1998 - 2009 K2 to K9 Suzuki DF90 100 115 140 outboard motor service repair workshop manual
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Official service manual for the Suzuki DF90, 100, 115 and 140 four stroke outboard motors.
This manual contains an introductory description on SUZUKI Outboard motor DF90/100/115/140 and procedures for the inspection, service and overhaul of its main components.
This official service repair manual gives complete step by step information on repair, servicing and preventative maintenance. The official manual is highly detailed to help guide you through every repair and troubleshooting procedure. This manual contains all you need to know to keep your Suzuki engine working right and is the only service repair manual you will need. It will help you understand, care for, and lower the repair and maintenance cost for your Suzuki engine.
With the abundance of service oriented companies provided in the global economy today, added with the addition of a fast paced, throw away society, repairing an Suzuki engine yourself may seem like a waste of time and money. With that said, the cost effectiveness and pride that comes with repairing an Suzuki engine at your home can be one of the greatest feelings in the world. This can be easily done with this official repair manual at your disposal, and a minimal amount of time and space.
The first and foremost benefit of having a repair manual for your Suzuki engine at arms reach is the fact that most problems associated with an Suzuki engine are simple and easy fixes. With all products, the manual will have a section that gives you many options on symptoms of the problem, and a troubleshooting method to go along with the issues at hand. The simple repairs included in this section can not only save you a large amount of money in repair and replacement costs, but also give you the added benefit of immediate results without the time having to be spent either taking it to the repair shop, or going to your local dealer to purchase a new product.
A small sample of some of the topics covered in this manual are: starter, starter solenoid, internal wiring harness, stator, regulator, drive assembly, ignition coils, starter switch, spark plugs, timer base, propellor, impeller, thermostat, housings, water pump, poppet relief valves, hose elbow, carburetor, fuel pump, needle, seat, fuel line assembly, floats, fuel water separator, cylinder, seal kit, gearcase, gears, gear set, inline pistons, piston sleeves, powerhead gasket, pistons, head gasket, bearings, connecting rods, piston rings, crankshaft, crankshaft seal, cables, reed plate, rewind springs, water jacket gaskets, pin bearings, crank bearings, air box, exhaust baffle, oil filter, starter pawl, exhaust leg, rubber sleeves, circlip, exhaust manifold, piston wristpins, water passage gaskets, split bearings, starter gears, thermostat gaskets, pull start rope, bulk seal, handle, deflector hose, shift housing, cover, intake manifold, retainer gaskets, power tilt motor gaskets, relief port, cylinder head o-ring, solenoid, oil seals, wiper gaskets, grommets, dipstick, molded seal, screws, filter bowl gaskets, shift rod washers, shift rod, water pump screws, reed plate gaskets, intake manifold gasket, reed box gasket, rewind springs, pwerhead base gaskets, water jacket gaskets, wrist pin, upper crank bearings, piston circlips, center main bearings, starter gears, thermostat regulators, thermostat gaskets, float bowl gaskets, shift housing seal, bypass cover gaskets, bypass cover, impeller housing seal, retainers, gearcase cover, gearcase, gearing, lower gearcase gaskets, relief port, rectifier mounting gaskets, pivot cap cover gaskets, solenoid cover gaskets, upper gearcase dipstick gaskets, dipstick, stainless steel bolts, nuts, molded seals, washer housings, brush holder assembly, timing lights, stop switch, switch box, stator, seal dampers, pump housings, insert cups, hose clamps, primer bulbs, hose clamps, pump assembly, diaphragm, fuel connectors, pump diaphragm, water sensor probe, propellor shafts, connectors, prop nut, oil seals, nut hardware, anodes, control cables, oil warning module, power trim relays, trigger assemblies, voltage regulator, temperature senders, pump bases, water coupling assembly, water tube guide, inline piston rings, connecting rod crank end bearings, dva tester, brush and spring, carburetor adapter flange gasket, flange, drain plug, lower wear plate gasket, o-rings, tab washers, cylinder drain reed plate, reed plate gasket, primer, contact set, condenser, internal wiring harness, power trim relays, starter drive assembly, starter solenoid, timer base, relief valve, by pass cover gasket, wrist pins, thermostats, pins, bearing, seals, gear sets, connecting rod, needles, float and much more.
As with any product in your home, the average Suzuki engine may come across a point in time when a more serious repair is needed. Many people in todays society will go and trade in a perfectly good Suzuki engine and purchase an over the top model that is not really used to its fullest capacity. While the cost of engines has gone down over the years, the repair kits and parts for the models are a fraction of the cost, and can easily installed with the proper repair manual. This manual will provide step by step instruction on disassembly, repair methods, and illustrations related to the repair. With this knowledge at your disposal, when the next issue comes up, you will have the knowledge and experience to fix the problem with ease.
In the end, you have a simple choice to make. You can be well informed, and pro active in your life by having the skill and drive to repair the items in your home using something as simple as a few inexpensive parts, a little time, and a good repair manual, or you can go about your way spending absurd amounts of money to purchase a product that will come across the same problem at some time or another, providing you with a never ending cycle of spending your hard earned money. At some point, every Suzuki engine will have an issue, as a machines quality is measured solely by the users commitment to maintenance. A good way to keep your engine giving you years of quality service without having years of service bills is to purchase a good repair manual, and learn to do it yourself.
Book marked chapters for easy navigation allowing you to identify exact repair service procedures in the quickest time possible.
Notes, cautions and warnings throughout each chapter pinpoint critical service information.
Numbered instructions guide you through every repair procedure in a step-by-step fashion.
Bold figured numbers help you quickly match illustrations with instructions.
Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure.
Numbered table of contents easy to use so that you can find the information you need fast.
Manual Language: English
File Format: PDF
File Delivery: PDF (Instant Download)
Pages:616
To purchase this repair manual just click on the green instant download button at the upper left hand corner of this page. After purchasing just download it to your computer to save it and print pages from it whenever you need it.
This manual contains an introductory description on SUZUKI Outboard motor DF90/100/115/140 and procedures for the inspection, service and overhaul of its main components.
This official service repair manual gives complete step by step information on repair, servicing and preventative maintenance. The official manual is highly detailed to help guide you through every repair and troubleshooting procedure. This manual contains all you need to know to keep your Suzuki engine working right and is the only service repair manual you will need. It will help you understand, care for, and lower the repair and maintenance cost for your Suzuki engine.
With the abundance of service oriented companies provided in the global economy today, added with the addition of a fast paced, throw away society, repairing an Suzuki engine yourself may seem like a waste of time and money. With that said, the cost effectiveness and pride that comes with repairing an Suzuki engine at your home can be one of the greatest feelings in the world. This can be easily done with this official repair manual at your disposal, and a minimal amount of time and space.
The first and foremost benefit of having a repair manual for your Suzuki engine at arms reach is the fact that most problems associated with an Suzuki engine are simple and easy fixes. With all products, the manual will have a section that gives you many options on symptoms of the problem, and a troubleshooting method to go along with the issues at hand. The simple repairs included in this section can not only save you a large amount of money in repair and replacement costs, but also give you the added benefit of immediate results without the time having to be spent either taking it to the repair shop, or going to your local dealer to purchase a new product.
A small sample of some of the topics covered in this manual are: starter, starter solenoid, internal wiring harness, stator, regulator, drive assembly, ignition coils, starter switch, spark plugs, timer base, propellor, impeller, thermostat, housings, water pump, poppet relief valves, hose elbow, carburetor, fuel pump, needle, seat, fuel line assembly, floats, fuel water separator, cylinder, seal kit, gearcase, gears, gear set, inline pistons, piston sleeves, powerhead gasket, pistons, head gasket, bearings, connecting rods, piston rings, crankshaft, crankshaft seal, cables, reed plate, rewind springs, water jacket gaskets, pin bearings, crank bearings, air box, exhaust baffle, oil filter, starter pawl, exhaust leg, rubber sleeves, circlip, exhaust manifold, piston wristpins, water passage gaskets, split bearings, starter gears, thermostat gaskets, pull start rope, bulk seal, handle, deflector hose, shift housing, cover, intake manifold, retainer gaskets, power tilt motor gaskets, relief port, cylinder head o-ring, solenoid, oil seals, wiper gaskets, grommets, dipstick, molded seal, screws, filter bowl gaskets, shift rod washers, shift rod, water pump screws, reed plate gaskets, intake manifold gasket, reed box gasket, rewind springs, pwerhead base gaskets, water jacket gaskets, wrist pin, upper crank bearings, piston circlips, center main bearings, starter gears, thermostat regulators, thermostat gaskets, float bowl gaskets, shift housing seal, bypass cover gaskets, bypass cover, impeller housing seal, retainers, gearcase cover, gearcase, gearing, lower gearcase gaskets, relief port, rectifier mounting gaskets, pivot cap cover gaskets, solenoid cover gaskets, upper gearcase dipstick gaskets, dipstick, stainless steel bolts, nuts, molded seals, washer housings, brush holder assembly, timing lights, stop switch, switch box, stator, seal dampers, pump housings, insert cups, hose clamps, primer bulbs, hose clamps, pump assembly, diaphragm, fuel connectors, pump diaphragm, water sensor probe, propellor shafts, connectors, prop nut, oil seals, nut hardware, anodes, control cables, oil warning module, power trim relays, trigger assemblies, voltage regulator, temperature senders, pump bases, water coupling assembly, water tube guide, inline piston rings, connecting rod crank end bearings, dva tester, brush and spring, carburetor adapter flange gasket, flange, drain plug, lower wear plate gasket, o-rings, tab washers, cylinder drain reed plate, reed plate gasket, primer, contact set, condenser, internal wiring harness, power trim relays, starter drive assembly, starter solenoid, timer base, relief valve, by pass cover gasket, wrist pins, thermostats, pins, bearing, seals, gear sets, connecting rod, needles, float and much more.
As with any product in your home, the average Suzuki engine may come across a point in time when a more serious repair is needed. Many people in todays society will go and trade in a perfectly good Suzuki engine and purchase an over the top model that is not really used to its fullest capacity. While the cost of engines has gone down over the years, the repair kits and parts for the models are a fraction of the cost, and can easily installed with the proper repair manual. This manual will provide step by step instruction on disassembly, repair methods, and illustrations related to the repair. With this knowledge at your disposal, when the next issue comes up, you will have the knowledge and experience to fix the problem with ease.
In the end, you have a simple choice to make. You can be well informed, and pro active in your life by having the skill and drive to repair the items in your home using something as simple as a few inexpensive parts, a little time, and a good repair manual, or you can go about your way spending absurd amounts of money to purchase a product that will come across the same problem at some time or another, providing you with a never ending cycle of spending your hard earned money. At some point, every Suzuki engine will have an issue, as a machines quality is measured solely by the users commitment to maintenance. A good way to keep your engine giving you years of quality service without having years of service bills is to purchase a good repair manual, and learn to do it yourself.
Book marked chapters for easy navigation allowing you to identify exact repair service procedures in the quickest time possible.
Notes, cautions and warnings throughout each chapter pinpoint critical service information.
Numbered instructions guide you through every repair procedure in a step-by-step fashion.
Bold figured numbers help you quickly match illustrations with instructions.
Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure.
Numbered table of contents easy to use so that you can find the information you need fast.
Manual Language: English
File Format: PDF
File Delivery: PDF (Instant Download)
Pages:616
To purchase this repair manual just click on the green instant download button at the upper left hand corner of this page. After purchasing just download it to your computer to save it and print pages from it whenever you need it.
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Automated PDF to Text preview page 4 to 6:
SYMBOL Listed in the table below are the symbols indicating instructions and other important information necessary for proper servicing. Please note the definition for each symbol. You will find these symbols used throughout this manual. Refer back to this table if you are not sure of any symbol(s) meanings. SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise specified. Apply SUZUKI OUTBOARD MOTOR GEAR OIL. Apply SUZUKI SUPER GREASE "A". Apply SUZUKI WATER RESISTANT GREASE. Apply SUZUKI BOND "1104". Use peak voltmeter "Stevens CD-77". Apply SUZUKI BOND "1207B". Use special tool. SYMBOL DEFINITION Apply THREAD LOCK "1342". Apply THREAD LOCK SUPER "1333B". Measure in DC voltage range. Measure in resistance range. Measure in continuity test range. Apply SUZUKI SILICONE SEAL. Apply SUZUKI MOLY PASTE. GENERAL INFORMATION 1-1 GENERAL INFORMATION 1 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 ___________________________________ 1- 2 1- 2 1- 4 1- 4 1- 4 1- 4 1- 5 1- 6 1- 6 1- 7 1- 9 1-16 1-18 1-21 1-2 GENERAL INFORMATION WARNING / CAUTION / NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. Indicates a potential hazard that could result in death or injury. Indicates a potential hazard that could result in motor damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the WARNING and CAUTION stated, you must also use good judgement and observe basic mechanical safety principles. GENERAL PRECAUTIONS · Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the outboard motor. · To avoid eye injury, always wear protective goggles when filing metals, working on a grinder, or doing other work, which could cause flying material particles. · When 2 or more persons work together, pay attention to the safety of each other. · When it is necessary to run the outboard motor indoors, make sure that exhaust gas is vented outdoors. · When testing an outboard motor in the water and on a boat, ensure that the necessary safety equipment is on board. Such equipment includes : flotation aids for each person, fire extinguisher, distress signals, anchor, paddles, bilge pump, first-aid kit, emergency starter rope, etc. · When working with toxic or flammable materials, make sure that the area you work in is wellventilated and that you follow all of the material manufacturer's instructions. · Never use gasoline as a cleaning solvent. · To avoid getting burned , do not touch the engine, engine oil or exhaust system during or shortly after engine operation. · Oil can be hazardous. Children and pets may be harmed from contact with oil. Keep new and used oil away from children and pets. To minimize your exposure to oil, wear a long sleeve shirt and moisture-proof gloves (such as dishwashing gloves) when changing oil. If oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil. Recycle or properly dispose of used oil. · After servicing fuel, oil / engine cooling system and exhaust system, check all lines and fittings related to the system for leaks. · Carefully adhere to the battery handling instructions laid out by the battery supplier. |
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