Suzuki Outboard DF90 DF100 DF115 DF140 Four Stroke Service Repair Manual

99500-92J00-01E

IMPORTANT NOTICE WARNING / CAUTION / NOTICE / NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words , , NOTICE and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. 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 , , and NOTICE stated, you must also use good judgment and observe basic mechanical safety principles. WARNING ! CAUTION ! Indicates a potential hazard that could result in death or serious injury. WARNING ! Indicates a potential hazard that could result in minor or moderate injury. CAUTION ! NOTICE Indicates a potential hazard that could result in damage to the motor or boat. NOTE Indicates special information to make maintenance easier or instructions clearer. WARNING ! CAUTION ! This service manual is intended for authorized Suzuki outboard motor dealers and qualified service technicians only. Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the engine unsafe for the boat operator and passengers. WARNING !

FOREWORD This manual contains an introductory description of the SUZUKI DF100A/115A/140A Outboard motors and procedures for inspection, service and overhaul of their main components. General knowledge information is not included. Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning this motor. Read and refer to the other sections in this manual for information regarding proper inspection and service procedures. This manual will help you better understand these outboard motors, assisting you in providing your customers with optimum and quick service. NOTE: This manual is compiled with the production model manufactured in August, 2012. © COPYRIGHT SUZUKI MOTOR CORPORATION 2012 * This manual has been prepared using the latest information available at the time of publication. Differences may exist between the content of this manual and the actual outboard motor. * Illustrations in this manual are used to show the basic principles of operation and work procedures and may not represent the actual outboard motor in exact detail. * This manual is intended for use by technicians who already possess the basic knowledge and skills to service SUZUKI Outboard motors. Persons without such knowledge and skills should not attempt to service Suzuki Outboard engines by relying on this manual only and should contact an authorized SUZUKI Out- board motor dealer.

00 0 1 2 3 4 5 6 7 8 9 10 11 12 Precautions............................................................... 00-i Precautions ............................................................ 00-1 General Information ................................................... 0-i General Information ............................................... 0A-1 Maintenance and Tune-Up..................................... 0B-1 Power Head................................................................. 1-i Precautions .............................................................. 1-1 Engine Control ....................................................... 1A-1 Engine Electrical Devices....................................... 1C-1 Power Unit Mechanical .......................................... 1D-1 Power Unit Lubrication ........................................... 1E-1 Power Unit Cooling System ................................... 1F-1 Fuel System ...........................................................1G-1 Ignition System....................................................... 1H-1 Starting System....................................................... 1I-1 Charging System.................................................... 1K-1 Mid Unit ....................................................................... 2-i Precautions .............................................................. 2-1 Housing and Bracket .............................................. 2A-1 Power Trim and Tilt ................................................ 2B-1 Lower Unit ................................................................... 3-i Precautions .............................................................. 3-1 Right Hand Rotation Unit ....................................... 3A-1 Left Hand Rotation Unit .......................................... 3B-1 Wire / Hose Routing ................................................... 4-i Precautions .............................................................. 4-1 Wire Routing .......................................................... 4A-1 Fuel / Water Hose Routing ..................................... 4B-1 TABLE OF CONTENTS

Table of Contents 00- i 00 Section 00 CONTENTS Precautions Precautions ............................................... 00-1 Precautions........................................................... 00-1 General Precautions ........................................... 00-1

00-1 Precautions: Precautions Precautions Precautions General Precautions CENDG2110000001 The WARNING, CAUTION and NOTICE messages below describe some general precautions that you should observe when servicing the outboard motor. These general precautions apply to many of the service procedures, but they will not necessarily be repeated for every procedure to which they apply. WARNING ! Failure to take proper precautions when servicing the outboard motor can cause severe personal injury. • To avoid eye injury, always wear protective glasses when filing metals, working on a grinder, or doing other work, which could cause debris. • When two 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, 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. • Whenever handling toxic or flammable materials, wear safety glasses to protect your eyes. Any toxic or flammable materials getting into your eye may cause inflammation. Also wear moistureproof gloves to protect your skin. • Do not swallow any toxic or flammable materials. Swallowing them could cause diarrhea, nausea or other health problems. Be especially careful not to allow children and pets to swallow these materials. • Keep all toxic or flammable materials out of reach of children and pets. • When working with toxic or flammable materials, make sure that the area you work in is well ventilated 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. • Avoid contact with new and used oil. Prolonged contact with used oil has been shown to cause skin cancer in laboratory animals. Brief contact with used oil may irritate the skin. 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 latex 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. • Never disconnect any of the fuel lines between the fuel pump and injectors without first releasing the fuel pressure, or fuel can be sprayed out under pressure. • After servicing the fuel, lubrication, cooling and/or the 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.

Precautions: 00-2 NOTICE Failure to take proper precautions when servicing the outboard motor can cause damage to the parts or the outboard motor. To prevent the parts or the outboard motor from damage, be sure to take the following precautions: • When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. • Be sure to use special tools where instructed. • Make sure that all parts used in assembly are clean and also lubricated when specified. • When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type. • When removing the battery, disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable. • When performing service to electrical parts, if the service procedures do not require using battery power, disconnect the negative cable at the battery. • Do not expose connectors and electrical parts to water, which will cause electrical systems problems. • Always be careful not to drop electrical components (ECM, relays, etc.) or handle them in a rough manner. • Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, locking nuts, cotter pins, circlips, and certain other parts as specified, always replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. • Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. • Use a torque wrench to tighten fasteners to the torque values when specified. • Remove grease or oil from screw / bolt threads unless a lubricant is specified. • After assembly, check parts for tightness and proper operation. NOTE • To protect the environment, do not unlawfully dispose of used motor oil, other fluids or batteries. • To protect the Earth’s natural resources, properly dispose of used motor parts. Replacement Parts NOTICE Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems and damage. Use only genuine SUZUKI replacement parts or their equivalent. Genuine SUZUKI parts are high quality parts which are designed and built specially for SUZUKI outboard motors. If parts replacement is necessary, Suzuki strongly recommends that you use genuine Suzuki parts or their equivalent. They are precision-made to ensure high quality and correct fit.

00-3 Precautions:

Table of Contents 0- i 0 Section 0 CONTENTS General Information General Information ................................ 0A-1 General Description ............................................. 0A-1 Symbols .............................................................. 0A-1 Abbreviations ...................................................... 0A-1 Wire Color Symbols ............................................ 0A-2 Warning, Caution and Information Label Locations........................................................... 0A-2 Outboard Motor Identification Number Location ............................................................ 0A-3 Fuel and Oil Recommendations .......................... 0A-3 Break-In Procedures ........................................... 0A-4 Propeller Selection Guide ................................... 0A-5 Battery Requirement ........................................... 0A-5 Powerhead Direction of Rotation Description ..... 0A-5 Specifications ....................................................... 0A-6 Specifications ...................................................... 0A-6 Service Data ....................................................... 0A-9 Tightening Torque Specifications ...................... 0A-14 Special Tools and Equipment ........................... 0A-15 Recommended Service Material ....................... 0A-15 Special Tool ...................................................... 0A-16 Maintenance and Tune-Up ...................... 0B-1 Precautions........................................................... 0B-1 Precautions for Maintenance .............................. 0B-1 General Description ............................................. 0B-1 Recommended Oil and Lubricants ...................... 0B-1 Scheduled Maintenance ...................................... 0B-1 Periodic Maintenance Schedule Chart ................ 0B-1 Lubrication Point ................................................. 0B-2 Service Instructions ............................................. 0B-3 Engine Oil Level Check ....................................... 0B-3 Engine Oil Change and Engine Oil Filter Replacement ..................................................... 0B-3 Gear Oil Change ................................................. 0B-5 Spark Plug Removal and Installation .................. 0B-6 Spark Plug Inspection and Cleaning ................... 0B-6 Tappet Clearance Inspection and Adjustment .... 0B-7 Idle Speed and Idle Air Control (IAC) Duty Inspection ........................................................ 0B-12 Ignition Timing Inspection ................................. 0B-12 Breather Line and Fuel Line Inspection ............ 0B-13 Low Pressure Fuel Filter Inspection .................. 0B-14 Water Pump and Water Pump Impeller Inspection ........................................................ 0B-15 Propeller / Propeller Nut and Cotter Pin Inspection ........................................................ 0B-15 Anode Inspection .............................................. 0B-16 Bonding Wire Inspection ................................... 0B-17 Battery Inspection ............................................. 0B-17 Bolts and Nuts Inspection ................................. 0B-18 Oil Pressure Check ........................................... 0B-19 Cylinder Compression Pressure Check ............ 0B-20

0A-1 General Information: General Information General Information General Description Symbols CENDG2110101001 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. Abbreviations CENDG2110101002 Abbreviations used in this service manual are as follows: A: ATDC: After Top Dead Center AC: Alternating Current B: BTDC: Before Top Dead Center C: CKP Sensor: Crankshaft Position sensor CMP Sensor: Camshaft Position sensor CTP: Close Throttle Position D: DC: Direct Current DOHC: Double Over Head Camshaft E: ECM: Engine Control Module EX (Ex.): Exhaust F: FP: Fuel Pump G: GND: Ground I: IAC: Idle Air Control IAT: Intake Air Temperature IG: Ignition Ign.: Ignition IN (In.): Intake L: LPS: Lever Position Sensor M: MAP: Manifold Absolute Pressure P: PCV: Positive Crankcase Ventilation PORT: Port PTT: Power Trim and Tilt S: SPS: Shift Position Sensor STBD: Starboard SIGP: Start-In-Gear Protection T: TPS: Throttle Position Sensor Symbol Definition Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI Outboard Motor Gear Oil. Apply SUZUKI Super Grease A. Apply SUZUKI Moly Paste. 99000-25140 Apply SUZUKI Water Resistant Grease. Apply SUZUKI Bond 1207B. Apply SUZUKI Silicone Seal. Apply SUZUKI Thread Lock 1342. Apply SUZUKI Thread Lock Super 1333B. Use special tool. Do not reuse. Note on reassembly. Use peak voltmeter Stevens CD-77.

Suzuki Outboard DF90 DF100 DF115 DF140 Four Stroke Service Repair Manual

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