Suzuki DF 90/100/115/140 Service Manual Download

 


1999-2011 Suzuki Outboard DF40 DF50 Service Manual 40/50 HP
  
1999-2011 Suzuki Outboard Models Covered In this Manual: 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 DF40QH (DF-40-QH, DF40-QH), DF50QH (DF-50-QH, DF50-QH), 1999 DF40T (DF-40-T, DF-40T), 1999 DF50T (DF-50-T, DF-50T), 2000 DF40 Y, 2000 DF50 Y, 2001 DF-40 W K1, 2001 DF-50 W K1, 2002 DF40 K2, 2002 DF50 K2, 2002 DF40 K3, 2003 DF50 K3, 2004 DF40/50 K4, 2005 DF-40/50 K5, 2006 DF-40/50 K6, 2007 DF-40/50 K7, 2008 DF-40/50 K8, 2009 DF-40/50 Models Supplement, 2010 DF 40-50 Supplement, 2011 DF 40-50 Supplement.
 
2000 2003 Suzuki DF25 DF30 Service Manual 25/30 HP 4-Stroke
 
2000 2001 2002 2003 Suzuki Outboard Models Covered in this Service Manual/Repair Manual: 2000 Suzuki Four Stroke DF25 (DF 25) 25HP (25 HP) Engine. 2000 Suzuki Four Stroke DF30 (DF 30) 30HP (30 HP) Engine. 2001 Suzuki Four Stroke DF25 (DF 25) 25HP (25 HP) Engine. 2001 Suzuki Four Stroke DF30 (DF 30) 30HP (30 HP) Engine. 2002 Suzuki Four Stroke DF25 (DF 25)25HP (25 HP) Engine. 2002 Suzuki Four Stroke DF30 (DF 30) 30HP (30 HP) Engine. 2003 Suzuki Four Stroke DF25 (DF 25) 25HP (25 HP) Engine. 2003 Suzuki Four Stroke DF30 (DF 30) 30HP (30 HP) Engine.
 
2001 2009 Suzuki DF 90 100 115 140 HP Service Manual Outboard 4-Stroke
 
2001 2002 2003 2004 2005 2006 2007 2008 2009 Suzuki Outboard Four Stroke Models Covered: DF90 (90HP 90 HP) DF 90 4-Stroke DF100 (100HP 100 HP) DF 100 4-Stroke DF115 (115HP 115 HP) DF 115 4-Stroke DF140 (140HP 140 HP) DF 140 4-Stroke
 
2002-2005 Suzuki Outboard Service Manual DF4/5/6 HP 4 Stroke 
 
This Suzuki 2002 2003 2004 2005 DF 4HP 5HP 6HP Service Manual Covers the following Model Years. 2002 Suzuki Outboard DF4 DF5 DF6 ( 4 HP 5 HP 6 HP) Four Stroke 2003 Suzuki Outboard DF4 DF5 DF6 ( 4 HP 5 HP 6 HP) Four Stroke 2004 Suzuki Outboard DF4 DF5 DF6 ( 4 HP 5 HP 6 HP) Four Stroke 2005 Suzuki Outboard DF4 DF5 DF6 ( 4 HP 5 HP 6 HP) Four Stroke.
 
2003 2007 Suzuki Service Manual DF60 DF70 60/70 HP Outboard 4-Stroke
 
This 2003 2004 2005 2006 2007 Suzuki Outboard 4 Stroke Service Maual Coveres The Followning Models: 2003 Suzuki Outboard 4 Stroke DF60 (DF 60) 60HP (60 HP), 2003 Suzuki Outboard Four Stroke DF70 (DF 70) 70HP (70 HP) Motor, 2004 Suzuki Outboard 4 Stroke DF60 (DF 60) 60HP (60 HP), 2004 Suzuki Outboard Four Stroke DF70 (DF 70) 70HP (70 HP), 2005 Suzuki Outboard 4 Stroke DF60 (DF 60) 60HP (60 HP), 2005 Suzuki Outboard Four Stroke DF70 (DF 70) 70HP (70 HP), 2006 Suzuki Outboard 4 Stroke DF60 (DF 60) 60HP (60 HP), 2006 Suzuki Outboard Four Stroke DF70 (DF 70) 70HP (70 HP), 2007 Suzuki Outboard 4 Stroke DF60 (DF 60) 60HP (60 HP), 2007 Suzuki Outboard Four Stroke DF70 (DF 70) 70HP (70 HP).
 
2003 2011 Suzuki DF9.9 DF15 Service Manual 9.9/15 HP 4-Stroke
 
2003 2004 2005 2006 2007 2008 2009 2010 2011 Suzuki Outboard Models Covered in this Service Manual/Repair Manual: 2003 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2003 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2004 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2004 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2005 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2005 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2006 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2006 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2007 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2007 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2008 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2008 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2009 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2009 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2010 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2010 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2011 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2011 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP) Engine.
 
2006 2010 Suzuki Service Manual DF150 DF175 150/175 HP 4-Stroke
 
This 2006 2007 2008 2009 2010 Suzuki Outboard 4 Stroke Service Maual Coveres The Followning Models: 2006 Suzuki Outboard 4 Stroke DF150 (DF 150) 150HP (150 HP), 2006 Suzuki Outboard Four Stroke DF175 (DF 175) 175HP (175 HP), 2007 Suzuki Outboard 4 Stroke DF150 (DF 150) 150HP (150 HP), 2007 Suzuki Outboard Four Stroke DF175 (DF 175) 175HP (175 HP), 2008 Suzuki Outboard 4 Stroke DF150 (DF 150) 150HP (150 HP), 2008 Suzuki Outboard Four Stroke DF175 (DF 275) 175HP (175 HP), 2009 Suzuki Outboard 4 Stroke DF150 (DF 150) 150HP (150 HP), 2009 Suzuki Outboard Four Stroke DF175 (DF 175) 175HP (175 HP), 2010 Suzuki Outboard 4 Stroke DF150 (DF 150) 150HP (150 HP), 2010 Suzuki Outboard Four Stroke DF175 (DF 175) 175HP (175 HP).
                             
1988 2003 Suzuki DT Models 2HP Through 225HP Workshop Manual Outboard
 
DT2 (DT-2) 2HP (2 HP) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995 & 1996, DT2.2 (DT-2.2) 2.2HP (2.2 HP)1997, DT4 (DT-4) 4HP (4 HP) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 & 1998, DT5Y (DT-5-Y) 5HP (5 HP) 1998, 1999, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1999, 2000, 2001 & 2002, DT6 ( DT-6) 6HP (6 HP) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 & 1997, DT8 (DT-8) 8HP (8 HP) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 & 1997, DT9.9 ( DT-9.9) 9.9HP (9.9 HP) 1988 thru 1997, DT15 (DT-15) 15HP (15 HP)1988-1989, DT20 (DT-20) 20HP (20 HP) 1988, DT25 (DT-25) 25HP (25 HP) 1990-1991, DT30 (DT-30) 30HP 30 HP 1989-1997, DT35 (DT-35) 35HP (35 HP) 1988-1997, DT40 (DT-40) 40HP (40 HP) 1988-1998, DT55 (DT-55) 55HP (55 HP) 1988-1997, DT65 (DT-65) 65HP (65 HP) 1988-1997, DT75 (DT-75) 75HP (75 HP) 1988-1997, DT85 (DT-85) 85HP (85 HP) 1988-2000, DT90 (DT-90) 90HP (90 HP) 1989-1997, DT100 (DT-100) 100HP (100 HP) 1989-1996 & 1996-2001 EFI, DT140 (DT-140) 140HP (140 HP) 1988-1996 & 1996-2001 EFI, DT150 (150) 150HP (150 HP) 1988-1994 & 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 & 2003 EFI, DT175 175HP (175) 1988-1992, DT200 200 HP (200) 1988-1992 & 1993-2000 EFI, DT225 225H (225) 1990-2003
 
SUPPLEMENT MANUAL- ADDITIONAL SERVICE DATA FOR 1999 & LATER MODELS (1999+ MODELS) INCLUDING CARBURETOR & IGNITION COIL SPECIFICATIONS.
 
1999+ DT4/DT5Y, 1999+ DT5 DT6 & DT8, 1999+ DT25C DT30C (DT25-C, DT30-C), 1999+ DT75 & DT85, 1999+ DT100TC, 1999+ DT115STC & DT140TC EFI (DT115-STC, DT140-TC), 1999+ DT150 / 175 / 200, 1999+ DT225 M

Related Suzuki Outboard DF 90/100/115/140 Searches:

POWERHEAD / POWER HEAD / POWER UNIT

INTAKE MANIFOLD ASSEMBLY
POWER UNIT
OIL PUMP
TIMING CHAIN / TENSIONER
CYLINDER HEAD ASSEMBLY
CYLINDER / CRANKSHAFT / PISTON
THERMOSTAT
WATER COOLING SYSTEM
ENGINE LUBRICATION SYSTEM
 
INTAKE MANIFOLD ASSEMBLY
 
REMOVAL
 
Before removing intake manifold :

• Relieve fuel pressure.
• Disconnect battery cables from battery.
• Remove both side covers.
 
1. Remove flywheel cover.
2. Remove two bolts and air duct.
3. Remove evaporation hose from cylinder head cover.
4. Disconnect fuel outlet hose and fuel inlet hose from low pressure fuel pump.
5. Loosen clamp and place a large cloth over end of fuel feed hose. Slowly pull fuel feed hose from fuel delivery pipe. Drain any excess fuel in hose into a small container.
6. Disconnect four fuel injector connectors.
7. Disconnect high pressure fuel pump connector from fuel vapor separator.
8. Remove bolts and low pressure fuel filter bracket.
9. Remove two (2) bolts securing fuel delivery pipe, then remove fuel delivery pipe and all fuel injectors.
10. Remove two (2) bolts and fuel return pipe.
11. Disconnect water inlet hose and water outlet hose from fuel return pipe.
12. Place a suitable container under fuel return pipe, then disconnect fuel inlet hose and fuel outlet hose from fuel return pipe.
13. Remove three (3) bolts and silencer case.
14. Disconnect breather hose from silencer case.
15. Disconnect IAT sensor connector.
16. Disconnect CTP switch connector.
17. Disconnect IAC valve connector.
18. Disconnect MAP sensor connector.
19. Disconnect water inlet hose and water outlet hose from 3-way joint.
20. Remove nine (9) bolts and two (2) nuts and then remove intake manifold assembly.
 
POWER UNIT REMOVAL
 
1. Remove bolts and fuel pump.
2. Remove all spark plugs.
3. Remove fifteen (15) cylinder head cover bolts, and then remove cylinder head cover.
4. Remove nut and positive battery cable.
5. Remove starter motor.
6. Remove flywheel.
7. Remove battery charge coil.
8. Remove CKP sensor.
9. Disconnect water return hose from thermostat cover.
10. Remove bolt and water return hose pipe.
11. Disconnect cylinder temp sensor lead wire connector.
12. Disconnect CMP sensor connector, then remove bolt and CMP sensor from cylinder head.
13. Disconnect two ignition coil connectors, then remove four bolts and ignition coil.
14. Remove oil level dipstick.
15. Remove bolt and oil level dipstick guide.
16. Remove nine (9) bolts and Rectifier & regulator.
17. Loosen screw A and disconnect lead wire from oil pressure switch.
18. Remove two bolts and front panel.
19. Disconnect water inlet hose and water outlet hose from crankcase.
20. Remove cotter pin and washer, then separate clutch lever link from clutch shaft arm.
21. Remove E-ring, clutch control lever and clutch shaft arm.
22. Remove two bolts and clutch lever holder.
23. Disconnect neutral switch lead wire connector.
24. Remove pins and side cover seal.
25. Remove sixteen (16) bolts.
26. Lift up and remove power unit from engine holder.
 
OIL PUMP INSPECTION
Inspect outer/inner rotors and oil pump body for wear or other damage and replace if necessary.
Seal Ring

Inspect of seal ring for nick, cut or wear.
Drive / Driven Sprocket
Inspect teeth of sprocket for wear or other damage and replace if necessary.
 
OIL PUMP INSTALLATION
 
Installation is reverse order of removal with special attention to the following steps.
• Assemble washer, pin, driven sprocket and circlip to oil pump shaft.
• Apply engine oil to seal ring, then install seal ring to oil pump body.
• Install oil pump to cylinder head block, then tighten three (3) bolts securely.
• Install oil pump drive sprocket and tighten bolt securely.
 
TIMING CHAIN / TENSIONER REMOVAL
 
1. Turn crankshaft in its normal running direction (R direction) until No.1 cylinder reaches top dead center.
NOTE : To bring No.1 cylinder top dead center, turn crankshaft to locate match mark (key) a position at the top as shown in figure of your service manual. When timing chain has been removed, never turn crankshaft or camshaft.
 
2. Remove bolt and oil pump drive sprocket.
NOTE: Hold camshaft by placing a wrench on the hexagon area of camshaft.
3. Remove bolts and timing chain guide.
4. Remove bolt, nut and chain tensioner adjuster.
5. Remove bolt and chain tensioner.
6. Remove timing chain, exhaust camshaft timing sprocket
9 and dowel pin.
7. Remove bolt and intake camshaft timing sprocket.
NOTE: Hold camshaft by placing a wrench on the hexagon area of camshaft.
8. Remove driven gear.
 
CYLINDER HEAD ASSEMBLY - (Cylinder head / valve / camshaft)
 
REMOVAL
Prior to removing cylinder head :

• Remove power unit.
• Remove timing chain.
 
1. Remove bolts and oil pump.
2. Remove oil relief valve and gasket.
3. Remove bolts securing camshaft housing to cylinder head, then remove each camshaft housing.
NOTE: For ease of assembly, note position of each individual camshaft housing.
 
4. Remove intake and exhaust camshafts.
5. Loosen eighteen (18) cylinder head bolts according to numerical order in figure and remove them.
6. Remove cylinder head assembly and head gasket.
NOTE: Use special tool (10 mm deep socket wrench) when loosening cylinder head bolts.
 
CYLINDER HEAD
Remove all carbon from combustion chambers.
NOTE:
• Do not use any sharp edged tool to scrape carbon off cylinder head or its components.
• Be careful not to scuff or nick metal surfaces when decarboning. Inspect cylinder head for crack in intake and exhaust ports, combustion chambers and head surface.
 
Valve seat

Inspect valve seat for crack or other damage. Replace if necessary.
Cylinder head distortion
Using a straightedge and thickness gauge, measure cylinder head distortion (gasket surface) at a total of six (6) locations as shown in figure of your service manual.
 
VALVE / VALVE GUIDE

Valve guide to valve stem clearance Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check guide to stem clearance. Be sure to take readings at more than one place along length of each stem and guide.
 
Valve stem outside diameter

Using micrometer, measure valve stem outside diameter.
 
Valve guide inside diameter
Using a small bore gauge, measure valve guide inside diameter.
 
CYLINDER / CRANKSHAFT / PISTON
 
DISASSEMBLY
Before performing service work in this section :
• Remove power unit
• Remove timing chain
• Remove cylinder head
 
1. Remove driven gear.
2. Remove oil filter.
3. Remove oil pressure switch.
4. Remove ten (10) bolts. Remove ten (10) bolts.
NOTE: Removal (loosening order) is reverse of installation (tightening order).
 
5. Remove crankcase from cylinder block.
 
NOTE: For proper assembly, mark cylinder number on all pistons, conrods, and conrod caps, using quick drying paint.
 
6. Remove all conrod cap nuts and conrod caps.
7. Remove crankshaft.
8. Remove oil seal from crankshaft.
9. Mark cylinder number on pistons using quick dry paint.
10. Push piston (with conrod) out through the top of cylinder bore.
11. Remove two compression rings (top and 2nd) and oil ring from piston.
12. Mark cylinder number on conrod using quick dry paint.
13. Remove piston pin circlips as shown.
14. Remove piston pin from conrod.
 
PISTON TO CYLINDER CLEARANCE
1. Measure piston diameter at a point 26.5 mm (1.04 in.) above piston skirt at a right angle to piston pin bore.
2. Measure cylinder bore at 50 mm (2.0 in.) below cylinder head gasket surface at a right angle to crankshaft pin.
3. Calculate the piston / cylinder clearance (Clearance equals difference between piston diameter and cylinder bore measurements).
 
PISTON
Inspect piston for faults, cracks or other damage. Replace if necessary.
 
Piston ring to groove clearance

Before checking, piston grooves should be clean, dry and free of carbon. Fit piston ring into piston groove, and measure clearance between ring and ring groove using thickness gauge. If measurement exceeds service limit, replace piston and/or piston ring.
 
THERMOSTAT
 
REMOVAL

1. Disconnect water hose from thermostat cover.
2. Remove the three (3) bolts securing the thermostat cover, then remove the cover and thermostat.
INSPECTION
Inspect thermostat for salt deposits, corrosion, wear or other damage. Clean or replace if necessary.
Thermostat operation
Check thermostat opening temperature as follows :
1. Insert a length of thread between thermostat valve / body and suspend thermostat in a container filled with water.
2. Place thermometer in container and heat water. Observe water temperature when thermostat valve opens and releases thread.
Thermostat operating temperature :
Standard : 58 – 62 °C (136 – 144 °F)
1
THERMOSTAT INSTALLATION
1
Installation is reverse order of removal with special attention to the following steps.
• Assemble thermostat and thermostat cover to cylinder head block and secure with bolts.
􀀢 Thermostat cover bolt : 10 N.m (1.0 kg-m, 7.0 Ib.-ft.)
 1
WATER COOLING SYSTEM
1
The water cooling system includes the lower unit water pump, lower unit to power unit water supply tube, oil pan water pressure valve, power unit water passages and thermostat. This system cools both the power unit and exhaust and is shown in schematic from below. If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion buildup or component damage.
Component inspection
 
Water pump / Impeller
Water tube
Thermostat
Water pressure valve
Cylinder head
Cylinder block
 
ENGINE LUBRICATION SYSTEM
1
A camshaft driven trochoid type pump provides engine oil to all power unit components requiring lubrication. Oil from the oil pan is drawn through the oil strainer and passed through a spin-on type oil filter before entering the main oil gallery. A pressure regulator (relief valve) is positioned between the oil pump and oil filter to maintain oil pressure at a constant level. From the main gallery, oil flow is directed through either drilled internal passages or by splash method to those surfaces requiring lubrication.

1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 Suzuki Outboard DF 90, 100, 115, 140, Service Manual, Repair Manual, Shop Manual, Owner's Service Manual, Repair Guide, Learning Guide, Handbook, Book, PDF 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 00, 01, 02, 03, 04, 05, 06, 07, 08, 09, Outboard Motor, Out Board, OutBoard Engine, HP, Horsepower, Horse Power, Specs, Specifications, DF9.9, DF15, DF25, Df30, Df40, DF50, Df70, 9.9HP, 15Hp, 25hp, 30hp, 40hp, 50hp, 70hp