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The service manual downloads for the above listed  Yamaha, Mercury, MerCrusier Mariner, Suzuki & Johnson/Evenrude models describes the service procedures for the complete inboard, outboard, jet drive or stern drive. Follow the Maintenance Schedule recommendations to ensure that the engine/jet drive/sterndrive is in peak operating condition. Performing the scheduled maintenance is very important. It compensates for the initial wear that occurs during the life of the engine/jet drive/sterndrive.
 
All chapters in the service manuals apply to the whole engine (inboard/outboard), jet drive, or sterndrive and illustrates procedures for removal & installation of components that are in detailed step-by-step fashion.
 
Most all service manual chapters start with an assembly or system illustration, diagrams, exploded parts view, quality pictures, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to the troubleshooting page for a list of causes and effects to determine the problem.

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CHAPTER INDEX

GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE CONTROL SYSTEM
ENGINE ELECTRICAL
FUEL SYSTEM
POWER UNIT
MID UNIT
POWER TRIM AND TILT
LOWER UNIT
WIRE / HOSE ROUTING

GENERAL INFORMATION

CONTENTS

WARNING / CAUTION / NOTE
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

CONTENTS

PERIODIC MAINTENANCE SCHEDULE
PERIODIC MAINTENANCE CHART
MAINTENANCE AND TUNE-UP PROCEDURES
ENGINE OIL / ENGINE OIL FILTER
GEAR OIL
LUBRICATION
SPARK PLUG
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 / COTTER PIN
ANODES AND BONDING WIRES
BATTERY
BOLT AND NUTS
FUEL MIXTURE CHECK (O2 FEEDBACK)
OIL PRESSURE
CYLINDER COMPRESSION

ENGINE CONTROL SYSTEM

CONTENTS

ENGINE CONTROL SYSTEM STRUCTURE
SYSTEM STRUCTURE 1
SYSTEM STRUCTURE 2
WIRING DIAGRAM FOR ENGINE CONTROL
COMPONENTS FOR SYSTEM CONTROL
ENGINE CONTROL MODULE (ECM)
ECM CONNECTOR / TERMINALS LAYOUT
ECM INTERNAL STRUCTURE
SENSOR AND SWITCH
IGNITION SYSTEM
IGNITION CONTROL SYSTEM
ELECTRONIC FUEL INJECTION SYSTEM
FUEL INJECTION CONTROL SYSTEM
FUEL DELIVERY SYSTEM COMPONENTS
FUEL PUMP CONTROL SYSTEM
AIR INTAKE COMPONENTS
IDLE AIR CONTROL SYSTEM
CAUTION SYSTEM
OVER-REVOLUTION CAUTION SYSTEM
LOW OIL PRESSURE CAUTION SYSTEM
OVERHEAT CAUTION SYSTEM
LOW BATTERY VOLTAGE CAUTION SYSTEM
SELF-DIAGNOSTIC SYSTEM
PRIORITY / CODE / PATTERN FOR SELF-DIAGNOSTIC
SYSTEM OPERATION
CONDITION FOR SELF-DIAGNOSTIC SYSTEM OPERATION
FAIL-SAFE SYSTEM
PRE-PROGRAMMED VALUE FOR FAIL-SAFE SYSTEM
OPERATING HOUR INDICATION SYSTEM
OIL CHANGE REMINDER SYSTEM
START-IN-GEAR PROTECTION SYSTEM
O2 FEEDBACK SYSTEM  INSPECTION
PRECAUTION ON SYSTEM INSPECTION
44-PIN TEST CORD
INSPECTION FOR ECM CIRCUIT VOLTAGE
INSPECTION FOR RESISTANCE
COMPONENT INSPECTIONS
TROUBLESHOOTING
REMOVAL / INSTALLATION
FLYWHEEL
CKP SENSOR / CMP SENSOR
OIL PRESSURE SWITCH

ELECTRICAL

CONTENTS

BATTERY CHARGING SYSTEM OUTLINE
INSPECTION
REMOVAL / INSTALLATION
ELECTRIC STARTER SYSTEM
OUTLINE
TROUBLESHOOTING
INSPECTION
STARTER MOTOR
REMOVAL / INSTALLATION
DISASSEMBLY
INSPECTION & SERVICING
ASSEMBLY
PERFORMANCE TEST
MONITOR-TACHOMETER
INSPECTION
ERECTRIC PARTS HOLDER
REMOVAL / INSTALLATION

FUEL SYSTEM

CONTENTS

PRECAUTION ON FUEL SYSTEM SERVICE
GENERAL PRECAUTION
FUEL PRESSURE RELIEF PROCEDURE
FUEL LINE
REMOVAL / INSTALLATION
FUEL LEAKAGE CHECK PROCEDURE
FUEL HOSE CONNECTION
FUEL PRESSURE INSPECTION
FUEL VAPOR SEPARATOR / HIGH PRESSURE FUEL PUMP
REMOVAL / INSTALLATION
DISASSEMBLY
INSPECTION
ASSEMBLY
FUEL INJECTOR
INSPECTION
REMOVAL
INSTALLATION
LOW PRESSURE FUEL PUMP
REMOVAL / INSTALLATION
DISASSEMBLY / REASSEMBLY
INSPECTION
FUEL TANK
DISASSEMBLY / REASSEMBLY
INSPECTION

POWER UNIT

CONTENTS

INTAKE MANIFOLD ASSEMBLY
REMOVAL
INSTALLATION
POWER UNIT
REMOVAL
INSTALLATION
OIL PUMP
REMOVAL
INSPECTION
INSTALLATION
TIMING CHAIN / TENSIONER
REMOVAL
INSPECTION
INSTALLATION
CYLINDER HEAD ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY
INSPECTION / SERVICING
REASSEMBLY
CYLINDER / CRANKSHAFT / PISTON
DISASSEMBLY
INSPECTION / SERVICING
REASSEMBLY
THERMOSTAT
REMOVAL / INSPECTION / INSTALLATION
OPERATION
WATER COOLING SYSTEM
ENGINE LUBRICATION SYSTEM

MID UNIT

CONTENTS

ENGINE SIDE COVER
REMOVAL
INSTALLATION
DRIVESHAFT HOUSING AND OIL PAN
REMOVAL
INSPECTION
ASSEMBLY
SWIVEL BRACKET, STEERING BRACKET AND
CLAMP BRACKET
REMOVAL
INSPECTION
REASSEMBLY
WATER PRESSURE VALVE
REMOVAL / INSPECTION / INSTALLATION

POWER TRIM AND TILT

CONTENTS

SYSTEM WIRING DIAGRAM
SERVICE PROCEDURE
OIL LEVEL
AIR BLEEDING
POWER TRIM AND TILT UNIT REMOVAL
DISASSEMBLY
INSPECTION
REASSEMBLY
PTT MOTOR
PTT MOTOR REMOVAL
PTT MOTOR DISASSEMBLY
PTT MOTOR INSPECTION
PTT MOTOR ASSEMBLY
PTT MOTOR INSTALLATION
IPTT MOTOR RELAY
PTT SWITCH
OPERATION
COMPONENTS
PRINCIPLES OF OPERATION

LOWER UNIT

CONTENTS

REMOVAL & DISASSEMBLY
PINION BEARING
INSPECTION
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
ASSEMBLY & INSTALLATION
TRIM TAB
LOWER UNIT GEARS-SHIMMING AND ADJUSTMENT

WIRE / HOSE ROUTING

CONTENTS

WIRING DIAGRAM
WIRE ROUTING
FUEL / WATER HOSE ROUTING


PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motor operating at peak performance and economy. Maintenance intervals should be judged by number of hours or months, whichever comes first.

NOTE: More frequent servicing should be performed on outboard motors that are used under severe conditions.

MAINTENANCE AND TUNE-UP PROCEDURES

1. Place outboard motor upright on a level surface.
2. Remove motor cover.
3. Remove oil level dipstick and wipe it clean.
4. Insert it fully into dipstick hole, then remove it to check oil level.
5. Oil level should be between full level hole (Max.) and low level hole (Min.). If level is low, add recommended oil to full level hole (Max.).

Recommended oil :

• 4 stroke motor oil
• API classification SE, SF, SG, SH, SJ.
• Viscosity rating SAE 10 W-40.

This section describes servicing procedures for each of periodic maintenance requirements.

ENGINE OIL / ENGINE OIL FILTER ENGINE OIL LEVEL CHECK

Inspect oil level before every use.

ENGINE OIL CHANGE / ENGINE OIL FILTER REPLACEMENT ENGINE OIL

Change initially after 20 hours (1 month) and every 100 hours (6 months).

ENGINE OIL FILTER

Replace initially after 20 hours (1 month) and every 200 hours (12 months).

NOTE:

• Engine oil should be changed while engine is warm.
• When replacing engine oil filter, change engine oil at the same time.

1. Place outboard motor upright on a level surface.
2. Remove oil filler cap.
3. Place a container under engine oil drain plug.
4. Remove engine oil drain plug and gasket to drain engine oil.
5. ENGINE OIL FILTER REPLACEMENT

NOTE: For engine oil change only, go to step 6.

To replace engine oil filter :

NOTE: Before fitting new oil filter, be sure to oil O-ring.

(1) Remove STBD side cover.
(2) Using oil filter wrench to loosen the oil filter, then remove filter and O-ring.
(3) Screw new filter on by hand until filter O-ring contacts the mounting surface.
(4) Tighten filter 3/4 turn from point of contact with mounting surface using an oil filter wrench.
(5) Install STBD side cover.

6. Install gasket and oil drain plug. Tighten engine oil drain plug to specified torque.
7. Pour recommended engine oil into oil filler opening, then install oil filler cap.

Engine oil amounts:

Oil change only : 5.5 L (5.8 / 4.8 US / Imp. qt)
Oil filter change : 5.7 L (6.0 / 5.0 US / Imp. qt)

8. To reset oil change reminder system’s operation time to zero (cancellation) ;

(1) Turn ignition key to “ON” position.
(2) Pull out emergency stop switch plate 1.
(3) Pull up emergency stop switch knob 2 three times in seven seconds. A short beep will be heard if cancellation is successfully finished.
(4) Turn ignition key to “OFF” position, then set emergency stop switch plate 1 in original position.

9. Start engine and allow it to run for several minutes at idle speed. Check oil filter for oil leakage. Turn off engine and wait for approx. two minutes, then recheck engine oil level.

GEAR OIL

Change initially after 20 hours (1 month) and every 100 hours (6 months).

1. Place outboard motor upright on a level surface.
2. Place a container under lower unit.
3. Remove lower gear oil drain plug before gear oil level plug and drain gear oil.
4. Fill with recommended gear oil through oil drain hole until oil just starts to flow out from oil level hole. Gear oil amounts : 1050 ml (35.5 / 37.0 US / Imp. oz) Recommended oil : Outboard Motor Gear Oil or SAE #90 Hypoid gear oil.
5. Install oil level plug before removing oil filler tube from drain hole.
6. Install oil drain plug.

Do not re-use gaskets once removed. Always use a new gasket.

NOTE: To avoid insufficient injection of gear oil, check gear oil level 10 minutes after doing procedure in step 6. If oil level is low, slowly inject gear oil up to the correct level.

LUBRICATION

Inspect every 50 hours (3 months). Apply  Water Resistant Grease to the following points.
 
Throttle / shift linkage
Propeller shaft
Swivel bracket
Swivel bracket

SPARK PLUG

• Inspect every 100 hours (6 months).
• Replace every 200 hours (12 months).

Standard spark plug : NGK BKR6E

CARBON DEPOSIT

Inspect for a carbon deposit on spark plug bases. If carbon is present, remove it with a spark plug cleaning machine or by carefully using a pointed tool.

SPARK PLUG GAP

Using thickness gauge, measure for spark plug gap. Adjust to within specified range if gap is out of specification. Spark plug gap : 0.7 – 0.8 mm (0.028 – 0.031 in.)

CONDITION OF ELECTRODE

Inspect electrode for a worn or burnt condition. If it is extremely worn or burnt, replace spark plug. Also, be sure to replace spark plug if it has a broken insulator, damaged thread, etc. Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the threaded portion of the plug hole resulting in possible engine damage.

TAPPET CLEARANCE

Inspect initially after 20 hours (1 month) and every 200 hours (12 months).

The tappet clearance specification is the same for both intake and exhaust valves. Too small a tappet clearance may reduce engine power, too large a tappet clearance increases valve noise and hastens valve and seat wear.

When the tappets are set to the specified clearance, the engine will run without excessive noise from the valve mechanism and will deliver full power. In this engine, the tappet clearance is increased or decreased by replacing the shim disc, made of a special wear resistant material, fitted to the top of the tappet. The shim discs are easy to remove and refit.

Tappet clearance adjustment should be checked and adjusted :

• at time of periodic inspection
• when valve mechanism is serviced
• when camshafts are disturbed by removing them for inspection

CHECKING AND ADJUSTING TAPPET CLEARANCE

1. Remove following parts :

• Engine side covers
• Flywheel cover
• Spark plugs

2. Remove breather hose 1 and evaporation hose 2 from cylinder head cover.
3. Remove fuel hose 3 and 4 from low pressure fuel pump.
4. Remove fifteen (15) bolts securing cylinder head cover 5 to cylinder head and remove cylinder head cover.

5. Rotate crankshaft counterclockwise to bring cam nose vertical to shim surface.
6. Measure tappet clearances by inserting thickness gauge between cam and shim surface.

Tappet clearance (cold engine condition) :
IN. : 0.23 – 0.27 mm (0.009 – 0.011 in.)
EX. : 0.23 – 0.27 mm (0.009 – 0.011 in.)

This is a left hand (LH) rotation powerhead. Rotate crankshaft counterclockwise to prevent water pump impeller damage.

NOTE:

• Rotate crankshaft and measure clearance for each tappet respectively by bringing cam nose vertical to shim surface.
• All tappet clearances can be measured during two turns of crankshaft.

7. If out of specification, adjust tappet clearance by changing shim.

ADJUSTMENT

Tappet clearances are adjusted by replacing tappet shim.

1. Close valve and turn tappet cut-away toward inside as shown in figure.
2. Rotate crankshaft to open (lift up) valve and then remove camshaft housing bolts where shim is to be replaced.
3. Install special tool with camshaft housing bolts as shown in figure.
4. Rotate top of cam 90 degree clockwise and remove shim from cut-away at tappet. (Two tappets can be adjusted at the same time)
5. After removing shim, measure thickness of original shim and determine correct thickness of shim for proper tappet clearance as calculated by following formula.

A = B + (C – 0.25 mm)

A : Correct thickness of shim for proper tappet clearance (mm)
B : Thickness of original shim (mm)
C : Original tappet clearance (mm)

6. Install shim. Identification number should face towards tappet.
7. Rotate crankshaft to be open (lift up) valve.
8. Remove tappet holder 1 and tighten camshaft housing bolts to specified torque.

Camshaft housing bolt : 11 N.m (1.1 kg-m, 8.0 lb.-ft.)

9. Recheck tappet clearance.

NOTE: After completing tappet clearance adjustment and securing camshaft housing bolts, inspect tappet clearance again.

INSTALLATION

After checking and adjusting all tappet clearances, install cylinder head cover. Installation is reverse order of removal.

IDLE SPEED

Inspect initially after 20 hours (1 month) and every 200 hours (12 months).

NOTE:

• Before checking idle speed, engine should be allowed to warm up.
• Check and/or adjust idle speed after engine speed has stabilized.
• Before checking idle speed, check throttle link mechanism and throttle valve for smooth operation.

1. Start engine and allow to warm up.
2. Attach engine tachometer to the ignition high-tension cord.
3. Check engine speed. Idle speed (in neutral gear) : 600 – 650 r/min.

ADJUSTMENT:

If idle speed is out of specification, perform following adjustment procedure.

4. Check that CTP switch is in ON position.
5. To set the IAC valve duty to constant 15%, raise engine speed to 1000 r/min. or higher by turning the by-pass air screw and hold that speed for 10 seconds. At this time, caution buzzer will sound to notify that IAC duty is in fixed mode.

Turning air screw counterclockwise :

Engine speed will increase.
Turning air screw clockwise :
Engine speed will decrease.

NOTE:

• While IAC valve duty is at fixed 15%, caution buzzer will sound for repeated 0.5 second with an interval of 3 seconds.
• The 15% fixed mode of IAC valve duty will continue for 5 minutes and then it will be automatically cancelled.

6. During fixed mode of IAC valve duty, adjust engine speed to 625 ± 25 r/min. by turning by-pass air screw.
7. Open warm-up lever to turn CTP switch off.

NOTE: The fixed mode of IAC valve duty can be manually cancelled by turning CTP switch off.

8. Close warm-up lever and then recheck engine speed. It should now be stable at 600 – 650 r/min.

NOTE: Idling / trolling speed of 600 – 650 r/min. is controlled by IAC (idle air control) system. If engine speed does not return to specification, IAC passage (including the IAC hose) may be clogged or IAC system may not be operating correctly.

NOTE: Trolling speed (in-gear idle speed) is same as idle speed.

IGNITION TIMING

Inspect every 200 hours (12 months).

NOTE: Before checking ignition timing, make sure idle speed is adjusted within specification.

1. Start engine and allow to warm up.
2. Attach timing light cord to No.1 ignition high-tension cord.
3. Check ignition timing while operating engine in neutral gear at 1000 r/min. Ignition timing : Approx. BTDC 8° at 1000 r/min.

BREATHER AND FUEL LINE

• Inspect initially after 20 hours (1 month) and every 50 hours (3 months).
• Replace every 2 years. If leakage, cracks, swelling or other damage is found, replace breather line and/or fuel line.

LOW PRESSURE FUEL FILTER

• Inspect every 50 hours (3 months).
• Replace every 400 hours or 2 years.

If water accumulation, sediment, leakage, cracks, or other damage is found, replace fuel filter.

WATER PUMP / WATER PUMP IMPELLER WATER PUMP

Inspect every 200 hours (12 months). Inspect case and under panel. Replace If wear, cracks, distortion or corrosion is found.

WATER PUMP IMPELLER

Replace every 200 hours (12 months). Inspect water pump impeller. Replace if vanes are cut, torn or worn.

PROPELLER / NUT / COTTER PIN

Inspect initially after 20 hours (1 month) and every 100 hours (6 months).

• Inspect propeller for bent, chipped or broken blades. Replace propeller if damage noticeably affects operation.
• Inspect propeller splines. Replace propeller if splines are worn, damaged or twisted.
• Inspect propeller bush for slippage. Replace if necessary.
• Make sure that propeller nut is torqued to specification and cotter pin is installed securely.

ANODES AND BONDING WIRES

Inspect every 50 hours (3 months).

ANODES

If 2/3 of zinc anode has corroded away, replace anode. The anode should be periodically cleaned with a wire brush to ensure maximum effectiveness.

NOTE: The anode securing bolt should be covered with Suzuki Silicone Seal.

BONDING WIRES

• If breakage or other damage is found on bonding wire, replace wire.
• If rust, corrosion or other damage is found on terminal, clean with cleaning solvent or replace wire.

BATTERY

Inspect every 50 hours (3 months)

CONNECTING BATTERY

Upon completion of connection, lightly apply grease to battery terminals.

How to connect:

1. Connect positive (+) terminal first.
2. Connect negative (–) terminal second.

How to disconnect:

1. Disconnect negative (–) terminal first.
2. Disconnect positive (+) terminal second.

BATTERY SOLUTION LEVEL CHECK

Battery solution level should be between UPPER level and LOWER level. If level is low, add distilled water only.

BATTERY SOLUTION GRAVITY CHECK

Measure gravity of battery solution using hydrometer. Battery solution gravity : 1.28 at 20°C

BOLT AND NUTS

Check that all bolts and nuts listed below are tightened to their specified torque.

ITEM TIGHTENING TORQUE

Cylinder head cover bolt
Flywheel bolt
Power unit mounting bolt
Clamp bracket shaft nut
Gearcase bolt
Propeller nut

FUEL MIXTURE CHECK (O2 FEEDBACK)

Perform every 2 years. To perform fuel mixture check (O2 feedback) operation, use personal computer and Diagnostic System software. For fuel mixture check (O2 feedback) operation, refer to Diagnostic System Operation Manual”.

OIL PRESSURE

Oil pressure (at normal operating temp.):

550 – 600 kPa (5.5 – 6.0 kg/cm2, 78 – 85 psi.) at 3000 r/min.

NOTE: The figure shown above is a guideline only, not an absolute service limit. If oil pressure is lower or higher than specification, following causes may be considered.

Low oil pressure:

• Clogged oil filter
• Leakage from oil passages
• Defective oil pump
• Defective oil pressure regulator
• Damage O-ring
• Combination of above items

High oil pressure:

• Using an engine oil of too high viscosity
• Clogged oil passage
• Clogged oil pressure regulator
• Combination of above items

TEST PROCEDURE

1. Check engine oil level.
2. Remove bolts and air duct
3. Loosen screw and disconnect blue lead wire from oil pressure switch. Remove oil pressure switch.
4. Install oil pressure gauge in place of pressure switch hole.
5. Attach engine tachometer to ignition coil high tension cord.
6. Start engine and allow to warm up as follows :

Summer : 5 min. at 2000 r/min.
Winter : 10 min. at 2000 r/min.

7. After warming up, shift into forward gear and increase engine speed to 3000 r/min. then compare pressure indicate on gauge to specifications.
8. After testing, reinstall oil pressure switch.
9. Reinstall air duct.

CYLINDER COMPRESSION

Cylinder compression :

Standard : 1300 – 1700 kPa (13 – 17 kg/cm2, 185 – 242 psi.)

Max. difference between any other cylinders : 100kPa (1.0 kg/cm2, 14 psi.)

NOTE: Figures shown are guidelines only, not absolute service limits. Low compression pressure can indicate one or more of following
:
• Excessively worn cylinder wall
• Worn piston or piston rings
• Stuck piston rings
• Poor seating of valves
• Ruptured or otherwise damaged cylinder head gasket

TEST PROCEDURE

1. Start engine and allow to warm up, then shut engine off.
2. Remove STBD / PORT side covers.(See page 7-2)
3. Remove all spark plugs.
4. Install compression gauge hose attachment into plug hole, then connect compression gauge hose to gauge hose attachment and compression gauge.

Compression gauge
Compression gauge hose
Compression gauge hose attachment

5. Disconnect safety lanyard (switch plate) from emergency stop switch. Disconnect the safety lanyard from the emergency stop switch prior to cranking the engine. This will prevent any residual fuel discharged from the cylinders being ignited by a spark discharge from the spark plug caps.
6. Disconnect remote control throttle cable from throttle lever.
7. Move and hold throttle lever in full-open position.
8. While cranking engine with starter motor, note maximum compression pressure reading on gauge for each cylinder.
9. Reinstall parts removed earlier. (spark plugs, side covers, etc.)


Service Manual, Repair Manuals, Owner's Manuals, Textbook, Handbook, Book, Repair Guide, PDF Download, Factory Manual, Shop Manual, Workshop Manual, Diagrams Manual, Cutaway, Parts Book, Parts Manual


Suzuki Outboard Service Manuals Available:

2000-2003 Service Manual Application: 2000 2001 2002 2003 Suzuki Outboard 4-Stroke DF25 (25HP, 25 HP) & DF30 (30HP, 30 HP) Models.
 
1999-2008 Suzuki DF40 DF50 Service Manual DF 40/50
 
1999-2008 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).

2001-2009 Suzuki DF90 DF100 DF115 DF140 Service Manual Outboard
1988 2003 Suzuki DT Outboard Service Manual 2 thru 225

2001-2009 Models Covered: Suzuki DF90 (DF-90) DF100 (DF-100), DF115 (DF-115), DF140 (DF-140) 4-Stroke Outboard boat engine.

1988-2003 Models Covered: DT2 (DT-2) DT2.2 (DT-2.2) / DT4 (DT-4) / DT5Y (DT-5-Y) / DT6 ( DT-6) / DT8 (DT-8) / DT9.9 ( DT-9.9) / DT15 (DT-15) / DT20 (DT-20) / DT25 (DT-25) / DT30 (DT-30) / DT35 (DT-35) / DT40 (DT-40) / DT55 (DT-55) / DT65 (DT-65) / DT75 (DT-75) / DT85 (DT-85) / DT90 (DT-90) / DT100 (DT-100) 1989-1996 & 1996-2001 EFI / DT140 (DT-140) EFI / DT150 (150) EFI / DT175 (175) / DT200 (200) EFI / DT225 (225) / DT4/DT5Y / DT5 DT6 & DT8 / DT25C DT30C (DT25-C, DT30-C) /  DT75 & DT85 / DT100TC /  DT115STC & DT140TC EFI (DT115-STC, DT140-TC) / DT150 / 175 / 200 /  DT225 "M"


Mercury - Mariner Service Manuals Available For Download:

1965-1989 Mercury Mariner 2 To 40 Hp  2 Stroke
1965-1989 Mercury Repair Manual  40 115hp 2 Stroke
1986-1990 Mercury Service Manual 6/8/9.9/15HP 2 Stroke
1995-2000 Mercury Mariner 40 45 50 HP Service Manual
1997-2000 Mercury Mariner 40 50 55 60hp Service Manual 2 Stroke
1997 1998 Mercury Optimax 200 & 225 HP Service Manual
1998-1999 Mercury Mariner 9.9 & 15 HP Service Repair Manual
1998-1999 Mercury 135HP (135 HP) & 150HP (150 HP) Service Manual
1999-2002 Mercury - Mariner 30 HP 40 HP Service Repair Manual 4-Stroke Outboard
1999-2000 Mercury/mariner Service Manual 4HP 5HP 6HP (4 Stroke)
2000 2001 Mercury 75/90 HP (75hp & 90hp) Outboard Service Manual
2000-2001 Mercury Optimax 115 135 150 175 Service Repair Manual DFI
2001 Mercury Mariner 50 HP & 2001 60 HP Service Manual
2001 2002 Mercury 115 HP (115HP) Service Manual 4-Stroke
2002-2004 Mercury 40 HP 50 HP 60 HP Service Manual


1965-1989 Service Manual Application: 2 hp To 40hp 2 Stroke 1 & 2 cylinder engines.

1965-1989 Mercury Service Manual Application: 45 HP, 4 CYL, 1965 1966 1967 1968 1969 1970, 50 HP, 3 CYL, 1986 1987 1988 1989, 500/50 HP, 4 CYL, 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985, 60 HP, 3 CYL, 1984 1985 1986 1987 1988 1989, 650/65 HP, 3 CYL, 1972 1973 1974 1975 1976, 650/65 HP, 4 CYL, 1965 1966 1967 1968 1969 1970 1971, 650,700/70 HP, 3 CYL, 1976 1977 1978 1979 1980 1981 1982 1983, 70 HP, 3 CYL, 1986 1987 1988 1989, 75 HP, 4 CYL, 1984 1985 1986, 80 HP, 3 CYL, 1987 1988 1989, 800/80 HP, 4 CYL, 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983, 800/85 HP, 4 CYL, 1973 1974 1975 1976 1977, 90 HP, 3 CYL, 1987 1988 1989, 850XS/90 HP, 4 CYL, 1976, 100 HP, 4 CYL, 1988 1989, 115 HP, 4 CYL, 1988 1989.

1986-1990 Service Manual Application: 6/8/9.9/15HP Motors 1986 and up With Serial Numbers OA1972112 and Above.

1995-2000 Mercury - Mariner 40hp · 45hp · 50hp Four Stroke (4-Stroke) Non-Big Foot and Bigfoot Engines With Starting Serial Numbers: 0G231123, 1995 & above with Serial Numbers 0G231123 & above. Mercury-Mainer 40 (4-Stroke) 4 cylinder 1998, 1999 & 2000 Non-Bigfoot, Mercury-Mainer 45 (4-Stroke) 4 cylinder 1998, 1999 & 2000 Non-Bigfoot and Big Foot, Mercury-Mainer 50 (4-Stroke) 4 cylinder 1995, 1996, 1997 & 1998.

1997-2000 Service Manual Model Application: 97-00 Mercury - Mariner 40-50-55-60 HP Two-Stroke Models with serial numbers OG531301 and above.

1997-1998 Service manual application: 1997-1998 Mercury 200HP ( 200 HP) & 225HP (225 HP) DFI (Direct Fuel Injection) outboard engine. V6 Cylinder, Two Cycle. Models covered are  200 & 225 OPTIMAX DIRECT FUEL INJECTION With Serial Numbers 0G386496 and Above.

1998-1999 Mercury/Mariner Outboard motor service manual application: 98-99 Mercury-Mariner 9.9hp (9.9 hp), 15hp (15 hp) Bigfoot and Non-Big Foot 4-Stroke Outboard Engine. Models Covered are Mercury - Mariner 9.9/15 (4-Stroke) (323 cc) & 9.9/15 Bigfoot (4-Stroke) (323 cc) with Serial Numbers 0G590000 and Above.

1998-1999 Service manual application: 98-99 Mercury 135HP (135 HP) & 150HP (150 HP) DFI (Direct Fuel Injection) outboard engine. V-6 Cylinder, Two Cycle, Direct Injected. Models covered are 135 & 150 OPTIMAX DIRECT FUEL INJECTION With Serial Numbers OG590000 and Above.

1999-2002 Service manual application: Mercury Outboard 30HP, 40HP (4-Stroke) - Non-Bigfoot & Bigfoot Engine-Motor (Four-Stroke) starting with serial number 0G760300 and above.

1999-2000 Mercury Service Manual Application: 99-00 Mercury 4 HP - 5 HP & 6 HP Four Stroke Engines.

2000-2001 Service Repair Manual Year Application: 2000 & 2001 Mercury 75hp (75 hp) 90hp (90 hp) 4-Stroke (Four-Stroke-FourStroke) Outboard boat motor engine. Starting model year 2000 & starting Serial Number 0G960500 and above.

2000-2001 Mercury OptiMax Outboard motor service manual application: 2000-2001 Mercury 115hp (115 hp) 135hp (135 hp) 150hp (150 hp) 175hp (175 hp) DFI (Direct Fuel Injection) outboard motor. Starting Model Year 2000  & Starting Serial Number OG960500 & above.

2001 Service Repair Manual Application: 2001 (01) Mercury-Mariner models 50 HP (50HP) & 60 HP (60HP) 4-Stroke (Four Stroke) Outboard Engines With Serial Numbers 0T178500 and Above. Covers Bigfoot (Big Foot) and Non-Bigfoot models.

2001-2002 Mercury 115 HP Service manual application: Mercury Outboard motor 01-02 Mercury 115 HP (115HP) EFI (Electronic Fuel Injection) outboard engine. 4 Cylinder InLine, 4 Stroke DOHC, 16 Valves. Starting Serial Number 0T178500.

2002-2004 Mercury/Mariner Outboard motor service manual application: 2002-2004 Mercury-Mariner 40HP EFI 4-Stroke (Four-Stroke), 2002-2004 Mercury-Mariner 60HP EFI 4-Stroke (Four-Stroke), 2002-2004 Mercury-Mariner 50 HP EFI 4-Stroke (Four-Stroke), 2002-2004 Mercury-Mariner 40 HP EFI 4-Stroke (FourStroke) Bigfoot, 2002-2004 Mercury-Mariner 60 HP EFI 4-Stroke (FourStroke) Bigfoot.


YAMAHA OUTBOARD ENGINE SERVICE MANUALS AVAILABLE

1995 Yamaha Outboard 9.9HP (9.9-HP) Service Manual 4-STROKE LIT-18616-01-24
1995 1997 Yamaha E48T C55T Service Manual 48 55 HP 2-STROKE LIT-18616-01-28
1996 1997 Yamaha 8HP & 9.9HP Service Manual 4-STROKE LIT-18616-01-35
1996 1997 Yamaha 60HP E60 E60H Service Manual 2 STROKE LIT-18616-01-29
1997 Yamaha 75HP 75-HP Service Manual E75V 2-STROKE LIT-18616-01-73
1997 1998 Yamaha 20HP 25HP Service Manual 2-STROKE LIT-18616-01-66
1998 1999 Yamaha Service Manual 40 50 HP 2-STROKE LIT-18616-01-81
1998 2005 Yamaha Outboard 15HP 15 HP Service Manual 4-STROKE
1998-2006 Yamaha 8HP & 9.9HP Service Manual 4-STROKE LIT-18616-01-83
1999 2005 Yamaha Outboard 4HP 4 HP Service Manual 4-STROKE LIT-18616-01-79
1999 2000 25HP 30HP Yamaha Service Manual 2-STROKE LIT-18616-01-94
1999 2002 100HP 100 HP Yamaha Service Manual 4-STROKE  LIT-18616-01-96
2000 2003 Yamaha 40HP 40 HP Service Manual 4-STROKE  LIT-18616-02-16
2001 2003 Yamaha F6Z & F8Z Service Manual 6HP-8HP 4-STROKE LIT-18616-02-19
2003 2006 Yamaha 250HP Service Manual 2-STROKE & 4-STROKE ALL 250 MODELS
2004 2005 Yamaha 2.5HP 2.5 HP Service Manual 4-STROKE LIT-18616-02-54
2004 2005 Yamaha 9.9C 15C Service Manual 9.9HP-15HP 2-STROKE LIT-1816-02-59
2004 2005 Yamaha Outboard 25HP 25 HP Service Manual 4-STROKE LIT-18616-02-61
2004-2005 Yamaha 40HP 50HP Service Manual 4-STROKE LIT-18616-02-65
2004-2005 Yamaha Outboard 70HP 70-HP Service Manual 2-STROKE
2004-2005 Yamaha Outboard 90HP 90-HP Service Manual 2-STROKE LIT-18616-02-66
2004 2005 Yamaha 130HP-115HP Service Manual 115C-130C 2-STROKE LIT-18616-02-72
2004 2005 Yamaha Outboard 150HP 150 HP Service Manual 4-STROKE LIT-18616-02-51
2004 2005 Yamaha Outboard 115HP 115 HP Service Manual 4-STROKE LIT-18616-02-71
2004 2005 Yamaha 150C V150C Service Manual 150HP 2-STROKE LIT-18616-02-73
2004-2005 Yamaha Outboard 60HP 60-HP Service Manual 2-STROKE LIT-18616-02-66
2004 2005 Yamaha 200 & 225 HP Service Manual 4-STORKE LIT-18616-02-76
2005 Yamaha 50 & 60 HP Service Manual 4-STROKE LIT-18616-02-85
2005 2006 Yamaha F90D Service Manual 90 HP 4-STROKE LIT-18616-02-86
 


LIT-18616-01-24 Service Manual Application: Yamaha Ouboard 9.9HP (9.9-HP) 4-stroke engines. Model Names: T9.9T (T9.9-T), F9.9T (F9.9T), T9.9MH (T9.9-MH), F9.9AM (F9.9-AM), F9.9AEM (FT9.9-AEM), T9.9ER (T9.9-ER), F9.9AE (F9.9-AE), F9.9MH (F9.9-MH), F9.9BM (F9.9-BM), T9.9EH (T9.9-EH), F9.9BEM (F9.9-BEM), F9.9BE (F9.9-BE).

LIT-18616-01-28 Service Repair Manual Application: 1995, 1996, 1997 (95, 96, 97) Yamaha Marine Outboard E48T (E48-T) C55T (C55-T) 48HP & 55HP 2-Stroke. Item Model Names: E48T, C55T, E48C, E48MH, E55C, 55BM, C55ER, 55BE, 55BEM, C55TR, 55BET.

LIT-18616-01-35 Service Manual Application: 1996-1997 Yamaha F8, T9.9, F9.9 8HP (8-hp) & 9.9Hp (9.9-hp) 4-stroke engines. Exact Models Covered (Covers All 1996-1997 Models World Wide): F8B (F8-B), F9.9A (F9.9-A), F9.9B (F9.9-B), T9.9U (T9.9-U), F9.9U (F9.9-U), F8BM (F8-BM), F8BEM (F8-BEM), F8BE (F8-BE), T9.9MH (T9.9-MH), T9.9AM (T9.9-AM), FT9.9AMH (FT-9.9-AMH), T9.9EH (T9.9-EH), F9.9AEM (FT9.9-AEM), T9.9ER (T9.9-ER), FT9.9AE (FT9.9-AE), F9.9MH (F9.9-MH), F9.9BM (F9.9-BM), F9.9EH (F9.9-EH), F9.9BEM (F9.9-BEM), F9.9BE (F9.9-BE).

LIT-18616-01-29 Service Repair Manual Application: 1996, 1997 (96, 97) E60, E60H 60HP (60-HP) Yamaha Marine Outboard 2-Stroke. Item Model Names: E60, E60H, E60HM, E60HE, E60HEM, E60MH, E60EH. Covers USA, Canada and wold wide models.

LIT-18616-01-73 Service Repair Manual Application: 1997 97' Yamaha Marine Outboard 75HP (75HP) 2-Stroke. Item Model Names: E75V, E-75-V, E75-V, E-75V 75AM, 75AEM, 75AE, 75AET, 85AEM, 85AE, 85AET, E75B, E60J, E75MH. Covers USA, Canada and wold wide models.

LIT-18616-01-66 Service Repair Manual Application: 1997-1998 Yamaha Marine Outboard 20HP (20-HP) & 25HP 25-HP) 10V, 25V, 25V2 2-Stroke Engines. Model Names 20DM (20-DM), 20DMO (20-DMO), 20DEM (20-DEM), 20DEMO (20-DEMO), 20DERO (20-DERO), 20MH (20-MH), 20MH2 (20-MH2), 20EH (20-EH), 20EH2 (20-EH2), 25DM (25-DM), 25NMO (25-NMO), 25NEMO (25-NEMO), 25NE (25-NE), 25NEO (25-NEO), 25NERO (25-NERO), 25MH (25-MH), 25MH2 (25-MH2), 25EH (25-EH), 25ER (25-ER).

LIT-18616-01-81 Service Repair Manual Application: 1998-1999 98-99 40HP (40-HP) & 50HP (50-HP) 40W 50W Yamaha Marine Outboard 2-Stroke Item Model Names: 40-W, 50-W, 40VMH, 40VMHD, 40VMHO, 40VMO, 40VWH, 40VE, 40VEO, 40VEHTO, 40VET, C40MH, 40MH, C40ER, 40ER, P40TH, C40TR, 40VETO, 50HMHO, 50HMHD, 50HMO, 50HMDO, 50HWHD, 50HEDO, 50HET, 50HETO, 40TR, 50ER, C50TR, 50TR Covers USA, Canada and wold wide models.

LIT-18616-F1-50 & LIT-18616-02-12 Service Repair Manual Application: 1998-2005 Yamaha Marine Outboard 15HP (15-HP) 4-Stroke Engines F15W (F15-W), F15Z (F15-Z) 1998, 1999, 2000, 2001, 2002, 2003, 2004 & 2005. This manual covers all 15HP 4-Stroke models world wide including USA CANADA. USA & CANADA MODELS: F15MHW (F15-MHW), F15EHW (F15-EHW), F15AMH (F15-AMH), F15AEH (F15-AEH), F15AEP (F15-AEP), F15AEHP (F15-AEHP), F15PR (F15-PR), F15PH (F15-PH), F15AEP (F15-AEP), F15AEHP (F15-AEHP). WOLD WIDE MODELS: F15AMH (F15-AMH), F15AEH (F15-AEH), F15AE (F15-AE).

LIT-18616-01-83 Service Manual Application: 1998-2006 Yamaha F8, T9.9, F9.9 8HP (8-hp) & 9.9Hp (9.9-hp) 4-stroke engines for 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 & 2006. Model Name: T9.9W (T9.9-W), F9.9W (F9.9-W), F8BMH (F8-BMH), F8BEH (F8-BEH), F8BE (F8-BE), T9.9MH (T9.9-MH) FT9.9AMH (FT-9.9-AMH), T9.9EH (T9.9-EH), FT9.9AEH (FT9.9-AEH), T9.9ER (T9.9-ER), FT9.9AE (FT9.9-AE), F9.9MH (F9.9-MH), F9.9BMH (F9.9-BMH), F9.9EH (F9.9-EH), F9.9BEH (F9.9-BEH), F9.9BE (F9.9-BE).

LIT-18616-01-79 Service Repair Manual Application: 1998-2005 Yamaha Marine Outboard 4HP (4-HP) 4-Stroke Engines F4X (F4-X, F-4X) 1999, 2000, 2001, 2002, 2003, 2004 & 2005. This manual covers all 4HP 4-Stroke models world wide including F4MSHX, F4MLHX, F4AMH, USA CANADA.

LIT-18616-01-94 Service Repair Manual Application: 1999-2000 99-00 25HP (25-HP) & 30HP (30-HP) 25X, 25-X, 30X, 30-X, 25J, 25-J, 30D, 30-D Yamaha Marine Outboard 2-Stroke. Model Names: 25JMH, 25MH3, 30DMH, 25JMHO, 30DMHO, 30MH, 25JEHO, 25EH3, 30DWH, 25JEO, 25JETO, 25TR3, 30DEHO, 30EH, 30DMO, 30DE, 30DEO, 30ER, 30DET, 30DETO, 30TR Covers USA, Canada and wold wide models.

LIT-18616-01-96 Service Repair Manual Application: 1999, 2000, 2001, 2002 99, 00, 01, 02 100HP (100-HP) F100X, F100-X, F-100X Yamaha Marine Outboard 4-Stroke. Model Names: F100TR, F100-TR, F-100TR, F100AET, F-100AET, F100-AET Covers USA, Canada and woldwide models.

LIT-18616-02-16 Service Repair Manual Application: 2000, 2001, 2002, 2003 Yamaha Marine Outboard 40HP (40-HP) F40B (F-40B-F40-B) 4-Stroke Engines. Model name F40BMHD, F40BWHD, F40BED, F40BET, USA and Canada name F40MH, F40ER, F40TR.

LIT-18616-02-19 Service Repair Manual Application: 2001, 2002, 2003, 01, 02, 03, Yamaha Marine Outboard 6HP & 8HP (F6Z F8Z) 4-Stroke Engines. Model Name: F6AMH, F8CMH, F6MH, F8MH (F6-AMH, F6-MH, F8-AMH, F8-MH).

ALL 250HP 2003-2006 MODELS ervice Repair Manual Application: 2003, 2004, 2005, 2006 Yamaha Marine Outboard 250HP (250-HP) 2-Stroke & 4-Stroke Engines. LIT-18616-02-78 -  2004-2005 Z250C & LZ250C LZ250TR 2-STROKE ENGINE. LIT-18616-02-43 - 2003-2005 Z250B & LZ250B MODEL NAME Z250TR/LZ250TR 2-STROKE ENGINE. LIT-18616-02-97 - 2005-2006 F250 & LF250 F250TR/LF250TR 4-STROKE ENGINE. 

LIT-18616-02-54 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 2.5HP (2.5-HP) F2.5C (F2.5-C, F 2.5C) F2.5MH 4-Stroke Engines.

LIT-1816-02-59 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 9.9HP & 15HP (9.9-HP 15-HP) 2-Stroke Engines. Model name 9.9CMH & 15CMH ( 9.9 & 15 CMH).

LIT-18616-02-61 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 25HP (25-HP) 4-Stroke Engines F25C, T25C (F-25C F25-C T25-C T-25C) F25MH, F25EH, F25ER, F25TR, T25TR.

LIT-18616-02-65 Service Repair Manual Application: 2004 04' & 2005 05' Yamaha Marine Outboard 40HP (40-HP) & 50HP (50-HP) 4-Stroke Engines. Exact model name 40VETO 50HETO, Both USA and CANADA models covered 40TR 50TR / 40C-50C.

LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 70HP (70-HP) 2-Stroke Engines. Model name 70BETO, USA and Canada name 70TR 70C (70-C).

LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 90HP (90-HP) 2-Stroke Engines. Model name 90AETO, USA and Canada name 90TR 90C (90-C).

LIT-18616-02-72 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 130HP & 115HP (115C 130C) 2-Stroke Engines. Model Name: 115CETO (115-CETO), 130BETO (130-BETO) 115TR, 130TR.

LIT-18616-02-51 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 150HP (150-HP) F150C & LF150C (LF-F-150C-F150-C) 4-Stroke Engines. Model name F150TR, LF150TR (F-LF-150-TR)

LIT-18616-02-71 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 115HP (115-HP) 4-Stroke Engines. Model name F115AET LF115AET, USA and Canada name F115TR LF115TR.

LIT-18616-02-73 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 150 HP (150HP) 150C & V150C 2-Stroke Engines. Model Name: 150FETO, 150GETO.

LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 60HP (60-HP) 2-Stroke Engines. Model name 60FETO USA and Canada name 60TR, 60C (60-C).

LIT-18616-02-76 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard F200C, LF200C, F225C, LF225C 200HP (200-HP) & 225HP (225-HP) V6 4-Stroke Engines.

LIT-18616-02-85 Service Repair Manual Application: 2005 Yamaha Marine Outboard 50HP & 60HP (50-HP, 60-HP) 4-Stroke Engines F50D T50D F60D T60D (F-50-D, T-50-D, F60-D, T60-D).

LIT-18616-02-86 Service Repair Manual Application: 2005-2006 05-06' Yamaha Marine Outboard F90D 90HP 4-Stroke Engines. Model Name F90TR


Mercury Marine Outboard Service Manual, Mariner Outboard Repair Manual, Owner's Shop Manual, Workshop Manual, Handbook, Book, 2004, 2003, 2002, 2001, 2000, 1999, 1998, 1997, 1996, 1995, 1994, 1993, 1992, 1991, 1990, 1989, 1988, 1987, 1986, 1985, 1984, 1983, 1982,1981, 1980, 1979, 1978, 1977, 1976, 1975, 1974, 1973, 1972, 1971, 1970, 1969, 1968, 1967, 1966, 1965 Exploded Views, Exploded Diagrams, Repair Guide, Engine Repair Guide, How To Fix, How Do you Repair and Fix, Parts Locations Diagrams, 13.9 HP (3.9HP), 6HP (6-HP), 9.8HP (9.8 HP), 20 HP (20-HP), 35 HP (35HP), 4.0 HP (4.0HP), 7.5 HP (7.5HP), 40 HP (40HP)  4.5 HP (4.5HP) 3.6 HP 18HP, (18 HP), 20 HP, 25HP, 2.2 HP (2.2HP) 6.0 (6.0HP), 8.0 (8.0HP), 9.9 (9.9HP), 20 HP (20HP), 25 HP,35 (35-HP), 15 HP (15HP)