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Suzuki DF70, DF80, and DF90 Outboard Engine Specifications

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Model Pre-fix

Item Unit Data
DF70AT DF80AT DF90AT
PRE-FIX 07002F 08001F 09002F

Dimensions and Weight

Item Unit Data
DF70AT DF80AT DF90AT
Overall length (front to back) mm (in.) 724 (28.5)
Overall width (side to side) mm (in.) 459 (18.1)
Overall height L mm (in.) 1 480 (58.2)
X mm (in.) 1 607 (63.3)
Weight (without engine oil) L kg (lbs) 155 (341)
X kg (lbs) 158 (348)
Transom height L mm (in. type) 510 (20)
X mm (in. type) 637 (25)

Performance

Item Unit Data
DF70AT DF80AT DF90AT
Maximum output kW (PS) 51.5 (70) 58.8 (80) 66.2 (90)
Recommended operating range r/min 5 000 – 6 000 5 000 – 6 000 5 500 – 6 300
Idle speed r/min 600 ± 50 (in-gear: Approx. 600)

Powerhead

Item Unit Data
DF70AT DF80AT DF90AT
Engine type 4-stroke DOHC
Number of cylinders 4
Bore mm (in.) 75 (2.95)
Stroke mm (in.) 85 (3.35)
Total displacement cm3 (cu. in) 1 502 (91.6)
Compression ratio : 1 9.5
Spark plug NGK DCPR6E
Ignition system Full-transistorized ignition
Fuel supply system Multi-point sequential electronic fuel injection
Exhaust system Through prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Electric
Throttle control Remote control

Fuel and Oil

Item Unit Data
DF70AT DF80AT DF90AT
Fuel Suzuki highly recommends the use of alcohol-free unleaded gasoline with a minimum pump octane rating of 87 (R/2+M/2 method) or 91 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane content may be used.

 

Item Unit Data
DF70AT DF80AT DF90AT
Engine oil • API classification: SG, SH, SJ, SL, SM or NMMA FC-W classification: SG, SH, SJ, SL, SM • Viscosity rating: SAE 10W-40 or NMMA FC-W 10W-40
Engine oil amounts L (US/lmp. qt) 4.0 (4.2 / 3.5): Oil change only 4.3 (4.5 / 3.8): Oil filter change
Gear oil SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear oil, API classification GL-5.
Gearcase oil capacity ml (US/lmp. oz) 850 (28.7/30.0)

Bracket

Item Unit Data
DF70AT DF80AT DF90AT
Trim angle degree 0 – 20 (-6 to 14)
Number of trim position PTT system
Maximum tilt angle degree 75 (-6 to 69)

Lower unit

Item Unit Data
DF70AT DF80AT DF90AT
Reversing system Gear
Transmission Forward-Neutral-Reverse
Reduction system Bevel gear
Gear ratio 12 : 25 (2.08)
Drive line impact protection Spline drive rubber hub
Propeller shaft rotation (when shift into forward) Clockwise
Blade x Dia. (in.) x Pitch (in.)
Propeller 3 x 14 x 13 3 x 13 and 7/8 x 15 3 x 13 and 3/4 x 17 3 x 13 and 3/4 x 19 3 x 13 and 3/4 x 21 3 x 13 and 3/4 x 23 3 x 13 and 1/2 x 15 3 x 14 x 17 3 x 14 x 19 3 x 14 x 21 3 x 14 x 23

Reduction system

Item Unit Data
DF70AT DF80AT DF90AT
1st reduction gear ratio (Crankshaft drive gear: Driven gear) 29 : 36 (1.24)
2nd reduction gear ratio (Lower unit gear) 12 : 25 (2.08)
Total reduction gear ratio 2.59 (36/29 x 25/12)

Powerhead

Item Unit Data
DF70AT DF80AT DF90AT
Recommended operating range r/min 5 000 – 6 000 5 000 – 6 000 5 500 – 6 300
Idle speed r/min 600 ± 50 (in-gear: Approx. 600)
**Cylinder compression pressure kPa (kgf/cm2, psi) 1 200 – 1 800 (12 – 18, 171 – 256)
**Cylinder compression pressure max. difference between cylinders kPa (kgf/cm2, psi) 100 (1.0, 14)
**Engine oil pressure kPa (kgf/cm2, psi) 400 – 600 (4.0 – 6.0, 57 – 85) at 3 000 r/min (at normal operating temp.)
Engine oil • API classification: SG, SH, SJ, SL, SM or NMMA FC-W classification: SG, SH, SJ, SL, SM • Viscosity rating: SAE 10W-40 or NMMA FC-W 10W-40
Engine oil amounts L (US/lpm. qt) 4.0 (4.2 / 3.5): Oil change only 4.3 (4.5 / 3.8): Oil filter change
Thermostat operating temperature °C (°F) 58 – 62 (136 – 144)

**Figures shown are guidelines only, not absolute service limits.

Cylinder Head / Camshaft

Item Unit Data
DF70AT DF80AT DF90AT
Cylinder head distortion Limit mm (in.) 0.03 (0.001)
Manifold seating faces distortion Limit mm (in.) 0.10 (0.004)
Cam height IN std. mm (in.) 38.620 – 38.780 (1.5205 – 1.5268) 39.620 – 39.780 (1.5598 – 1.5661) 41.120 – 41.280 (1.6189 – 1.6252)
Limit mm (in.) 3.8520 (1.5165) 39.520 (1.5559) 41.020 (1.6150)
EX std. mm (in.) 40.420 – 40.580 (1.5913 – 1.5976) 40.920 – 41.080 (1.6110 – 1.6173)
Limit mm (in.) 40.320 (1.5874) 40.820 (1.6071)
Camshaft journal oil clearance Top, 2nd, 3rd, 4th, 5th std. mm (in.) 0.045 – 0.087 (0.0018 – 0.0034)
Limit mm (in.) 0.120 (0.0047)
Camshaft journal (housing) inside diameter Top, 2nd, 3rd, 4th std. mm (in.) 23.000 – 23.021 (0.9055 – 0.9063)
Limit mm (in.) —
5th std. mm (in.) 26.000 – 26.021 (1.0236 – 1.0244)
Limit mm (in.) —
Camshaft journal outside diameter Top, 2nd, 3rd, 4th std. mm (in.) 22.934 – 22.955 (0.9029 – 0.9037)
Limit mm (in.) —
5th std. mm (in.) 25.936 – 25.957 (1.0211 – 1.0291)
Limit mm (in.) —
Camshaft runout Limit mm (in.) 0.10 (0.004)
Cylinder head bore to tappet clearance std. mm (in.) 0.025 – 0.062 (1.0010 – 1.0024)
Limit mm (in.) 0.150 (0.0059)
Tappet outer diameter std. mm (in.) 27.959 – 27.975 (1.1007 – 1.1014)
Cylinder head tappet bore std. mm (in.) 28.000 – 28.021 (1.1024 – 1.1032)

 

Valve / Valve Guide Cylinder / Piston / Piston Ring Crankshaft / Conrod

Item Unit Data
DF70AT DF80AT DF90AT
Valve diameter IN mm (in.) 27.5 (1.08)
EX mm (in.) 22.9 (0.90)
Tappet clearance (Cold engine condition) IN std. mm (in.) 0.23 – 0.27 (0.009 – 0.011)
EX std. mm (in.) 0.30 – 0.34 (0.012 – 0.013)
Valve seat angle IN — 30°, 45°, 60°
EX — 15°, 45°
Valve guide to valve stem clearance IN std. mm (in.) 0.020 – 0.047 (0.0008 – 0.0019)
Limit mm (in.) 0.070 (0.0028)
EX std. mm (in.) 0.045 – 0.072 (0.0018 – 0.0028)
Limit mm (in.) 0.090 (0.0035)
Valve guide inside diameter IN, EX std. mm (in.) 5.500 – 5.512 (0.2165 – 0.2170)
Valve guide protrusion IN, EX std. mm (in.) 10.8 – 11.6 (0.43 – 0.46)
Valve stem outside diameter IN std. mm (in.) 5.465 – 5.480 (0.2152 – 0.2157)
EX std. mm (in.) 5.440 – 5.455 (0.2142 – 0.2148)
Valve stem deflection IN Limit mm (in.) 0.14 (0.006)
EX Limit mm (in.) 0.18 (0.007)
Valve stem runout IN, EX Limit mm (in.) 0.05 (0.002)
Valve head radial runout IN, EX Limit mm (in.) 0.08 (0.003)
Valve head thickness IN std. mm (in.) 0.75 (0.03)
Limit mm (in.) 0.5 (0.02)
EX std. mm (in.) 0.95 (0.04)
Limit mm (in.) 0.7 (0.03)
Valve seat contact width IN std. mm (in.) 1.1 – 1.3 (0.04 – 0.05)
EX std. mm (in.) 1.1 – 1.3 (0.04 – 0.05)
Valve spring free length std. mm (in.) 33.1 (1.30)
Limit mm (in.) 31.8 (1.25)
Valve spring preload std. N (kg, lbs) 95 – 111 (9.6 – 11.2, 21.1 – 24.6) at 28.5 mm (1.12 in)
Limit N (kg, lbs) 87 (8.8, 19.4) at 28.5 mm (1.12 in)
Valve spring squareness Limit mm (in.) 2.0 (0.08)

 

Item Unit Data
DF70AT DF80AT DF90AT
Cylinder distortion Limit mm (in.) 0.03 (0.001)
Piston to cylinder clearance std. mm (in.) 0.020 – 0.040 (0.0008 – 0.0016)
Limit mm (in.) 0.100 (0.0039)
Cylinder bore std. mm (in.) 75.000 – 75.020 (2.9598 – 2.9535)
Cylinder measuring position mm (in.) 50 (1.969) from cylinder top surface
Piston skirt diameter std. mm (in.) 74.970 – 74.990 (2.9516 – 2.9524)
Piston measuring position mm (in.) 13 (0.512) from piston skirt end
Cylinder bore wear Limit mm (in.) 0.10 (0.039)
Piston ring end gap 1st std. mm (in.) 0.15 – 0.30 (0.0059 – 0.0118)
Limit mm (in.) 0.70 (0.028)
2nd std. mm (in.) 0.30 – 0.45 (0.0118 – 0.0177)
Limit mm (in.) 1.00 (0.039)
Piston ring free end gap 1st std. mm (in.) Approx 9.9 (0.3898)
Limit mm (in.) 7.9 (0.3110)
2nd std. mm (in.) Approx 9.7 (0.3819)
Limit mm (in.) 7.8 (0.3070)
Piston ring to groove clearance 1st std. mm (in.) 0.030 – 0.070 (0.0012 – 0.0028)
Limit mm (in.) 0.12 (0.005)
2nd std. mm (in.) 0.020 – 0.060 (0.0008 – 0.0024)
Limit mm (in.) 0.10 (0.004)
Piston ring groove width 1st std. mm (in.) 1.02 – 1.04 (0.040 – 0.041)
2nd std. mm (in.) 1.21 – 1.23 (0.048 – 0.048)
Oil std. mm (in.) 2.01 – 2.03 (0.079 – 0.080)
Piston ring thickness 1st std. mm (in.) 0.97 – 0.99 (0.038 – 0.039)
2nd std. mm (in.) 1.17 – 1.19 (0.046 – 0.047)
Pin clearance in piston pin hole std. mm (in.) 0.006 – 0.019 (0.0002 – 0.0007)
Limit mm (in.) 0.005 (0.0019)
Piston pin outside diameter std. mm (in.) 17.995 – 18.000 (0.7085 – 0.7087)
Limit mm (in.) 17.980 (0.7079)
Piston pin hole diameter std. mm (in.) 18.006 – 18.014 (0.7089 – 0.7092)
Limit mm (in.) 18.030 (0.7098)
Pin clearance in conrod small end std. mm (in.) 0.003 – 0.016 (0.0001 – 0.0006)
Limit mm (in.) 0.050 (0.0020)
Conrod small end bore std. mm (in.) 18.003 – 18.011 (0.7088 – 0.7091)

 

Item Unit Data
DF70AT DF80AT DF90AT
Conrod small end inside diameter std. mm (in.) 18.003 – 18.011 (0.7088 – 0.7091)
Conrod big end oil clearance std. mm (in.) 0.032 – 0.050 (0.0013 – 0.0020)
Limit mm (in.) 0.080 (0.0031)
Conrod big end inside diameter std. mm (in.) 45.000 – 45.018 (1.7717 – 1.7724)
Crank pin outside diameter std. mm (in.) 41.982 – 42.000 (1.6528 – 1.6535)
Crank pin outside diameter difference (out-of-round and taper) Limit mm (in.) 0.010 (0.0004)
Conrod bearing thickness std. mm (in.) 1.487 – 1.502 (0.0585 – 0.0591)
Conrod big end side clearance std. mm (in.) 0.100 – 0.250 (0.0039 – 0.0098)
Limit mm (in.) 0.350 (0.0138)
Conrod big end width std. mm (in.) 21.950 – 22.000 (0.8642 – 0.8661)
Crank pin width std. mm (in.) 22.100 – 22.200 (0.8071 – 0.8740)
Crankshaft center journal runout Limit mm (in.) 0.04 (0.002)
Crankshaft journal oil clearance std. mm (in.) 0.016 – 0.032 (0.0006 – 0.0014)
Limit mm (in.) 0.056 (0.0022)
Crankcase bearing holder inside diameter std. mm (in.) 56.000 – 56.018 (2.2047 – 2.2054)
Crankshaft journal outside diameter std. mm (in.) 51.994 – 52.012 (2.0470 – 2.0477)
Crankshaft journal outside diameter difference (out-of-round and taper) Limit mm (in.) 0.010 (0.0004)
Crankshaft bearing thickness std. mm (in.) 1.992 – 2.008 (0.0784 – 0.0791)
Crankshaft thrust play std. mm (in.) 0.11 – 0.31 (0.004 – 0.012)
Limit mm (in.) 0.35 (0.014)
Crankshaft thrust bearing thickness std. mm (in.) 2.47 – 2.52 (0.0972 – 0.0992)

Electrical

Item Unit Data
DF70AT DF80AT DF90AT
Ignition timing Degrees at r/ min BTDC 0 – 26 BTDC 0 – 27
Over revolution limiter r/min 6 200 6 400
CKP sensor resistance Ω at 20 °C 168 – 252
CMP sensor resistance Ω at 20 °C —
Ignition coil resistance Primary Ω at 20 °C —
Secondary kΩ at 20 °C —
Battery charge coil resistance Ω at 20 °C 0.10 – 0.30
Battery charge coil output (12 V) Watt 324
Standard spark plug Type NGK DCPR6E
Gap mm (in.) 0.8 – 0.9 (0.031 – 0.035)
Fuse amp. rating A Main fuse: 40 Starter motor: 30 Ignition coil, Injector, ECM, Fuel pump: 30 PTT switch: 10 IAC: 10
Recommended battery capacity (12 V) Ah (kC) 100 (360) or larger
Fuel injector resistance Ω at 20 °C 10 – 14
IAC valve resistance Ω at 20 °C 25 – 34
IAT sensor / Cylinder temp. sensor / Ex. mani. temp. sensor (Thermistor characteristic) kΩ at 25 °C 1.8 – 2.3
ECM main relay coil resistance Ω at 20 °C 145 – 190
Starter motor relay coil resistance Ω at 20 °C 145 – 190
PTT motor relay coil resistance Ω at 20 °C 25 – 37

 

Starter Motor

Item Unit Data
DF70AT DF80AT DF90AT
Max. continuous time of use Sec. 30
Motor output kW 1.4
Brush length std. mm (in.) 16.0 (0.63)
Limit mm (in.) 12.0 (0.47)
Commutator undercut std. mm (in.) 0.5 – 0.8 (0.02 – 0.03)
Limit mm (in.) 0.2 (0.01)
Commutator outside diameter std. mm (in.) 29.0 (1.14)
Limit mm (in.) 28.0 (1.10)

PTT Motor

Item Unit Data
DF70AT DF80AT DF90AT
Brush length std. mm (in.) 9.8 (0.39)
Limit mm (in.) 5.5 (0.22)
Commutator outside diameter std. mm (in.) 22.0 (0.87)
Limit mm (in.) 21.0 (0.83)

Self-Diagnostic Code

0: OFF, 1: ON

Failed item Code Lamp flashing pattern Fail-safe system activating
MAP sensor 1 3 – 4 1 0 MCODE00D34-0-01 YES
Cylinder temp. sensor 1 – 4 1 0 MCODE00D14-0-01 YES
IAT sensor 2 – 3 1 0 MCODE00D23-0-01 YES
CKP sensor 4 – 2 1 0 MCODE00D42-0-01 NO
CMP sensor 2 – 4 1 0 MCODE00D24-0-01 NO
Air intake system 2 – 2 1 0 MCODE00D22-0-01 YES
MAP sensor 2 3 – 2 1 0 MCODE00D32-0-01 NO
Exhaust manifold temp. sensor 1 – 5 1 0 MCODE00D15-0-01 YES
Fuel injector 4 – 3 1 0 MCODE00D43-0-01 NO
Throttle position sensor 2 – 1 1 0 MCODE00D21-0-01 YES
Shift position sensor 1 – 2 1 0 MCODE00D12-0-01 YES
Neutral switch 3 – 3 1 0 MCODE00D33-0-01 NO
Trim sensor 3 – 7 1 0 MCODE00D37-0-01 NO

 

Failed item Code Lamp flashing pattern Fail-safe system activating
Trim sensor 3 – 7 1 0 MCODE00D37-0-01 NO
Oil pressure switch 5 – 3 1 0 MCODE00D53-0-01 NO
Rectifier/Regulator (Over-charging) 1 – 1 1 0 MCODE00D11-0-01 NO
Tightening Torque Specifications

Important Fasteners

Item Thread Diameter Tightening Torque
Nâ‹…m kgf-m lbf-ft
Cylinder head cover bolt 6 mm 11 1.1 8.0
Cylinder head bolt 8 mm 23 2.3 16.6
10 mm 70 7.0 51.0
Crankcase bolt Outside 8 mm 25 2.5 18.0
Inside 10 mm 47 4.7 34.0
Conrod cap bolt 9 mm 47 4.7 40.0
Camshaft housing bolt 6 mm 11 1.1 8.0
Oil pump bolt 6 mm 15 1.5 11.0
IN. camshaft timing sprocket — 78 7.8 56.0
EX. camshaft timing sprocket 6 mm 11 1.1 8.0
Chain tensioner adjuster bolt 6 mm 11 1.1 8.0
Timing chain guide bolt 8 mm 23 2.3 16.6
Intake manifold bolt / nut 8 mm 23 2.3 16.5
Oil pressure switch — 13 1.3 9.5
Fuel delivery pipe bolt 8 mm 23 2.3 16.5
Fuel delivery pipe plug / union bolt Upper 14 mm 35 3.5 25.5
Lower 14 mm 35 3.5 25.5
Low pressure fuel pump bolt 6 mm 10 1.0 7.0
Thermostat cover bolt 6 mm 10 1.0 7.0
Flywheel bolt 16 mm 196 19.7 142.0
Starter motor mounting bolt 8 mm 23 2.3 16.6
Engine oil filter — 14 1.4 10.0
Engine oil drain plug 12 mm 13 1.3 9.5
Power unit mounting bolt 8 mm 23 2.3 16.5
10 mm 50 5.0 36.0
Driveshaft housing bolt 10 mm 50 5.0 36.0
Upper mount nut 12 mm 80 8.0 57.8
Upper mount cover bolt 10 mm 50 5.0 36.0
Lower mount bolt 12 mm 60 6.0 43.4
Clamp bracket shaft nut 7/8-14 UNF 43 4.3 31.0
Water pump case bolt 8 mm 17 1.7 12.3
Driveshaft oil seal housing 8 mm 23 2.3 16.5
Gearcase bolt 10 mm 55 5.5 40.0
Propeller shaft bearing housing bolt 8 mm 23 2.3 16.6
Pinion gear nut 14 mm 120 12.0 86.8
Propeller nut 18 mm 55 5.5 40.0

 

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