Posts Tagged ‘DF80’

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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