1996-2002 SUZUKI DF9.9 15 4-STROKE OUTBOARDS

DF§o§ DF1J§ FOUR STROKE

of its main sidered as Read miliarize refer to service This ''';'H'' lJ-ff motor tamers with proper you know the you can service. for and your cus- to may not repre- sent the actual outboard motor in for those who COPYRIGHT CORPORATION 999 I GENERAL INFORMATION PERIODIC MAINTENANCE IGNITION AND ELECTRICAL SYSTEM RECOIL STARTER POWER UNIT MID UNIT I LOWER UNIT II & 11197 H MODEL ".,u.hUir'li.m 1Ii.li!.ft,,!!,,'ftn CORPORATION Marine & Power Products Division

SE E manual is into 2. The title of these sections are listed on the previous page in a G P IN the you as page of the section a table of contents item and page you need. 70 N"m E E Clean flywheel and crankshaft , mating surfaces with cleaning solvent. i1l

SOL Listed in the table below are symbols special instructions and other information necessary for proper servicing. Please note the definition for each symbol. You will these symbols used through-out 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. oil. Use engine oil unless otherwise specified. Apply SUZUKI OUTBOARD MOTOR GEAR OIL Apply KI SUPER GREASE Apply SUZUKI WATER RESISTANT GREASE KI NO "1207B". SUZUKI SILICONE SEAL. DEFINITION Apply THREAD LOCK "1342". THREAD LOCK SUPER "13338". Measure voltage range. Measure in resistance range. Measure in current range. Use peak voltmeter Stevens CD-77. Use special tool.

DF9.9/DF15 CONSTRUCTIO S

GENERAL INFORIVIATION CONTENTS ------------------~ WARNING / CA UTION / NOTE ........................................................ . GENERAL PRECAUTIONS············································ ··················1- 1 IDENTIFICATION NUMBER LOCATION ·······································1- 3 FUEL AND OIL ...................................................... ·························1- 3 GASOLINE RECOMMENDATION .. ······································ .. 1- 3 ENGINE OIL ...................................................... ·····················1- 3 ENGINE BREAK-IN·············································· ···························1- 4 PROPELLERS············································ ······································1- 5 SPEC/FICA TlONS ........................................................................... 1- 6 SERVICE DATA ...................................................... ························1- 8 TIGHTENING TORQUE·· .. ······························································1-14

to NOTE: i • INFORMATION l E its instructions ! CAUTION and words, , the to maintenance easier or instructions clearer, s , or you must use good when cannot cover motor. In addition basic mechanical safety metals, on a material particles. 2'H'on,i",r,n to the safety each necessary to nm indoors, sure that exhaust gas is vented an outb()ar'd in on a boat, ensure that the necessary safety Flotation aids for each person, fire pump, first-aid tool emer- gency starter rope, etc. toxic or materials, sure that the area you and that you follow all of the material oil. Toil, <::\/<::T&:'I"n for leaks. .... I.~", ... '.." .... solvent. do not touch the engine, to the battery "",,..,,r,,na; oil or 2I'"fn!'>,n from contact with oil. in is or

CAUTION - If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. - When removing parts that are to be reused, keep them arranged in an nll"l"lpl"iiv manner so that they may be reinstalled in the propel' order and orientation. - Be sure to use special tools when instructed. - Make sure that all parts used in reassembly 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 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 battery power, disconnect the negative cable at the battery. -Tighten cylinder head and case bolts nuts, with iarger diameter with smaller diameter, from inside to outside , to the specified - Whenever you remove seals, , packing, O-rings, nuts, i cotter pins, circiips, and certain other parts as , be sure to them with new ones. Also, before installing these new , be sure to remove any left over material from the mating surfaces. • Never reuse a circiip. When , take care not to expand the end gap larger than required to slip the over . After a , always ensure that it is completely seated in its groove and -Use a wrench to fasteners to the - To protect the """"un..,., do not dispose of used motor oil, other fluids, protect the Earth's natural resources, " ... r.n<>.,..", cm;;ocIse of used motor

GENERAL INfORMATION IDE FICATIO E • PRE-fiX' SERIAL NUMBER The MODEL, PRE-FIX and NUMBER of motor are stamped on the plate attached to the PRE-FIX Serial number ENGINE SERIAL NUMBER A serial number plate can be found nr<'",,,,,,, a boss on the cylinder block. FUEL AND 01 GASOLINE Suzuki highly recommends gasoline with a minimum method) or 91 (Research leaded gasoline and may be used. Allowable maximum a tion); 5% Methanol, 10% 15% !A CAUTION, ENGINE OIL Use only oils which are rated SE, SF, SG, API (American Petroleum viscosity rating should be SAE 10W-40. tor oil is not available, select an right chart. nr"_Tre,e unleaded octane content or under the

E E The 10 hours are to ensure correct of either a brand new motor, or a motor that has been reconditioned or rebuilt. How the motor is operated time will have direct bearing on its lifespan and PR Allow sufficient 10 hours MEN N than 5 for the to warm-up after cold engine TH NOTE: R MEN Do not maintain constant speed for an extended break-in; vary the at any time the throttle occasionally. the gear at the and 45 In gear at less than 1 /2 NOTE: The throttle may be above recommended the but must be reduced after 2. NEXT R gear at less than 3/4 (three-quarter) gear at desired speed. at full throttle for more than 5 GENERAL INFORMATION

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1996-2002 SUZUKI DF9.9 15 4-STROKE OUTBOARDS

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