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Ralph woodJul 23, 2026
Water pump replacement 09 DF50
Water pump replacement 09 DF50
Introduction to the service manual and its intended use by technicians.
Guidance on navigating the manual to find specific information and procedures.
Explanation of symbols used throughout the manual for service instructions.
Overview of topics covered in the General Information section.
Technical data for DF40T, DF50T models including dimensions, weight, and performance.
Specified tightening torque values for important fasteners in the outboard motor.
List and illustrations of special tools required for servicing the outboard motor.
List of required materials, lubricants, and sealants for maintenance and repair.
Recommended intervals for periodic service work to maintain peak performance and economy.
Procedures for checking, changing engine oil, and replacing the engine oil filter.
Procedure for changing the gear oil in the lower unit.
Specific points requiring lubrication with Suzuki Water Resistant Grease.
Inspection, gap adjustment, and condition check of the spark plug.
Procedure for checking and adjusting tappet clearance for intake and exhaust valves.
Procedure for inspecting and adjusting the engine idle speed.
Procedure for inspecting the ignition timing at a specified engine speed.
Inspection of anodes for corrosion and bonding wires for damage.
Procedures for inspecting the battery and proper connection/disconnection methods.
Checking that all bolts and nuts are tightened to their specified torque.
Procedure for performing a fuel mixture check using O2 feedback.
Test procedure for checking engine oil pressure.
Procedure for measuring cylinder compression and identifying low compression causes.
Overview of the integrated control system and system structure diagrams.
Detailed wiring diagram for the engine control system.
Description of ECM controls for fuel injection, ignition, and idle air.
Layout of ECM connectors and terminal circuits.
Description of CKP, CMP, and other sensors and switches used by the ECM.
Explanation of the transistorized, electronic microcomputer ignition system.
Overview of the speed-density, multi-point, sequential electronic fuel injection system.
Description of fuel tank, pumps, filters, regulator, and injectors.
Explanation of how the ECM controls the IAC valve for idle speed regulation.
Description of the four caution systems that alert the operator to engine abnormalities.
Alerts provided by the self-diagnostic system via CHECK ENGINE lamp and buzzer.
Diagnostic flowcharts for troubleshooting specific self-diagnostic codes.
Outline and circuit diagram of the battery charging system.
Procedure for inspecting the fuse case and replacing fuses.
Procedure for measuring resistance of the rectifier & regulator.
Step-by-step instructions for removing and installing the starter motor.
Methods for testing the starter motor relay's resistance and operation.
Procedure for checking the continuity of the ignition switch at different key positions.
Procedure for checking the continuity of neutral switches in the remote control box and on the cylinder block.
Procedure for inspecting the monitor-tachometer's lamp functionality.
Safety precautions when working with gasoline and servicing the fuel system.
Steps to safely relieve fuel pressure before working on the fuel system.
Instructions and precautions for removing and installing fuel hoses.
Procedure to check for fuel leakage after servicing the fuel system.
Procedure for measuring fuel pressure in the fuel feed line.
Removal, installation, disassembly, and inspection of the fuel vapor separator and high-pressure fuel pump.
Inspection, removal, and installation procedures for the fuel injectors.
Removal, installation, disassembly, reassembly, and inspection of the low pressure fuel pump.
Inspection of the fuel tank, fuel connector, primer bulb, fuel hose, and tank cap.
Step-by-step procedure for removing the intake manifold assembly.
Procedure for removing the power unit from the engine holder.
Removal, disassembly, inspection, and assembly of the oil pump and case.
Procedures for removing, inspecting, and installing the timing chain and tensioner.
Procedures for removing, assembling, disassembling, inspecting, and servicing the cylinder head.
Disassembly, inspection, servicing, and reassembly of cylinder, crankshaft, and piston components.
Inspection and measurement of piston ring end gap, groove width, and thickness.
Inspection and measurement of conrod and crankshaft components.
Removal, inspection, operation check, and installation of the thermostat.
Overview of the water cooling system and component inspection.
Description of the engine oil lubrication system and chart.
Wiring diagram for the power trim and tilt system.
Procedure for checking and refilling the oil level in the power trim and tilt unit.
Step-by-step instructions for removing the power trim and tilt unit.
Instructions for disassembling the power trim and tilt unit.
Procedures for cleaning and inspecting metal components of the PTT unit.
Removal, disassembly, inspection, and assembly of the PTT motor.
Methods for testing PTT motor relays using resistance and continuity checks.
Procedure for testing the continuity of the PTT switch.
Explanation of how the power trim and tilt system is operated via the rocker switch.
Detailed explanation of the hydraulic circuit for trim/tilt 'up' operation.
Detailed explanation of the hydraulic circuit for trim/tilt 'down' operation.
Explanation of the shock absorber circuit's function in dampening impacts.
Operation of the manual release valve for tilting or lowering the outboard.
Explanation of the thermal valve's role in protecting internal components from excessive pressure.
Step-by-step procedure for removing and disassembling the lower unit.
Tools and procedures for removal and installation of the pinion bearing.
Inspection of the propeller for damage and propeller bush for wear.
Inspection of the gearcase for cracks or damage and visual check of the pinion bearing.
Inspection of gear teeth, engaging dogs, and gear bearings for wear or damage.
Inspection of push rod, clutch dog shifter, dog pin, and propeller shaft splines.
Inspection and replacement of oil seals in the driveshaft bearing housing.
Inspection of the driveshaft and its bearing for wear or damage.
General procedures for assembling and installing the lower unit components.
Procedure for adjusting gear contact and backlash after component replacement.
Procedure for measuring and adjusting gear backlash using a gauge.
Procedure for checking and adjusting tooth contact pattern for pinion and forward gear.
Procedure to check for oil seal or O-ring leakage using an oil leakage tester.
Procedure for installing the water pump impeller and case.
Procedure for installing the lower unit onto the engine.
Procedure for filling the gearcase with the specified gear oil.
Procedure for adjusting the clutch cable to the shift rod.
Wiring diagram for DF40T/DF50T/DF50WT remote control models.
Diagrams illustrating the routing of various wires and harnesses.
Diagrams showing the correct routing of fuel and water hoses.
Introduction to the supplementary service manual for K5 (2005) models.
Technical specifications for DF40T/DF40QH/DF50T/DF50TH models.
Service data for powerhead and engine oil pump components.
Specified tightening torque values for important fasteners.
Information on the over-revolution limiter change for DF50 models.
Explanation of the safety relay system to prevent starter motor operation when engine is running.
Details on changes to flywheel bolt, washer, and crankshaft machining.
Outline of the battery charging system circuit.
Circuit overview and components of the electric starter system.
Flowcharts for troubleshooting electric starter system issues.
Methods for testing the starter motor relay.
Instructions for disassembling the starter motor.
Tests for pull-in/hold-in function and plunger/pinion return.
Information on changes to the remote control box and wire.
Details on changes to the cylinder head shape and protection anodes.
Information on changes to upper mount, bolts, nuts, and tightening torque.
Details on changes to lower mount bracket, inner tube, bolt, washers, and nut torque.
Information on changes to clamp bracket washer, shape, and shaft shape.
Details on changes to swivel bracket bush and tiller handle wire connector.
Information on changes to the PTT relays (for UP and DOWN).
Details on changes to driveshaft and related parts, including bearing types.
Information on changes to water pump case and shift rod guide O-ring.
Information on changes to the gearcase magnet shape.
Information on changes to the number of propeller shaft bearings.
Wiring diagram for DF40T/DF50T/DF50WT remote control models.
Diagrams illustrating the routing of wires for different models.
Diagrams showing the correct routing of fuel hoses.
Introduction to the supplementary service manual for K6 (2006) models.
Technical specifications for DF40T/DF40QH/DF50T/DF50TH models.
Service data for powerhead and engine oil pump components.
Recommended intervals for periodic service tasks.
Information about changes to the ECM warning memory condition program.
Details on changes to the silencer, seal, flame arrester, bolt, washer, and clamp.
Information on changes to the tiller handle bracket and related parts.
Explanation of the changed method for fixing clutch and throttle cables.
Details on changes to the shape of the clutch shaft arm and side arm.
Information on changes to detent spring free length and shift cam notches.
Details on changes to clutch dog shifter width and return spring free length.
Information on changes to the shape of side covers and securing screws.
Introduction to the supplementary service manual for K7 (2007) models.
Technical specifications for DF40T/DF40QH/DF50T/DF50TH models.
Service data for powerhead and engine oil pump.
Specified tightening torque values, noting changes from the 2007 model year.
Recommended intervals for periodic service tasks, with fuel mixture check abolished.
Information about changes to the ECM warning memory condition program.
Details on changes to silencer, seal, flame arrester, bolt, washer, and clamp.
Information on changes to tiller handle bracket, pivot bolt, and nut torque.
Details on changes to clutch shaft arm and side arm shape, and screw to bolt.
Information on changes to detent spring free length and shift cam notches.
Details on changes to clutch dog shifter width and return spring free length.
Information on changes to the shape of side covers and securing screws.
General| Engine Type | 4-Stroke |
|---|---|
| Cylinders | 3 |
| Displacement | 941 cc |
| Starting System | Electric |
| Steering | Remote |
| Engine Type Detail | DOHC 12-Valve |
| Maximum Output | 50 HP |
| Ignition System | Digital CDI |
| Alternator | 12V 19A |
| Gear Ratio | 2.27:1 |
| Exhaust | Through Prop Hub Exhaust |
| Trim Method | Power Trim and Tilt |
| Max Power | 50 HP |
| Alternator Output | 12V 19A |
| Fuel Delivery System | Sequential Multi Point Electronic Fuel Injection |
| Full Throttle Operating Range | 5, 300 - 6, 300 rpm |
| Engine Oil Capacity | 2.7 L |
| Full Throttle RPM Range | 5300 - 6300 RPM |
| Oil Capacity | 2.7 L |
| Bore x Stroke | 72.5 x 76.0 mm (2.85 x 2.99 in.) |
