Suzuki Outboard DF9.9 DF15 DF25 DF30 DF40 DF50 DF70 HP Four Strokes Shop Service Manual

Chapter 1: General Information Chapter 2: Tools and Techniques Chapter 3: Troubleshooting and Testing Chapter 4: Lubrication, Maintenance and Tune-Up Chapter 5: Synchronization and Adjustment Chapter 6: Fuel System Chapter 7: Electrical and Ignition Chapter 8: Power Head Chapter 9: Gearcase Chapter 10: Manual Start Chapter 11: Hydraulic Trim and Midsection Chapter 12: Remote Control Chapter 13 Index Chapter 14 Wiring Diagrams

MAINTENANCE REQUIREI\iIENTSAND INTERVALS (continued) Initial 20 hOl,lr~ or.1 month Every 50 hc;>urs or 3. mO!lths Every 200 houfsor.12 montl'ls. Every two years. Inspect all hoses and clamps. Changee!1gine oil. Replace. QiI.fllter. Chang~ gearcasell,lbricant. Adjustidte speed. Adjustcarburetor pilot screw.* Adjust valvecl.earance. Tighten propeller nut. Check for loose fasteners. Inspect all hosesand.clamps. InsPect Iow pressure fuel.filter; InspectJueltank, hoses and. fittings • .Cbeckgearc!,8e lubricant level and C9n(ntion~ .Lubricate. the throttle and shift linkage. Lubrica.te the.swivel and tUtpins. · Inspect al.1 anodes and ground wires: Ch.eck the battery cQndition andflu!d level. Inspect all hOses and clamps.·· Inspect low pressure fuel. filter.· Inspect fuel tank, hoses and . fittings. ll,lbric.ate the throttle and shift linkage •. Lubricate the swivel andtilf pin~. . Ihspectall.anodes. and groutyd. wires. · C:he~~ the baUerycond!tion and fhlidle.vel: cte~mand inspectthe spark plugs. Chan9~engine QiI. . c:;hangegearcase JUt)rlcant, Ad) liSt carburetorpilof screw. * Tighten propeller nut. ·Check for loose fa.steners. Im~pect all hoses. and ~Iamps. .Inspect low pj'essurefuelfU~er. Inspectfue.1 tank; hoses and fittings. Lubricate the tl)rotfle and shift linkage. L.ubrlcate .the SWiV~.1 and tilt pins; Inspect aif.anodesand ground wires. Che~Kt~e~attery conditicm and fluid level •. ~eplace the.spatkplogs, .. · Cnangeengine 011.· Replace oil.fnter; .. Cl)aflge Qea.rcase . lubricant .lnsPecttfrnin:9belt;* CheCk ignition timing. Adj~.Il~t .idle speed. Adjust valve clearance. Inspect water pump components. Replacewater pump impeller; Tighten the ptopeflernut. Inspect all hoses and clamps. Inspect Jow pressure fuel fiiter. Inspect fuel tank; hoses and fittings. L,ubricate the throttle and sh ift linkage. lu~ricate the .swivel and tilt pins. . Insp~ctan anodes and grounding .. wires. Check ttJe battery condition and fluid level. Replace the spark plugs. Change engine oiL (continUed)

Chapter One General Information This detailed, comprehensive manual con- tains complete information on maintenance, tune-up, repair and overhaul. Hundreds of photos and drawings guide you through every step- by -step procedure. Troubleshooting, tune-up, maintenance and repair are not difficult if you know what tools and equipment to use and what to do. Anyone not afraid to get their hands dirty, of average intelligence and with some mechanical ability, can perform most of the procedures in this book. See Chapter Two for more information on tools and techniques. A shop manual is a reference. You want to be able to find information fast. Books are designed with you in mind. All chapters are thumb tabbed and important items are indexed at the end of the book. All procedures, tables, photos, etc., in this manual assume that the reader may be working on the machine or using this manual for the first time. Keep this book handy in your tool box. It will help you to better understand how your machine runs, lower repair and maintenance costs and generally increase your enjoyment of your marine equipment. MANUAL ORGANIZATION This chapter provides general information useful to marine owners and mechanics. Chapter Two discusses the tools and techniques for preventive maintenance, troubleshooting and repair. Chapter Three describes typical equipment problems and provides logical troubleshooting procedures. Following chapters describe specific systems, providing disassembly, repair, assembly and adjustment procedures in simple step- by- step form. Specifications concerning a specific system are included at the end of the appropriate chapter. NOTES, CAUTIONS AND WARNINGS The terms NOTE, CAUTION and WARN- ING have specific meanings in this manual. A NOTE provides additional information to make a step or procedure easier or clearer. Disregard- ing a NOTE could cause inconvenience, but would not cause damage or personal injury.

CHAPTER ONE A CAUTION emphasizes areas where equipment damage could result. Disregarding a CAU- TION could cause permanent mechanical damage; however, personal injury is unlikely. A WARNING emphasizes areas where personal injury or even death could result from negligence. Mechanical damage may also occur. WARNINGS are to be taken seriously. In some cases, serious injury or death has resulted from disregarding similar warnings. TORQUE SPECIFICATIONS Torque specifications throughout this manual are given in foot-pounds (ft.-lb.) and either Wew- ton meters (N.m) or meter-kilograms (mkg). Newton meters are being adopted in place of meter-kilograms in accordance with the Intema- tional Modernized Metric System. Existing torque wrenches calibrated in meter-kilograms can be used by perfoming a simple conversion: move the decimal point one place to the right. For example, 4.7 mkg = 47 N.m. This conversion is accurate enough for mechanics' use even though the exact mathematical conversion is 3.5 mkg = 34.3 N.m. ENGINE OPERATION All marine engines, whether 2- or 4-stroke, gasoline or diesel, operate on the Otto cycle of intake, compression, power and exhaust phases. A 4- stroke engine requires two crankshaft revolutions (4 strokes of the piston) to complete the Otto cycle. Figure I shows gasoline 4-stroke engine operation. Figure 2 shows diesel 4-stroke engine operation. 2-stroke Cycle A 2-stroke engine requires only I crankshaft revolution (2 strokes of the piston) to complete the Otto cycle. Figure 3 shows gasoline 2-stroke engine operation. Although diesel 2-strokes ex- ist, they are not commonly used in light marine applications. FASTENERS The material and design of the various fasteners used on marine equipment are not arrived at by chance or accident. Fastener design deter- mines the type of tool required to work with the fastener. Fastener material is carefully selected to decrease the possibility of physical failure or corrosion. See Cah~ani Corrosiolz in this chapter for more information on marine materials. Threads Nuts, bolts and screws are manufactured in a wide range of thread patterns. To join a nutand bolt, the diameter of the bolt and the diameter of the hole in the nut must be the same. It is just as impoflant that the threads on both be properly matched. The best way to deternine if the threads on two fasteners are matched is to turn the nut on the bolt (or the bolt into the threaded hole in a piece of equipment) with fingers only. Be sure both pieces are clean. If much force is required, check the thread condition on each fastener. If the thread condition is good but the fasteners jam, the threads are not compatible. Four important specifications describe every thread: a. Diameter. b. Threads per inch. c. Thread pattern. d. Thread direction. Figure 4 shows the first two specifications. Thread pattern is more subtle. Italian and British

GENERAL INFORMATION 3

4 CHAPTER ONE

GENERAL INFORMATION 5 5

Suzuki Outboard DF9.9 DF15 DF25 DF30 DF40 DF50 DF70 HP Four Strokes Shop Service Manual

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