Suzuki DF70, DF80, and DF90 Outboard Engine Specifications
Wednesday, March 5th, 2014
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 | ||||
---|---|---|---|---|---|---|
N⋅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 |