CONTENTS OF THIS SERVICE MANUAL: This 1999-2008 Suzuki DF40 & DF50 (DF-40, DF-50) 4-stroke (four stroke) service manual contains fully detailed step-by-step repair procedures with hundreds of photos and illustrations to guide you through any repair, maintenance, overhaul, service specifications or troubleshooting procedure. It has a 1,360 cc G13C engine, later enlarged to 1,493 cc (G15A, introduced around 2000) and then 1,590 cc. Internal codenames for these models are ST130, ST150, and ST160 respectively; the ST130 Suzuki Carry Futura was also referred to as the SL413, ST150 as the SL415 and ST160 as the SL416. Beginning in 1994, the rear doors received wind-down.

The Suzuki G engine is a series of three- and four-cylinder internal combustion engines manufactured by Suzuki Motor Corporation for various automobiles, primarily based on the GM M platform, as well as many small trucks such as the Suzuki Samurai and Suzuki Vitara and their derivatives.

Straight-threes[edit]

G10/G10 Turbo[edit]

The G10 (sometimes referred to as the 'G10A' to set it apart from the later G10B) is a 1.0 L (993 cc) straight-three gasoline four-stroke engine using aluminum alloy for the block, cylinder head and pistons. It is equipped with either a carburetor or electronic fuel injection and was also offered as the G10T with an IHI RHB31/32 turbocharger and either MPFI or a carburetor. It has a single overhead camshaft driving six valves. Cylinder spacing is 84 mm (3.31 in), as for the four-cylinder G13/G15/G16 engines.

A 74 mm × 77 mm (2.91 in × 3.03 in) bore and stroke give the engine a total of 1.0 L; 60.6 cu in (993 cc) of displacement. It produces 48 hp (36 kW; 49 PS) at 5100 rpm and 77 N⋅m (57 lb⋅ft) at 3200 rpm with 9.5:1 compression in the carbureted model, 55 hp (41 kW; 56 PS) at 5700 rpm and 79 N⋅m (58 lb⋅ft) at 3300 rpm in the fuel-injected model. The original home market version originally offered a carbureted 60 PS (44 kW; 59 hp) JIS at 5500 rpm, later power output fluctuated around 52–55 PS (38–40 kW; 51–54 hp).

From 1984 to 1988 the standard G10 engine used a hemispherical head carbureted design with mechanical lifters. From 1989 to 2001 the engine received updates in the form of throttle-body fuel injection and hydraulic lifters. A detuned 49 hp (37 kW; 50 PS) unit, with a slightly different camshaft, two-ring pistons and differently tuned engine control unit, was used in the ultra-fuel-efficient Geo Metro XFi model, which delivered as much as 58 mpg_‑US (4.1 L/100 km; 70 mpg_‑imp). In the US, the G10 in the 2000 Chevrolet Metro became the last engine available on an American-sold vehicle to use throttle body injection for fuel delivery.

Through the 1985-1991 model years a turbocharged MPFI version of the G10 was offered in some markets. This engine delivered 70 hp (52 kW; 71 PS) at 5500 rpm and 79 lb⋅ft (107 N⋅m) at 3500 rpm. This turbocharged engine, with mechanical lifters, was available in both the US and Canadian Firefly/Sprint/Forsa from 1987-88. Only the Canadian Firefly/Sprint had this option, with hydraulic lifters, in the 1989-1991 model years. In the Japanese domestic market, the car was originally carbureted (80 PS (59 kW; 79 hp) JIS at 5500 rpm, 118 N⋅m (87 lb⋅ft) at 3500 rpm) and went on sale in June 1984. In October 1987, along with a facelift, the home market Turbo received fuel injection and power output went up to 82 PS (60 kW; 81 hp) JIS, torque to 120 N⋅m (89 lb⋅ft). It was a short-lived version, however, as by September 1988 the car was no longer on sale in the Japanese domestic market. As the only market in the world, Canada did continue to receive this engine for its versions of the second generation Cultus.

Because of the physics of the straight-three engine, the G10 tends not to idle as smoothly as other engines such as a straight-six engine. This engine has a non-interference valvetrain design.

Applications:

• 1985–2001 Suzuki Cultus and global nameplate siblings: Chevrolet Sprint, Geo/Chevrolet Metro, Pontiac Firefly, Suzuki Swift, Suzuki Forsa
• November 1984– Suzuki Cultus AA41S AB41S
• 1988– Suzuki Cultus AA43S AA43V AB43S AA44S AB44S

Ultralight aircraft

Straight-fours[edit]

G10B[edit]

The G10B was an all-aluminium engine, a four-cylinder 1.0 L (993 cc) 72 mm × 61 mm (2.83 in × 2.40 in) SOHC 16-valve engine which produces 60 PS (44 kW) at 6000 rpm and 78 N⋅m (58 lb⋅ft) of torque at 4500 rpm. It was sold in both carburetted and MPFI form. It was widely used in motorsport in India due to its light weight and tunability. The mounting points of the engine block were similar to that of the G13 and so an engine swap was a relatively easy task. It was phased out when production of Zen ceased in 2006. It was made only in India but was sold in all countries the Zen was sold.But the Zen which was sold as Suzuki Alto 1.0 in Europe came with a detuned G10B 8-valve engine which produces 54 PS (40 kW) at 5500 rpm and 77 N⋅m (57 lb⋅ft) of torque at 4500 rpm.The engine head & above spares are exactly idential to the Zen Carburettor sold in India from 1993 to 1999.

• 1993–2006 Maruti Zen (sold as Suzuki Alto in Europe, Australia).
• 2007–2017 Suzuki Cultus hatchback (Pakistan)^[1]

G12[edit]

The G12B is an inline-four engine using aluminum alloy for the block, cylinder head and pistons. It is derived from the G13BB engine by reducing the bore to 71 mm (2.80 in) to displace 1.2 L (1,196 cc). Stroke remains the same at 75.5 mm (2.97 in). It has a SOHC 16V head and the fuel delivery is by multi-point fuel injection. It is BS6 (equal to early Euro 6) emissions compliant. It has lighter pistons and other detail improvements to be a more fuel efficient engine than the G13BB on which it is based. Maruti modified the engine to displace less than 1200 cc to take advantage of the reduced excise duty on such vehicles in India.It produces 73 PS (54 kW; 72 hp) at 6000 rpm and 98 N⋅m (72 lb⋅ft) at 3000 rpm for petrol variant and 65 PS (48 kW; 64 hp) at 6000 rpm and 85 N⋅m (63 lb⋅ft) at 3000 rpm for CNG variant.

• 2010–present– Maruti Eeco
• 2016–present– Maruti Suzuki Super Carry (CNG only)

G13 series[edit]

The G13 is an inline-four engine using aluminum alloy for the block, cylinder head and pistons. Displacing 1.3 L (1,324 cc) for the G13A and 1.3 L; 79.2 cu in (1,298 cc) for all other G13 engines, fuel delivery is either through a carburetor, throttle body fuel injection or multi-point fuel injection.

This engine was made with different valvetrain designs: 8 or 16 valve SOHC or 16 valve DOHC. All G13 engines have a bore and a stroke size of 74 mm × 75.5 mm (2.91 in × 2.97 in) except for the G13A engine which has a 77 mm (3.03 in) stroke. There was also a 1,360 cc (1.4 L; 83 cu in) 'G13C variant built in Indonesia, combining the longer stroke with a 75 mm (2.95 in) bore.

G13A[edit]

The 1324 cc SOHC 8-valve G13A has a non-interference valvetrain design. Horsepower ranges from 60-70 PS with 90-100 N.m of torque. It was used in the following vehicles:

• November 1984–1988 Suzuki Cultus/Swift
• 1984–1988 Suzuki Jimny 1300 (JA51)
• 1985–1988 Holden Barina MB/ML (Australia/New Zealand)
• 1986–1990 Suzuki Samurai
• 1992–1998 Suzuki Margalla (Pakistan)^[2]

G13B[edit]

This 1298 cc DOHC 16-valve engine is well known, it uses the older distributor driven off the intake camshaft, and produces approximately 96–113 hp (72–84 kW; 97–115 PS) at 6500 rpm / 109–112 N⋅m (80–83 lb⋅ft) at 5000 rpm. Redline is set at 7400–7600 rpm. The compression ratio is between 10.0–11.5:1. This engine has an interference valvetrain design, making periodic timing belt changes vital to the engine's life. It was used in the following vehicles:

• 1985 Suzuki RS/1 (prototype)^[3]
• 1986–1994 Suzuki Cultus/Swift GTi AA33S/AA34S

G13BA[edit]

The SOHC 8-valve G13BA with carburettor or single-point fuel injection and produces 68–73 PS (50–54 kW; 67–72 hp) and 100–103 N⋅m (74–76 lb⋅ft) of torque. It has 9.5:1 compression ratio and also an non-interference valvetrain design. 1995 to 1997 U.S. and Canadian-market engines gained hydraulic lash adjusters. It was used in the following vehicles:

• 1989 Suzuki Sidekick (JA trim)^[4]
• 1989–1993 Holden Barina - (carburetor: 71 hp (53 kW; 72 PS) at 6,000 rpm; 102 N⋅m (10 kg⋅m; 75 lb⋅ft) at 4,000 rpm)
• 1989–1997 Suzuki Swift
• 1991–1995 Suzuki Samurai
• 1991–2004 Chevrolet Swift
• 1992–1997 Geo Metro
• 1993–1998 Suzuki Jimny (JB31/32)
• 1994–2000 Maruti Esteem
• 1996–2004 Subaru Justy
• June 1994–March 2000 Maruti Gypsy King

G13BB[edit]

The SOHC 16-valve G13BB (introduced in March 1995) has electronic multi-point fuel injection (MPFI), generating 56–63 kW (76–86 PS; 75–84 hp) and 104–115 N⋅m (11–12 kg⋅m; 77–85 lb⋅ft).^[5] The G13BB uses a wasted spark arrangement of two coils bolted directly to the valve cover.This engine uses a MAP sensor to monitor manifold pressure, similar to the G16B series. This engine has a non-interference valvetrain design. It uses the same G series block found in many other Suzuki models and so it is a popular conversion into the Suzuki Sierra/Samurai, which uses either a G13A (85-88) or G13BA (88.5-98). This allows the engine to fit into the engine bay simply as engine and gearbox mounts are identical and both engines are mounted North-South. It was used in the following vehicles:

• 1995–2002 Suzuki Cultus Crescent
• 1997–2003 Suzuki Swift
• 1998–2001 Chevrolet Metro/Pontiac Firefly/Suzuki Swift
• 1998–2003 Suzuki Jimny
• 1998–2007 Maruti Esteem
• 1999–2015 Changan Linyang
• 2000–2004 Suzuki Every Landy/Carry 1.3
• 2000–2017 Maruti Gypsy King

G13C[edit]

The G13C was bored out by one millimeter, for a bore and stroke of 75.0 mm × 77.0 mm (2.95 in × 3.03 in) and a displacement of 1,360 cc (1.4 L; 83 cu in). Maximum power was listed at 73 PS (54 kW) at 6000 rpm in 1999.^[6] This engine was developed by Suzuki's Indonesian subsidiary and also available for Malaysian market Suzuki Futura 1400.^[7] It was first used in the 1991 Suzuki Carry Futura.^[8] It was used in the following vehicles:

• 1991–1999 Suzuki Carry Futura SL413 (ST130)

G13K[edit]

'G13K' is the JDM version of G13B. It has different cams, intake and exhaust manifolds and ECU with cutoff at 8600rpm. It makes 115 hp.It was used in the Japanese version of Swift GTi called Cultus GT-i, replacing the first generation Swift GTi.

G15A[edit]

This engine is a 1.5 L (1,493 cc) 16-valveSOHCengine configuration, generating between 78–105 PS (57–77 kW) at 5500–6500 rpm and 120–128 N⋅m (89–94 lb⋅ft) at 3000–4000 rpm. It has a 75 mm (2.95 in) bore in conjunction with an 84.5 mm (3.33 in) stroke. Applications:

• 1991–1995 Suzuki Cultus sedan
• 1995–2002 Suzuki Cultus Crescent/Baleno
• 2000–2018 Suzuki Carry Futura (ST150, Indonesia)
• 2004–present Suzuki APV (Indonesia/Pakistan)
• 2011–2019 Suzuki Mega Carry (Indonesia)

G16[edit]

The G16 is an inline-four engine displacing 1.6 L (1,590 cc). It shares the G15's 75 mm (2.95 in) bore, in a long block with a 90 mm (3.54 in) stroke.^[9]

G16A[edit]

Either 8-valve SOHC carb or EPI before 1990 or 16-valve SOHCEPI after 1990.^[10] The 16-valve G16A mainly used in Japan and some selected markets. Applications:

• 1989–1992 Suzuki Sidekick (8-valve)
• 1988–1990 Suzuki Escudo (8-valve)
• 1990–2000 Suzuki Escudo (16-valve)
• 1990–2001 Suzuki Cultus sedan
• 1996–1998 Suzuki X-90
• 1997–2000 Suzuki Carry Futura (ST160, Indonesia)
• 2005–present Suzuki APV (except for Indonesia and Pakistan)

G16B[edit]

The SOHC G16B was the 16-valve version of G16A for worldwide market. Used in the following vehicles:

• 1992–1994 Suzuki Vitara
• 1992–1997 Suzuki Cultus/Swift/Esteem
• 1995–2002 Chevrolet Tracker (Americas)
• 1995–2007 Suzuki Baleno/Esteem
• 1996–1998 Geo Tracker
• 1996–1998 Suzuki Sidekick

See also[edit]

Notes[edit]

1. ^Ansari, Usman. '17 Years of Suzuki Cultus in Pakistan'. Car Spirit PK.
2. ^'Suzuki Margalla GL Specifications'. Pakwheels.
3. ^Spoelstra, Marcel. 'Suzuki RS Prototypes'. www.suzuki-collection.com. Retrieved 23 July 2020.
4. ^'History Of The Suzuki Sidekick 1989-1998'. Zuki Offroad.
5. ^'PKW Suzuki'(PDF). Victor Reinz. p. 1332 (p. 4 of pdf). Archived from the original(PDF) on 2011-07-19. Retrieved 2011-01-19.
6. ^Suzuki Carry 1.3 Grand Real Van (brochure) (in Indonesian), PT Indomobil Niaga International, 1999, p. 4
7. ^Schaefers, Martin. 'Japanese Kei Minivans'. Far East Auto Literature.
8. ^Suzuki SL413 Service Manual (in Indonesian), Jakarta, Indonesia: PT. Indomobil Suzuki International Service Department, November 1993, p. 6A-51, 4 B/SM/SERV - R4/93V
9. ^Åhman, Michael, ed. (1991), BilKatalogen 1992 (Swedish edition of German Auto Katalog) (in Swedish), Borlänge, Sweden: Bilkatalogen AB, p. 260
10. ^Büschi, Hans-Ulrich, ed. (5 March 1992). Automobil Revue 1992 (in German and French). 87. Berne, Switzerland: Hallwag AG. p. 537. ISBN3-444-00539-3.

References[edit]

• 'Silniki Suzuki'. Archived from the original on May 26, 2006. Retrieved April 14, 2006.

Download Now - Here

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Service Manual Application: Suzuki DF40QH, DF50QH, DF40 (DF-40HP, DF-40 HP) & DF50 (DF-50HP, DF-50 HP) 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 & 2008 Outboard boat 4-stroke (four stroke) engine (motor).

CONTENTS OF THIS SERVICE MANUAL: This 1999-2008 Suzuki DF40 & DF50 (DF-40, DF-50) 4-stroke (four stroke) service manual contains fully detailed step-by-step repair procedures with hundreds of photos and illustrations to guide you through any repair, maintenance, overhaul, service specifications or troubleshooting procedure. This expert text guide ebook will give you the knowledge and experience you need to perform simple basic maintenance or more complicated service procedures such as engine overhaul. Covers every thing you will ever need to know to fix anything on your 1999-2008 Suzuki DF40 & DF50 99, 00, 01, 02, 03, 04, 05, 06, 07 & 08 Outboard boat engine (motor).

Exact models covered:

DF40QH (DF-40-QH, DF40-QH)
DF50QH (DF-50-QH, DF50-QH)
DF40T (DF-40-T, DF-40T)
DF50T (DF-50-T, DF-50T)
DF40 Y 2000 MODEL
DF50 Y 2000 MODEL
DF-40 W K1 2001 MODEL
DF-50 W K1 2001 MODEL
DF40 K3 2003 MODEL
DF50 K3 2003 MODEL
DF40/50 K4 2004 MODEL
DF-40/50 K5 2005 MODEL
DF-40/50 K6 2006 MODEL
DF-40/50 K7 2007 MODEL
DF-40/50 K8 2008 MODEL

Book Marked Chapters for easy navigation, this repair manual will permit you to easily and efficiently find the exact repair procedure you need in the quickest time possible.

Payment and download Instructions:

1 Click on the green instant download button at the top of this page to buy your repair manual now.
2. Pay with your credit card through Paypal (No Registration Required).
3. After Payment you will be redirected to the download page.
4. After Download is complete you can save it to your download folder to view it, save it, and print pages whenever you need it.

The following is a small sample of topics covered in each chapter. Technical highlights of chapters include: Specifications, Inspection, Exploded Diagrams, Removal, Disassembly, Assembly, Installation, Servicing, Reassembly, Special Tools, Seals, Lubricants and more.

BOOK MARKED CHAPTERS INCLUDE:

4 STROKE MODELS

INDEX

GENERAL INFORMATION FOR SUZUKI Outboard motor DF40 (DF-40) DF50 (DF-50)

General Precautions, Identification Number Location, Fuel and Oil, Gasoline Recommendation, Engine Oil, Engine Break-In, Propellers, Powerhead Direction of Rotation, Specifications, Service Data, Tightening Torque, Special Tools, Materials Required.

PERIODIC MAINTENANCE FOR SUZUKI Outboard motor DF40 (DF-40) DF50 (DF-50)

Periodic Maintenance Schedule, Periodic Maintenance Chart, Maintenance and Tune-Up Procedures, Engine Oil, Engine Oil Filter, Gear Oil, Lubrication, Spark Plug, Spark Plugs, Tappet Clearance, Idle Speed, Ignition Timing, Breather and Fuel Line, Low Pressure Fuel Filter, High Pressure Fuel Filter, Water Pump, Water Pump Impeller, Propeller Nut and Cotter Pin, Adodes and Bonding Wires, Battery, Bolt and Nuts, Fuel Mixture Check (O2 Feedback), Oil Pressure, Cylinder Compression.

ENGINE CONTROL SYSTEM FOR SUZUKI Outboard motor DF40 (DF-40) DF50 (DF-50)

Engine Control System Structure, System Structure, Wiring Diagram for Engine Control, Components for System Control, Engine Control Module (ECM), Ecm Connector and Terminal Layout, ECM Internal Structure, Sensor and Switch, Ignition System, Electronic Fuel Injection System, Fuel Injection, Fuel Delivery, Fuel Pump Control System, Air Intake Components, Idle Air Control System, Caution System, Over-Revolution Caution, Low Oil Pressure, Overheat Caution System, Low Battery, Self-Diagnostic, Priority, Code, Pattern for Self-Diagnostic, Condition for Self-Diagnostic, Fail-Safe System, Pre Programmed Value for Fale-Safe System, Oil Change Reminder, Star-In-Gear Protection, O2 Feedback System, Inspection, Precaution on System Inspection, Inspection for ECM Circuit, Inspection for Resistance, Component Inspections, Troubleshooting, Removal, Installation, Flywheel, CKP Sensor, CMP Sensor, Oil Pressure Switch and much more.

ELECTRICAL FOR SUZUKI Outboard motor DF40 (DF-40) DF50 (DF-50)

Battery Charging System, Outline, Inspection, Removal, Installation, Disassembly, Assembly, Electric Starter System, Troubleshooting, Starter Motor, Monitor-Tachometer, Electric Parts Holder.

Suzuki G15a Engine Manual Transmission

FUEL SYSTEM FOR SUZUKI Outboard motor DF40 (DF-40) DF50 (DF-50)

Precaution on Fuel System Service, General Precaution, Fuel Pressure Relief Procedure, Fuel Line, Fuel Leakage Check, Fuel Hose, Fuel Pressure Inspection, Fuel Vapor Separator, High Pressure Fuel Pump, Fuel Injector, Low Pressure Fuel pump, Fuel Tank and more.

POWER UNIT FOR SUZUKI Outboard motor DF40 (DF-40) DF50 (DF-50)

Suzuki G15a Engine Manual Free

Intake Manifold, Power Unit, Oil Pump, Timing Chain, Tensioner, Cylinder Head, Cylinder, Crankshaft, Piston, Thermostat, Water Cooling System, Engine Lubrication System and more.

MID UNIT FOR SUZUKI Outboard motor DF40 (DF-40) DF50 (DF-50)

Engine Side Cover, Driveshaft Housing and Oil Pan, Swivel Bracket, Steering Bracket and Clamp Bracket, Water Pressure Valve.

POWER TRIM AND TILT FOR SUZUKI Outboard motor DF40 (DF-40) DF50 (DF-50)

System Wiring Diagram, Oil Level, Service Procedure, Air Bleeding, Power Trim and Tilt Unit, PTT Motor, PTT motor Relay, PTT Switch, Principle’s of Operations and more.

LOWER UNIT FOR SUZUKI Outboard motor DF40 (DF-40) DF50 (DF-50)

Suzuki G15a Engine Manual Pdf

Pinion Bearing Propeller, Gearcase, Gears, Propeller Shaft Components, Propeller Shaft Bearing Housing, Shift Rod Guide, Housing Components, Water pump and Related Items, Driveshaft Oil Seal Housing, Driveshaft, Trim Tab, Lower Unit Gears-Shimming and Adjustment.

WIRE, HOSE ROUTING FOR SUZUKI Outboard motor DF40 (DF-40) DF50 (DF-50)

Wiring Diagram, Wire Routing, Fuel and Water Hose Routing, Exploded View, Picture Illustrations of Wiring Diagrams
.
Other Chapters Include:

Suzuki G16a Engine Manual

Examples of tabled specifications supplied in this service manual are: Dimensions and weight, overall length, overall height, weight without oil, transom height, performance, horsepower (HP), maximum output, recommended operating range, idle speed, power head, engine type, number of cylinders, bore, stroke, total displacement, compression ratio, spark plug type, what type of spark plugs, which spark plugs, ignition system, fuel supply, exhaust system, cooling system, throttle control, fuel and oil type, engine oil viscosity and weight, engine oil amounts, what gear oil, gear case oil capacity, bracket, trim angle, number of trim position, maximum tilt angle, gear ration, propeller (aluminum propeller, stainless steel propeller) and much more.

This Service Manual also contains important information on periodic maintenance to help you care for and maintain your engine for a longer life of the engine.

Information includes:

1. Periodic maintenance schedule chart for the recommended intervals for the required periodic service work necessary to keep the motor running a peak performance and economy.

2. Maintenance and tune-up procedures of engine oil, engine oil filter, engine oil filter replacement, gear oil, lubrication point, spark plug inspection, spark plug gap, tappet clearance, checking and adjusting tappet clearance, idle speed adjusting, ignition timing, breather and fuel line, low pressure fuel filter, fuel mixture check and much more.

MANUAL LANGUAGE: ENGLISH
PAGES: 578
FORMAT: PDF
DELIVERED IN: PDF FORMAT
ZOOM IN/ OUT: YES
BOOK MARKED BY CHAPTER: YES
COMPATIBLE ON ALL COMPUTERS

Tags: Suzuki Outboard boat engine (motor), Boat Motor, Part, Parts, New Parts, Used Parts, Aftermarket Parts, Manual Review, specifications Review, Repair Test, Service Test, Prop Inspection, Prop, Outboard Motor, Outboard engine, Suzuki 40/50 HP, Owners Service Repair Manual, Workshop Manual, Repair Guide, Handbook, Owners Service Manual, 40HP, 40 HP, 50HP, 50 HP, Horsepower, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 4-Stroke engine, 4-Stroke Suzuki Outboard Engine

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