A repair manual is a book of repair instructions. Its purpose is to guide the user of the manual through maintenance, troubleshooting, service and repair procedures based on factory specifications.
As with all books, a repair manual contains a cover page, table of contents, main chapters and rear cover. Electronic manuals, or manuals that can be downloaded, look just like a printed book you would obtain in a store — no difference.
Repair manuals contain information about part removal, part disassembly, inspection, cleaning, assembly and part installation. You will find complete specifications such as torque specifications, part specification, troubleshooting guides and more.
There are two repair manuals available for the Suzuki DF horsepower outboards. Inspect pump case. Replace if cracked, distorted or other abnormal conditions are noted. Remove the lower unit. Remove the propeller. Remove the water pump and related parts. Place a drain pan under oil drain plug. Remove oil drain plug 1 first then oil level plug 2 and allow gear oil to drain.
Inspect oil for water, contaminates or metal. Remove the bolts 3 and shift rod guide housing assembly 4. Remove two bolts 5 securing the propeller shaft bearing housing to the gearcase. Using special tools, pull out the propeller shaft bearing housing. Remove the propeller shaft and bearing housing assembly 6. Special tool A : — Sliding hammer B : — Propeller shaft remover Hold the pinion nut securely, then fit special tool to the driveshaft and loosen the pinion nut.
Remove pinion nut 7. Special tool C : — Driveshaft holder Remove the four bolts securing driveshaft oil seal housing 8 , then remove oil seal housing and pinion gear shim.
Lift out driveshaft assembly 9. Remove driveshaft collar 10 from driveshaft If necessary. Remove the pinion gear Remove reverse gear 12 with reverse gear retainer 13 and thrust bearing Remove the reverse gear 12 from reverse gear retainer Remove the bearing thrust washer 15 and back-up shim Remove the reverse gear bearing housing 17 and dowel pin To disassemble propeller shaft components, refer to following. Remove horizontal slider 29 and spacer Remove the spring 31 from the clutch dog shifter Special tool D : — Shift lock pin remover f Remove the clutch dog shifter 32 and connector pin 34 from propeller shaft.
To disassemble shift rod components, refer to following. Removal and Installation Tools To remove the pinion bearing from the gearcase, use the following special tools. Place the attachment D inside the pinion bearing. Insert the removal shaft A into attachment D. Thread sliding hammer E into top of removal shaft A. Put wood block under pinion bearing.
Drive the pinion bearing out downwards by striking top of shaft A with sliding hammer E. Pinion bearing 2. Place the installer shaft A with pinion bearing on end of installer shaft into the gearcase. Secure the plate B by tightening the bolt C. Thread the sliding hammer E into the top of the installer shaft A. Assemble the lower unit. Gearcase Inspect the gearcase. Replace if cracked, damaged or other abnormal conditions are noted. Replace gears if damaged, worn or other abnormal conditions are noted.
Inspect forward gear thrust bearing. Replace if cracked or damaged. Visually check each bearings. Replace if pitted, noisy or rough. Propeller Shaft Components Inspect horizontal slider and connector pin. Replace if wear, damage or other abnormal condition. Inspect detent balls. Replace if wear, damage or other abnormal conditions are noted.
Inspect dog pin. Replace if bent, worn or other abnormal conditions are noted. Check detent spring by measuring its free length. If free length is not within specifications, replace detent spring. Service limit: Propeller Shaft Bearing Housing Inspect housing. Inspect shifter yoke. Replace if worn, damaged or other abnormal conditions are noted. Inspect O-ring. Replace if nicked, cut, torn, swollen or other abnormal conditions are noted.
Driveshaft Oil Seal Housing Inspect housing. Replace if worn, nicked, cut or other abnormal conditions are noted. Remove the propeller shaft bearing housing. Remove the retaining ring 1 and washer 2. Extract the seals 3 with oil seal remover. Special tool A : — Oil seal remover Apply water resistant grease to the inner circumference of the housing. Assemble the propeller shaft bearing housing. Driveshaft Oil Seal Replacement Remove the driveshaft oil seal housing.
Using special tool, remove two oil seals out of the driveshaft oil seal housing. Special tool A : — Oil seal remover Removing the oil seal can cause damage to the seal lips, causing oil to leak.
Apply water resistant grease to inner circumference of driveshaft oil seal housing. Assembly is in reverse order of disassembly with special attention to the following steps. Reverse Gear Bearing Housing Install dowel pin 1 and reverse gear bearing housing 2 in position.
Reverse Gear Place reverse gear back-up shim 1 and bearing thrust washer 2 in position. Driveshaft Assemble the driveshaft collar 1 to driveshaft. Lower the driveshaft assembly 2 down into the gearcase until the bottom of shaft protrudes through center of pinion gear.
Install the bearing outer race 3 and pinion gear shim 4 to driveshaft. Driveshaft Oil Seal Housing Apply water resistant grease to the driveshaft oil seal. Install the driveshaft oil seal housing on the gearcase, then tighten four bolts 3 securely.
Pinion Nut Apply thread lock to the threads of pinion nut 1 before threading it onto driveshaft. Insert two small detent balls 3 , large detent ball 4 , detent spring 5 and large detent ball 6 into connector pin 7.
Insert the connector pin 7 with detent balls into propeller shaft 1. Install the spacer 10 to propeller shaft. Apply Water Resistant Grease to O-ring 1 , then install the O-ring into the groove on the propeller shaft bearing housing. Install forward gear back-up shim 7 , forward gear thrust washer 8 , forward gear thrust bearing 9 and forward gear 10 to propeller shaft bearing housing.
To keep overall size to a minimum our engineers utilized an offset drive shaft system with a reduction gear incorporated at the bottom Upstream of the pressure regulator, a Fuel Cooler is now incorporated in place of a water jacket to cool the fuel. All fuel-related components are located on the intake manifold. Intake Manifold The aluminum-cast intake manifold is designed with a comparatively long branch to boost the engine's mid range torque.
The E. Engine Control Module system controls the engine's ignition system and provides an ideal fuel supply under all running conditions. The data from these sensors is conveyed to a computer that instantly calculates Speed-Density type the optimum amount High Output Alternator Both the DF90 and DF arc equipped with high output alternators that deliver a total of 4 A 12V lor increased electri- blades incorpo- diameter flywheel magneto circulate cooled regulator large capacity power generator.
A spin on oil filter is utilized and the oil filler cap is attached to the top of the cylinder head to provide easy access cover Lach model may be discontinued without milice I. Your most recent searches Delete. Frequent searches. Chapters and sup-chapters include…. This manual provides step-by-step directions through the process of part removal, disassembly, inspection, cleaning, assembly and reinstallation. You will find troubleshooting guides to help you complete the repair work successfully.
So whether you need a Suzuki DF repair manual to do simple maintenance, engine overhaul or restoration, a download repair manual covers it all. So what are you waiting for, download your copy now! Suzuki Df Service Manual Free Suzuki Df Manual Jul 28, suzuki dfa dfa dfa 4-stroke outboard repair manual download pdf This outboard repair manual With its superb step by step photographs and detailed diagrams is to enable every owner to understand the workings of an outboard motor 2 or 4 stroke and be able to fix it with relative ease.
Payment and download Instructions: 1 Click on the green instant download button at the top left corner of this page to buy your repair manual now. Information includes: 1. What is a repair manual? The manual contains high-end photos, illustrations and diagrams.
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