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4-Stroke Outboard Engine Workshop Manual Application: 1997, 1998, 1999, 2000 Suzuki DF 9.9, DF 15, DF 25, DF 30, DF40, DF 50, DF70 HP Owners Workshop Manual. 9.9HP, 15HP, 25HP, 30HP, 40HP, 50HP, 70HP Four-Stroke Outboard Motors.
This workshop service repair manual gives step by step information on maintenance, repair and mechanic overhaul. This manual is detailed with hundreds of photos, pictures and illustrations to help guide you through repair procedures. It will help you understand, care for, and
lower the repair and maintenance cost for your Suzuki Outboard Engine (motor) for a overall improved satisfaction with your ownership.
NOTE: This manual is a workshop manual and is the only manual for download for the model and years listed. The only difference with this manual is that it is the cheapest! Why is it the Cheapest? The quality of this scanned manual is not the best but it is very useful, the text is legible but picture quality is not the best. The manual is well organized with bookmarks to help you find what you need in the quickest time possible. This Suzuki manual is also word/key word phrase searchable too.
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EXACT MODELS COVERED IN THIS WORKSHOP MANUAL:
Suzuki DF9.9 (9.9HP, 9.9-HP DF-9.9)
Suzuki DF15 (15HP, 15-HP, DF-15)
Suzuki DF25 (25HP, 25-HP, DF-25)
Suzuki DF30 (30HP, 30-HP, DF-30)
Suzuki DF40 (40HP, 40-HP, DF-40)
Suzuki DF50 (50HP, 50-HP, DF-50)
Suzuki DF70 (70HP, 70-HP, DF-70)
CHAPTERS IN THIS SUZUKI DF WORK SHOP 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
MANUAL LANGUAGE: ENGLISH
PAGES: 430
FORMAT: PDF
DELIVERED IN: PDF FORMAT
ZOOM IN/ OUT: YES
BOOK MARKED BY CHAPTER: YES
WORD SEARCH: YES
COMPATIBLE ON ALL COMPUTERS
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COMMON SUZUKI RELATED SEARCHES
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Adjustment choke solenoid and choke linkage . . . . 169
dashpot . . . . . . . . . . . . . . . . . . 169-170
idle speed . . . . . . . . . . . . . . . . 167- 169
neutral-only start cable . . . . . . 170-171
pilot screw . . . . . . . . . . . . . . . 166-1 67
shift cable and linkage . . . . . . 160-165
throttle cable and linkage . . . . 155-1 60
trim position sender . . . . . . . . 171-172
trim tab . . . . . . . . . . . . . . . . . . . . . 1. 7 2
valve . . . . . . . . . . . . . . . . . . . .1 48-155
Battery maintenance . . . . . . . . . . . . .. 222 .227
Carburetor DF25 and DF30 models synchronization . . . 165-1 66
overhaul . . . . . . . . . . . . . . . . .1 87- 192
removal and installation . . . . . 186-187
Charging system . . . . . . . . . . . . .21 0-214
troubleshooting . . . . . . . . . . . . . .5 9-63
Choke solenoid and choke linkage adjustment . . . 169
Cooling system troubleshooting . . . . . . 90-92
Cylinder block assembly . . . . .. . . .. 2 76 .280
cleaning . . . . . . . . . . . . . . .26 6.268
component removal . . . . . . 2 58 .262
disassembly . . . . . . . . . . . .2 62-266
inspection . . . . . . . . . . . . .. 2 68 .275
head . . . . . . . . . . . . . . . . . . . .2 44-257
Dashpot adjustment . . . . . . . . . . . . . . . 169-1 70
Electrical battery. maintenance. . . . . . . . 2 22-227
charging system . . . . . . . . . . .2 10-214
ignition system . . . . . . . . . . .. 2 14 -220
starting system . . . . . . . . . . .. 2 00 -210
warning system . . . . . . . . . . . . 2 20 -222
wiring diagrams . . . . . . . . . . .40 6.425
Electronic fuel injection, troubleshooting . . . . . .1 00-1 09
Engine operation . . . . . . . . . . . . . . . . . .2
Fasteners . . . . . . . . . . . . . . . . . . . . . . .2. 8
Flywheel . . . . . . . . . . . . . . . . . .. 2 29 .232
Fuel pump, low pressure . . . . . . 183- 185
Fuel system carburetor overhaul . . . . .1 87-1 92
removal and installation . . . 186-1 87
injection system . . . . . . . . . . .1 92-198
pump. low pressure . . . . . . . . 183- 185
Service precautions . . . . . . . .1 75- 183
silencer cover . . . . . . . . . . . . .1 85-1 86
troubleshooting . . . . . . . . . . . . . .4 1-52
Fuses and wire harness troubleshooting . . .8 1-82
Galvanic corrosion . . . . . . . . . . . . .1 1-13
protection . . . . . . . . . . . . . . . . . .1 3-14
Gasket sealant . . . . . . . . . . . . . . . . .1 0-11
Gearcase general procedures . . . . . . . . . . . . .3 03
inspection . . . . . . . . . . . . . . . .3 3 1-334
maintenance . . . . . . . . . . . . . .1 39-141
operation . . . . . . . . . . . . . . . .. 2 90 -291
propeller . . . . . . . . . . . . . . . .. 2 91 -292
shim adjustments . . . . . . . . . . . .. 3 39 -340
selection . . . . . . . . . . . . . . .3 34-339
DF9.9-DF15. . . . . . . . . . . . 3 03 -310
DF15 and DF30 . . . . . . . . . 310 .317
DF40 and DF50 . . . . . . . . . 3 1 7-323
DF60 and DF70 . . . . . . . . . 323 .33 1
troubleshooting . . . . . . . . . . . . . .9 2-95
water pump inspection . . . . . . . . . .. -. . . . . . 302
service . . . . . . . . . . . . . . . .. 2 95 .302
Idle speed adjustment . . . . . . . . . 167-169
Ignition system . . . . . . . . . . . . . . 2 14-220
troubleshooting . . . . . . . . . . . . . . 6 3-75
Linkage shift cable adjustment . . . . . . . 1 60-165
throttle cable adjustment . . . . 155- 160
Lubricants . . . . . . . . . . . . . . . . . . . . . 8- 10
Maintenance battery . . . . . . . . . . .22 2.227
gearcase . . . . . . . . . . . . . . . . .1 39-14 1
midsection . . . . . . . . . . . . . . . 136- 13 8
power head, routine . . . . . . . . 1 26-13 6
storage preparation . . . . . . . . .1 4 1. 1 42
Manual starter . . . . . . . . . . . . . .. 3 41 .350
Midsection . . . . . . . . . . . . . . . . .3 69-391
maintenance . . . . . . . . . . . . . . 136-138
Neutral-only start cable.
adjustment . . . . . . . . . . . . . . . 170- 171
Outboard engine identification . . . . 33-35
Pilot screw adjustment . . . . . . . . 1 66- 167
Power head break-in procedure . . . . . . . . . . . . . 280
cylinder block assembly . . . . . . . . . . . . . . .27 6-280
cleaning . . . . . . . . . . . . . . .26 6.268
component removal . . . . . .25 8.262
disassembly . . . . . . . . . . . . 262-266
inspection . . . . . . . . . . . . . . 268-275
cylinder head . . . . . . . . . . . . .24 4.257
flywheel . . . . . . . . . . . . . . . . . 229-232
maintenance, routine . . . . . . . 126- 136
removal, installation. repair . . .. . . .23 2.244
troubleshooting . . . . . . . . . . . . . . 83-90
Propeller . . . . . . . . . . . . . 14.20,29 1.292
Remote control . . . . . . . . . . . . . . 398-403
Shift cable and linkage adjustment . . . . 160- 165
Silencer cover . . . . . . . . . . . . . . . 185-186
Starting system . . . . . . . . . . . . . .20 0-2 10
difficulty . . . . . . . . . . . . . . . . . . . 38-41
troubleshooting . . . . . . . . . . . . . . 52-59
Storage preparation . . . . . . . . . . . . . . . 14 1 . 142
Synchronization and adjustment . . . . . . . . . . . . . . . 148-1 55
carburetor, DF25 and DF30 models … 165-166
Test equipment. troubleshooting . . . . . . . . . . . . . . 35-38
Throttle cable and linkage
adjustment . . . . . . . . . . . . . . . 155-160
Tools basic hand . . . . . . . . . . . . . . . . . . 2 1-26
test equipment . . . . . . . . . . . . . . 2 6.28
troubleshooting . . . . . . . . . . . . 35-38
Torque specifications . . . . . . . . . . . . . . . 2
Trim system . . . . . . . . . . . . . . . . 351-369
position sender adjustment . . . 17 1 – 172
tab adjustment . . . . . . . . . . . . . . . . 172
troubleshooting . . . . . . . . . . . . . 95- 100
Troubleshooting charging system . . . . . . . . . . . . . 59-63
cooling system . . . . . . . . . . . . . . 90-92
electronic fuel injection . . . . . 100-109
fuel system . . . . . . . . . . . . . . . . . 4 1-52
fuses and wire harness . . . . . . . . 8 1-82
gearcase . . . . . . . . . . . . . . . . . . . 92-95
ignition system . . . . . . . . . . . . . . 63-75
outboard engine identification . . . . . . . . . . . . . . 33-35
power head . . . . . . . . . . . . . . . . . 83-90
preparation . . . . . . . . . . . . . . . . . . . . 38
starting difficulty . . . . . . . . . . . . . . . . . 38-4 1
starting system . . . . . . . . . . . . 52-59
test equipment . . . . . . . . . . . . . . 35-38
trim system . . . . . . . . . . . . . . . . 95-100
warning system . . . . . . . . . . . . . . 7 5-80
wire harness . . . . . . . . . . . . . . . . 82-83
Tune-up . . . . . . . . . . . . . . . . . . . 143-144
Valve adjustment . . . . . . . . . . . . 148- 155
inspection . . . . . . . . . . . . . . . . . . . . 302
Service . . . . . . . . . . . . . . . . . . . .29 5.302
Wire harness troubleshooting . . . . . . . . . . . . . . 82-83
Wiring diagrams . . . . . . . . . . . . .40 6.425
TAGS: Suzuki Shop Manual, Workshop Manual, Service Manual, Repair Manual, Repair Guide, Owners Service Repair Guide Manual, Owner’s Manual, Specifications, Specs, Engine Specifications, Propeller Selection, 3 Blade Propeller, Aluminum Propeller, Steel Propeller, Parts, Used Parts, New Parts Replacement, Impeller, Impeller Change, Oil Change, Oil Viscosity, Oil Brand, Spark Plug, Spark Plugs, Spark Plug Gap, Parts Exploded View, Picture Drawing, Illustration, Parts Manual, 97, 98, 99, 00, 1997, 1998, 1999, 2000, Horespower, Horse Power, Torque Specs, Top Speed, Backfire, Idle, Stalling, Stall, Smoke, Black Smoke, Blue Smoke, White Smoke, 500 RMP, 1000 RPM, Trolling Speed, Maintenance, Maintenance Intervals, Chart, Storage, Flushing The Engine, How To Flugh the Motor, When Do you Change The Oil.
