2009 Suzuki 9.9/15HP (DF9.9/DF15) 4-Stroke Outboards OEM Service & Repair Manual

FOREWORD This manual contains an introductory description on SUZUKI Outboard motor DF9.9/15 and procedures for the inspection, service and overhaul of its main components. General knowledge information is not included. Please read the GENERAL INFORMA TION section to familiarize yourself with basic information concerning this motor. Read and refer to the other sections In this manual for information regarding inspection and service procedures. This manual will help you better understand this outboard motor so that you may provide your custom- ers with and quick service. This manual has been prepared using the lat- est information available at the time of publi- cation. If a modification has been made since then, differences may exist between the content of this manual and the actual outboard motor. * Illustrations this manual are used to show the basic nrll-lr>rnic; and may not outboard motor in exact detail. and work the actual * This manual is intended for use techni- cians who already possess the basic know/- and skills to service SUZUKI outboard motors. Persons without such know/edge and skills should not or do-it-yourself mechanics that don't have the tools and not be able to the services n"'<~ ... ,... ual. the mechanic and unsafe for the boat NOTE: This manual is render the engine and passen- based on 2003 (K3) model. © COPYRIGHT SUZUKI MOTOR CORPORATION 2002 GROUP INDEX I GENERAL INFORMATION I PERIODIC MAINTENANCE I IGNITION AND ELECTRICAL FUEL SYSTEM RECOIL STARTER I POWER UNIT I MID UNIT I LOWER UNIT ROUTING AND Marine & Power Products Division

TO 1. 2. The 3. 4. Under vice SE YOU ARE this manual is titles are listed on the INDEX. Select the section needed for wi!! allow to of the section of each ccc,t~t'f"1,n of contents to eas- item and page you need. name of each such as 80N·m 8.0 kgt-m) 58.5 Ib-ft . ~ /W ~~ __ -~--c'--~~----------i Clean the ",,,,,,ncol and the crankshaft mating surfaces with rb"",i",.. Stator base (1 ) ~1 Dowel pin other ser-

for instructions and other information necessary for each symbol. You will find these symbols used throughout are not sure of any Torque control required. Data it indicates OIL unless SUPER GREASE "A". the SUZUKI WATER RESISTANT BOND iSYMBOL! meanings. DEFINITION the LOCK "1342". llieTHREADLOCKSUPER Measure Measure in test range. Use peak voltmeter "Stevens CD-77". tool.

GENERAL INfORMATION 1·1 GENERAL INFORMATION ,..-------------- CONTENTS ------------, WARNING/CAUTION/NOTE ......................................................................... 1- 2 GENERAL PRECAUTIONS ........................................................................... 1- 2 IOENTIFICA TlON NUMBER tOCA TlON •.......•........•...•....•.•................••....... 1- 4 FUEL AND OIL .............................................................................................. 1- 5 GASOLINE RECOMMENDATION ......................................................... 1- 5 ENGINE OIL ........................................................................................... 1- 5 ENGINE BREAK-IN ....................................................................................... 1- () WARM-UP RECOMMENDA nON .......................................................... 1- 6 THROTTLE RECOMMENDATION ......................................................... 1- 6 PROPELLERS ............................................................................................... 1- 7 SPEC/FICA TIONS ......................................................................................... 1- 8 SERVICE DATA ............................................................................................. 1-10 TIGHTENING TORQUE ................................................................................. 1-17 SPECIAL TOOLS .......................................................................................... 1-19 MATERIALS REQUIRED .............................................................................. 1-22

1-2 WARNING/CAUTION/NOTE Indicates a NOTE Indicates'i:i/JIt;;'l-/,:1/ its instructions and could result death or that in motor ril':lm:::lln~ to make maintenance easier or instructions clearer. Please contained in this cannot uu;:,<:>/w principles. '* Proper service and the safety and '" When 2 or more no,."""' .... '* When it is 1t=\,;t=::li::liClii '*When or flammable ventilated and that follow all of the material '" Never use as a ,. To avoid getting shortly after '" Oil can be hazardous, used oil solvent, do not touch the shirt and moisture-proof NI .. ",,",",, tacts wash with oU. Recycle or properly '* After servicing fuel, oU/engine r-r"."liln'N related to the system for " Carefully adhere to the ,.,.21" ... ',.,'" outboard motor. observe the ~J:ll·;::;.nl of the make sure that vented work in is oil or exhaust or or rags if wet and

GENERAL lent. " When removing that are to be them in an manner so that be reinstalled in the order and orientation. * Be sure to use special tools when instructed. " Make sure that all parts used in are clean and also lubricated when <> ... ",,,,,,'1",,,,,1"1 " When use of a certain of bond or sealant is be sure to use the "' ..... , ... ,- fied * When When * When ... .,. .. f" ... ...., ;, surfaces. connect the cable first and then the cable first and then the service to electrical if the service "",.,.,,,,,,,t'I disconnect the cable at the head and case bolts and with larger diameter and to the specified cable. ' .. U· ..... ,l" nuts, as replace them with new. be sure to remove any left over material from the a new over the shaft. After fitted. " To nl't"n-""j~T the Earth's natural resources, nw..-"u",.. of used motor 1·3

1-4 GENERAL "~.-"n"'" IDENTIFICATION NUMBER LOCATION MODEL, PRE-FIX, SERIAL NUMBER The MODEL, PRE-FIX and SERIAL NUMBER the motor are stamped on a plate attached to the clamp bracket Example ENGINE SERIAL NUMBER A second engine serial number plate is pressed into a boss on the cylinder block.

El AN 01 GASOLINE RECOM ENDATION Suzuki highly recommends that you use alcohol-free unleaded gasoline with a minimum pump octane rating of 87 (R+M /2 method) or 91 (Research method). blends of unleaded gasoline and alcohol with equivalent octane content may be used. Allowable maximum blend of a single additive combination): 5% Methanol, 10% Ethanol, 15% MTBE result. ENGI E OIL Use only oils that are rated SE, SF, SG, SH or SJ under the API (American Petroleum Institute) classification system. The should be SAE 10W-40. If an SAE OW-40 motor oil is not according to the chart at select an alternative GENERAL INFORMATION 1·5

1-6 GENERAL INFORMATION EN E BREAK-I The first 10 hours are of either a brand new motor ditioned or rebuilt will have direct Break~in ,",,,,,.nn,,,,, NOTE: to ensure correct run- a motor that has been recon- this 5 for the A void maintaining a constant (;''''Jrlln", speed for an extended at any time during the break-in by the throttle position occasionally. 1. 2 HOURS For first 15 speed. the engine NOTE: at less than 1 12 The throttle may be the at and 45 beyond the recommended to the boat, but must be reduced to the recommended setting after 2. NEXT at less than 3/4 3. LAST7 speed. throttle for more than 5 minutes.

You're Reading a Preview

2009 Suzuki 9.9/15HP (DF9.9/DF15) 4-Stroke Outboards OEM Service & Repair Manual

Description

Reviews

Q&A

Recently Viewed