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Suzuki DF40ATL Specifications
The Suzuki DF40ATL is a four-stroke three-cylinder double overhead camshaft gasoline long shaft outboard engine. This engine has a multi-point sequential electronic fuel injection, integral fuel pump, water cooled with thermostat, and full-transistorized ignition system. A 57.4 cu.in (941 cc) outboard motor has a cylinder bore of 2.85" (72.5 mm), piston stroke of 2.99" (76 mm), and maximum power of 40 hp (29.5 kW) at 5000-6000 rpm. The boat motor is equipped with an electric starting system, 3-blades aluminum standard propeller, power trim and tilt, and tiller handle or remote control steering system. The fuel tank has a capacity of 6.6 gal (25 liters).
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| General Technical Data |
Engine Model ................ Suzuki DF40ATL, DF40ATHL
Engine Type ................ 4-stroke three-cylinder DOHC gasoline outboard engine
Number of Cylinders ................ 3
Displacement, cu.in (cc) ................ 57.4 (941)
Cylinder Bore, in (mm) ................ 2.85 (72.5)
Piston Stroke, in (mm) ................ 2.99 (76.0)
Maximum Engine Power, hp (kW) ................ 40.0 (29.5)
Maximum Engine Speed, rpm ................ 5000-6000
Idle Speed, rpm ................ 800±50
Compression Ratio ................ 9.7:1
Lubrication System ................ Wet sump by trochoid pump
Exhaust System ................ Through prop
Cooling System ................ Water-cooled
Ignition System ................ Full-transistorized
Starting System ................ Electric starter
Electrical System Rating, Volts ................ 12
Charging System ................ Alternator
Alternator Rating, Amps ................ 19
| Dimensions and Weight |
Overall Length (DF40ATL), in (mm) ................ 27.5 (699.0)
Overall Length (DF40ATHL), in (mm) ................ 32 (814.0)
Overall Width, in (mm) ................ 14.8 (377.0)
Overall Height (Long Shaft), in (mm) ................ 54.6 (1385.0)
Transom Height (Long Shaft), in (mm) ................ 20 (508)
Outboard Weight (DF40ATL, Long Shaft), lbs (kg) ................ 229.0 (104.0)
Outboard Weight (DF40ATHL, Long Shaft), lbs (kg) ................ 238.0 (108.0)
| Fuel System |
Fuel System Type ................ Multi-point sequential electronic fuel injection
Fuel Pump Type ................ Integral
Fuel Type ................ Unleaded gasoline (87 or 91 octane minimum)
Fuel Tank Capacity, gal (L) ................ 6.6 (25.0)
| Gear Housing |
Reversing System ................ Gear
Gear Shift ................ F-N-R
Gear Ratio ................ 2.28:1
Reduction System ................ Bevel gear
Gear Oil Capacity, qts (L) ................ 0.65 (0.61)
| Mid Section |
Trim System ................ Power Trim/Tilt
Transom Height (Long Shaft), in (mm) ................ 20 (508)
Steering System (DF40ATL) ................ Remote Control
Steering System (DF40ATHL) ................ Tiller Handle
Trim Angle, deg ................ 0-19
Tilt Angle (Max), deg ................ 72
| Propeller Information |
Diameter, in (mm) ................ 11.25 (285), 11.5 (292)
Pitch, in (mm) ................ 9 (228) - 16 (406)
Number Of Blade ................ 3
Material ................ Aluminum
| Cylinder Block |
Cylinder Bore Inside Diameter, in (mm) ................ 2.8543-2.8551 (72.500-72.520)
Cylinder Bore (Max Out of Round), in (mm) ................ 0.002 (0.050)
Crank Pin Outside Diameter, in (mm) ................ 1.4954-1.4961 (37.982-38.000)
Crank Pin Width, in (mm) ................ 0.7913-0.7953 (20.100-20.200)
Crankshart Thrust Play, in (mm) ................ 0.004-0.012 (0.11-0.31)
Crankshaft Journal Outside Diameter, in (mm) ................ 1.7709-1.7717 (44.982-45.000)
Crankshaft Journal Oil Clearance, in (mm) ................ 0.0006-0.0013 (0.014-0.034)
Connecting Rod Inside Diameter (Big End), in (mm) ................ 1.6142-1.6149 (41.000-41.018)
Connecting Rod Oil Clearance (Big End), in (mm) ................ 0.0012-0.0019 (0.031-0.049)
Connecting Rod Side Clearance (Big End), in (mm) ................ 0.0039-0.0098 (0.100-0.250)
Connecting Rod Width (Big End), in (mm) ................ 0.7854-0.7874 (19.950-20.000)
Connecting Rod Inside Diameter (Small End), in (mm) ................ 0.7088-0.7092 (18.003-18.013)
Piston Skirt Diameter, in (mm) ................ 2.8531-2.8539 (72.470-72.490)
Piston to Cylinder Clearance, in (mm) ................ 0.0008-0.0016 (0.020-0.040)
Piston Pin Outside Diameter, in (mm) ................ 0.7085-0.7087 (17.995-18.000)
Piston Pin Bore Inside Diameter, in (mm) ................ 0.7089-0.7092 (18.006-18.014)
Piston to Piston Pin Clearance, in (mm) ................ 0.0002-0.0007 (0.006-0.019)
Top Ring Width, in (mm) ................ 0.040-0.041 (1.02-1.04)
Second Ring Width, in (mm) ................ 0.048-0.049 (1.21-1.23)
Oil Ring Width, in (mm) ................ 0.079-0.080 (2.01-2.03)
Top Ring End Gap, in (mm) ................ 0.0059-0.0118 (0.15-0.30)
Second Ring End Gap, in (mm) ................ 0.0118-0.0177 (0.30-0.45)
Top Ring Side Clearance, in (mm) ................ 0.0012-0.0028 (0.030-0.070)
Second Ring Side Clearance, in (mm) ................ 0.0008-0.0024 (0.02-0.06)
| Cylinder Head and Valves |
Cylinder Head Warp Limit ................ 0.002 (0.050)
Valve Head Diameter (Intake), in (mm) ................ 1.05 (26.6)
Valve Head Diameter (Exhaust), in (mm) ................ 0.85 (21.5)
Valve Head Thickness (Intake), in (mm) ................ 0.040 (1.00)
Valve Head Thickness (Exhaust), in (mm) ................ 0.045 (1.15)
Valve Stem Outside Diameter (Intake), in (mm) ................ 0.2152-0.2157 (5.465-5.480)
Valve Stem Outside Diameter (Exhaust), in (mm) ................ 0.2142-0.2148 (5.440-5.455)
Valve Guide Inside Diameter (Intake), in (mm) ................ 0.2165-0.2170 (5.500-5.512)
Valve Guide Inside Diameter (Exhaust), in (mm) ................ 0.2165-0.2170 (5.500-5.512)
Valve Stem To Valve Guide Clearance (Intake), in (mm) ................ 0.0008-0.0019 (0.020-0.047)
Valve Stem To Valve Guide Clearance (Exhaust), in (mm) ................ 0.0018-0.0028 (0.045-0.072)
Valve Seat Width (Intake), in (mm) ................ 0.043-0.051 (1.1-1.3)
Valve Seat Width (Exhaust), in (mm) ................ 0.043-0.051 (1.1-1.3)
Valve Spring Free Length, in (mm) ................ 1.30 (33.10)
Cam Height (Intake), in (mm) ................ 1.5039-1.5102 (38.200-38.360)
Cam Height (Exhaust), in (mm) ................ 1.4858-1.4921 (37.740-37.900)
Camshaft Journal Outside Diameter, in (mm) ................ 0.9029-0.9037 (22.934-22.955)
Camshaft Journal Inside Diameter, in (mm) ................ 0.9055-0.9063 (23.000-23.021)
Camshaft Journal Oil Clearance, in (mm) ................ 0.0018-0.0034 (0.045-0.087)
| Maintenance Data |
Engine Fuel Type ................ Unleaded 87 or 91 octane minimum
Engine Oil Type ................ SAE 10W-30, 10W-40
API Service Classifications ................ SG, SH, SJ, SL, or SM
Engine Oil Capacity, qts (L) ................ 2.85 (2.70)
Gear Lubricant Type ................ Suzuki Outboard Motor Gear Oil or GL5 SAE 90
Gearcase Capacity, qts (L) ................ 0.64 (0.61)
Ignition Timing, degrees ................ 2-22 BTDC
Spark Plug Type ................ NGK DCPR6E
Spark Plug Gap, in (mm) ................ 0.031-0.035 (0.8-0.9)
Valve Lash (Intake), in (mm) ................ 0.007-0.009 (0.18-0.22)
Valve Lash (Exhaust), in (mm) ................ 0.011-0.013 (0.28-0.32)
| Service Intervals |
Check Battery ................ Every 100 hours
Change Engine Oil ................ Every 100 hours
Change Gear Oil ................ Every 100 hours
Check Spark Plug ................ Every 100 hours
Check Breather and Fuel Line ................ Every 100 hours
Check Low Pressure Fuel Filter ................ Every 100 hours
Check Anodes ................ Every 100 hours
Check Thermostat ................ Every 100 hours
Check Propeller Nut and Pin ................ Every 100 hours
Replace Oil Filter ................ Every 200 hours
Check Valve Lash ................ Every 200 hours
Check Timing Belt ................ Every 200 hours
Check Idle Speed ................ Every 200 hours
Check Water Pump ................ Every 200 hours
Check Water Pump Impeller ................ Every 200 hours
Replace Spark Plug ................ Every 300 hours
Replace Water Pump Impeller ................ Every 300 hours
Replace Low Pressure Fuel Filter ................ Every 400 hours
| Tightening Torques |
Cylinder head cover bolt, Nm (lb-ft) ................ 11 (8.2)
Cylinder head bolt, Nm (lb-ft) ................ 59 (42.7)
Crankcase bolt (Inside), Nm (lb-ft) ................ 46 (33.5)
Crankcase bolt (Outside), Nm (lb-ft) ................ 25 (18.0)
Conrod cap bolt, Nm (lb-ft) ................ 15 (11.0)
Flywheel nut, Nm (lb-ft) ................ 166 (120.0)
Camshaft housing bolt, Nm (lb-ft) ................ 11 (8.2)
Fuel delivery pipe bolt, Nm (lb-ft) ................ 11 (8.2)
Low pressure fuel pump bolt, Nm (lb-ft) ................ 11 (8.0)
Intake manifold bolt/nut, Nm (lb-ft) ................ 23 (16.5)
Oil pressure switch, Nm (lb-ft) ................ 13 (9.5)
Timing chain guide bolt, Nm (lb-ft) ................ 11 (8.2)
Starter motor mounting bolt, Nm (lb-ft) ................ 23 (16.5)
Oil pump bolt, Nm (lb-ft) ................ 11 (8.2)
Engine oil filter, Nm (lb-ft) ................ 14 (10.5)
Water pump case nut, Nm (lb-ft) ................ 8 (5.8)
Power unit mounting bolt, Nm (lb-ft) ................ 50 (36.0)
Driveshaft housing bolt, Nm (lb-ft) ................ 50 (36.0)
Propeller nut, Nm (lb-ft) ................ 55 (40.0)
Gearcase bolt, Nm (lb-ft) ................ 23 (16.5)
Tiller handle bolt, Nm (lb-ft) ................ 37 (27.0)
Spark plug, Nm (lb-ft) ................ 10-12 (7.5-9.0)
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| Engines Technical Specifications |