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Chapter Twelve

Power Trim System

The power trim system (Figure 1) is factory-installed

on all models covered in this manual. This chapter pro-

vides power trim removal, repair and installation instruc-

tions.

Disassembly and assembly of the hydraulic cylinders

requires special tools and some practical experience in hy-

draulic system repair. Have the hydraulic cylinder(s) re-

paired at a reputable marine repair facility.

Table 1 provides torque specifications for the power trim

system. Tables 2-4 provide electric motor repair specifica-

tions. Tables 1-4 are located at the end of this chapter.

Identification

An externally mounted pump is used on 1994-1997

DT75 and DT85 and 1992-1995 DT115 and DT140 mod-

els. See Figure 1. An internally mounted pump (except

Showa) is used on 1995 and 1996 DT75 and DT85, all

DT90 and DT100 models and 1992-on DT150, DT175,

DT200 and DT225 models. See Figure 2. A Showa sys-

tem with an internally mounted pump is used on 1997-on

DT75 and DT85 1996-on DT115 and DT140 models. See

Figure 3.

External Mounted Trim Pump

Removal and Installation

WARNINGNever work under any part of the enginewithout providing suitable support. The en-gine-mounted tilt lock or hydraulic systemmay collapse and cause the engine to drop.Support the engine with blocks or an over-head cable before working under the en-gine.

Note all component mounting locations and orientation

prior to removal. Make a sketch of the wire routing (trim

motor) before removal. Apply Suzuki water-resistant

grease to all bushings and pivot points on assembly. Ap-

ply ThreeBond 1342 (Suzuki part No. 99000-32050) to

12

the threads of all trim system fasteners. Note the size and

location of plastic tie clamps and replace them if they are

removed.

1. Disconnect both battery cables from the battery. Re-

move the spark plugs and connect the spark plug leads to

an engine ground.

2. Locate the electric motor and pump assembly (Figure

4) and rotate the manual relief valve (Figure 4 or Figure

5) 3-4 turns counterclockwise. Tilt the unit to the full-up

position, then securely tighten the manual relief valve.

3. Use an overhead hoist or wooden blocks to support the

engine as indicated in Figure 6.

4. Disconnect the blue and green wires from the trim re-

lays (Figure 7). Route the wires out the lower engine

cover opening (Figure 8).

410 CHAPTER TWELVE

1

2 5

4

3Tohoist

6

5. Remove the port and starboard side circlips (Figure 9)

that secure the upper pivot pin to the tilt bracket. Using a

punch, drive the upper pivot pin from the tilt bracket and

tilt cylinder.

6. Loosen—but do not remove—the electric motor/pump

mounting bolts (Figure 10). Search for and remove any

ground wires and clamps that may interfere with removal

of the system.

7. Support the tilt cylinder while loosening and removing

the eight bolts (four on each side) that retain the trim sys-

tem to the clamp brackets (Figure 11). Support the entire

tilt system and remove the motor/pump mounting bolts

(Figure 10).

8. Lower the tilt system and pull it away from the engine.

Place it on a suitable work surface. To allow quicker air

bleeding, place the tilt system in the upright position.

9. Inspect all bushings and pivot points for wear or dam-

age. Replace any defective components.

10. Inspect all bolts, nuts, clamps and circlips for wear,

damage or corrosion.

11. Ensure the engine is securely mounted in the full-tilt

position. Place the upper end of the tilt cylinder into its re-

cess in the tilt bracket. Align the pinhole in the cylinder

with the pinhole in the tilt bracket.

12. Coat the upper pivot pin and its bore with Suzuki wa-

ter-resistant grease. Carefully drive the pin through its

hole in the tilt bracket and trim cylinder bushings (if so

equipped). Ensure the pin protrudes the same amount on

both the port and starboard sides. Install the circlip into

the grooves on both ends of the pin (Figure 12).

13. Pivot the tilt system inward until the motor/pump

mounting holes align with the threaded holes in the clamp

bracket. Install the motor/pump mounting bolts (Figure

10). Do not tighten them at this time.

14. Pivot the trim system until its mounting bolt holes

align with the corresponding holes in the clamp brackets.

Install all mounting bolts and tighten them securely.

POWER TRIM SYSTEM 411

12

7

8

9

10

11

15. Route the electric motor wire harness through the

clamp and lower engine cover (Figure 8). Connect the

wires to the proper relay terminals.

16. Install the spark plugs and spark plug leads. Clean the

terminals and connect the battery cables to the battery.

Close the manual relief valve.

17. Carefully remove the overhead support. Open the

manual relief valve and slowly lower the engine. Refer to

Fluid Filling and Air Bleeding Procedures in this chapter.

Correct the fluid level and bleed any air from the system.

Integral Trim Pump Removal and Installation

(Except Showa)

Mark the components mounting locations and their ori-

entation prior to removal. Make a sketch of the electric

motor wire harness routing before removal. Apply Suzuki

water-resistant grease to all bushing and pivot points on

assembly. Apply ThreeBond 1342 (Suzuki part No.

99000-32050) to the threads of all trim system fasteners.

Note the size and location of plastic tie clamps and replace

them if removed.


move the spark plugs then connect the spark plug leads to

a suitable engine ground.

2. Rotate the valve 3-4 turns counterclockwise. Tilt the

unit to the full up position and securely tighten the manual

relief valve (Figure 13).

3. Use an overhead hoist or other secure means to support

the engine as indicated (Figure 6).




5. Remove the port and starboard side circlips (Figure 9)

that retain the upper pivot pin to the tilt bracket. Using an

appropriately sized punch, drive the upper pivot pin from

the tilt bracket and tilt cylinder.

6. Remove any ground wires and clamps that may inter-

fere with removal of the system. Support the tilt cylinder

and remove the lower pivot bolt.

7. Support the trim system and remove the eight (four on

each side) trim system mounting bolts (Figure 14).

8. Lower the trim system while pulling it away from the

engine. Place it on a suitable work surface. To allow

quicker air bleeding, place the trim system in the upright

position.

9. Inspect all bushing and pivot points for worn or dam-

aged surfaces. Replace any defective components.

10. Inspect all bolts, nuts, clamps and circlips for wear,

damage or corrosion. Replace them if defects are noted.

11. Support the engine (Figure 6) in the full-tilt position.

Place the upper end of the tilt cylinder into its recess in the

tilt bracket. Align the pinhole in the cylinder with the pin-

hole in the tilt bracket.

12. Coat the upper pivot pin and its bore with Suzuki wa-

ter-resistant grease. Carefully drive the pin through its

hole in the tilt bracket and tilt cylinder bushings (if so

equipped). Ensure the pin protrudes the same amount on

both the port and starboard sides. Install the circlip (Fig-

ure 12) into the grooves on both sides of the pin.

412 CHAPTER TWELVE

14

12

13

13. Pivot the trim system into position between the clamp

brackets. Align the mounting bolt holes in the trim system

with their corresponding holes in the clamp brackets.

14. Insert the eight mounting bolts through the clamp

bracket and into trim system. Securely tighten the bolts.


clamp bracket and lower engine cover. Connect the wires

to the proper relay terminals.



Close the manual relief valve (Figure 13).


manual relief valve then slowly lower the engine to the

normal or upright position. Refer to Fluid Filling and Air

Bleeding (in this chapter). Correct the fluid level and

bleed any air from the system.

Removal and Installation

(Showa Integral Trim Pump)

Note all component mounting locations and orienta-

tions prior to removal. Make a sketch of the electric motor

wire harness routing before removal. Apply Suzuki wa-

ter-resistant grease to all bushings and pivot points on as-

sembly. Apply ThreeBond 1342 (Suzuki part No.

99000-32050) to the threads of all trim system fasteners.

Note the size and location of plastic tie clamps and replace

them if removed.


move the spark plugs, then connect the spark plug leads to

a suitable engine ground.

2. Rotate the manual relief valve (Figure 13) 3-4 turns

counterclockwise. Tilt the unit to the full-up position and

securely tighten the manual relief valve.


engine (Figure 6).




5. Using needlenose pliers, remove the port side circlip

(Figure 9) from the upper pivot pin.

6. Using a punch, drive the upper pivot pin from the tilt

bracket and tilt cylinder.

7. Remove any grounding wire and clamps that may in-

terfere with removal of the system.

8. Remove the port side circlip from its groove on the

lower pivot pin (Figure 15). Support the trim system

while carefully driving the lower pivot pin through the

clamp brackets and trim system (Figure 16).

9. Lower the trim system and pull it out and away from

the engine. Place it on a suitable work surface. To allow

quicker air bleeding, place the trim system in the upright

position.

10. Inspect all bushing and pivot points for excessive

wear or damage. Replace any defective components.

11. Inspect all bolt, nuts, clamps and circlips for wear,

damage or corrosion. Replace them if defects are noted.

12. Mount the engine securely in the full-tilt position.

Place the upper end of the trim cylinder into its recess in

the tilt bracket. Align the pinhole in the cylinder with the

pinhole in the tilt bracket.

13. Coat both the upper pivot pin and the pin bore with

Suzuki water-resistant grease. Carefully drive the upper

pin through its hole in the starboard side of the tilt bracket

and trim cylinder bushings (if so equipped). Seat the step

on the starboard side of the pin against the clamp bracket.

Install the circlip into the grooves on port side of the pin

(Figure 12). Seat the circlip in the groove of the pin.


12

15

16

14. Pivot the trim system inward and down until its lower

pivot pinhole aligns with the corresponding holes in the

clamp brackets.

15. Coat the lower pivot pin and pin bores with Suzuki

water-resistant grease. Carefully drive the lower pin

through the starboard clamp bracket, trim system pin

opening and the port clamp bracket. Ensure the pin is pro-

truding the same amount on both the port and starboard

sides. Install the circlip into the groove on port side of the

pin (Figure 15). Seat the circlip in the groove on both

sides of the pin.


clamp bracket and lower engine cover (Figure 8). Con-

nect the wires to the proper relay terminals.


terminals, then connect the battery cables to the battery.

Close the manual relief valve (Figure 13).


manual relief valve, then slowly lower the engine to the

normal or upright position. Refer to Fluid Filling and Air

Bleeding in this chapter. Correct the fluid level and bleed

any air from the system.

Electrical Motor Removal

(External Trim Pump)

WARNINGThe trim systems contain fluid under highpressure. Always use protective eyewearand gloves while working with the trim sys-tem. Never remove any components or plugs(Figure 17) without first bleeding the pres-sure from the system.

CAUTIONThe trim system must operate with cleanfluid. A small amount of contamination cancause damage to the trim system. Thor-oughly clean the trim system external sur-faces with soapy water. Use compressed airto dry the trim system.

Work in a clean area and use lint-free towels to wipe

components after removal. Cover any openings immedi-

ately after removing the electric motor to prevent acciden-

tal contamination of the fluid.

1. Disconnect both battery cables from the battery.

2. Locate the electric motor and pump assembly (Figure

4) on the starboard clamp bracket. Locate the manual re-

lief valve on the pump body (Figure 5). Rotate the manual

relief valve three to four turns counterclockwise. Tilt the

unit to the full-up position, then securely tighten the man-

ual relief valve.

414 CHAPTER TWELVE

17

ELECTRIC TRIM MOTOR

(EXTERNAL TRIM PUMP)

18

1. Throughbolt

2. Top cover

3. Brush

4. Brush plate

5. O-ring

6. Frame

7. O-ring

8. Armature

9. Fluid reservoir


engine (Figure 6).




5. Support the electric motor while fully loosening—but

not removing—both electric motor throughbolts (1, Fig-

ure 18).

6. Grasp the electric motor at the frame (6, Figure 18),

then carefully lift the electric motor and armature (8) from

the reservoir (9).

7. Remove then discard the O-ring (7, Figure 18) from

the frame or reservoir.

Electric Motor Removal (Integral Trim Pump,

Except Showa)

Make a sketch of the electric motor wire harness rout-

ing before removal.

1. Thoroughly clean the trim system area before remov-

ing any components.

2. Refer to Trim System Removal and Installation in this

chapter, then remove the complete trim system.

3. Secure the trim system in a bench vise with padded

jaws. Mount the system in the upright position. Mark the

mating surfaces of the trim system and electric motor to

ensure correct orientation on assembly.

4. Remove the three bolts that retain the electric motor to

the trim system (Figure 19), then carefully lift the electric

motor from the trim pump assembly.

5. Remove the O-ring from the electric motor or trim

pump. Discard the O-ring. Note which side is facing up,

then remove the drive coupler from the hydraulic pump

shaft.

6. Note its direction or placement on the pump and care-

fully pull the filter from the trim pump opening. Clean the

filter with a suitable solvent. Cover the pump opening

with a clean lint-free shop towel to prevent contamination

of the fluid.

Electric Motor Removal


Mark all component mounting locations and orienta-

tions prior to removal. Make a sketch of the electric motor

wire harness routing before removal.

1. Thoroughly clean the trim system area prior to remov-

ing any components.

2. Refer to Trim System Removal and Installation in this

chapter, then remove the complete trim system from the

engine.

3. Secure the trim system in a bench vise with padded

jaws. Mount the system in the upright position. Mark the

mating surfaces of the trim system and electric motor to

ensure correct orientation upon assembly.

4. Remove all four mounting bolts (2, Figure 20), then

carefully remove the electric motor (3, Figure 20) from

the trim system. Remove and discard the O-ring (4, Fig-

ure 20).


12

19

ELECTRIC TRIM MOTOR

(SHOWA)20

1. Manual relief valve

2. Bolt

3. Electric motor

4. O-ring

5. Filter

6. Drive coupler

5. Note the UP side, then remove the drive coupler (6,

Figure 20) from the hydraulic pump or electric motor.

6. Note its direction or placement on the pump, then care-

fully pull the filter (5, Figure 20) from the trim pump.

Clean the filter with a suitable solvent. Cover the pump

opening with a clean lint-free shop towel to prevent con-

tamination of the fluid.

Electric Motor Disassembly

Work in a clean environment to avoid contaminating

the internal components of the trim system. Use electrical

contact cleaner to clean the electric motor components.

Electrical contact cleaner is available at most electrical

supply sources. It evaporates rapidly and leaves no resi-

due. Avoid touching the brushes and commutator after

cleaning; naturally occurring oils on the fingers contami-

nate these components, possibly shortening their service

life.

CAUTIONMark the top cover, frame and lower coverof the electric motor prior to disassembly.Use paint dots or removable tape. Neverscratch the components, as it promotes cor-rosion of metal components.

NOTEThe magnets in the electric motor frame as-sembly are quite strong. Considerable effortmay be required to remove the frame assem-bly from the armature. Make sure all fasten-ers are removed, then carefully pull theframe from the armature.

External trim pump

1. Refer to Electric Motor Removal and remove the elec-

tric motor from the fluid reservoir (10, Figure 21).

2. Mark the top cover (2, Figure 21) and frame (6) for

reference during assembly.

3. Hold the frame assembly (6, Figure 21) and remove

both throughbolts (1). Pull the top cover (2, Figure 21)

along with the wire harness and brush plate (4) from the

frame assembly.

4. Remove the O-ring (5, Figure 21) from the frame as-

sembly. Discard the O-ring.

5. Grasp the frame assembly (6, Figure 21), then pull the

armature (8) from the frame.

416 CHAPTER TWELVE

ELECTRIC MOTOR

(EXTERNAL TRIM PUMP)

21

1. Throughbolt

2. Top cover

3. Brush

4. Brush plate

5. O-ring

6. Frame

7. O-ring

8. Armature

9. Seal

10. Fluid reservoir

11. Manual relief valve

12. O-ring

13. Hydraulic pump

14. Bolt

15. Mounting stud

16. Bolt

17. Fill/check plug

18. Gasket

19. Lockwasher

20. Nut

21. Coupler

Integral trim pump (except Showa)


tric motor from the engine.

2. Mark the frame and upper cover mating surfaces (Fig-

ure 22) for reference during assembly.

3. Hold the frame (2, Figure 23) so it firmly contacts the

lower cover (12) and remove all three mounting screws

(1).

4. Hold the frame assembly (2, Figure 23), then grasp the

armature shaft with pliers and a shop towel (Figure 24).

Pull the armature and lower cover from the frame assem-

bly.

5. Use two small screwdrivers to collapse the brush

springs (11, Figure 23) and move the brushes away from

the commutator. Carefully pull the armature (4, Figure

23) from the lower cover. Slowly release the brush

springs.

6. Remove the O-ring (3, Figure 23) from the lower

cover (12). Mark the orientation of the plate (9, Figure

23) to the lower cover (12). Remove the screws (6 and 8,

Figure 23), then disconnect the terminal connector. Lift

the brush and lead assembly (7, Figure 23) and plate (9)

from the lower cover (12).

7. Disconnect the terminal, then lift the breaker and brush

assembly (10, Figure 23) from the lower cover (12). Re-

move the thrust washer (5, Figure 23) from the lower

cover (12). Carefully lift both brush springs (11, Figure

23) from the lower cover (12).

Integral trim pump (Showa)


tric motor from the engine.

2. Mark the frame (4, Figure 25) and lower cover (10) for

reference during assembly.

3. Hold the frame (4, Figure 25) while removing both

mounting screws (3) from the lower cover (10).

4. Hold the frame (4, Figure 20) and grasp the armature

shaft with pliers and a shop towel as indicated in Figure

24. Pull the armature and lower cover from the frame as-

sembly.

5. Use two small screwdrivers to collapse the brush

springs (9, Figure 25), then move the brush away from the

commutator. Pull the armature (5, Figure 25) from the

lower cover. Slowly release the brush springs.

6. Remove the thrust washer (13, Figure 25) from the ar-

mature (5). Remove the O-ring (14, Figure 25) from the

lower cover (10). Discard the O-ring.

7. Remove both screws (6, Figure 25), then lift both

brush retainers (7) from the lower cover (10). Disconnect

the wire terminals, then lift the brush lead and breaker and

brush assembly (8, Figure 25) from the lower cover (10).

8. Note the seal lip direction, then carefully push or pry

the seal and bushing (11 and 12, Figure 25) from the

lower cover.

Electric Motor Inspection

Prior to performing any test or measurement, clean all

components. Inspect the magnets in the frame assembly

for broken or loose magnets and replace the frame assem-

bly if defects are noted.

1. Connect an ohmmeter between each brush and termi-

nal end of the brush wire (Figure 26). Continuity must be

present.

2. On models equipped with a breaker assembly in the

cover, connect an ohmmeter between the brush surface

(Figure 27) and the terminal of the breaker. Continuity

must be present.

3. Carefully grip the armature in a vise (Figure 28). Use

only enough clamping force to retain the armature. Polish

the commutator surfaces with 600-grit wet or dry abrasive

paper or carburundum. Polish the surface only. Remove

only contamination and glazed surfaces. Periodically ro-

tate the armature to polish evenly. Avoid removing too

much material.

4. Use a disposable fingernail file to remove the mica and

brush material from between the commutator segments

(Figure 29).

5. Connect an ohmmeter between each commutator seg-

ment (Figure 30) while noting the meter. Continuity must


12

22

418 CHAPTER TWELVE

ELECTRIC MOTOR

(INTEGRAL TRIM PUMP,

EXCEPT SHOWA SYSTEM)

23

1. Screws

2. Frame

3. O-ring

4. Armature

5. Thrust washer

6. Screw

7. Brush/lead

8. Brush plate screw

9. Plate

10. Breaker/brush assembly

11. Brush/spring

12. Lower cover

24

ELECTRIC MOTOR

(INTEGRAL SHOWA TRIM PUMP)

1. Screw

2. Retainer

3. Screw

4. Frame

5. Armature

6. Screw

7. Brush retainer

8. Brush/lead

9. Brush spring

10. Lower cover

11. Bushing

12. Seal

13. Thrust washer

14. O-ring

25

be present between each segment or the armature must be

replaced.

6. Connect the ohmmeter between each commutator seg-

ment and each armature lamination (Figure 31), then the

armature shaft. No continuity should be present between

any commutator segment and armature laminations or

shaft. If continuity is noted, the armature is shorted and

must be replaced.

7. Using a micrometer or vernier caliper, measure the

commutator diameter at the points indicated (Figure 32).

Compare the measurements with the specification in Table

2. Replace the armature if the measurements are not within


12

26

27

28

29

30

31

32

the listed specification. Inspect the bearing surfaces on the

armature for excessive wear or damage and replace as re-

quired. Inspect the bushings in the covers or frame assem-

bly and replace them if they are worn or damaged.

8. Using a depth micrometer, measure the depth of the

undercut between the commutator segments at the points

indicated in Figure 33. Compare the measurements with

the commutator undercut specification listed in Table 3.

Replace the armature if the measurements are not within

the specification.

9. Inspect the brush springs for damage or corrosion. Re-

place the brush springs if there is corrosion or lost spring

tension. Measure the brush length as shown (A and B,

Figure 34). Replace both brushes if the length of either

brush is at or below the minimum specification in Table 4.

External Motor Assembly Trim Pump

1. Clean and dry all components. Apply a light coat of

Suzuki water-resistant grease to the bushings, O-rings,

seals and armature shaft (at the bushing contact surfaces).

Do not allow any grease to contact the brushes or commu-

tator.

2. Install the brush springs and brushes into the brush

plate (4, Figure 21).

3. Use two small screwdrivers to position the brushes

fully into the brush holders; the springs must be fully col-

lapsed. Carefully install the commutator end of the arma-

ture into the brush holder, then release the brushes. Never

force the armature into the cover, as the brushes will be

damaged.

4. Carefully position the brush plate (4, Figure 21) and

armature (8) into the top cover (2). Ensure that the wires

leading to the brushes are pulled up and away from the

brushes and armature.

5. Install a new O-ring (5, Figure 12) onto the frame as-

sembly (6). Hold the armature firmly into the top cover.

Carefully slide the frame assembly over the armature until

it contacts the top cover. Ensure the O-ring is properly po-

sitioned on the stepped portion of the frame and the refer-

ence marks (Figure 22) are aligned.

Integral Motor Assembly Trim Pump

(Except Showa)





tator.

2. Insert the breaker/brush lead (10, Figure 23) into the

lower cover (12). Connect the wire terminal to the

breaker.

3. Place the brush springs (11, Figure 23) into the re-

cesses provided in the lower cover. Place the thrust

washer (5, Figure 23) into the lower cover (12), then in-

stall the plate (9) onto the lower cover.

4. Place the brush lead (7, Figure 23) onto the plate (9).

Install the screw (6, Figure 23) through the brush lead

connector, plate and lower cover. Securely tighten the

screw. Connect the wire terminal to the brush lead con-

nector. Position both brushes into the brush springs

(within the lower cover).

5. Install both plate-retaining screws (8, Figure 23), then

securely tighten them. Install a new O-ring onto the lower

cover (12).

6. Use two small screwdrivers to position the brushes

fully into the brush holders (the springs must be fully col-

lapsed). Carefully install the commutator end of the arma-

ture into the brush holder then release the brushes. Never

force the armature into the cover, or the brushes will be

damaged.

7. Apply Suzuki water-resistant grease to the bushing in

the frame assembly. Grasp the armature shaft with pliers

and a shop towel, as indicated in Figure 24. Carefully slip

the frame assembly (2, Figure 23) over the armature

while guiding the armature shaft into the bushing in the

frame assembly.

8. Position the armature against the lower cover. Ensure

the O-ring is properly positioned on the lower cover. Ro-

tate the frame assembly until the reference marks (Figure

22) align. Install all three screws (1, Figure 23) then

tighten them securely.

9. Refer to Electric Motor Installation and install the

electric motor to the trim system.

420 CHAPTER TWELVE

33

Integral Motor Assembly Trim Pump (Showa)





tator.

2. Insert the breaker/brush lead (8, Figure 25) into the

lower cover (10). Connect the wire terminal to the breaker

and brush retainer.

3. Install the seal into the lower cover with the seal lip

facing down or away from the armature. Place the brush

springs (9, Figure 25) into the recesses provided in the

lower cover. Place the thrust washer (13, Figure 25) onto

the upper portion of the armature shaft.

4. Install the brush retainers (7, Figure 25) onto the lower

cover. Install the screws and washers (6, Figure 25) and

securely tighten them. Position both brushes into the

brush springs within the lower cover.

5. Apply Suzuki water-resistant grease to the bushing in

the lower cover. Use two small screwdrivers to position

the brushes fully into the brush holders; the springs must

be fully collapsed. Carefully install the commutator end

of the armature into the brush holder then release the

brushes. Never force the armature into the cover; the

brushes will be damaged.

6. Install a new O-ring (14, Figure 25) onto the lower

cover. Apply Suzuki water-resistant grease to the bushing

(in the frame). Place the thrust washer (13, Figure 25)

onto the armature shaft. Grasp the armature shaft with pli-

ers and a shop towel (Figure 24). Carefully slip the frame

assembly (4, Figure 25) over the armature while guiding

the armature shaft into the bushing in the frame assembly.

7. Position the armature against the lower cover. Ensure

the O-ring is properly positioned on the lower cover. Ro-

tate the frame assembly until the reference marks align

(Figure 22). Install both screws (3, Figure 25), then se-

curely tighten them.


electric motor to the trim system.

Electric Motor Installation (External Trim Pump)

Apply Suzuki water-resistant grease to all O-rings,

bushings and pivot points on assembly. Apply ThreeBond

1342 (Suzuki part No. 99000-32050) to the threads of all

trim system fasteners.

1. Perform this step only if the shaft seal (9, Figure 21) is

removed. Using an appropriately sized socket, push the

seal into its bore in the reservoir. Ensure the seal lip faces

away from the electric motor.

2. Install a new O-ring (7, Figure 21) onto the stepped

portion of the frame (6). Hold the armature into the frame

while positioning the electric motor onto the reservoir.

Rotate the frame until the electric motor drops down

against the reservoir. This indicates the armature shaft is

aligned with the oil pump shaft. Continue to rotate the

frame until the reference marks on the frame (made before

removal) and the reservoir align.

3. Apply a generous amount of liquid neoprene (avail-

able at automotive parts stores) to the underside of the

throughbolt heads (1, Figure 21). Install both

throughbolts into the top cover. Slightly rotate the frame

to align the bolts with the threaded holes in the reservoir.

Securely tighten the throughbolts. Apply liquid neoprene

to the exposed portions of the throughbolts to seal any po-

tential water leakage.


clamp and lower engine cover (Figure 8). Connect the

wires to the proper relay terminals.



Close the manual relief valve.


manual relief valve, then slowly lower the engine. Refer

to Fluid Filling and Air Bleeding in this chapter. Correct

the fluid level and bleed any air from the system.

Electric Motor Installation

(Integral Trim Pump, Except Showa)

Apply Suzuki water-resistant grease to all O-rings,

bushings and pivot points during assembly. Apply


12

Electric motor shaft

Shaft coupling

34

ThreeBond 1342 (Suzuki part No. 99000-32050) to the

threads of all trim system fasteners.

1. Thoroughly clean the electric motor mounting surface

prior to installing it.

2. Install a new O-ring onto the step of the electric motor

mating surface. Place the drive coupler (Figure 34) onto

the shaft coupling portion of the hydraulic pump.

3. Carefully lower the armature shaft onto the coupling.

Rotate the electric motor until the shaft and coupling align

(Figure 34) and the electric motor drops into position.

Rotate the electric motor to align the marks (made before

removal). Route the wire harness to prevent interference

with moving components.

4. Install the mounting screws (1, Figure 23) through the

lower cover and into the electric motor mounting pad.

Tighten the screws to the specification in Table 1.

5. Refer to Trim System Removal and Installation and in-

stall the trim system,

Electric Motor Installation


Apply Suzuki water-resistant grease to all bushing and

pivot points during assembly. Apply ThreeBond 1342

(Suzuki part No. 99000-32050) to the threads of all trim

system fasteners.

1. Thoroughly clean the electric motor mounting surface

prior to installation.

2. Place the filter (5, Figure 20) onto the trim pump. Seat

the filter into its mounting recess.

3. Install a new O-ring (4, Figure 20) onto the step of the

electric motor mating surfaces. Place the drive coupler (6,

Figure 20) onto the shaft coupling portion of the hydrau-

lic pump.

3. Carefully lower the armature shaft onto the coupling.

Rotate the electric motor until the shaft and coupling align

(Figure 34) and the electric motor drops into position.

Rotate the electric motor to align the orientation marks

(made prior to removal). Route the wire harness to pre-

vent interference with moving components.

4. Install the mounting bolts (2, Figure 20) through the

lower cover and into the electric motor mounting pad.

Tighten the bolts to the specification in Table 1.

5. Refer to Trim System Removal and Installation and in-

stall the complete trim system onto the engine.

Trim Relay Removal and Installation

1. Disconnect both battery cables from the engine. Re-

move the electric component cover to gain access the trim

relays.

2. Mark all wire terminal connections and wire routing

(Figure 7). Carefully disconnect all wire terminals from

the relay.

3. Mark the up side of the relay.

4. Remove the two bolts, washers and grommets (if so

equipped) that retain the trim relay to the mounting

bracket.

5. Place the relay onto its mount with the up marking cor-

rectly oriented. Install the bolts, washer and grommets to

the relay mounting holes. Securely tighten the bolts.

6. Carefully attach all wires to the relay (Figure 7). Route

all wires to prevent them from interfering with other com-

ponents.

7. Install the electric component cover (if removed).

Clean the terminals and connect the cables to the battery.

Check for proper trim system operation.

Trim Position Sender Removal and Installation

The trim sender is located on the inside of the port

clamp bracket (Figure 35). Sketch the sender wire routing

and connections prior to removal. This important step

helps to ensure a proper installation and prevent interfer-

ence with other moving components.

Perform trim sender adjustment after installation. Refer

to Chapter Five for adjustment instructions. Note the size

and location of plastic tie clamps and replace them as re-

quired.

1. Position the engine to full-tilt and engage the tilt lock

lever. Support the engine with blocks or an overhead cable

(Figure 6).

2. Trace the sender wires to the harness connection inside

the motor cover and disconnect them. Route the wires out

of the motor cover to allow removal of the wire and

sender. Remove all clamps prior to removal. Inspect the

422 CHAPTER TWELVE

35

clamps for corrosion or damage and replace them as re-

quired.

3. Use a felt-tip marker to trace the sender outline on the

mounting location. This allows for quicker adjustment

and proper orientation during installation. Remove both

fasteners and the sender (Figure 35). Route the wires

through the opening in the port clamp bracket and remove

the assembly.

4. Clean the mounting location and threaded holes.

5. Installation is the reverse of removal. Align the sender

with the outline marks and securely tighten the attaching

screws (Figure 35). Remove the engine supports or over-

head cable. Lower the engine.

6. Refer to Chapter Five and adjust the trim sender.

Check for proper operation.

Manual Relief Valve Removal and Installation

(External Pump)

The manual relief valve is located on the side of the hy-

draulic pump (Figure 36).

1. Position the engine in the full-up tilt position. Engage

the tilt lock lever and support the engine with an overhead

cable (Figure 6) or suitable blocks.

2. Slowly loosen and remove the manual relief valve

(Figure 36) from its opening in the hydraulic pump.

3. Use a light and a pick, screwdriver or tweezers to re-

move any remnants of the valve or O-ring from the open-

ing. Avoid damaging any of the machined surfaces in the

opening.

4. Lubricate the manual relief valve with Dexron II auto-

matic transmission fluid, then carefully slide the new

O-rings onto the valve. Lubricate the O-rings with Dexron

II automatic transmission fluid or its equivalent and install

the valve into the opening. Do not tighten the valve at this

time.

5. Rotate the valve clockwise until slight resistance can

be felt. Rotate the valve 1/4 turn clockwise, then 1/8 turn

counterclockwise. Repeat this process until the valve is

fully seated. Refer to Oil Filling and Air Bleeding (in this

chapter), then correct the fluid level and purge air from the

system.

Manual Relief Valve Removal and Installation

(Integral Trim Pump)

The manual relief valve is mounted to the side trim sys-

tem housing. Access the valve through an opening in the

clamp bracket (Figure 37).

1. Position the engine in the full-up tilt position. Engage

the tilt lock lever then support the engine with an over-

head cable (Figure 6) or blocks.

2. Using needlenose pliers, remove the circlip from the

valve opening. Slowly loosen the valve by rotating it in

the direction indicated on the clamp bracket (Figure 37).

Remove the valve from the opening.

3. Use a light and a pick, small screwdriver and/or tweez-

ers to remove any remains of the valve or O-ring from the

opening. Avoid damaging any of the machined surfaces in

the opening.

4. Lubricate the manual relief valve with Dexron II auto-

matic transmission fluid and carefully slide the new

O-rings (if removed) onto the valve. Lubricate the O-rings

with Dexron II automatic transmission fluid or its equiva-

lent, then install the valve into the opening. Do not tighten

the valve at this time.

5. Rotate the valve in the direction indicated on the clamp

bracket (Figure 37) to close the valve until slight resis-

tance is felt. Rotate the valve 1/4 turn in the closed direc-

tion, then 1/8 turn in the open direction. Repeat this

process until the manual relief valve is fully seated.

6. Using needlenose pliers, install the circlip to its groove

in the valve opening. Refer to Filling and Bleeding in this

chapter to correct the fluid level and purge air from the

system.


12

36

37

Hydraulic Pump Removal and Installation

WARNINGThe trim/tilt system creates very high pres-sure. Always wear eye and hand protection.Never disconnect any hydraulic lines or re-move any fittings without relieving the pres-sure from the system. Tilt the engine to thefull-up position and provide adequate sup-port against falling. Open the manual reliefvalve 2-3 complete turns to relieve the pres-sure.

Pump removal and installation (external pump)

1. Disconnect both battery cables from the battery.

2. Rotate the manual relief valve (Figure 36) 3-4 turns

counterclockwise. Tilt the engine to the full up position

and securely tighten the manual relief valve.


engine as indicated in Figure 6.

4. Trace the electric motor wire harness from the electric

motor to the wire connection points on the relays (Figure

7). Mark the large blue and green wire terminals, then dis-

connect them from the relay. Route the wires out the lower

engine cover openings (Figure 8) and clamp them to al-

low for removal of the trim pump.

5. Mark the connection points of the hydraulic lines to the

pump assembly. Place a suitable container under the

pump to catch spilled hydraulic fluid. Loosen each line to

relieve residual fluid pressure (Figure 38). Disconnect the

hydraulic lines from the pump assembly.

6. Support the pump while removing the bolts, nuts and

washers (Figure 10) that retain the pump to the clamp

bracket. Carefully lift the pump from the clamp bracket.

Open the fluid level/fill and pour the fluid from the pump

reservoir.

7. Mark the orientation of the hydraulic pump (13, Fig-

ure 21) to the reservoir (10) with a suitable marker. Trans-

fer these marks to any new components prior to assembly.

Remove the four bolts (14, Figure 21) and use a blunt tool

to carefully pry the pump (13, Figure 21) from the reser-

voir (10). Note the up direction and remove the shaft

coupler (21, Figure 21) from the hydraulic pump (13) or

armature (8).

8. Remove and discard the O-ring (12, Figure 21). Clean

the hydraulic pump and reservoir. Dry all components

with compressed air.

9. Lubricate with Dexron II and install a new O-ring (12,

Figure 21) onto the protruding shaft of the hydraulic

pump (13, Figure 21).

10. Install the shaft coupler (21, Figure 21) onto the hy-

draulic pump shaft in the direction noted prior to removal

(Figure 34).

11. Ensure the O-ring (12, Figure 21) is properly seated

over the step on the pump. Rotate the hydraulic pump to

align the shaft coupling (Figure 34) as you position it onto

the reservoir. Align the markings on the reservoir and hy-

draulic pump, then install the pump mounting bolts (14,

Figure 21). Securely tighten the bolts (Table 1).

12. Mount the pump assembly onto the clamp bracket.

Securely tighten the mounting bolts and nuts. Attach the

hydraulic lines to the pump and securely tighten the fit-

tings.

13. Route the wires through the lower engine cover and

to the relays. Clean the wire terminals then connect them

to the relay. Route the wires to prevent contact with any

moving components.

14. Refer to Filling and Bleeding in this chapter to cor-

rect the fluid level and purge air from the system.

Integral pump (except showa)


tric motor and filter from the trim system. Place a suitable

container under the trim system to catch any spilled fluid.

2. Mark the up side, then remove the drive coupler (6,

Figure 39) from the hydraulic pump (3).

3. Loosen and remove both retaining screws and washers

(4, 5, Figure 39) from the hydraulic pump.

4. Carefully lift the hydraulic pump (3, Figure 39) from

the trim system housing (1).

5. Using a syringe or bulb-type suction pump, siphon all

trim fluid from the pump cavity.

6. Remove both O-rings (2, Figure 39) from their open-

ings on the trim system housing (1). Discard the O-rings.

424 CHAPTER TWELVE

38

7. Using lint-free shop towels, carefully wipe the pump

cavity portion of the trim system housing.

8. Apply a light coat of water-resistant grease to the sur-

faces of both O-rings (2, Figure 39). Place both O-rings

onto the individual openings on the trim system manifold.

Do not place them over the threaded holes for the pump

attaching screws.

9. Align the two small orifices in the bottom of the re-

placement hydraulic pump with the O-rings (2). Position

the hydraulic pump into its cavity and carefully lower it

into position.

10. Align the mounting screw holes with the correspond-

ing holes. Do not move the O-ring (2, Figure 39) out of

position.

11. Install both mounting screws (6, Figure 39). Evenly

tighten both screws.


electric motor and filter onto the trim system.

Integral pump (Showa)

The hydraulic pump is integrated into the pump mani-

fold (Figure 40). Replace the entire pump manifold if the

hydraulic pump fails.


tric motor and filter from the trim system.

2. Place a suitable container under the trim system to

catch any spilled fluid. Refer to Manual Relief Valve Re-

moval and Installation and remove the manual relief

valve from the trim system.

3. Support the pump manifold while removing the

three Allen bolts from the port side of the manifold.

Carefully pull the manifold from the trim system (Fig-

ure 40).


12

HYDRAULIC PUMP

(INTEGRAL TRIM PUMP,

EXCEPT SHOWA)

39

1. Trim system

2. O-rings

3. Hydraulic pump

4. Washers

5. Screws

6. Drive coupler

7. Filter

8. Plug

9. Spring

10. Check valve

11. Seat

12. O-ring

Filter

O-ring

O-ring

O-ring

Aligning collar

Pump manifold

40

4. Note the size and location of the O-rings on the trim

system (Figure 40). Remove and discard the O-rings.

5. Using lint-free shop towels, clean the manifold mount-

ing surface on the trim system.

6. Carefully press a new filter (Figure 40) into the filter

opening of the replacement pump manifold.

7. Apply a light coat of water-resistant grease to all five

O-rings. Position the new O-rings into position on the trim

system as indicated (Figure 40).

8. Without dislodging the O-rings, place the pump mani-

fold onto its mounting surface. Align the collar with the

upper hole in the pump manifold.

9. Hold the pump manifold in position and align the Al-

len bolt holes in the pump manifold with the threaded

holes in the trim system.

10. Install the Allen bolts and evenly tighten them.


electric motor and filter onto the trim system.

Hydraulic Tilt Cylinder Removal and Installation

On all models using the Showa system, the hydraulic

tilt cylinder is integrated into the trim system housing.

This arrangement prevents its removal as a separate com-

ponent. The entire system must be disassembled and re-

paired if any of the cylinder components fail. On all other

systems, the hydraulic tilt cylinder is a separate compo-

nent allowing replacement of the component. Refer to

Power Trim Removal and Installation in this chapter to

identify the system used on the engine.

1. Refer to Power Trim System Removal and Installation

(in this chapter) and remove the trim system from the en-

gine.

2. Secure the trim system in a vise with soft jaws or small

pieces of wood for padding.

3. Place a container under the hydraulic cylinder(s) to

catch any spilled fluid. Mark the trim line connections and

use a suitable flare nut wrench loosen the lines. Allow any

residual fluid pressure to subside, then remove the lines

from the cylinder(s).

4. Locate the lower pivot pin (6, Figure 41) at the point

where it passes through the lower end of the trim system.

5. Drive the lower pivot pin from the trim system.

6. Support the hydraulic tilt cylinder (5, Figure 41) while

driving the pin from its bore in the trim system and the hy-

draulic tilt cylinder.

7. Carefully lift the hydraulic tilt cylinder from the trim

system. Remove both washers (3, Figure 41) from the

area near the pivot pin bore.

8. Position the new cylinder into position on the trim sys-

tem with the upper line fitting facing the port side. Align

the lower pivot pin bore on the cylinder and the trim sys-

tem.

9. Place a washer (3, Figure 41) on each side of the tilt

cylinder, in the original position before removal, so that it

aligns with the lower pivot pin bore.

10. Carefully drive the lower pivot pin through its bore in

the trim system and the hydraulic tilt cylinder. Ensure the

lower pivot pin protrudes the same amount on each side of

its bore.

11. Refer to Trim/Tilt System Removal and Installation

and install the trim system.

426 CHAPTER TWELVE

HYDRAULIC TILT CYLINDER

(INTEGRAL MOUNTED TRIM PUMP

[EXCEPT SHOWA SYSTEMS])

41

1. Hydraulic line

2. Hydraulic line

3. Washer

4. Grease fitting

5. Tilt cylinder

6. Lower pivot pin

7. Circlip

8. Bushing

9. Tilt ram

Reservoir Removal and Installation (External Pump)

1. Refer to Hydraulic Pump Removal and Installation

and remove the hydraulic pump.

2. Refer to Electric Motor Removal (in this chapter) and

remove the electric motor.

3. Using a suitable solvent, clean the inner and outer sur-

faces of the reservoir.

4. Inspect the reservoir for cracks or other imperfections. In-

spect the O-ring mating surfaces for scratches or other dam-

age. Replace the fluid reservoir if any defects are found.

5. Install the hydraulic pump on the fluid reservoir.

6. Install the electric motor on the fluid reservoir.

Reservoir Removal and Installation

(Integral Pump, Showa)

1. Refer to Power Trim System Removal and Installation (in

this chapter) and remove the trim system from the engine.




catch any spilled fluid.

4. Clean all debris from the external surfaces in and

around the fluid reservoir (5, Figure 42).

5. Slowly remove the fluid fill/check plug and gasket (3,

Figure 42) from the fluid reservoir.

6. Support the fluid reservoir and remove the three

screws and washers (1 and 2, Figure 42) from the reser-

voir.

7. Carefully lift the fluid reservoir from the trim system.

Remove the O-ring (6, Figure 42) from its location on the

trim system or fluid reservoir. Discard the O-ring.

8. Using a lint-free shop towel, carefully clean all debris

or contaminants from the reservoir mounting surface on

the trim system. Inspect the O-ring contact surfaces for

scratched, pitted or damaged areas. Replace the trim sys-

tem housing if defects are noted.

9. Thoroughly clean the fluid reservoir with solvent. In-

spect the reservoir for cracked or damaged areas. Replace

the reservoir if any defects are noted.

10. Apply a light coat of water-resistant grease onto the

new O-ring (6, Figure 42). Place the O-ring onto the trim

system at the reservoir mounting area. Ensure the O-ring

is centered over the reservoir opening.

11. Position the fluid reservoir onto the trim system with

the flat side facing the starboard side of the trim system

(Figure 42). Avoid dislodging the O-ring while lowering

the reservoir into position.

12. Align the screw holes in the reservoir with their cor-

responding threaded holes in the trim system.

13. Install all three mounting screws and washers (1 and

2, Figure 42) and securely tighten them.

14. Install the fill check plug and washer (3 and 4, Figure

42). Do not tighten the plug at this time.

15. Install the trim system onto the engine.

Reservoir Removal and Installation

(Showa Integral Pump)

1. Refer to Power Trim System Removal and Installation

in this chapter and remove the trim system from the engine.




catch any spilled fluid.


12

FLUID RESERVOIR

(INTEGRAL MOUNTED TRIM PUMP

[EXCEPT SHOWA])

42

1. Screw

2. Washer

3. Fill/check plug

4. Gasket

5. Fluid reservoir

6. O-ring

7. Allen screw

8. Washer

9. Valve body

10. Check valves

11. Spring

12. Plugs

13. Check ball

14. Trim system

4. Clean all debris from the external surfaces in and

around the fluid reservoir (Figure 43).

5. Support the fluid reservoir while removing the three

reservoir mounting screws. Carefully pull the reservoir

away from the trim system (Figure 43).

6. Remove the O-ring from the trim system or the align-

ing collar (Figure 43). Discard the O-ring.

7. Remove the fluid fill/check cap from the fluid reser-

voir. Using a solvent, clean the inner and outer surfaces of

the reservoir.

8. Use a lint-free shop towel to clean the fluid reservoir

mating surface of the trim system.

9. Inspect the fluid reservoir and trim system for deep

scratches, pitting or damage at the reservoir-to-trim sys-

tem mating surfaces. Replace any component with de-

fects.

10. Inspect the fluid reservoir for cracked or damaged ar-

eas. Replace the reservoir if it is defective.

11. Apply a light coat of water-resistant grease to the new

O-ring, then place it in position on the trim system as indi-

cated (Figure 43).

12. Without dislodging the O-ring, position the fluid res-

ervoir onto the trim system. Ensure the aligning collar en-

ters its opening in the trim system.

13. Align the mounting holes in the fluid reservoir with

their corresponding threaded holes in the trim system.

14. Install the three mounting bolts and securely tighten

them.

15. Install the trim system onto the engine.

FLUID FILLING

Perform this procedure to correct the level if a compo-

nent has been replaced. Use Dexron II automatic trans-

mission fluid in all trim systems covered in this manual.

1. Use the power trim/tilt system or open the manual re-

lief valve then position the engine in the full up position.

Engage the tilt lock lever then support the engine with

blocks or an overhead cable. Close the manual relief

valve.

2. Clean the area around the oil fill/check plug.

a. The plug is located on the side of the hydraulic

pump assembly (Figure 44) on external mounted

trim pump systems.

b. The plug is accessible through an opening in the

port side clamp bracket (Figure 45) on integral

mounted trim pump systems (except Showa sys-

tems).

c. The plug is located on the rearward end of the fluid

reservoir (Figure 46) on Showa systems. It is acces-

sible only if the engine is in full up position.

3. Slowly loosen and remove the fill/check plug. Ensure

the gasket remains on the plug (except Showa systems).

4. Fill the unit to the lower edge of the fill/check plug

opening. Install the fill/check plug in the reservoir, then

tighten it securely. Remove the supports and disengage

the tilt lock lever.

428 CHAPTER TWELVE

O-ring

Aligning collar

Fluid reservoir43

44

45

5. Cycle the trim to the full up then down position several

times. Recheck and correct the fluid level as necessary.

Securely tighten the oil fill/check plug.

AIR BLEEDING

A spongy feel or inability to hold trim under load is a

common symptom if air is present in the system. In many

cases, the engine tucks under when power is applied and

tilts out when the throttle is reduced. Minor amounts of air

in the system purge into the reservoir during normal oper-

ation. When major components have been removed, a sig-

nificant amount of air can enter the system. Bleeding the

air is then required.

1. Operate the trim system or open the manual relief

valve (Figure 36 or Figure 37) to position the engine

fully up. Refer to Fluid Filling in this section, then correct

the fluid level. Install the fill/check plug and tighten the

manual relief valve.

2. Operate the trim system until the engine is positioned

in the full-down position. Operate the trim in the up posi-

tion. Stop the trim immediately if the electric pump motor

begins to ventilate. Open the manual relief valve and posi-

tion the engine in the full up position and support the en-

gine with suitable means. Correct the fluid level. Close the

manual relief valve and install the fill/check plug.

3. Repeat Step 2 until the motor reaches full tilt without

ventilating the pump. If a large amount of foam is in the

reservoir, allow the engine to rest for one hour and repeat

the process.

4. Cycle the trim full up and down several times to purge

the remaining air from the system. Refer to Fluid Filling

to make the final fluid level correction.


12

46

Table 1 TIGHTENING TORQUE

Bolt size/marking N•m ft.-lb in.-lb.

Specific tightening torque

Trim system mounting

bolt/nut

All models 15-20 11-15 –

Tilt cylinder cap/cover

DT75, DT85 100-140 74-103 –

DT90, DT100 80-100 59-74 –

DT115, DT140

(1992-1995 models) 100-140 74-103 –

(1996-on) 130 96 –

DT150, DT175 80-100 59-74 –

DT200, DT225 80-100 59-74 –

Trim cylinder cap/cover

DT75, DT85 80-100 59-74 –

DT90, DT100 70-80 52-59 –

DT115, DT140

(1992-1995 models) 80-100 59-74 –

(1996-on) 80 59 –

DT150, DT175 70-80 52-59 –

DT200, DT225 70-80 52-59 –

Electric motor throughbolts

All models 15-20 11-15 –

Electric motor to pump

DT90, DT100 5-7 – 44-62

DT115, DT140

(1996-1999 models) 6 – 53

(continued)

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