Suzuki DF140 Set-Up Manual

$ET"UP
ffiAilUA[
IMPORTANT
..--/
AWARNINGICAUTION/NOTE
information,
thesymbolA
Toemphasize
special
carefully,
Ptease
readthismanual
andfollowitsinstructions
attention
to themesPayspecial
meanings.
andNOTEhavespecial
andthewordsWARNING,
CAUTION
sageshighlighted
bythesesignalwords.
Indicatesa potentlalhazardthat could result in deathor Iniury.
CAUTION
Indicatesa potentialhazardthat could result in motor damage.
NOTE:
lndicatesspecialinformationto makemaintenanceeasieror instructiansclearer.
that the warningsand cautionscontainedin this manualcannotpossiblycoverall
Pleasenote,however,
potentialhazardsrelatingto the servicing,or lack of servicing,of the outboardmotor.In additionto the
safetyprinciples.
andbasicmechanical
stated,youmustusegoodjudgement
WARNINGS
andCAUTIONS
FOREWORD
motorhasbeendesigned
andproduced
Thisoutboard
utilizing
Suzuki's
mostmoderntechnology.
Thefinest
product,however,
cannotperformproperlyunlessit is correctly
assembled
Thisset-upmanual
andserviced.
hasbeenproducedto aid youin properlyassembling
andservicingthisoutboardmotor.
. This manualhas beenpreparedon the basisof the
latestspecifications
at the timeof publication.
lf
modifications
havebeenmadesincethen,differences
mayexistbetweenthe contentof this manual
andthe actualoutboardmotor.
. lllustrations
in this manualare usedto showthe basicprinciples
of operation
andworkprocedures
and maynot representthe actualoutboardmotorexactlyin detail.
t Thismanualis intended
forthosewhohaveenoughknowledge
andskillsto serviceSUZUKIoutboard
motors.
Withoutsuchknowledge
andskills,youshouldnotattemptservicingby relyingon thismanual
only.lnstead,pleasecontactyournearbyauthorized
SUZUKIoutboardmotordealer.
Apprenticemechanicsor do-it-yourselfmechanicsthat don't have the proper tools and equlpment rnay not be able to properlyperformthe servicesdescribedin this manual.lmproperassemblyand/orservicing may result in injury to the mechanieand may renderthe engine unsafe
for the boat operatorand passengers.
CONTENTS
SYMBOL.
........,.........
I
MATERIALSREAURED
......,...1
OUTBOARDMOTOR INSTALLATION
......2
HORSEqOWERSELECTTON
.............
.......,.......
2
MOTORDIMENSIONS
,,...2
MOUNTINGTO THE TRANSOM
.,..... g
TRANSOMDTMENSIIONS
.................
s
CONT4OLCABLES INSTALLATTON
.......4
REMOTECONTROLBOX SiDE
.......4
ENGTNE
SIDE
......,............
4
WIRE HARNESSINSTALLATION
...........,.
8
DRAGLINK TNSTALLATTON
g
.........,-..........
couNTER ROTAnONMODELOR DUAL ENGINE,T\E-RODKtT (O?T\ONAL ?ARTS)
iN9TALLATION........
..................
11
INSTALLATION
WITHTHE PRE-RIGGEDITEMSFOR 2 CYCLEMODEL............,..14
wtRtNc DTAGRAM
.....,...........
16
WIRINGDIAGRAMFOR DUAL ENGINE
.................
17
SUZUKI MOTORCORPORATION
O COPYRIGHT
SUZUKIMOTOBCORPORATION
2OO1
Marine& PowerproductsDivision
SYMBOL
-
Listedin thetablebeloware symbolsindicatingspecialinstructions
andotherimportantinformation
necessaryforproperservicing.
foreachsymbol.You
Pleasenoiethedefinition
willfindthesesymbols
usedthroughoutthismanual,Fleferbackto thistableif you are notsureof anysymbol(s)meanings.
SYMBOL
g
DEFINITION
Torquecontrolrequired.
Data besideit indicatesspecified
torque.
@
ApplySUZUKIWATERFIESISTANT
GREASE.
@
ApplySUZUKISILICONE
SEAL.
MATERIALS
REOUIRED
SUZUKISILICONESEAL
99000-31120
(50 g/1.7oz)
SYMBOL
DEFINITION
.-
ApplyTHHEADLOCK"1342".
1J1E13l
@
Usespecialtool,
OUTBOARDMOTORINSTALLATION
HORSEPOWER
SELECTION
Do not overpoweryour boat. Neverinstall an outboardmotor wlth horsepowerexceedingthe
boat manufacturer'srecommendedmaximum.Excessivehorsepowerwill havean adverseeffect
on hull safety and may causeoperating/handlingdifficulties.
NOTE:
' Stafe the maximumhorsepoweroutboardmotor that can be safelyused on that boat.Thereis severe
productliabilitypotentialconnectedwithriggingand sellinga boat withan outboardmotorexceedingthe
horsepower capacityIimitatian.
' The rig shouldnot be underpowered,as this will not allow the performancebalanceyou are trying to
achieve.Determinethe customefs needs,applicatianand use of the perspectiverig to make the best
overalI horsepower recommendation.
MOTORDIMENSIONS
L:998(39.3)
UL:1116(43.9)
t
$
@
F.
^cY
N (o
FN
J
J
:>(O
6(O
6(o
-i5
2
.MOUNTINGTOTHE TRANSOM
t--lContained parts
Item
Partname
@
@
@
Bolt(M12)
Washer(Large)
Washer(Small)
Lockwasher
Nut
cap
o
{ F)
r F!
v
[l
Part number
09100-12083
09160-12044
09160-12066
09162-12005
09140-12028
41153-94500
Q'ty
4
4
4
4
4
4
r.rutO: 55N.m(5.skg-m,40.0
tb-ft]
Drillthe upperholesat least2s mn (1.0 in)awayfromthe transomtop surface.
lnstallthe largediameterwasher@ on the transomboardside.
Toensurea water-tightengineinstallation,sealant(SUZUKISTLICONE
SEAL or equivalent)shouldbe
appliedto all bolt holes.
lf tighteningtorquecannotreachta the specifiedtorquedue to weak transommaterial,it is necessaryto
reinforcethe transomboardwithan attachmentplate.
'\--ITRANSOMDIMENSIONS
Transomtop surlace
"l
3
CONTROLCABLESINSTALLATION
Containedparts
Part name
Remotecontrolbox
Part number
Q'ty
67200-99E10-0EP 1
ForU.S.A.model,remotecontrolboxis optional.
Requiredparts
Part name
Controlcable
7ft (2.1m)
Controlcable8ft @A m)
Controlcable
10ft(3.1m)
Controlcable
12fi(8.7m)
Controlcable
14ft(a.Bm)
Part number
Part name
Part number
Q'ty
Controlcable
16ft(a.9m)
Controlcable
18ft(5.5m)
Controlcable
2oft(6.1m)
Controlcable22ft(6.7m)
67320-89J50
67320-89J60
67320-89J70
67320-89J80
2
2
2
2
Q'ty
67320-89J00
67320-89J10
67320-89J20
67320-89J30
67320-89J40
2
z
2
2
2
Ghooseone itemwhichis matchedto the boatin length.
REMOTE CONTROL BOX SIDE
Fortheprocedure
to connectthethrottlecontrolcableandclutchcontrolcableto the remotecontrolbox,refer
to the "REMOTE
CONTROLBOXSET-UPINSTRUCTION'that
comessuppliedwith each unitof remote
controlbox.(forRemotecontrolmodelonly)
ENGINESIDE
Containedparts (Remotecontrol model)
Item
Part name
Part number
Q',ty
@
@
Grommet
Cablestopper
Bolt
Cableconnector
Washer
Lockpin
61124-90J00
67343-90J01
01550-06257
67467-89J01
09160-06055
0938s-0601
2
1
1
6\
v
@
@
o
J
2
/A\
\E/.
V
I
2
NOTE:
Beforeperformingthe foltowingprocedures,be sure that the
throttle/clutchcontrol cablesare instattedin the remotecontrol
box accordingto the "REMOTECONTROLBOX SET-{JPtNSTRUCTION".
(for Remotecontrolmodelonty)
\
b
4
.
Procedure
/1) Removethe nine(9) bolts,thenremovethe bothsidelower
coversfromthe outboardmotor.
'2\ Installthe clutchcontrolcableO and throttlecontrolcable
,_-,/ @ to tne grommet@.
(3) SecurethecableO and@ in tne cableholder@ oy titting
grooveon the cableintoa sloton the holder.
NOTE:
Referto thepageI for installingwireharnessto the grommet.
(4) Installthe cablestopper@ by the bolt @.
(5) Positionthe remotecontrolhandleinto "NEUTRA|-'.
$:
5
r--.-..-...-
I
- Clutchcontrolcable(6) Makesurethatthe clutchcontrolarm @ is in the neutralposition.
\-:
(7) Threadtheconnector
holealignswiththepivotpin
O ontotheclutchcontrolcable
C untiltheconnector
@ on the clutchcontrolarm @.
(8) Settheconnector@ ontothe pivotpin@ withtheflat sideof connectortowardstne arm.
(9) Installthe
washer(p and lockpin@ , thentightenthetocknut@,
(10)Makesurethatbothforwardand reversegearcanbe engagedwiththe sameangleof remotecontrol
handletravelfrom"NEUTRAHoosition,
- Throttlecontrolcable(11)Makesurethatthethrottlelever@ is fullyclosed.(TheCTP
svvitch
@ mustbe in "ON- pushed"position.)
Alsomakesurethatthe stitmarkon the throttlecontrolarm
@ alignswiththe slit markon the bracket@.
(12)Whilepushingthe throttlecontrolcable@ as shownby arrow,threadtheconnector
@ ontothecableuntiltheconnectorholealignswiththe pivotpin@ on thethrottlecontrolarm
@.
(13)Settheconnector
@ ontothepivotpin@ withtheflatsideof
connector
towardsthe arm.
(14)lnstallthe washer@ and lockpin @ , thentightenthe lock
nut@,
(15)Movethe remotecontrolhandle
to thefullyopenedposition
andreturnit to the neutralposition
again.Makesurethatthe
throttleis fullyclosed.
CAUTION
Cableconnectorsand turnbacklesmust be threadedat
least8 mm (0.3in) onto cable.
NOTE:
After assembly,make sure that the cablesare not stretchedor
otherwisesfressedwhenthe outboardmotoris turnedallthe wav
to the rightand left.
Aftercompleting
above,performthe folstep No.15mentioned
lowingprocedure
ThrottlePosition)
to verifythattheCTP(Closed
switchis correctlyadjusted.
(1) Removethe CTP switchharnessleadand connecta VoltOhmmeterto the switchterminalandto engineground,
(2) Movetheremotecontrolhandteoncemoreto tnetuilyopened
position,
thenreturnit slowlyto the fullyclosedthrottle,in
gearidleposition(lowerunitstillengagedin fonvardgear
withthrottleat fullclose.)
6
-_-/
to theCTPswitch.lt mustindicatetheswitchhasturnedto the"ON"oosition
'(3) Checkthemeterconnected
(meierwill indicatecontinuity).
(4)
lf the CTPswitchis in the "OFF"position(Nocontinuity)
at the in gearidleposition,loosenthe remote
controlcableconnector
locknutand readjust
the cableconnector
slightlyuntiltheCTPswitchis in the
"ON"condition(continuity
indicated).
(5) Afterreadjusting
thecableconnector,
tightenthelocknutandmovetheremotecontrolhandleto thefully
openedpositionand backto the in gearidle positionto confirmthatthe CTP switchis now correctly
(switchin the "ON"position,
adjusted
indicated).
continuity
.'-.{6)
Whencorrectswitchadjustmenthas beenconfirmed,removethe volt-Ohmmeterand reconnectthe
CTPswitchharnesslead.
Neutral
N
NOTE:
Failureto properlyadjustthe CTP switchmay cause the engineto stallwhenretrurnedto the in-gearidle
position.Thismay occur to non-activationof the ECM electricdash-potfunctionwhichis controltedby the
CTPswitch's"ON"/ "OFF"position.
WIRE HARNESSINSTALLATION
Contalnedparts
Item
@
@
/6r
\r'
@
Partname
Monitor-tachometer
Monitorgaugewire
Trimmeterwire harness
lnstrument
wire harness
Part number
34200-99E00
36682-92E00
36682-90J00
36630-92E00
Q'ty
1
1
1
1
Procedure
(1) Removethe bothsidelowercovers.(Seepage5.)
(2) Boutethefollowingitemsthroughthe grommete as shown
position.
. Remotecontrolwireharness@.
. Monitorgaugewireharness@.
.Trimmeterwireharness@.
.Batterycable@.
. Speedmeterpickuptube @.
NOTE:
For the procedureto installoptionaltrim sender/meterand related parts,referto the'TRIM SENDERKIT TNSTALLATION
lNSTRUCTIONS"
that comessuppliedwitheachunitof trimsender
kit.
(3) Connectthe monitorgaugewireharness@ to the engine
side,thenpressfit theconnector
intotheholder@.
(4) Connectthe remotecontrolwire harness@ and PTTwires
@ to the engineside,then pressfit the connectorintothe
holder@.Routethemonitorgaugewireharness@ andPTT
wires@ behindthe connectorol @.
(5) Pushthe grommetO intothe frontpanel.
NOTE:
For the remotecontrolbox/meter/wireharnessconnection,refer
to the WIRINQDIAGRAMon page 16.
I
1RAG LINK INSTALLATION
lf the drag link and related parts are not Installedcorrectly the steeringsystemmay bind,causingthe operaJtor to lose steeringcontrol of the boat.
NOTE:
These instructionsare for connectinga mechanicalpush-pull
steeringsystemwith the followingspecifications:
.
, Singlecable
v
Starboardcableentryinto the motor tilt tube.
. Steeringcablemeetingthe currentAmericanBoat and Yacht
CouncilESafetystandard(P-17).
Containedparts
Item
@
@
/Fr
\r'
@
\EJ
@
Partname
Pad number
Q'ty
Draglinkassy
. Draglink
. Spacer
. Bolt
. Safetynut
. Washer
Steering
cableseal
67701-90J00
. Notavailableseparately
.67721-99E00
.67725-99E00
.67726-99E00
.67728-99E00
41161-94400
1
1
1
2
4
1
CAUTION
Neverreusethe safetynut (D afterit havebeenthreaded
into position and torqued.
Procedure
(1) Threadthesteeringcableseal@ ontothe portsideendof
the motortilttrrrbe
O.
\*-(2) ApplySUZUKIWATEBRESISTANT
GREASEto the steeringcable@.
(3) Insertthecable@ intothetubeO fromthestarboard
side,
thentightenthecableretaining
nut@ to thetorquespecified
by the cablemanufacturer.
NOTE:
it will be necessaryto inOn mostoutboardmotor installations,
siaiithesieeringcabieprior io ihe ouiboarcirrptot'irisiailation.
I
l.D.mark:
67711-90J00
(4) Connectthe drag link @ to the steeringcableend @ with
thenut@ to
washers@ andsafetynutO as shown'Tighten
torque,thenBAGKTHENUTOFF1/BTURN'
thespecified
[t
satety nut (D : 10 N'm (1.0kg-m,7'0lb-ft)
(s) Movethe steeringcableuntilthe holeof draglink@ aligns
withthe rearthreadholeon the steeringbracket@'
(6) Connectthe draglinkto thesteeringbracket@ bytightening
thebolt@ withthe spacer@ andwashers@ as shown'
[l
T-'\
\,,
aon @ : 34 N'm (3.4kg-m,24'slb'ft)
Tightenthe safe$ nut @ withthe washer@'
[l
Satetynut (D :34 N'm (3.4 kg-m,24'5 lb-ft)
NOTE:
checkfor smoothand free steeringoperationby
Afterassembly,
turningthe steeringwheet all thewayto the rightand tefl'
KtT (OpilONAL
couNTER ROTATTON
MODELOR DUAL ENG|NE,TTE-ROD
- PARTS)TNSTALLATTON
parts
TIE-ROD
KIT(OPTIONAL
PARTS)
Contained
Item
Part Name
Q'ty
1
2
3
TIE.RODASSY
1
BRACKET,
TIE-ROD
BOLT,TrE-ROD(UNF)
2
4
NUI TIE-ROD
2
5
BOLI TIE-ROD
2)
BRACKET(MI
o
WASHER.TIE-RODBRACKET
SPACER.
TIE.ROD
INSTRUCTION,
TIE-ROD
TAPE
4
4
7
8
I
z
2
4
1
pertorminstallation
Suzukirecommends
thatonlyauthorized
Suzukioutboardmotordealerora qualifiedservicemechanic
of thiskit.
Parts installationProcedure
(1) lnstaltthetie-rodbracket@ on the endof steeringbracketusingthe bolts@ andwashers@.
[t eot @ : 85 N'm (8.5kg-m,61.0lb-ft)
'-
\/.
(2) Installthe tie-rodassye on the bottomsideof tie-rodbracket@ withthe spacer@ positioned
in
between
usingthebolt@.
[! aon @ : 5o N.m(5.0kg--, 36.0lb-ft)
(3) Tightenthenut@ to tneendof bolt@ thathasbeeninstalled
in thestep2) above.(Whentightening
the
nut@, holdthe bolt@ securelyso as notto comeloose.)
S ttut @ : 30 N'm(3.0kg-m,21.5lb-ft)
11
AdjustmentProcedureof tie-rod length
(1) LoosenthenutsA and B.
(2) Adjustthetie-rodtengthby turningtheturnbuckte.
(3) lvhen thetie-rodlengthhasbeenadjusted,
tightenthe nutsA andB.
Q Hur 85 N.m(8.5kg-m,61.0tb-ft)
Therequired
lengihof tie-roddependson thecondition.
Adjustthelengthso thatthebestresultcanbe
obtained.
The followingis an exampleof adjustment
to obtaintheoptimumresult.
Example:
Toe-out
position
(1) Adjustthetie-rodlengthso thatthetwoenginecenterlines
in
forwarddirectionare awayfromeachotherwiththe differentialL1 - L2 within25 mm (1 inch).
NOTE:
The center to center distancefor twin engine instailationis minimum 635mm (25 in.).
Toe-outposition
(2) Thetwoenginewakesshouldmeettogetherat approximately
20rn- 25mbehindthem.
Recommendrigging procedure
Forthe bestresult,it is recommended
thatthe following
be
checked,
(1) Asshowninillustration,
cutfourpiecesoftape@ whichcomes
providedin this kit and stickthemat the swivelstopperarea
of boththe STBDand PORTsideengines.
Prior to sticking the tape, make sure to degreasethe attaching surfacethoroughly.
ON
For Increasedadhesion,press and scrape the tape surface. At this time, however,use caution not to cause
wrinkle,scratch,etc.on the tape.
t2
(2) Performdouble-check
to makesure that all the boltsand nut are tightenedproperlyto the specified
torque.
performanothercheckto makesurethatall theboltsandnutsaretightened
(3) Afteronehourof operation,
proplerly
to thespecified
torque.
..-.(a)
furtherto the above,checkagainvisuallyforthe surfaceconditionof
Afteranotheronehourof operation
tapesshowthe signof equalcontact,it showsthe rigginghas
aluminum
tape.lf allthe fouraluminum
is found,adjustthetie-rodlength
in contactcondition
lf anydifference
successfully.
beenaccomplished
instructions;
observing
thefollowing
shortertie-rodlength:
@ Requiring
tapeof thestarboard
sideengineas wellas on
sidealuminum
Thereis a damageon thestarboard
the portsidetapeof the portsideengine.
longertie-rodlength:
@ Requiring
sideengineas wellas on the
Thereis a damageon theportsidealuminumtapeof thestarboard
port
engine'
side
sidetapeof the
starboard
(s)
presents,
adjustthetie-rodlengthto eithershorteror longeras approprilf anyof theaboveconditions
in the steps(1)to (4) untilall the four
Repeat
the procedures
time.
5 mm at a
ate by approximately
aluminum
tapesshowthe equalcontactcondition.
Damagedaluminumtapes can no longer be used for the subsequentadiustmentand therefore
shouicibe repiaceci.
the riggingcompletes.
aboveperformed,
Withtheprocedures
O Dependingon the boat and adjustment conditlon, the initial setting of toe-in can turn to toe-out
later. Especially when the boat is equipped with outrigger, such a variation may become more
evident.
O Double-checkall the bolts and nuts for proper Installationand tightness.
O After two hours of operation, perform another check to make sure that all the bolts and nuts are
tightened properly to the.specified torque.
O At the end of every 50 hours of operation, lubricate and check all the parts for wear, installation
conditionand tightening torque.
13
INSTALLATION
WITHTHE PRE-RIGGED
ITEMSFOR2 CYCLEMODEL
Whenthe DF90/115
is installed
on theboatwhichhasalreadybeenriggedwiththe itemsfor 2 cyclemodel,\
performriggingby usingthe followingitems.
Requiredparts
Item
@
@
/Fr
\:,/
Part name
Part number
Adapterwireharness(meterside)
Adapterwireharness(engineside)
Flemo-con
linkplate
34711-99E00
36661-99E00
67220-95630
Q'ty
{T
1
1
NOTE:
Followingprocedureare basedon the boat which hasatreadybeenriggedwith"J4700-92E1. ".
"34200-92E0.", "36660-g2EI " and "67200-g7D3.(pull-to-open-type)".
Procedure
- Wireharnessand Meter(1) Remove
the monitorgaugeO, thenplugthemounthole.
(2) Removethetachometer
@.
(3) connectthe adapterwire harness@ betweenthe monitor-tachometer
O and monitorgaugewireharness@ as shown.
(4) Installthemonitor-tachometer
@ to the holeof originaltachometer
@.
(5) Connectthe adapterwire harness@ betweenthe engineand the monitorgaugewire harness as
@
snown.
Instrument wire harness
Lbr€
P-Ef,
Y-GF
t-------l=-R/c
E--B-
342o0-92E o. --- =- - t
RiG_G-R/G
w- I=
B-B_B
Ef_B
EFGr
1
36660-92E
34700-92E1
-Remotecontrolbox_..(6) Removethe screws,backcover@ and@.
(7) Removethe warm-upleverscrews@.
\-,'
(B) Removethe drum@, then reinstall
the drum@ with 180'
turnedpositionby the screws@.
(e) Afterdisconnectingthe throttlecontrolcable,removethe original link plate@ (forpull-to-open).
( 1 0)Installthelink plate@ (for push{o-open).
.. - ( ' t 1)lnstallthe upper back cover @ by the screws.
( 1 2)After connectingthe throttlecontrolcable,installthe lower
|,l2p14 6rlryor
6
hrr fhe
e^rori/q
NOTE:
. For theprocedureto connectthe controlcablesto the remote
controlbox, refer to the "REMOTECONTROLBOX SETUP
INSTRUCTION"
thatcomessuppliedwitheachunitof remote
controlbox.
. Be carefulnot to missany items (washer,spaceretc.) when
reassembling
the remotecontrolbox.
. Afterassembly,checkfor smoothoperation.
15
WIRINGDIAGRAM
(Forremotecontrotbox/meterfuiire
harness)
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16
WIRINGDIAGRAMFOR DUAL ENGINE
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Prepared
by
SUZUKI IIOTOR CORPORATION
Marine & Power Products Division
D ecember,2U U l
Part No. 99505-92J00-0lE
Printed in Jaoan