. Clamp the bearing cassier into a vice eq~~ipped with
first) through the opening in tlie reverse gear. Seat the pro- soft Jaws.
peller shaft against the reverse gear. Lubricate the b. Engage the jaws of a slide hammer into the bearing
gearcase opening with gearcase lubricant. as indicated in Figure 35.
10. Position the gearcase with the drive shaft facing up. c. Use short hammer strokes to reinove the bearing.
Grasp the splined section of the propeller shaft to retain 6. Engage the Jaws of a slide hammer to the propeller
the shaft into the cassier. Align the fosward side of the pro- shaft seals as indicated in Figure 36. Use short hanln~er
peller shaft with the opening in the forward gear while strokes to remove the seals from the carrier.
sliding the carries into the housing. Rotate the drive shaft 7. Reinove the needle bearings (28, Figure 51) only if
clockwise to align the reverse and pinion gear teeth while they must be replaced. Remove the bearing as follows:
seating the cassier into the gearcase. a. Select an appropriately sized socket or section of
11. Lightly tap oil the carrier until it h l l y seats against the tubing for use as a bearing installation tool. The tool
gearcase. Rotate the cassier until the bolt holes align. must be large enough in diameter to contact the
Thread the bolts and washers (31, Figure 48) into the bearing cage yet not contact the bearing carsier dur-
gearcase. T~ghtenthe bolts to the specification in Table 1. ing removal.
12. Refer to Shi111Selection in this chapter if the gear b. Place the bearing cassier on a sturdy work surface
alignment is corsect. Install the water pump components with the seal bore facing down.
and gearcase as described in this chapter. c. Hold the tool in firm contact with the inner bcasing
and lightly tap on the tool (Figure 49). Continue un-
til the outer bearing is free from the carrier. Repeat
Gearcase Service the process to remove the inner bearing.
DF40 and DF50 Models 8. Use a suitable solvent and soft bristle bnish to clean
corsosion and other contaninants fsom the carrier.
ewing carrier removal and disussetnb&
9. Inspect the cassier for cracked, pitted or damaged sur-
1. Remove both cassier mounting bolts and washers (Fig- faces. Replace the tarsier if defects are noted.
ure 32).
2. Thread the adapter (Suz~ikipart No. 09930-301 61) onto Propeller slzajt disassenzbly
the end of the propeller shaft (Figure 33).
3. Thsead the slide hammer into the adapter. Use short 1 . Use a screwdriver to unwind the spring from the c1~1tch
strokes to pull the cassier slightly away from the gearcase. (Figure 38).
Reinove the slide ha~ninerand adapter. Grasp the end of 2. Pull the cam follower from the propeller shaft (Figure
propcller shaft and pull the carsier from the gearcase (Fig- 39).
ure 34). Remove the O-ring (3 1 , Figure 51) from the car- 3. Use a pin piincli to push the cross pin from tlie c l ~ ~ t c h
rier. If necessary to ease removal, use a torch to apply heat and propeller shaft (Figure 40).
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318 CHAPTER NINE
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GEARCASE 319
GEARCASE COMPONENTS
DF40 AND DF50 MODELS
1. Shim 25. Propeller shaft 4. Remove the cross pin connector (20, Figure 51) and
2. Washer 26. Bolt
3. Thrust bearing 27. Propeller shaft spring (24) from the propeller shaft.
4. Splined section seals 5. Remove the forward thrust washer (18, Figure 51)
5. Drive shaft 28. Needle bearings from the propeller shaft or forward gear (17).
6. Pin 29. Bearing carrier 6. Refer to Gearcase Component Inspection in this chap-
7. Lower drive she 30. Reverse gear
bearing bearing
ter and inspect the propeller shaft components for exces-
8. Sealing washer 31. O-ring sive wear or defects.
9. LeveUvent plug 32. Shim
10. Levellvent plug 33. Reverse gear
11. Sealing washer 34. Thrust washer Drive shaft removal and disassembly
12. ear case housing 35. Thrust washer
13. Sealing washer 36. Propeller 1 . Engage the splined adapter (Suzuki part No.
14. Drainlfill plug 37. Propeller hub 0992 1-295 10) onto the upper end of the drive shaft (Fig-
15. Forward gear 38. Splined washer ure 50). Hold the pinion nut (47, Figure 51) with a
bearing 39. Plain washer
16. Shim 40. Cotter pin breaker bar and socket. Rotate the adapter counterclock-
17. Forward gear 41. Propeller nut wise until the pinion nut is free from the drive shaft.
18. Thrust washer 42. Preload spring 2. Thread two 8 mm bolts into the bearing and seal hous-
19. Cam follower 43. Washer ing as indicated in Figure 23. Evenly tighten the bolts to
20. Cross pin 44. Tab washer
push the housing away from the gearcase.
connector 45. Collar
21. Clutch 46. Pinion gear 3. Carefully pull the bearing and seal housing along with
22. Cross pin 47. Pinion nut the drive shaft and shift shaft from the gearcase (Figure
23. Clutch spring 48. O-ring 52). Remove the O-ring (48, Figure 51) from the bearing
24. Spring and seal housing or the gearcase.
4. Slide the drive shaft (5, Figure 51) from the bearing
and seal housing.
5. Remove the shims, washer and thrust bearing (1-3,
Figure 51) from the drive shaft (5).
6. Use a pin punch to drive the pin (6, Figure 51) from
the drive shaft (5). Remove the preload spring (42, Figure
51) from the drive shaft.
7. Lift the spring collar from the drive shaft bore (Figure
53). Remove the washer and tab washer from the drive
shaft bore (Figure 54).
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320 CHAPTER NINE
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GEARCASE 321
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322 CHAPTER NINE
6. Placc the shim (1 6, Figure 51) onto the hub of the gear pin (1 1, Figure 55) through the guide and shift shaft. The
(17). Push the gear and shim into the bore of the bearing pin must be centered in the guide.
until firmly seated. 4. Install the shift cam (13, Figure 55) onto the shift
7. Align the splined bore of the pinion gear (46, Figure shaft. Rotate the cam until the reference marks made prior
51) with the drive shaft bore while installing it into the to removal align with the mark on the guide. Drive the pin
gearcase. Ensure the pinion gear teeth mesh with the for- (12, Figure 55) through the cam and shift shaft. The pin
ward gear teeth. must be centered in the cam.
5. Drive the pin (9, Figure 55) into the hole in the shift
shaft until it protrudes the same amount on each side.
Bearing and seal housing assembly 6. Snap the magnet onto the shift shaft. Position the mag-
net directly below the bend in the shaft.
1. Select an appropriately sized socket or section of tub-
7. Carefully slide the shift shaft assembly into the bottom
ing for use as a seal installation tool. The tool must be of a
side of the bushing. Rotate the shift shaft to position the
diameter to contact near the outer circumference of the
detent ball recess in the cam facing the forward side of the
seal yet not contact the housing during installation.
bearing and seal housing.
2. Place the bearing and seal housing on a sturdy work
surface with the bottom side facing up.
3. Position the new inner seal into the bore opening with Drive shaft assembly and installation
the lip side facing down. Position the seal installation tool
firmly against the seal. Gently drive the seal into the bore 1. Place the tab washer (44, Figure 51) into the drive
until its surface is just below the bore opening. shaft bore. Align the tab with the recess in the bore. Place
4. Position the outer seal into the bore opening with the the washer (43, Figure 51) directly on top of the tab
lip side facing down. Position the seal installation tool washer.
firmly against the seal. Drive both seals into the bore until 2. Carefully slide the collar (45, Figure 51) into the drive
the inner seal contacts the bore seat. shaft bore. Rotate the collar to align the protrusion on the
5 . Select an appropriately sized socket or section of tubing collar with the recess in the housing. Seat the collar into
for use as a bearing installation tool. The tool must be of a the bore.
diameter to contact near the outer circumference of the nee- 3. Slide the preload spring (42, Figure 51) onto the pin-
dle bearing (Figure 56) yet not contact the bearing bore. ion end of the drive shaft (5). Drive the pin (6, Figure 51)
into its opening in the drive shaft to secure the spring.
6. Position the needle bearing into the bore opening with
4. Lubricate the surfaces with gearcase lubricant and in-
the number side facing out. Place the installation tool
stall the thmst bearing (3, Figure 51), washer (2) and
firmly against the bearing. Gently drive the bearing into
shims (1) onto the upper end of the drive shaft (5).
the bore until firmly seated.
5. Carefully slide the drive shaft into the bearing and seal
7. Apply a bead of silicone seal (Suzuki part No.
housing.
99000-3 1120) to the groove for the O-ring (48, Figure
6. Align the drive shaft and shift shaft with their respec-
51). Place the O-ring into the groove.
tive openings while lowering the bearing and seal housing
8. Apply a bead ofwater resistant grease (Suzuki part No.
onto the gearcase. Rotate the drive shaft clockwise to
99000-25 160) to the lips of both seals. Lubricate the nee-
align the drive shaft splines with the pinion gear splines.
dle bearing with gearcase lubricant. The drive shaft drops into the pinion gear as the splines
align.
Shift shaft assembly and installation 7. Press down to seat the bearing and seal housing against
the gearcase. Move the shift up and down to verify correct
1 Lubricate the surfaces with water resistant grease and orientation of the detent notch. A distinct detent is felt
install the O-rings (5 and 6, Figure 55) onto the bushing when the shaft reaches the neutral position. Remove and
(4). Lubricate the surfaces with gearcase lubricant and re-install the shift shaft andlor detent ball as needed.
slide the boot (3, Figure 55) onto the bushing. 8. Apply Suzuki thread lock (part No.99000-32050) to
2. Slide the bushing into its opening in the top side of the the threads of the drive shaft and pinion nut (47, Figure
bearing and seal housing. Install the snap ring (7, Figure 51). Thread the pinion nut onto the drive shaft.
55) into the groove to secure the bushing. 9. Engage the splined adapter (Suzuki part No.
3. Install the guide (17, Figure 55) onto the shift shaft. 09921 -295 10) onto the upper end of the drive shaft (Fig-
Rotate the guide until the reference marks made prior to ure 50). Hold the pinion nut with a breaker bar and socket.
removal align with the mark on the shift shaft. Drive the Tighten the pinion nut to the specification in Table 1.
Page: 330 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
Propeller shaft assembly and installation a. Select an appropriately sized socket or section of
tubing for use as a bearing installation tool. The tool
I . Insert the spring (24, Figure 51) into the opening in the must be of a diameter to contact the outer race ofthc
forward side of the propeller shaft. bearing yet not contact the bearing bore during in-
2. Place the cross pin connector (20, Figure 51) into the stallation.
opening and seat it against the spring. Insert the cam fol- b. Lubricate the bearing with gearcase lubricant. Posi-
lower into the opening with the smaller diameter side fac- tion the bearing into the bore opening with the num-
ing out (Figure 39). bered side facing out. Place the bearing carrier seal
3. Slide the clutch over the propeller shaft with the F side down on a sturdy work surface.
mark facing the forward gear side of the shaft (Figure 44). c. Hold the installation tool firmly against the bearing
4. Align the cross pin opening in the clutch with the slot and tap the bearing into the bore (Figure 46). The
in the propeller shaft (Figure 45). Remove and reposition bearing must seat against the step within the bore.
the clutch as needed. 7. Position the shim (32, Figure 51) onto the hub of the
5. Push in and rotate the cam follower (19, Figure 51) to reverse gear (33). Lubricate the reverse gear with
align the hole in the cross pin connector (Figure 45) with gearcase lubricant. Slide the reverse gear hub into the bore
the cross pin hole in the clutch. Push the cross pin (22, of the reverse gear bearing until seated against the shim
Figure 51) through both holes and release the cam fol- and bearing (32 and 30, Figure 51).
lower. 8. Lubricate the O-ring (3 1, Figure 51) with water resis-
6. Ensure the ends of the cross pin are flush with the tant grease and position it onto the groove of the bearing
clutch surfaces. Carefully wind the spring onto the clutch carrier. Lubricate the surfaces with grease and slide the
(Figure 38). Ensure the spring spans both ends of the thrust washer (34, Figure 51) onto the rear side of the pro-
cross pin. Reposition the spring as needed. peller shaft. Seat the washer against the step near the
7. Apply grease to the surfaces and install the thrust clutch.
washer (8, Figure 51) onto the forward gear side of the 9. Carefully slide the propeller shaft (splined section
propeller shaft. first) through the opening in the reverse gear. Seat the pro-
8. Install the propeller shaft assembly along with the peller shaft against the reverse gear. Lubricate the
bearing carrier as described in this chapter. gearcase opening with gearcase lubricant.
10. Position the gearcase with the drive shaft facing up.
Bearing carrier assembly and installation Grasp the splined section of the propeller shaft to retain
the shaft into the carrier. Align the forward side of the pro-
1. Place the inner needle bearing (28, Figure 51) into the peller shaft with the opening in the forward gear while
bore opening with the number side facing out. Use the sliding the carrier into the housing. Rotate the drive shaft
bearing removal tool to carefully drive the bearing into the clockwise to align the reverse and pinion gear teeth while
carrier. Seat the bearing against the step at the bottom of seating the carrier into the gearcase.
the bore. Install the outer bearing into the bore with the 11. Lightly tap on the carrier until it fully seats against the
number side out until it seats against inner bearing. gearcase. Rotate the carrier until the bolt holes align.
2. Select an appropriately sized socket or section of tub- Thread the bolts and washers (26, Figure 51) into the
ing for use as a seal installation tool. The tool must be of a gearcase. Tighten the bolts to the specification listed in
diameter large enough to contact near the outer circumfer- Table 1.
ence of the seal yet not contact the seal bore during instal- 12. Refer to Shim Selection in this chapter to determine if
lation. the gear alignment is correct. Install the water pump com-
3. Place one of the seals into the bore in the propeller side ponents and gearcase as described in this chapter.
of the carrier with the lip side facing out. Slowly drive the
seal into the bore until it restjust below the bore opening. Gearcase Service
4. Place the remaining seal into the bore with the lip side
(DF60 and DF70 Models)
facing out. Slowly drive the seal into the bore until it con-
tacts the inner seal. Bearing carrier removal and disassembly
5. Carefully drive both seals into the bore until the inner
seal fully seats in the bore. Apply a bead of Suzuki watcr Rcfcr to Figure 57.
resistant grease (part No. 99000-25 160) to the lip surfaces 1. Bend the tab(s) away from the cover nut (Figure 58).
of both seals. 2. Slide the cover nut tool (Suzuki part No. 0995 1 - 18720)
6. Install the reverse gear bearing as follows: over the propeller shaft. Engage the tool to the cover nut
Page: 331 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
324 CHAPTER NINE
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GEARCASE 325
ARCASE COMPONENTS
DF60 AND DF70 MODELS
CAUTION
When using heat, make sure to keep the
flame awayfrom the seals or 0-imgs Never
heat the housing to the point that the fim'sli
1.5 burned Continually move the flame
around the mating surface to appl\ even
heating. Excessive w e o f heat can dl \tort or
melt the gearcase
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326 CHAPTER NINE
4. Pull the spacer (38. Figure 57) from the bearing carrier
or gearcase opening. Remove the O-ring (39, Figure 57)
from the carrier.
5. Pull the propeller shaft (29, Figure 57) from the car-
rier. Place the carrier on a sturdy work surface with the
gear side up. Lift the thrust washer, reverse gear and shim
(30. 33 and 34, Figure 57) from the bearing carrier (40).
6. Remove the reverse gear bearing (35, Figure 57) only
if it must be replaced. Refer to Gearcase Component In-
spection in this chapter to determine the need for replace-
ment. Remove the bearing as follows:
a. Clamp the bearing carrier into a vice equipped with
soft jaws.
b. Engage the jaws of a slide hammer into the bearing
as indicated in Figure 35.
c. Use short hammer strokes to remove the bearing.
Discard the bearing after removal.
7. Engage the jaws of a slide hammer to the propeller
shaft seals as indicated in Figure 36. Use short hammer
strokes to remove the seals from the carrier.
8. Remove the needle bearings (36, Figure 57) only if
they must be replaced. Remove the bearing as follows:
a. Select an appropriately sized socket or section of
tubing for use as a bearing installation tool. The tool
must be large enough in diameter to contact the
bearing cage yet not contact the bearing carrier dur-
ing removal.
b. Place the bearing carrier on a sturdy word surface
with the seal bore facing down. Propeller shaft disassembly
c. Hold the tool in firm contact with the inner bearing
and lightly tap on the tool (Figure 49). Continue LIII-
1. Use a screwdriver to unwind the spring from the clutch
til the outer bearing if free from the carrier. Repeat
(Figure 38).
the process to remove the inner bearing.
9. Use a suitable solvent and soft bristle brush to clean 2. Pull the cam follower from the propeller shaft (Figure
corrosion and other contaminants from the carrier. 39).
10. Inspect the carrier for cracked, pitted or damaged sur- 3. Use a pin punch to push the cross pin from the clutch
faces. Replace the carrier if defects are noted. and propeller shaft (Figure 40).
Page: 334 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
GEARCASE 327
1 . Remove the four bolts from the bearing and seal hous-
ing (Figure 61).
2. Engage the splined adapter (Suzuki part No.
0992 1-28710) onto the upper end of the drive shaft (Fig-
ure 50). Hold the pinion nut (31, Figure 57) with a
breaker bar and socket. Rotate the adapter counterclock-
wise until the pinion nut is free from the drive shaft.
3. Carefully pull the drive shaft (8, Figure 57) along with
the bearing and seal housing (2) from the gearcase. Slide
the drive shaft (8, Figure 57), bearing race (6) and shim
(5) from the bearing and seal housing (2).
4. Pull the thrust washers (A and B, Figure 62) and collar
(C) from the gearcase. Slidc the spring (9, Figure 57)
from the drive shaft.
5. Remove the tapered roller bearing from the drive shaft
only if it must bc replaced. Refer to Gearcase Component
Inspection in this chapter. Replace the bearing as follows:
a. Position a bearing separator onto the open jaws of a
vice as indicated in Figure 37.
b. Open the separator enough to allow the shaft to just
slide through.
c. Slide the drive shaft into the separator with the pin-
ion gear side facing down. Rest the drive shaft bear-
ing against the separator.
d. Use a block of wood to protect the splined end of the
drive shaft and carefully drive the shaft from the
bearing.
1. Bolt 13. Collar
2. Cover 14. Large diameter pin
6. Place the bearing and seal housing (2, Figure 57) on a
3. O-ring 15. Small diameter pin sturdy work surface right side up. Use a blunt tip pry bar to
4. Seal 16. Shift cam push both seals from the housing.
5. Washer 17. Spring
6. Sleeve 18. Spacer
7. O-ring 19. Detent ball Shift shaft removal and disassembly
8. Snap ring 20. Magnet
9. Pin 21. Clamp 1 . Remove the three bolts (Figure 63) from the shift shaft
10. Shift shaft 22. Washer
11. Spring 23. O-rings
cover. Grip the top of the shift shaft with pliers and lift the
12. Spacer 24. Alignment pin assembly from the gearcase. Remove the O-ring (3, Fig-
ure 64) from the cover or gearcase. Remove the align-
ment pin (24, Figure 64) from the cover (2).
2. Remove the snap ring (8, Figure 64) and pull the cover
(2) from the shift shaft.
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328 CHAPTER NINE
Page: 336 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
made prior to removal. Use a pin punch to drive the larger
diameter pin (14, Figure 64) through the shift cam and
shift shaft. Drive the smaller diameter pin into the larger
Bearing and
diameter pin. Ensure both pins are centered in the shift
seal housing cam.
I /
Bearing race 5. Use a pin punch to drive the pin (9, Figure 64) into its
opening in the shift shaft. Ensure the pin protrudes the
same amount on each side of the shift shaft.
6. Carefully slide the shift shaft into the opening of the
cover (2, Figure 64). Push in on the shaft to compress the
spring (1 1. Figure 64) and install the snap ring (8). Ensure
the snap ring fully engages the groove in the bottom of the
cover.
7. Lubricate the surfaces with grease and install a new
O-ring (3, Figure 64) onto the cover (2). Insert the align-
ment pin (24, Figure 64) into the opening in the cover.
8. Rotate the shift shaft to align the detent ball notch and
the cover with the forward side of the gearcase.
9. Carefully lower the shift shaft into the gearcasc. Align
the pin of the cover with its respective opening in the
and race into the gearcase bore with the tapered side fac- gearcase and seat the cover against the gearcase. Move the
ing out. shift shaft up and down to verify correct orientation of the
4. Select an appropriately sized socket and extension or detent notch. A distinct detent is felt when the shaft
section of tubing for use as an installation tool. The tool reaches the neutral position. Remove and re-install the
must be of a diameter to contact near the outer circumfer- shift shaft and/or detent ball as needed.
ence of the race yet not contact the housing during instal- 10. Thread the three bolts into the shift shaft cover (Fig-
lation. Slowly drive the race and shims into the housing ure 63). Securely tighten the bolts.
until fully seated (Figure 66). Place the tapered roller
bearinginto the race.
5. Lubricate the surfaces with grease and place the Drive shaft assembly and installation
spacer, spring and detent ball (1 7-19, Figure 64) into their
1. Select a section of tubing for use as a drive shaft bcar-
opening. The opening is located at the front of the
ing installation tool. The inner diameter of the tubing must
gearcase and directly in line with the shift shaft bore.
be slightly larger than the drive shaft. Clamp the pinion
6. Place the tapered roller bearing into the bearing race.
gear end of the drive shaft into a vice equipped with soft
Install the hub of the gear into the bore of the bearing. En-
jaws.
sure the gear seats against the bearing.
2. Slide the tapered roller bearing (6, Figure 57) over the
7. Install the pinion gear into the gearcasc. Align the upper end of the drive shaft with the tapered side facing
splined opening in the gear with the drive shaft bore and away from the pinion gear end.
engage the pinion gear teeth to the forward gear teeth.
3. Slide the installation tool over the drive shaft and seat
it against the bearing. Carefully tap on the upper end of the
Shift shaft asseinb/y and installation tool until the bearing seats against the step on the shaft.
4. If replacing the drive shaft (8, Figure 57). bearing (6)
1. Snap the magnet and clamp (20 and 21, Figure 64) or pinion gear (32), use the shim gauge (Suzuki part No.
onto the shift shaft. Position the magnet just above the 09951-08720) to determine the correct drive shaft shim
bend in the shaft. thickness as follows:
2. Lubricate the surfaces with grease and install the seal a. Assemble the pinion gear, bearing and seal housing,
(4, Figure 64), washers (5 and 22), sleeve (6) and O-rings bearing race and spacers on the drive shaft as shown
(23) into the cover (2). in Figure 67. Do not install the shims (5, Figure 57)
3. Place the spring, spacer and collar (1 1-13, Figure 64) at this time.
onto the shift shaft. b. Attach the drive shaft bearing housing to the shim
4. Slide the shift cam (16, Figure 64) onto the shift shaft gauge. Securely tighten the bolts that retain the
(10). Rotate the shift cam to align the reference mark bearing housing on the shim gauge. Ensure the
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330 AFTER NINE
drive shaft rests on the support (Figure 67) during 11. Apply Suzuld thread lock (pan No.99000-32050) to
the measurement. the threads of the drive shaft and pinion nut (3 1, Figure
c. Lightly pull the drive shaft to seat the bearing 57). Thread the pinion nut onto the drive shaft.
against the housing and measure the gap between 12. Engage the splined adapter (Suzuki part No.
the pinion gear and the gauge with a feeler gauge. 0992 1-28710) onto the upper end of the drive shaft (Fig-
d. Use a shim with the same thickness as the feeler ure 50). Hold the pinion nut with a breaker bar and socket.
gauge. Assemble the drive shaft to the shimming Tighten the pinion nut to the specification in Table 1.
gauge with the shim installed.
e. Repeat the measurement. If the correct shim is in-
stalled, there will be no gap at the measurement Propeller shaft assembly and installation
point, but the drive shaft will be able to rotate in the
shim gauge. Use a thinner or thicker shim to achieve 1. Insert the spring (28, Figure 57) into the opening in the
the desired measurement. Remove the pinion gear, forward side of the propeller shaft.
bearing race, spacers and seal housing from the 2. Place the cross pin connector (24, Figure 57) into the
drive shaft. opening and seat it against the spring. Insert the cam fol-
5. Select an appropriately sized socket or section of tub- lower into the opening with the smaller diameter side fac-
ing for use as a seal installation tool. The tool must contact ing out (Figure 39).
near the outer circumference of the seal yet not contact the 3. Slide the clutch over the propeller shaft with the Fmark-
housing during installation. Install the drive shaft seals as ing facing the forward gear side of the shaft (Figure 44).
follows: 4. Align the cross pin opening in the clutch with the slot
a. Place the bearing and seal housing on a sturdy work in the propeller shaft (Figure 45). Remove and reposition
surface with the open side facing up. the clutch as needed.
b. Place the inner seal into the bore opening with the 5. Push in and rotate the cam follower (23, Figure 57) to
lip side facing up. Use the seal installation tool to align the hole in the cross pin connector (Figure 45) with
push the seal into the bore. Stop when the seal stir- the cross pin hole in the clutch. Push the cross pin (25,
face is just below the bore opening. Figure 57) through both holes and release the cam fol-
c. Place the outer seal into the bore opening with the lower.
lip side facing up. Push the outer seal into the bore 6. Ensure the ends of the cross pin are flush with the
until the inner seal seats in the bore. clutch surfaces. Carefully wind the spring onto the clutch
d. Apply a bead of water resistant grease to the lip of (Figure 38). Ensure the spring spans both ends of the
both seals. cross pin. Reposition the spring as needed.
6. Slide the spring (9, Figure 57) onto the pinion end of 7. Apply grease to the surfaces and install the thrust
the drive shaft (8). Seat the spring against the step on the washer (22, Figure 57) onto the forward gear side of the
drive shaft. propeller shaft.
7. Install the collar (C, Figure 62) into the drive shaft 8. Install the propeller shaft assen~blyalong with the
bore. Rotate the collar to align the tab with the recess in bearing carrier as described in this chapter.
the housing during installation. Align the opening in the
thmst washers (A and B, Figure 62) with the drive shaft
bore and seat them against the bottom of the collar. Bearing carrier assembly and installation
8. Carefully insert the drive shaft into the collar. Rotate
the drive shaft clockwise to align the pinion gear and drive I . Place the inner needle bearing (36, Figure 57) into the
shaft splines. The drive shaft drops into position as the bore opening with the numbered side facing out. Use the
splines align. bearing removal tool to carefully drive the bearing into the
9. Apply grease to the surfaces and place a new O-ring (3, carrier. Seat the bearing against the step at the bottom of
Figure 57) onto the bearing and seal housing (2). Slide the the bore. Install the outer bearing into the bore with the
bearing race, shims and bearing and seal housing (2, 5, numbered side out until it seats against the inner bearing.
and 6, Figure 57) onto the upper end of the drive shaft. 2 Select an appropriately sized socket or section of hib-
10. Rotate the bearing and seal housing until the F mark ing for use as a seal installation tool. The tool must be of a
on the housing faces the shift shaft. Seat the housing diameter large enough to contact near the outer circumfer-
against the gearcase and install the four bolts (1, Figure ence of the seal yet not contact the seal bore during instal-
57). Tighten the bolts to the specification in Table 1. lation.
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10. Position the gearcase with the drive shaft facing up.
Grasp the splined section of the propeller shaft to retain
the shaft into the carrier. Align the forward side of the pro-
peller shaft with the opening in the forward gear while
sliding the carrier into the housing. Rotate the drive shaft
clockwise to align the reverse and pinion gear teeth while
seating the carrier into the gearcase.
I I. Lightly tap on the carrier until it fully seats against the
gearcase. Rotate the carrier until the key slot in the carrier
and gearcase align. Use needle nose pliers to install the
key (4 1, Figure 57).
12. Place the tab washer (42, Figure 57) into the gearcase
3. Place one of the seals into the bore in the propeller side opening with the o//'mark facing out. Align the protrusion
of the carrier with the lip side facing out. Slowly drive the 011 the bearing carrier with the notch in the washer and
seal into the bore until it rest just below the bore opening. seat the washer against the carrier.
4. Place the remaining seal into the bore with the lip side 13. Apply Suzuki bond (part No. 99000-31030) to the
facing out. Slowly drive the seal into the bore until it con- threads of the cover nut (43, Figure 57). Carefully thread
tacts the inner seal. the cover nut into the gearcase opening.
5. Carefully drive both seals into the bore until the inner 14. Slide the cover nut tool (Suzuki part No. 0995 1-18720)
seal fully seats in the bore. Apply a bead of Suzuki water over the propeller shaft. Engage the tool to the cover nut as
resistant grease (part No. 99000-25 160) to the lip surfaces indicated in Figure 59. Tighten the cover nut to the specifi-
of both seals. cation in Table 1. Bend one or more of the tabs against the
6. Install the reverse gear bearing as follows: cover nut to retain the nut. If necessary, tighten the cover
Select an appropriately sized socket or section of nut slightly to align the tabs with the nut.
tubing for use as a bearing installation tool. The tool 15. Refer to Shim Selection in this chapter to determine if
must be of a diameter to contact the outer race of the the gear alignment is correct. Install the water pump com-
bearing yet not contact the bearing bore during in- ponents and gearcase as described in this chapter.
stallation.
Lubricate the bearing with gearcase lubricant. Posi-
tion the bearing into the bore opening with the 11~1111- Gearcase Component Inspection
bered side facing out. Place the bearing carrier with
This section provides instruction for inspecting and
the seal side down on a sturdy work surface.
measuring all internal gearcase components. Never use
Hold the installation tool firmly against the bearing
damaged, worn or questionable components. The cost of
and tap the bearing into the bore (Figure 46). The
the new component is usually far less than the cost to re-
bearing must scat against the step within the bore.
pair the gearcase if it fails.
7. Position the shim (34, Figure 57) onto the hub of the
reverse gear (33). Lubricate the reverse gear with
gearcase lubricant. Slide the reverse gear hub into the bore Shift shaft
of the reverse gear bearing until seated against the shim
and bearing (34 and 35, Figure 57). I . Inspect the bore in the propeller shaft for the presence
8. Lubricate the O-ring (39, Figure 57) with water resis- of debris or damaged or worn areas. Clean debris from the
tant grease and position it onto the groove of the bearing bore.
carrier. Lubricate the surfaces with grease and slide the 2. Inspect the clutch spring for damage, corrosion or
thrust washer (30, Figure 57) onto the rear side of the pro- weak spring tension, replace it if necessary.
peller shaft. Seat the washer against the step near the 3. Inspect the cross pin for damaged, rough or worn sur-
clutch. faces. Replace as required. Inspect the cam follower and
9. Carefully slide the propeller shaft (splined section spring for damage or corrosion and replace them as re-
first) through the opening in the reverse gear. Seat the pro- quired.
peller shaft against the reverse gear. Install the spacer (38, 4. Inspect the can1 follower for cracked, broken or worn
Figure 57) into the gearcase opening and seat it against areas. Replace any worn or defective components.
the step in the housing. Lubricate the gearcase opening 5. Inspect the shift cam (Figure 68), located at the lower
with gearcase lubricant. end of the shift shaft, for worn, chipped, cracked or cor-
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332 CHAPTER NINE
Propeller shaft
1. Inspect the clutch (B, Figure 71) and gear surfaces for
chipped, damaged, worn or rounded over surfaces. Re-
place the clutch and gears if any of these conditions are
found on either component.
2. Inspect the gear for worn, broken or damaged teeth (A,
Figure 71).
3. Note the presence of pitted, rough or excessively worn
(highly polished) surfaces. Replace all of the gears if any
of these conditions is found. This is especially important
on engines with high operating hours.
CA UTION
Replace all gears i f any require replace- 5 . Replace all bearings if the gear lubricant drained from
ment. A wearpattern forms on each gear gf- the gearcase was heavily contaminated with metal parti-
ter a few hours of use If a new gear is used cles. The particles tend to collect inside the bearing as-
along with usedgears, the wearpattern will sembly.
be disturbed andpremature wear will occ~u:
6. Inspect the roller bearing (Figure 72) and bearing race
4. Thoroughly clean all bearings in solvent and air dry surfaces for pitting, rusting, discoloration or rough sur-
prior to inspection. faces.
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7. Inspect the bearing race for highly polished or un-
evenly worn surfaces. Replace the bearing assembly if
any of these defects is noted.
8. Rotate ball bearings and note any rough operation.
Move the bearing in the directions shown in Figure 73.
Note the presence of axial or radial play. Replace the bear-
ing if rough operation or excessive play is noted.
Axial
9. Inspect the needle bearings (Figure 74) located in the
bearing carrier, gearcase and drive shaft seal and bearing
housing. Replace the bearing if flattened rollers, discolor-
ation, rusting, rough surfaces or pitting is noted.
10. Inspect the propellcr shaft and drive shaft at the bear-
ing contact area. Replace the drive shaft and/or propeller
shaft along with the needle bearing if any discoloration,
pits, transferred bearing material or rough surfaces exist.
Spring measurement
Radial Measure the spring that fits within the bore of the pro-
peller shaft at tlie points indicated in Figure 75. Do not
conipress the spring during tlie measurement. Compare
tlie measurement with tlie specification in Table 2. Re-
place the spring if not within the specification.
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334 CHAPTER NINE
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GEARCASE 335
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336 CHAPTER NINE
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69
Dia
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338 CHAPTER NINE
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GEARCASE 339
b. On DF25 and DF30 models select a thinner pinion and install the next thinner size shim in this location. In-
gear shim (9, Figure 48) and a thicker forward gear stall the propeller shaft and bearing carrier. Measure the
shim (49, Figure 48). drive shaft thrust play as described in this chapter. Install a
c. On DF40 and DF50 models select a thinner pinion progressively thinner shim until the drive shaft thrust play
gear shim (1, Figure 51) and a thicker forward gear is equal with or without the carrier installed. Do not use a
shim (16, Figure 51). thinner shim than necessary to achieve equal measure-
d. On DF60 and DF70 models select a thinner pinion ments.
sear shim (10. Figure 57) and a thicker forward
u
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340 CHAPTER NINE
and measure the thmst play. Perform additional changes On all other models, the forward gear bearing shim (2,
as needed. Figure 90) is located between the forward gear and the
forward gear bearing.
Disassemble the gearcase until the shims are accessible
Gear Backlash Adjustment as described in this chapter. Install thicker shims to de-
crease the backlash. Install thinner shims to increase the
gear backlash. Change the shim thickness in the sn~allest
Correct the gear backlash by changing the thickness of possible increments. Reassemble the gearcase and mea-
the shim(s) next to the forward gear bearing. Shim loca- sure the gear backlash. Make additional shim changes as
tions in the gearcase vary by model. needed.
On DF60 and DF70 models, the forward gear bearing Perform a gear pattern inspection as described in this
shims (19, Figure 57) are located between the forward section to verify correct gear alignment. Make additional
gear bearing race and the gearcase housing. shim changes to correct the gear pattern.
Page: 348 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
Chapter Ten
Manual Starter
This chapter provides replacement and repair proce- As the rope is released, the starter spring unwinds, caus-
dures for the manual starter. Cleaning, inspection and lu- ing the sheave to rotate counterclockwise. Counterclock-
brication of the internal components are necessary if the wise rotation of the sheave causes the drive pawl spring
manual starter does not engage properly or the starter (8, Figure 1) to contact and pivot the drive pawl (1 1) away
binds when activated. from the starter pulley. The manual starter is then released
from the flywheel.
The neutral-only start mechanism (1, Figure 1) pre-
MANUAL STARTER vents the flywheel from rotating when the engine is in for-
ward or reverse gear. The gear shift linkage on the engine
operates this cable actuated lockout mechanism. Adjust-
Operation
ment is required when any components of the mechanism
are changed or disturbed. Refer to Chapter Five for adjust-
The manual starter mounts to the top of the power head ment instructions.
directly above the flywheel. It also serves as the flywheel
cover and houses the timing pointer. Pulling the rope (3,
Figure 1) rotates the sheave (7), causing the drive pawl
(1 1) to pivot and engage the starter pulley or bosses on the
flywheel. This causes the flywheel to rotate with the Use the standard torque specifications for all fasteners.
sheave. As the sheave rotates, the starter spring (6) winds Standard torque specifications are listed in the Quick Ref-
within the rewind housing (5). erence Data section at the front of the manual. Mark all
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342 CHAPTER TEN
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ANUAL STARTER 343
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344 CHAPTER TEN
ANUAL STARTER
F9.9 AND DF15 MODELS
1. Stopper arm
2. Spring
3. Cotter pin
4. Washer
5. Stopper lever
6. Neutral-only start cable
7. Manual starter housing
8. Rope guide
9. Handle
10. Bolt
11. E-clip
12. Drive pawl
13. Spring link
14. Spring
15. Washer
16. Sheave retaining bok
17. Friction plate
18. Friction spring
19. Sheave
20. Rope
21. Starter spring
5. Align the three mounting bolt holes with the corre- Clean all components, except the rope, in solvent suit-
sponding openings on the power head. Instal1 and se- able for composite or plastic components. Dry the coinpo-
curely tighten the mounting bolts (Figure 5). nents with compressed air immediately after cleaning.
6. Connect the cable end to the shift linkage. Guide the Apply Suzuki water-resistant grease (part No.
neutral-only start cable into the slot provided in the man- 99000-25610) to all bushing, drive pawl, spring and pivot
ual starter housing (Figure 4). Adjust the neutral only surfaces. Also apply grease to the starter spring and its
start cable as described in Chapter Five. Securely tighten contact surfaces inside the starter housing.
the cable adjusting nuts. Apply Three bond 1342 (part No. 99000-32050) to the
7. Install the spark plugs and leads. Connect the negative threaded portion of the sheave retaining bolt during as-
batte~ycable. sembly.
8. Check for proper operation of the manual staster and Tighten all fasteners to the standard torque specifica-
the neutral-only start mechanism. tions. Mark all component mounting locations and orien-
tation prior to removal. Refer to the instructions f o the
~
selected model.
Repair
CA UTION
When seivicir~gthe manual statatei;wear eye
If starter rope replacement is necessary, replace the rope protection, gloves and adeqziate covering
with one that is specifically designed for the outboard. over all exposed portions of the L m l y . The
Other types may not withstand the rigorous use and fail. starter spring may unexpectedly release
Page: 352 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
konz the housing with considerable force
and result in bodily injury.
NOTE
Remove the starter spring (21, Figzwe 6,
typical) from the rewind housiizg oidy if it
must be replaced. Inspect the spring as de-
scribed in this chapter to determine the need
.for replacement.
Disussem bly
(DF9.9 and DF15 models)
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346 CHAPTER TEN
Assembly
(DF9.9 and DFl5 nzodels)
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ANUAL STARTER 347
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348 CHAPTER TEN
facing out. The friction spring must fit over the diameter
of the friction plate. Rotate the friction plate to align the
hole with the square protrusion on the sheave.
11. Apply ThreeBond 1342 (Suzuki part No. 99000-
32050) to the threads ofthe bolt (16, Figure 6). Install and
securely tighten the bolt.
12. Place the rope into the notch as indicated in Figure
19. Hold the rope in this position and rotate the sheave
counterclockwise, as viewed from the open end, five com-
plete turns.
13. Hold the sheave to prevent rotation and route the end
of the rope through the rope guide and handle. Tie a suit-
able knot (Figure 20) in the rope near the handle, then
trim away the excess rope. Place the knot into the recess in
the handle. Release the rope from the notch.
14. Pivot the stopper lever (5, Figure 6) away from the
housing and place the end of the cable (6) into its slot in
the lever. Apply grease to the spring end of the cable and
position the cable into its recess in the housing.
15. Install the manual starter as described in this chapter. Leave 114-112 in. reserve
length at end of rope
Disassembly
(DF25 and DF30 models)
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MANUAL STARTER 349
MANUAL STARTER
DF25 AND DF30 MODELS
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350 CHAPTER TEN
attention to the starter spring. Inspect the entire length of 7. Position the rope guide roller, sleeve and washer
the spring for cracks or other defects. Inspect the entire (18-20, Figure 21) onto the housing (6) and secure with
length of rope for worn, cut or frayed surfaces. Replace all the bolt (17).
defective or suspect components. 8. Guide the rope (16, Figure 21) through the rope guide
and into its corresponding hole in the sheave (8). Tie a
suitable knot in the end of the rope and position the knot
Assembly into the recess in the sheave (Figure 17). Ensure the knot
(Dm5a11dDF3O models) does not protrude from the recess.
9. Align the hooked end of the starter spring with the
groove on the sheave (Figure 18) and place the sheave
1. Apply Suzuki water-resistant grease to the manual into the manual starter housing.
starter housing at the starter spring contact surfaces. 10. Rotate the sheave slightly counterclockwise to check
2. Place the hooked end of the starter spring over the tab for spring engagement. Spring engagement is indicated if
in the housing. Wind the starter spring into the housing resistance is felt.
(Figure 12) counterclockwise one loop at a time until the 11. Repeat Steps 9 and 10 until spring engagement is in-
entire length of the spring is installed. dicated.
12. Slip the tip of the friction spring (9, Figure 21) into
3. Lubricate the pivot point with grease and slide the the opening in the spring link (13). Place the friction plate
stopper arm into the manual starter housing. Ensure the (10, Figure 21) onto the sheave (8) with the concave side
pivot end of the stopper fits securely through the opening facing out. The friction spring must fit over the diameter
at the top of the housing. of the friction plate. Rotate the friction plate to align the
4. Install the spring (2, Figure 21) onto the housing pin. hole with the square protrusion on the sheave.
The longer end of the spring must fit against the tab on the 13. Apply ThreeBond 1342 (Suzuki part No. 99000-
housing. 32050) to the threads of the bolt (1 1, Figure 21). Install
and securely tighten the bolt.
5. Hook the cable onto the spring (5, Figure 21). Connect 14. Place the rope into the notch as indicated in Figure
the other end of the spring onto the housing pin. Carefully 19. Hold the rope in this position and rotate the sheave
press the cable (1, Figure 21) into the recess in the hous- counterclochwi.se, as viewed from the open end, five com-
ing. plete turns.
6. Lubricate the pivot point with grease and place the 15. Hold the sheave to prevent rotation and route the end
drive pawl into the opening in the sheave (Figure 16). In- of the rope through the rope guide and handle. Tie a suit-
stall the E-clip (15, Figure 21) onto the groove of the able knot (Figure 20) in the rope near the handle, then
drive pawl pivot. Connect the spring link and spring (12 trim away the excess rope. Place the knot into the recess in
and 13, Figure 21) to the drive pawl post (14) and sheave the handle. Release the rope from the notch.
(8). 16. Install the manual starter as described in this chapter.
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Chapter Eleven
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352 CHAPTER ELEVEN
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HYDRAULIC TRIM AND MIDSECTION 353
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354 CHAPTER ELEVEN
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HYDRAULIC TRIM AND MIDSECTION 355
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356 CHAPTER ELEVEN
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HYDRAULIC TRIM AND MIDSECTION 357
Trim System
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358 CHAPTER ELEVEN
8. Installation is the reverse of removal while noting the 6. Refer to Midsection and locate the tilt tube nut. Loosen
following: the nut until the clamp brackets separate slightly. Remove
Apply a good water resistant grease to the pivot the side engine mounting bolts from the clamp brackets.
points of all pins and bushings during assembly. Spread the clamp brackets enough to pull the trim system
Apply Suzuki thread lock 1342 (part No. and lower bushing from the engine.
99000-32050) to the threads of the lower trim sys- 7. Inspect all trim system mounting pins, bushings. bolts
tem mounting bolts. Tighten the bolts to the specifi- and circlips for worn or damaged surfaces. Replace any
cation listed in Table 1. worn or suspect components.
Apply marine grade silicone sealant to the engine 8. Installation is the reverse of removal while noting the
mounting bolt opening in the boat transom. Install following:
then securely tighten the starboard side engine Apply a good water resistant grease to the pivot
mounting bolts and nuts. points of all pins and bushings during assembly.
Tighten the tilt tube nut as described in Midsection. Tighten the lower trim system mounting bolt and
Open the n~anualrelief valve and manually extend t the specification in Table 1. Install the tilt pin
n ~ ito
the ram to align the upper pin bores. Push the upper to the clamp bracket holes noted prior to removal.
pin into position using an appropriately sized sec- Securely tighten the tilt pin.
tion of tubing or steel rod. Install the circlips fully Apply marine grade silicone sealant to the engine
into the grooves of the upper pin. mounting bolt opening in the boat transom. Install
Route the wires to avoid interference then connect then securely tighten the starboard side engine
the blue and green wires to the relays. mounting bolts and nuts.
9. Remove the overhead support and disengage the tilt Tighten the tilt tube nut as described in Midsection.
lock lever. Connect the negative cable. Check and fill the Open the manual relief valve and manually extend
trim fluid level as described in this chapter. the ram to align the upper pin bores. Push the upper
10. Cycle the trim system to the full UP and DOWN posi- pin into position with an appropriately sized section
tion. Check for improperly installed components if binding of tubing or steel rod. Install the circlips fully into
occurs. the grooves of the upper pin.
Route the wires to avoid interference then connect
the blue and green wires to the relays.
DF40 and DF50 models
9. Remove the overhead support and disengage the tilt
1. Turn the manual relief valve 3-4 turns counterclock- lock lever. Connect the negative battery cable. Check and
wise then manually raise the engine to the full UP posi- fill the trim fluid level as described in this chapter.
tion. Securely tighten the manual relief valve. Engage the 10. Cycle the trim system to the full UP and DOWN posi-
tilt lock level (Figure 10) then support the engine with tion. Check for improperly installed con~ponentsif bind-
blocks or an overhead cable (Figure 2). ing occurs.
2. Disconnect the negative battery cable. Locate and dis-
connect the larger diameter blue and green wires from the DF60 and DF70 models
trim relays (Figure 11). Route the disconnected wires out
of the lower engine cover. 1. Turn the manual relief valve 3-4 turns counterclock-
3. Using appropriate snap ring pliers (Figure 7), care- wise then manually raise the engine to the full UP posi-
fully remove both circlips from the upper cylinder pin. tion. Securely tighten the manual relief valve. Engage the
Using a section of tubing or steel rod, carefully drive the tilt lock lever (Figure 10) then support the engine with
pin from the cylinder and clamp brackets. blocks or an overhead cable (Figure 2).
4. Turn the manual relief valve 3-4 turns c0~1ntercloc1~- 2. Disconnect the negative battery cable. Remove the
wise then manually push the cylinder ram down into the electrical components cover from the front and starboard
cylinder. Securely tighten the manual relief valve. Mark side of the power head. Locate and disconnect the larger
or note the tilt pin mounting holes in the clamp brackets. diameter blue and green wires from the trim relays (Fig-
Loosen the nut then remove the tilt pin. ure 11). Route the disconnected wires out of the lower en-
5. Remove the trim system mounting nut on the lower gine cover.
port side clamp bracket. Support the trim system then pull 3. Using appropriate snap ring pliers (Figure 7), care-
the lower trim system mounting bolt from the lower star- fully remove both circlips (1 6 and 2 1, Figure 13) from the
board side clamp bracket. upper cylinder pin (17). Using a section of tubing or steel
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HYDRAULIC TRIM AND MIDSECTION 359
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360 CHAPTER ELEVEN
rod, carefully drive the pin from the cylinder and clamp
brackets.
4. Turn the manual relief valve 3-4 turns counterclock-
wise then nlanually push the tilt cylinder ram (19, Figure
13) down into the cylinder. Securely tighten the manual
relief valve.
5. Using appropriate snap ring pliers (Figure 14), care-
fully remove both circlips (1 and 29, Figure 13). Support
the trim system while removing the lower mounting pin.
Using an appropriately sized section of tubing or steel rod
(Figure 15), carefully drive the pin (3, Figure 13) from
the clamp brackets and trim system.
6. Pull the trim system back and away from the clamp
brackets. Inspect all trim system mounting pins, bushings,
bolts and circlips for worn or damaged surfaces. Replace
any worn or suspect components.
7. Installation is the reverse of removal while noting the
following:
a. Apply a good water resistant grease to the pivot
points of all pins and bushings during assembly.
b. Align the lower mounting pin bores and carefully
drive the lower pin into the trim system and clamp
brackets. The lower pin must protrude evenly on
each side of the clamp brackets.
c. Open the manual relief valve and manually extend
the tilt ram (19, Figure 13) to align the upper pin
bores. Push the upper pin into position with an ap-
propriately sized section of tubing or steel rod.
d. Install the circlips fully into the grooves of the up-
per and lower mounting pins.
e. Route the trim motor wires to avoid interference
then connect the blue and green wires to the relays.
8. Remove the overhead support and disengage the tilt
lock lever. Connect the negative battery cable. Check and lever and support the engine with blocks or an overhead
fill the trim fluid level as described in this chapter. cable (Figure 2). Disconnect the negative battery cable.
9. Cycle the trim system to the full UP and DOWN posi- 2. Use needle nose pliers, remove the circlip from the
tion. Check for improperly installed components if bind- valve opening. Rotate the valve in the open direction until
ing occurs. free from its bore. Pull the valve from the opening.
3. Use a pick, small screwdriver andlor tweezers to re-
move all remnants of the valve or O-ring from the open-
Manual Relief Valve
ing.
This section provides removal and installation instmc- 4. Lubricate the valve with Dexron I1 automatic trans-
tions For the manual relief valve. Access the valve through mission fluid and carefully slide the O-rings (if removed)
an opening (Figure 1) in the starboard side clamp bracket. onto the valve. Ensure that the O-rings fully seat into their
On DF25 and DF30 models, the opening is located in the respective grooves on the valve.
starboard side clamp bracket. On all other models the 5. Lubricate the O-rings and valve with Dexron I1 auto-
opening is located on the port side clamp bracket. Use an matic transmission fluid and install the valve into the
o ,si head lift or other method (Figure 2) to support the en- opening. Do not tighten the valve at this time.
ginc while replacing the manual relief valve. 6. Rotate the valve in the closed direction until slight re-
1. Operate the trim system or open the manual relief sistance is felt. Rotate the valve 114 turn in the closed di-
valve to position the engine full UP. Engage the tilt lock rection, then 118 turn in the open direction. Repeat this
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HYDRAULIC TRIM AND MIDSECTION 361
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362 CHAPTER ELEVEN
@ IM MOTOR COMPONENTS
Electrical contact cleaner is available at most electrical
DF40 AND DF50 MODELS
supply sources. It evaporates rapidly and leaves no resi-
due. Avoid touching the brushes and commutator after
cleaning; naturally occurring oils on the fingers containi-
nate these components, possibly shortening their service
life. Refer to the instructions for the selected model.
CA UTION
Mark the top cover frame and lower cover
of the electric motor prior to disassembly.
Use paint dots or removable tape. Never
scratch the components, as it promotes cor-
rosion o f metal components.
NOTE
The magnets in the electric motor frame as-
sembly are quite strong. Considerable effort
may be required to remove theframe assem-
bly from the armature. Checkfor remaining
fastefiers, then carefullypull theframe from
the arn~atz~re. 1. Frame
2. Screws
3. Armature
DF25 and DFSO models 4. O-ring
5. Lower cover
1. Mark the frame and lower cover mating surfaces (Fig-
ure 17) for reference during assembly.
2. Hold the frame so it firmly contacts the lower cover
5. Remove the O-ring from the lower cover. Use a suit-
and remove both screws.
able solvent to clean all contaminants from the trim motor
3. Lightly tap the lower cover to separate it from the
components. Inspect the trim motor components as de-
frame. Hold the frame assembly, then grasp the armature
scribed in this chapter.
shaft with pliers and a shop towel (Figure 18). Pull the ar-
mature and lower cover from the frame assembly.
4. Use two small screwdrivers to collapse the brush DF40 and DF50 models
springs and move the brushes away from the commutator.
Carefully pull the armature from the lower cover. Slowly 1. Mark the frame and upper cover mating surfaces (Fig-
release the brush springs. ure 17) for reference during assembly.
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H Y D U U L I C TRIM AND 363
1. Mark the frame (4, Figure 20) and lower cover (1 0) for
reference during asseinbly.
2. Hold the frame (4, Figure 20) while removing both
n~o~inting screws (3) from the lower cover (10).
3. Hold the fraine (4, Figure 20) and grasp the arniature
shaft with pliers and a shop towel as indicated in Figure
I.Screw 8. Brushllead
18. Pull the armature and lower cover away from the
2. Retainer 9. Brush spring frame assembly. Disconnect both leads connected to tlie
3. Screw 10. Lower cover cover mounted brushes.
4. Frame 11. Bushing 4. Use two sniall screwdrivers to collapse the brush
5. Armature 12. Seal springs (9, Figure 201, then move the brush away froni tlie
6. Screw 13. Thrust washer
7. Brush retainer 14. O-ring
comnutator. Pull the armature (5, Figure 20) from the
lower coL1er. Slowly release the brush springs.
5. Remove the thrust washer (13, Figure 20) from the ar-
mature (5). Remove the O-ring (14, Figure 20) from the
lower cover (10).
6. Reniove both screws (6, Figure 201, then lift both
b~xishretainers (7) from the lower cover (10). Disconnect
2. Hold the fraine (1, Figure 19) so it firmly contacts the the wire terminals, then lift the brush lead and breaker and
lower cover (5) and remove all three mounting screws ( 2 ) . b~usliassembly (8, Figure 20) from the lower cover (10).
3. Hold the frame assembly ( I , Figure 191, then grasp the 7. Note the seal lip direction, then carefully push or ply
armature shaft with pliers and a shop towel (Figure 18). the seal and b~ishing(12 and 1 1 , Figure 20) from the
Pull the annature and lower cover from the frame assem- lower cover.
bly.
4. Use two small screwdrivers to collapse the brush Trim Motor Inspection
springs and move the brushes away froni the comnutator.
Carefully p~illthe annat~ire(3, Figure 19) from the lower Tl~oro~igl~lyclean all components prior to testing or
cover. Slowly release the brush springs. measuring. Inspect the magnets in the franie assembly for
5. Remove the O-ring (4, Figure 19) from the lower broken or loose magnets and replace the frame assembly
cover (5). Mark the orientation of the plate to the lower if defective.
cover (5). Reniove the screws, then disconnect the tenni- I . Connect an olimmeter between each brush and ternii-
nal connector. Lift the brusli and lead assembly and plate nal end of the brusli wire (Figure 21). Continuity mist be
fioin the lower cover. present, otherwise replace the bruslies and leads,
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3 64 CHAPTER ELEVEN
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ULIC TRIM AND MIDSECTION 365
DF25 and DF30 models 1. Insert the breakerhn~slllead (8, Figure 20) into the
lower cover (10). Connect the wire terminal to the breaker
and blush retainer.
I. Insert the brushes, springs and leads into their respec- 2. Install the seal into the lower cover with the seal lip
tive recess in the lower cover. Install a new O-ring onto facing down or away from the armature. Place the brush
the lower cover. springs (9, Figure 20) into the recesses provided in the
2. Use two small screwdrivers to position the brushes lower cover. Place the thrust washer (1 3, Figure 20) onto
fully into the blush holders (the springs 111ust be fully col- the upper portion of the armature shaft.
lapsed). Carefully install the commutator end of the a m a - 3. Install the b r ~ ~ retainers
sh (7, Figure 20) onto the lower
ture into the brush holder then release the brusl~es.Never cover. Install the screws and washers (6, Figure 20) and
force the armature into the cover, or the brushes will be securely tighten thein. Position the brushes into the brush
damaged. springs within the lower cover.
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366 CHAPTER ELEVEN
Tl~orougl~ly clean the trim motor mounting surface DF40 and DFSO models
prior to installation. Always install a new O-ring onto the
trim motor-to-trim system mating surface. Using a dete- I. Install a tzew O-ring onto the step of the electric motor
riorated or damaged O-ring allows water intrusion and mating surface. Place the drive coupler onto the shaft cou-
probable damage to internal trim system components. Ap- pling portion of the hydraulic pump. Fill the cavity below
ply a light coating of water resistant grease to the O-ring the trim motor with triin fluid.
prior to installation. To allow for easier filling and air 2. Carefully lower the asmature shaft onto the coupling.
bleeding, fill the cavity below the motor mounting surface Rotate the electric motor until the shaft and coupling align
with Dexron I1 automatic transmission fluid prior to in- (Figure 29) and the electric motor drops into position.
stalling the motor. Refer to the instructions for the se- Rotate the electric motor to align the inarks made before
lected model. removal. The wires must exit the trim motor at tlie point
opposite the hydraulic cylinder.
3. Ensure the O-ring senlains in position then install the
DFZS and DF30 models three mounting screws. Tighten the screws to 6 Nem. (54
in-lb.).
1. Install a new O-ring onto the step of the motor mating 4. Refer to Trim System and install the trim system.
surface. Place the drive coupler onto tlie shaft coupling
portion of the hydraulic pump. Fill the cavity below the
DF60 and DF70 nzodels
tsim motor with trim fluid.
2. Carefully lower the armature shaft onto the coupling. I . Place the filter (5, Figure 16) onto the triin pump. Scat
Rotate the electric motor until the shaft and coupling align the filter into its mounting recess. Fill the trim motor
(Figure 29) and the electric motor drops into position. mounting cavity with Dexron I1 auto~natictransmission
Rotate the electric motor to align the marks made before fluid until even with the top of the filter.
renioval. The wires must exit the trim motor at the point 2. Install a tzew O-ring (4, Figure 16) onto the step of the
opposite the hydraulic cylinder. electric motor mating surface. Place the drive coupler ( 6 ,
3. Install a new fluid reservoir seal onto the trim motor. Figure 16) onto the shaft coupling portion of the 11ydrau-
Apply a light coat of water resistant grease to the seal. lic pump.
Slide the fluid resesvoir over the trim motor with the fill 3. Carefully lower the asmature shaft onto the coupling.
plug facing rearward. Seat the reservoir on the seal and Rotate the electric motor until thc shaft and coupling align
k i m motor. (Figure 29) and the electric niotor drops into position.
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ULIC TRIM AND MIDSECTION 367
system (Figure 30). Remove the O-ring from the trim sys-
/
Fluid reservoir tem or the alignment collar (Figure 30).
3. Remove the fluid fill/clieck cap from the fluid reser-
voir. Using a solvent, clean the inner and outer surfaces of
the reservoir. Use a lint-free shop towel to clean the fluid
reservoir mating surface of the trim system.
4. Inspect the fluid reservoir and trim systeni for deep
scratches, cracks, pitting or damage at thc reser-
voir-to-trim systeni mating surfaces. Replace any dcfec-
tive coniponents.
5. Apply a light coat of water-resistant grease to thc i7ew
O-ring, then place it in position on the trim system as indi-
cated (Figure 30). Witlio~~t dislodging the O-ring, posi-
tion the fluid reservoir onto the trim system. Ensure tlic
aligning collar enters its corresponding opening in thc
trim system.
Rotate the electric motor to align the orientation marks 6. Align the mo~~nting holes in the fluid reservoir with
made prior to removal. The wires must exit the motor on their cossesponding threaded holes in the trim systcni. In-
the front side or opposite both tsim cylinders. stall the three mounting bolts and tighten them to the spec-
4. Install the mounting bolts (2, Figure 16) through tlie ification in Table 1.
lower cover and into the electsic motor mounting pad. Se- 7. Fill the rescwoir with fluid and install the trini systeni
curely tighten the screws. onto the engine.
5. Refer to Einz System and install the cosnplete trim sys-
tem onto the engine.
Hydraulic Pump
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368 CHAPTER ELEVEN
Trim Relay
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HYDRAULIC TRIM AND MIDSECTION 369
MIDSECTION
WARNING
Never work under any part of the engine
without first providing suitable support. The
engine-mounted tilt lock or hydraulic sys-
tem may collapse and cause the engine to
drop. Support the engine with blocks or an
overhead cable before working under the
engine.
CA UTION
Do not use excessive amounts of sealer on
the anode bolt threads. The anodes cannot
protect the engine without maintaining elec-
trical continuity to the engine ground.
Check for electrical continuity after instal-
lation. Remove the anode and clean the
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370 CHAPTER ELEVEN
Anodes
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HYDRAULIC TRIM AND MIDSECTION 371
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372 CHAPTER ELEVEN
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(18). Pull the pins and spring from the lower mount
bracket (33, Figure 40).
4. Remove the mounts from the drive shaft housing as
follows:
a. On DF9.9 and DF15 models remove the four bolts
(16, Figure 37) then carefully pry the mount from
the drive shaft housing.
b. On DF25 and DF30 models remove the rear nuts
(24, Figure 38), washer (25) and cushion (26) from
the mount bolts (28). Remove the nuts and washers
(29 and 30, Figure 38) and carefully pry the lower
1. Gasket mounts (27) and bolts (28) away from the drive
2. Oil pan
3. Grommet
shaft housing (34). Slide the mount from the bolt.
4. Water stream tube c. On DF40 and DF50 models remove the rear nuts
5. O-ring (37, Figure 39), washer (38) and cushion (39) from
6. Plug the mount bolts (41). Remove the nuts and washers
7. O-ring (29 and 30, Figure 39) and carefully pry the lower
8. Hose
9. Plug
mounts (40) and bolts (41) away from the drive
10. Washer shaft housing (20). Slide the mounts from the bolts.
11. Bolt d. On DF60 and DF70 models remove the bolts (32,
12. Clamp Figure 40) and carefully pry the lower mount
13. Water pressure relief brackets (33) from the drive shaft housing. Remove
valve
14. Gasket the rear nuts (34, Figure 40), washer (35) and cush-
15. Bolt ion (36) from the mount bolts (39). Remove the nuts
16. Grommet and washers (21 and 22, Figure 40) and carefully
17. Water pump tube pry the lower mounts (37) and bolts (39) away from
18. Grommet the drive shaft housing (1 8). Slide the mounts and
19. Gasket
20. Exhaust cover washer (38, Figure 40) from the bolts.
21. Bolt 5. Clean the mounting bolts, threaded bolt holes and
22. Bolt mount contact surfaces.
23. Mount cover 6. Inspect all fasteners for wear, corrosion or damage.
24. Nut
Replace any questionable or defective fasteners. Inspect
25. Washer
26. Cushion the mounts for wear or damage. Replace the mount if de-
27. Lower mount fective.
28. Mount bolt 7. Inspect the mount contact surfaces in the drive shaft
29. Washer housing for cracked or damaged areas. Replace the drive
30. Front nut shaft housing if cracks or excessively worn areas arc
31. Ground wire
32. Screw noted.
33. Insulating washer 8. Apply ThreeBond 1342 (Suzuki part No.
34. Drive shaft housing 99000-32050) to the threads of all mount and mount cover
35. Alignment pin bolts. Install the mounts and all applicable fasteners.
36. Washer Tighten the mount fasteners to the specification in Table
37. Bolt
38. Alignment bushing 1.
39. Gasket 9. Install all removed mount covers, ground wires, cush-
40. Oil drain plug ions and brackets. Securely tighten all fasteners.
10. Carefully remove the overhead support from the en-
gine. Connect the negative cable.
Tilt Pin
The tilt pin passes through the tilt pin holes (Figure 35)
in the port and starboard clamp brackets. It is important
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374 CHAPTER ELEVEN
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ULIC TRIM AND MIDSECTION 375
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376 CHAPTER ELEVEN
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HYDRAULIC TRIM AND MIDSECTION 377
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378 CHAPTER ELEVEN
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HYDRAULIC TRIM AND MIDSECTION 379
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380 CHAPTER ELEVEN
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HYDRAULIC TRIM AND MIDSECTION 381
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382 CHAPTER ELEVEN
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HYDRAULIC TRIM AND MIDSECTION 383
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384 CHAPTER ELEVEN
Page: 392 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
HYDRAULIC TRIM AND MIDSECTION 385
Tilt Tube
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386 CHAPTER ELEVEN
Page: 394 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
4. Disconnect the steering linkage and cables from the erly installed components if unusual noise or binding oc-
swivel tube and tilt tube. curs. Repair as required.
5. Remove the large nut that secures the tilt tube to the
starboard clamp bracket.
Swivel Housing
6. Use a one-foot section of pipe or tubing to drive the tilt
tube through the clamp brackets and swivel tube. The se- 1. Remove the trim system (if so equipped) as described
lected tool must be slightly smaller in diameter than the in this chapter.
tilt tube.
2. Support the engine with an overhead cable.
7. Provide just enough overhead support to keep the tube
3. Disconnect the engine from the swivel housing as fol-
from binding during removal. Do not use excessive force
lows:
to remove the tube. Excessive force can cause the end of
the tube to flare out preventing removal from the swivel a. On DF9.9 and DF 15 models remove the lower mo-
housing and port clamp bracket. tor mounts as described in this chapter. Remove the
8. Support the engine, then slowly remove the driver tool. bolts (1 2, Figure 37), nuts (9) and washers (1 0). Re-
Retain the washers as they drop from the clamp brackets move the four bolts (13, Figure 37) to free the en-
and swivel housing. Remove the sealing boot and bushing gine from the upper motor mounts (1 1).
from the port side of the tilt tube. b. On DF25 and DF30 models support the drive shaft
9. Thoroughly clean the tilt tube. Inspect the tilt tube for housing while removing the nuts and washers (29
excessive wear, corrosion, cracking or damage. Replace a and 30, Figure 38) from the lower motor mount.
damaged or worn tilt tube. Remove the four mount cover bolts (1, Figure 44)
10. Thoroughly clean all surfaces of the swivel housing and pull the drive shaft housing (34, Figure 38)
and clamp brackets. Inspect the tilt tube bushings in the from the swivel bracket. Pull the cover (2, Figure
swivel housing for excessive wear, corrosion, or damage. 44) and mount (6) from the power head adapter
If defects are noted, remove the grease fittings and replace (35).
the bushings. Ensure the holes in the bushing bore align c. On DF40 and DF50 models support the drive shaft
with the grease fitting openings. housing while removing the nut and washer (29 and
11. Apply Suzuki water-resistant grease to the tilt tube 30, Figure 39) from the lower engine mount. Re-
bore in the swivel bracket and clamp brackets. move the nuts, washers and cushions (9-1 1, Figure
12. Place the washer (if so equipped) between the clamp 45) then pull the drive shaft housing (20, Figure 39)
brackets and swivel housing and align with the tilt tube from the swivel bracket.
bore. d. On DF60 and DF70 models support the drive shaft
13. Apply a coat of Suzuki water-resistant grease to the housing while removing the nut and washer (2 1 and
external surfaces of the tilt tube. Place the tilt tube into its 22, Figure 40) from the lower engine mount. Re-
opening in the port clamp bracket with the grooved end move the nuts, washers and cushions (9-1 1, Figure
facing the port side. Align the tilt tube bores in the clamp 45) then pull the drive shaft housing (1 8, Figure 40)
brackets, washers and swivel housing during installation from the swivel bracket.
of the swivel tube. 4. While supported with an overhead cable, pull the en-
14. Using a block of wood for a cushion, carefully tap the gine away from the swivel housing. Refer to Figures
tilt tube through the port clamp bracket, swivel bracket 41-43 to identify the swivel housing components and their
and starboard clamp bracket until the threaded end fully orientation.
extends from the starboard clamp bracket. 5. Remove the clamp brackets, tilt lock lever and reverse
5 . Install the large nuts, bushing and washers on the lock mechanism as described in this chapter.
clamp brackets. Tighten the large tilt tube nuts to the spec- 6. Clean the swivel housing. Inspect the housing for wear
ification in Table 1. or damage. Replace the swivel housing if it is defective.
16. Apply Suzuki water-resistant grease to the steering 7. Move the swivel tube through its full range of motion.
cable and tilt tube. Attach the steering cable and linkage to Remove the swivel tube as described in this chapter if it
the tilt tube and swivel tube. Securely tighten all fasteners binds or feels loose.
and engage any fastener locking devices. 8. Assembly is the reverse of disassembly while noting
17. Carefully remove the overhead support from the en- the following:
gine. Connect the negative battery cable. a. Carefully slide the engine mount bolts into their
18. Operate the trim and steering system through the en- openings while positioning the engine to the swivel
tire operating range. Inspect the midsection for improp- bracket.
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b. Apply ThreeBond 1342 (Suzuki part No. e. On DF40, DF50, DF60 and DF70 models ensure the
99000-32050) to the threads of all mount, mount splines in the lower mount bracket (1 1, Figure 43)
cover and mount bracket bolts. properly align the splines of the swivel tube (20).
c. Tighten all fasteners to the specification in Table 1. f. Fit the circlip fully into the groove at the lower end
d. Apply Suzuki water-resistant grease to all bushings, of the swivel tube.
sliding surfaces and pivot points. 9. Install the swivel housing as described in this chapter.
9. Refer to Clamp Bracket and install the clamp brackets
on the swivel housing, Drive Shaft Housing
10. Install the trim system (if so equipped) as described in
this chapter. 1. Remove the power head as described in Chapter Eight.
11. Tilt the engine and operate the steering through the 2. Remove the upper and lower motor mounts as de-
entire operating range. Inspect the midsection for improp- scribed in this chapter.
erly installed components if unusual noise or binding oc- 3. Refer to Figures 37-40 to identify the drive shaft hous-
curs. Repair, as required. ing components and their orientation.
4. Disassemble the drive shaft housing as follows:
On DF9.9 and DF15 models remove the oil pan (38,
Swivel tube Figure 37) as described in this chapter.
On DF25 and DF30 models remove the oil pan (2,
1. Remove the swivel housing as described in this chap- Figure 38) as described in this chapter. Carefully
ter. pull the water pump tube (17, Figure 38) from the
2. Refer to Figures 41-43 to identify the swivel housing oil pan or drive shaft housing.
components and their orientation. On DF40 and DF50 models remove the oil pan (1 7,
3. Remove the circlip (1 1, Figure 41), (44, Figure 42) or Figure 39) as described in this chapter. Remove the
(10, Figure 43) from its groove on the lower end of the bolt (2, Figure 39) and lift the water tube (1) from
swivel tube. Inspect the circlip for corrosion, cracks or the drive shaft housing.
lost spring tension. Replace damaged circlips. On DF60 and DF70 models remove the oil pan (7,
4. Support the lower mount bracket while pulling the Figure 40) as described in this chapter. Remove the
swivel tube up and out of the swivel bracket. bolt (41, Figure 40) and lift the water pump tube
a. On DF25 and DF30 models remove the key (23, (40) from the drive shaft housing. Remove the
Figure 42) from its groove on the lower end of the grommet (42, Figure 40) from the water tube or its
swivel tube. opening in the oil pan.
5. Remove the lower mount bracket, spacers and washers 5. Inspect the drive shaft housing for worn areas, crack-
from the lower end of the swivel bracket in the swivel tube ing or corrosion. Replace the housing if it is defective.
bore. Remove the washers from the upper side of the 6. Inspect all alignment pins and their bores for worn or
swivel tube or swivel tube bore. damaged pins or elongated holes. Replace any defective
6. Inspect the bushings at the upper end of the swivel tube components.
7. Assembly is the reverse of disassembly. Note the fol-
bore in the swivel housing. Remove and replace both
lowing:
bushings if worn or damaged.
a. Install the oil pan as described in this chapter. Install
7. Inspect the swivel tube for cracks, wear or corrosion.
new gaskets, O-ring and seals.
Replace as required.
b. Apply ThreeBond (Suzuki part No. 99000-32050)
8. Assembly is the reverse of disassembly. Note the fol- to the threads of all exhaust tube, engine mount and
lowing: adapter plate attaching bolts.
a. Apply Suzuki water-resistant grease to the swivel c. Install the grommet onto the upper and lower ends
tube bushings and swivel tube. of the water tube. Slide the water tube into the drive
b. Install all washers, bushings and spacers as shown shaft housing.
in Figures 41-43. d. On DF40, DF50, DF60 and DF70 models install
c. Position the lower seal with the seal lip facing up and securely tighten the water tube attaching bolt.
and the upper seal with the lip facing down. e. Tighten all fasteners to the specification in Table 1.
d. On DF25 and DF30 models ensure the key (23, Fig- 8. Install the upper and lower motor mounts as described
ure 42) aligns with its respective slot in the swivel in this chapter.
tube (22). 9. Refer to Chapter Eight and install the power head.
Page: 396 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
HYDRAULIC TRIM AND MIDSECTION 3
Oil Pan 17. Install the upper and lower motor mounts as dc-
scribed in this chapter.
Refer to Figures 37-40 to identify the oil pan and relate 18. Install the power head as described in Chapter Eight.
components. Refer to the instructions for the selected Fill the engine with oil as described in Chapter Four.
model.
Page: 397 Suzuki Outboard Shop Manual 9.9-70HP Four :-Stroke - 1997-2000
~ - - -
htt~://www.ReadManuals.Com
390 CHAPTER ELEVEN
12. Align the pin opening with the alignment pin (35, 9. Align the pin opening with the alignment pin (25, Fig-
Figure 38) while mating the oil pan to the drive shaft ure 39) while mating the oil pan to the drive shaft housing.
housing. 10. Install and evenly tighten the six bolts (2 1, Figure 39)
13. Install and evenly tighten the six bolts and washers to the specification in Table 1.
(36 and 37, Figure 38) to the specification provided in Ta- 11. Install a new gasket (13, Figure 39) and install the
ble 1. power head adapter as described in this chapter.
14. Install a new gasket (1, Figure 38) and install the 12. Install the upper and lower motor mounts as de-
power head adapter as described in this chapter. scribed in this chapter.
15. Install the upper and lower motor mounts as de- 13. Install the power head as described in Chapter Eight.
scribed in this chapter. Fill the engine with oil as described in Chapter Four.
16. Install the power head as described in Chapter Eight.
Fill the engine with oil as described in Chapter Four.
DF60 and DF70 models
DF40 and DFSO models 1. Remove the power head as described in Chapter
Eight.
1 Remove the power head as described in Chapter 2. Remove the upper and lower n~otormounts as de-
Eight. scribed in this chapter.
2. Remove the upper and lower motor mounts as de- 3. Remove the power head adapter as described in this
scribed in this chapter. chapter. Remove the gasket (1, Figure 40) from the mat-
3. Remove the power head adapter as described in this ing surface.
chapter. Remove the gasket (13, Figure 39) from the mat- 4. Remove the eight bolts and washers (5 and 6, Figure
ing surface. 40) and carefully lift the oil pan from the drive shaft hous-
4. Remove the six bolts (21, Figure 39) and carefully lift ing.
the oil pan from the drive shaft housing.
5. Thread the water stream fitting (8, Figure 40) from the
5. Remove the four bolts (3, Figure 39) and lift the cover oil pan. Pull the plug and O-ring (9 and 10, Figure 40)
(4), water pressure relief valve (6) and grommet (5) from
from the fitting. Replace the O-ring during installation.
the housing (7). Tap the housing (7, Figure 39) to remove
6. Carefully pry the exhaust grommet (1 1, Figure 40)
it from the oil pan. Carefully scrape the gasket (8, Figure
from the oil pan. Remove the flush fitting (13, Figure 40)
39) from the mating surfaces.
from the oil pan. Replace the O-ring (12, Figure 40) dur-
6. Thread the water stream fitting (9, Figure 39) fro111
ing installation.
the oil pan. Pull the cover and O-ring (10 and 11, Figure
7. Use a suitable solvent to clean all contaminants from
39) from the fitting. Replace the O-ring during installa-
the oil pan. Inspect the oil pan for cracked or corrosion
tion.
damaged surfaces. Replace the oil pan if it is defective.
7. Use a suitable solvent to clean all contaminants from
8. Assembly is the reverse of disassembly while noting
the oil pan. Inspect the oil pan for cracked or corrosion
the following:
damaged surfaces. Replace the oil pan if it defective.
8. Assembly is the reverse of disassembly while noting a. Install new O-rings at all locations during assembly.
the following: b. Coat all O-ring, grommets and seals with Suzuki
Install a new gasket (8, Figure 39) to relief valve water resistant grease during assembly.
housing (7). Install the water pressure relief valve c. Apply Suzuki silicone seal (part No. 99000-3 1120)
with the cupped plate side facing out or away from to the oil pan and drive shaft housing mating sur-
the oil pan. faces.
Install new O-rings at all locations during assem- d. Align the water tube and grommets with their open-
bly. ing in the oil pan during installation.
Coat all O-ring, grommets and seals with Suzuki e. Tighten all fasteners to the specification in Table 1.
water resistant grease during assembly. 9. Align the pin opening with the alignment pin (16,
Apply Suzuki silicone seal (part No. 99000-3 1120) Figure 40) while mating the oil pan to the drive shaft
to the oil pan and drive shaft housing mating sur- housing .
faces. 10. Install and evenly tighten the six bolts and washers (5
Align the water tube and grommets with their open- and 6, Figure 40) to the specification in Table 1.
ing in the oil pan during installation. I I . Install a new gasket (1, Figure 40) and install the
Tighten all fasteners to the specification in Table 1. power head adapter as described in this chapter.
Page: 398 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
M AND MIDSECTION 39
12. Install the upper and lower motor mounts as de- 4B. On DF60 and DF70 models remove thc three oil
scribed in this chapter. pump bolts (3 1, Figure 44) and lift the oil pump from the
13. Install the power head as described in Chapter Eight. adapter. Replace the O-ring (24) during installation.
Fill the engine with oil as described in Chapter Four. 5. Remove the oil pressure relief valve (23, Figure 44)
from the adapter. Replace the sealing washer (22, F'g * I ure
44) during assembly.
Power Head Adapter
6. Remove all plugs, fittings. gaskets and seals from the
DF25 and DF30 models adapter.
7. Use a suitable solvent to thoroughly clean the power
1. Remove the power head as described in Chapter Eight. head adapter.
2. Remove the upper and lower motor mounts as de- 8. Disassemble and inspect the oil pump as described in
scribed in this chapter. Chapter Eight.
3. Remove the four bolts (12, Figure 44) and carefully 9. Assembly is the reverse of disassembly while noting
pry the power head adapter from the oil pan. the following:
4. Remove the two bolts (34, Figure 44) and pull the oil a. Fill the oil pump with engine oil prior to installa-
pickup tube (32) from the adapter. Replace the O-ring (33, tion.
Figure 44) during assembly. b. Install new O-rings, gaskets and seals if removed.
5. Remove the three oil pump bolts (3 1, Figure 44) and c. Apply Suzuki water resistant grease to all seal and
lift the oil pump from the adapter. Replace the O-ring (24, O-rings during assembly.
Figure 44) during installation. d. Tighten all fasteners to the specification in Table 1.
6. Remove the oil pressure relief valve (23, Figure 44) 10. Install the drive shaft housing as described in this
from the adapter. Replace the O-ring (22, Figure 44) dur- chapter.
ing assembly.
7. Remove all plugs, fittings, gaskets and seals from the
adapter. Tiller Control Repair
8. Use a suitable solvent to thoroughly clean the power
head adapter. 1. Refer to the following illustrations during disassembly
9. Assembly is the reverse of disassembly noting to: and determine which components need to be removed to
a. Fill the oil pump with engine oil prior to installa- access the defective component(s):
tion. a. Figure 46 for DF9.9 and DFl5 models.
b. Install new O-rings, gaskets and seals if removed. b. Figure 47 for DF25 and DF30 models.
c. Apply Suzuki water resistant grease to all seal and c. Figure 48 for DF40-DF70 models.
O-rings during assembly. 2. Inspect all components and fasteners for wear or dam-
d. Align the oil pump shaft to the camshaft as de- age. Never reuse a questionable component.
scribed in Chapter Eight. 3. Inspect the throttle and lor shift cables, especially
e. Tighten all fasteners to the specification provided in where they pass through the opening in the tiller handle
Table 1 . bracket. Make sure the cable moves smoothly in its 110~1s-
10. Install the drive shaft housing as described in this ing. Replace any damaged or worn cables. Refer to Chap-
chapter. ter Five for adjustment procedures.
4. Inspect all bushings and pivot bolts or tubes. Replace
D M ,DF50, DF60 any that are damaged.
and DF70 models 5. Use ThreeBond 1342 (Suzuki part No. 99000-32050)
on all fastener threads during assembly. Use Suzuki wa-
1. Remove the power head as described in Chapter Eight. ter-resistant grease on all bushings, pins, rods and pivot
2. Remove the upper and lower motor mounts as de- surfaces. Apply this grease to the grip mating surface (20,
scribed in this chapter. Figure 47) and throttle rod assembly.
3. Remove the six bolts and washers (3 and 4, Figure 40) 6. Route all wires to avoid interference during assembly.
and carefully pry the power head adapter from the oil pan. 7. Refer to Table 1 for torque specifications. Use the
4A. Remove the two bolts (1, Figure 45) and pull the oil standard torque specification (QRD) if one is not listed.
pickup tube (2) from the adapter. Replace the O-ring (3, 8. Check for proper steering and tilting when assembly is
Figure 45) during assembly. complete.
Page: 399 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
392 CHAPTER ELEVEN
1. Oil pressure light 11. Pin 22. Cable bracket 32. Washer
2. Insulator 12. Stopllanyard switch 23. Grommet 33. Washer
3. Protective wrap 13. Lanyard cord 24. Screw 34. Tiller bolt
4. Throttle cable 14. Plastic nut 25. Clamp 35. Clamp
5. Plastic locking 15. Cap 26. Remote steering 36. Screw
clamp 16. Bolt bracket 37. Washer
6. Grommet 17. Washer 27. Bolt 38. Bolt
7. Grommet 18. Sleeve 28. Pad 39. Spring
8. Plastic nut 19. Grip 29. Support 40. Stop
9. Starter button 20. Screw 30. Screw
10. Nut 21. Grip liner 31. Tiller arm
Page: 400 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
HYDRAULIC TRIM AND MIDSECTION 393
1. Bushing
2. Wave washer
3. Washer
4. Spacer
5. Washer
6. Cover
7. Lockwasher
8. Bolt
9. Throttle rod
10. Throttle cables
11. Pin
12. Friction pin
13. Bushing
14. Friction screw
15. Spring
16. Bolt
17. Washer
18. Stop
19. Grip
20. Grip mating surface
21. Tiller arm
Page: 401 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
394 CHAPTER ELEVEN
Page: 402 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
HYDRAULIC TRIM AND MIDSECTION 395
Page: 403 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
CHAPTER ELEVEN
Page: 404 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
Commutator diameter
DF25, DF30 18.5-19.5 mm (0.728-0.768 in.)
DF40, DF50, DF60, DF70 21 .O-22.0 mm (0.827-0.866 in.)
Commutator undercut
DF25, DF30 0.5-1.6 mm (0.020-0.063 in.)
DF40, DF50, DF60, DF70 0.5-0.8 mm (0.020-0.031 in.)
Brush length
DF25, DF30, DF40, DF50 4.8-9.8 mm (0.189-0.386 in.)
DF60, DF70 9.0-12.5 mm (0.354-0.492 in.)
Page: 405 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
Chapter Twelve
Remote Control
Page: 406 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com~
MOTE CONTROL 399
(0.43 in.)
7 r-
Page: 407 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
400 CHAPTER TWELVE
1. Back plate
2. Throttle arm
3. Throttle cable connector
4. Throttle only cam
5. Retainer
6. Roller bushing
7. Gear
8. Shift lever
9. Shift cable connector
10. Detent roller
11. Spring
12. Throttle only roller
13. Throttle only lever
14. Remote control wire
harness
15. Lanyard
16. Shiftlthrottle handle
17. Trim switch
18. Neutral lock cam
19. Control housing
20. Neutral switch
9. Remove the E-clip that secures the shift cable (Figure proper remote control operation after assembly. Improper
4). assen~blycan cause internal binding or reversed cable
10. Repeat Steps 6-8 for the shift cable. movement.
11. Position the support clamp over both cables at the rear If complete disassembly is not required to access the
portion of the remote control. Carefully slip the support faulty component(s), perform the disassenlbly steps until
clamp into its recess in the control housing. the desired component is accessible. Reverse the disas-
12. Install the lower back cover and screws (Figure 3). scmbly steps to assemble the remote control.
Securely tighten the screws. Slip the tabs of the small Use compressed air to blow debris from the external
cover into the opening and snap it into position. surfaces prior to disassembling the remote control. Clean
13. Install the control and attaching screws, spacers, all components (except electric switches and the warning
washers and nuts as indicated in Figure 1. Refer to Chap- buzzer) in a suitable solvent and blow them dry with coin-
ter Five and adjust the throttle and shift cables. pressed air. Inspect all components for wear or damage.
14. Connect the negative battery cable. Check for proper Replace any defective components. Apply Suzuki wa-
shift and throttle operation. Correct any problems before ter-resistant grease to all pivot points or sliding surfaces
operating the engine. on assembly. Test all electric components when they have
been removed to ensure proper operation after assembly.
Refer to Chapter Three to test the warning buzzer,
Remote Control Disassembly, switches and other electrical components. Refer to Figure
Inspection and Assembly
6 during disassembly and assembly.
NOTE 1. Disconnect both cables from the battery.
Apply ThreeBoid 1342 (Suzuki part No. 2. Refer to Control Cable Removal and Insta//at~onin
99000-32050) to the threads of the remote this chapter and remove the throttle and shift cables from
control handle nut or bolt on assembly.
the remote control.
Always mark the orientation of all components prior to 3. Disconnect the control wire harness from the eni.' mine.
removing them. This important step can help ensure Route the wire harness away from any boat structure to al-
Page: 408 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
REMOTE CONTROL 401
Throttle
friction screw
Circlip
Throttle
friction band
@
switch arm
Page: 409 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
402 CHAPTER TWELVE
Detent roller
@
Neutral position lever
Page: 410 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
REMOTE CONTROL 403
Page: 411 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
A Cylinder Fuel system
block carburetor
Adjustment
assembly . . . . . . . . . . . . . . . 2 76.280 overhaul . . . . . . . . . . . . . . . 187-192
choke solenoid and
cleaning . . . . . . . . . . . . . . . 2 66.268 removal and installation . . . 186-187
choke linkage . . . . . . . . . . . . . . . 169
component removal . . . . . . 2 58.262 injection system . . . . . . . . . . . 192-198
dashpot . . . . . . . . . . . . . . . . . . 169-170
disassembly . . . . . . . . . . . . 262-266 pump. low pressure . . . . . . . . 183- 185
idle speed . . . . . . . . . . . . . . . . 167-169
inspection . . . . . . . . . . . . . . 2 68.275 Service precautions . . . . . . . . 175-183
neutral-only start cable . . . . . . 170-17 1
head . . . . . . . . . . . . . . . . . . . . 2 44.257 silencer cover . . . . . . . . . . . . . 185- 186
pilot screw . . . . . . . . . . . . . . . 166-167
shift cable and linkage . . . . . . 160-165 troubleshooting . . . . . . . . . . . . . . 4 1.52
throttle cable and linkage . . . . 155-160 Fuses and wire harness
D troubleshooting . . . . . . . . . . . . . . 8 1-82
trim position sender . . . . . . . . 171- 172
trim tab . . . . . . . . . . . . . . . . . . . . . . 172 Dashpot
valve . . . . . . . . . . . . . . . . . . . . 148-155 adjustment . . . . . . . . . . . . . . . 169-170
Page: 412 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke .1997-2000 http://www.ReadManuals.Com
INDEX 405
Page: 413 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke .1997-2000 http://www.ReadManuals.Com
406 WIRING DIAGRAMS
Oil
Lanyard1 pressure Fuse
20A Battery Diagram Key
stop light
I switch n Connectors
Ground
Â
33 - Frame ground
No connection
Rectifier1
regulator
(120 watt
Y
system)
R
Color Code
B Black
W White
R Red
G Green
L Blue
Y Yellow
0 Orange
pressure P Pink
B/W BlackIWhite
BIR BlackIRed
~l~wheel- 1 \
WIG WhiteIGreen
Battery charge Ignition
Spark coil (30 & 80 charge coil R/W RedIWhite
. -
uluas watt systems) Rff Red/Yellow
Page: 414 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
WIRING DIAGRAMS 407
Neutral Oil
Lanyard1
stop
only
start
pressure
light ST Battery Diagram Key
7- switch switch
Connectors
CDI unit
I Efl Ground
- Frame ground
Color Code
B Black
W White
R Red
G Green
L Blue
Y Yellow
0 Orange
P Pink
Br Brown
Oil B/W BlackWhite
pressure BIR BlackIRed
switch WIG WhiteIGreen
RAW Redwhite
~l~wheel' \ R N RedNellow
Battery charge Ignition
Spark coil (30 & 80 charge coil UR BlueIRed
plugs watt systems) YIG YellowIGreen
Page: 415 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
4ns WIRING DIAGRAMS
Oil Neutral
Lanyard1 pressure only Starter Electric Diagram Key
stop light start button starter
switch
n switch connectors
Ground
Â
- Frame ground
a3
+
Connectio
No connection
I Battery
:0
as
AA W White
R Red
c G Green
0 Ã
S 0 L Blue
C 0
-
m Y
0
Yellow
Orange
P Pink
Br Brown
Battery / Ignition
Oil Starter B/W Black~White
charge pressure relay BIR BlackIRed
charge switch
coil WIG WhiteIGreen
Flywheel coil
R/W RedWhite
R/Y RedNellow
Spark
YIG YellowIGreen
Plugs
Page: 416 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
WIRING DIAGRAMS 409
Oil Neutral
Lanyard1 Pressure only Starter Electric Diagram Key
stop light start
switch n switch
+ No connection
Battery
Page: 417 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
410 WIRING DIAGRAMS
Optional
dash mounted
gauges
TT
I!
Dash
light
switch
Page: 418 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
WIRING DIAGRAMS 411
Color Code
B Black
W White
R Red
G Green
1 With L Blue
optional Y Yellow
120 watt 0 Orange
I system P Pink
Br Brown
Gr Gray
B W BlacklWhite
BIR BlackIRed
WIG WhiteIGreen
FUW RedWhite
RIG RedIGreen
YIG YellowIGreen
Page: 419 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
412 WIRING DIAGRAMS
Low oil
pressure1
Lanyard1 overheat Diagram Key
stop warning light
switch Connectors
@mn
Â
Ground
Frame ground
Connection
-I-
No connection
R
B
R/W
WIB
0
Bff
BIG
WlR
G
I Battery
Br
YIB
v/w
LN
UR
UB
P
B
G
L
0
Color Code
B Black
W White
R Red
G Green
L Blue
Engine Y Yellow
temperature 0 Orange
sensor P Pink
V Violet
Spark Br Brown
BIG BlackiGreen
Plug Bff BlackNellow
WIB WhitelBlack
WIR White/Red
RiW RediWhite
UB BlueIBlack
UR BlueIRed
LN Blueffellow
YIB YellowIBlack
ViW VioletJWhite
Page: 420 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
WIRING DIAGRAMS 413
Low oil
pressure1
overheat Neutral
Lanyard1 warning only Starter Diagram Key
stop light start button
switch switch ~onnectors
G) (=\ Z, Ground
T J Â
Frame ground
+ .
Connection
1
No connection
Color Code
B Black
G Green
L Blue
Y Yellow
0 Orange
P Pink
V Violet
Spark Spark Spark Br Brown
plug Plug Plug BIG BlacWGreen
BN Black~Yellow
WIB WhiteIBlack
WIR WhiteIRed
R/W Redwhite
UB BlueIBlack
UR BlueIRed
L/Y BlueNellow
YIB YellowlBlack
V/W VioletlWhite
Page: 421 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
414 WIRING DIAGRAMS
1
I
I
dash mounted I
I
gauges
Dash
light
switch
Harness
connector
Page: 422 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
WIRING DIAGRAMS 415
Low oil
pressure1
overheat
warning choke
light On'Y solenoid
start
switch I
à ‘
I 10- Diagram Key
CDI unit
I I connectors
Ground
Frame ground
No connection
5z
c Ã
Page: 423 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
416 WIRING DIAGRAMS
ootional n n
Sn^
dash mounted
gauges Meter
W
&mm$
Dash light
switch
I Warning
I Ignition
I switch buzzer
I
t--- ---..---------..
Remote control
Spark Spark Spark
Plug Plug Plug
Page: 424 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
CDI unit
WIRING DIAGRAMS 419
5 Ground
Frame ground
+ No connection
r'^
Battery
Color Code
B Black
W White
R Red
G Green
L Blue
Y Yellow
0 Orange
P Pink
V Violet
Br Brown
Sb Sky blue
BIG BlackIGreen
BN BlackNellow
WIB WhiteIBlack
WIR WhiteIRed
fVW ReWhite
UB BluelBlack
UR BlueIRed
UY BlueNellow
YIB YellowlBlack
0lG OrangeIGreen
6
ON OrangeNellow
VIW VioleWhite
Idle air
Lanyard Warning Ignition
control switch buzzer switch
motor
Page: 427 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
420 WIRING DIAGRAMS
DF40
REMOTE CO
Page: 428 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
422 WIRING DIAGRAMS
Throttle
position
switch
Air
temp
sensor
- Manifold
temp
Oil
pressure
switch
Engine
temp
sensor
Neutral
switch
0A
no
Electric Diagnostic
Fuel injectors Fuse fuel connector
15A pump with cover
Page: 430 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
WIRING DIAGRAMS 423
Color Code
B Black
W White
R Red
G Green
L Blue
Y Yeliow
0 Orange
P Pink
V Violet
Br Brown
sb Sky blue
BIG BlacWGreen
BN BlackNellow
WIB WhiteIBlack
WIR WhitelRed
RiW RedIWhite
30A Electric
.-.- ".. switch buzzer switch
UB
L/R
BlueIBlack
BlueIRed
starter motor
UY BlueNellow
YIB YellowIBlack
0IG OrangeIGreen
ON OrangeNeliow
ViW VioletiWhite
Page: 431 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com
424 WIRING DIAGRAMS
Flywheel
Throttle Air
position temp
switch sensor
with cover
Page: 432 Suzuki Outboard Shop Manual 9.9-70HP Four Stroke - 1997-2000 http://www.ReadManuals.Com