Suzuki outboard motor DF90 / DF115 / DF140, repair e-manual

Content

Periodic maintenance

• Periodic maintenance schedule
• Maintenance and tune-up procedures
• Oil pressure
• Cylinder compression

Engine control system

• Engine control system structure
• Components for system control
• Ignition system
• Electronic fuel injection system
• Caution system
• Self-diagnostic system
• Fail-safe system
• Operating hour indication system
• Oil change reminder system
• Start-in-gear protection system
• Feedback system
• Inspection
• Troubleshooting
• Removal / installation

Electrical

• Battery charging system
• Electric starter system
• Monitor-tachometer
• Electric parts holder

Wire / hose routing

• Wiring diagram
• Wire routing
• Fuel / water hose routing

Fuel system

• Precaution on fuel system service
• Fuel line
• Fuel vapor separator / high pressure fuel pump
• Fuel injector
• Low pressure fuel pump
• Tank

Power unit

• Intake manifold assembly
• Power unit
• Oil pump
• Timing chain / tensioner
• Cylinder head assembly
• Cylinder / crankshaft / piston
• Thermostat
• Operation

Mid unit

• Engine side cover
• Driveshaft housing and oil pan
• Swivel bracket, steering bracket and clamp bracket
• Water pressure valve

Power trim and tilt

• System wiring diagram
• Service procedure
• Power trim and tilt unit
• PTT motor relay
• PTT switch
• Operation

Lower unit

• Removal and disassembly
• Pinion bearing
• Inspection
• Assembly and installation
• Trim tab
• Lower unit gears-shimming and adjustment

DF140 “K2” (’02) model

• General information
• Engine control system
• Power unit
• Mid unit
• Power trim and tilt
• Lower unit (normal rotation model)
• Counter rotation lower unit (DF140Z)
• Wiring diagra
• Hose routing

DF90 / 115 “K2” (’02) model

• Specifications
• Service data
• Tightening torque
• Materials required
• Fuel/water hose routing
• Over-revolution caution system
• Crank pin and conrod bearing
• Conrod assy and bearing
• Crankshaft and flywheel
• Camshaft and tappet shim
• Engine holder gasket
• Engine holder bolt
• Upper mount front nut
• Clutch linkage

DF90 / 115 / 140 “K3” (2003) model

• Specifications
• Service data
• Tightening torque
• ECM
• ECM main relay and starter motor relay
• Battery charge coil
• Rectifier and regulator
• Exhaust cam shaft (for DF115 only)
• Remote control cable holder
• Cylinder head instllation
• Crankcase to cylinder instllation
• Upper mount
• Drive shaft
• Propeller shaft bearing housing
• Wiring diagra
• Water hose routing

DF90 / 115 / 140 “k4” (’04) model

• Specifications (DF90T / 115T / 115WT)
• Specifications (DF140T / 140WT / 140Z)
• Service data (DF90 / 115)
• Service data (DF140)
• Temperature sensor
• Cylinder block
• Rectifier and regulator
• Power trim and tilt (P.T.T.) relay
• Electric parts holder
• P.T.T. Motor
• Tilt limit switch system
• Swivel bracket
• Clamp bracket shaft
• Port clamp bracket
• Driveshaft
• Pinion gear back up shim
• Lower unit gears-shimming and adjustment
• Wiring diagram

DF90 / 115 / 140 “k5” (2005) model

• Specifications (DF90T / 115T / 115WT)
• Specifications (DF140T / 140WT / 140Z / 140WZ)
• Service data (DF90T / 115T / 115WT)
• Service data (DF140T / 140WT / 140Z / 140WZ)
• Engine wiring harness
• Safety relay system
• ECM
• Sub-battery cable
• Remote control box and remote control wire
• Tilt limit switch cover
• Piston oil ring
• Tensioner adjuster
• Engin holder
• Upper and lower mount
• Transom bolt
• Wire / hose routing
• Wiring diagram

DF90/115/140 “K6” (2006) model

• Specifications (DF90T / 115T / 115WT)
• Specifications (DF140T / 140WT / 140Z / 140WZ)
• Service data (DF90T / 115T / 115WT)
• Service data (DF140T / 140WT / 140Z / 140WZ)
• Tightening torque
• Periodic maintenance schedule
• ECM
• Neutral switch
• Fuel filter
• Delivery pipe
• Oil strainer
• Oil cooler (for DF140)
• Engine holder and cylinder block
• Cltuch link
• Swivel bracket bushing grease path
• Clamp bracket (for DF90 AND DF115)
• Swivel bracket
• Steering bracket
• Upper mount
• Water pump
• Water pump tube
• Exhaust seal rubber
• Shift rod guide housing
• Shift rod, shifter yoke and horizontal slider
• Drive shaft
• Propeller shaft and connector pin
• Forward gear and clutch dog
• Wiring / hose routing
• Wiring diagram

DF90 / 115 / 140 “K7” (2007) model

• Specifications (DF90T / 115T / 115WT)
• Specifications (DF140T / 140WT / 140Z / 140WZ)
• Service data (DF90T / 115T / 115WT)
• Service data (DF140T / 140WT / 140Z / 140WZ)
• Periodic maintenance schedule
• ECM
• Fuel hose, cable grommet and front panel
• Pinion / gear set

DF90 / 115 / 140 “K8” (2008) model

• Specifications (DF90T / 115T / 115WT)
• Specifications (DF140T / 140WT / 140Z / 140WZ)
• Service data (DF90T / 115T / 115WT)
• Service data (DF140T / 140WT / 140Z / 140WZ)
• Periodic maintenance
• Engine control system
• Digital gauge system
• Engine holder
• Wiring diagram
• Wire routing

DF100 “K9” (2009) model

• General information
• Engine control
• Power unit
• Wire / hose routing

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