This service manual covers the following model years:
2002 Suzuki Outboard DF4 DF5 DF6 (4 HP 5 HP 6 HP) Four Stroke
2003 Suzuki Outboard DF4 DF5 DF6 (4 HP 5 HP 6 HP) Four Stroke
2004 Suzuki Outboard DF4 DF5 DF6 (4 HP 5 HP 6 HP) Four Stroke
2005 Suzuki Outboard DF4 DF5 DF6 (4 HP 5 HP 6 HP) Four Stroke
The service manual for the above listed Suzuki Outboard models describes the service procedures for the complete outboard. It is useful for both professional mechanics and DIY enthusiasts. Following the Maintenance Schedule recommendations is crucial to ensure the engine operates at its peak. Performing scheduled maintenance compensates for the initial wear that occurs during the motor's life.
All chapters in the service manuals apply to the whole engine and illustrate procedures for removal & installation of components in a detailed step-by-step fashion.
Most service manual chapters start with an assembly or system illustration, diagrams, exploded parts view, pictures, service information, and troubleshooting for the section. The subsequent pages provide detailed procedures. This is a simple to book, just like any book you would buy in a store except this book is delivered to you instantly upon purchase. No special software required as this manual works on all computers. Manual is in PDF format and delivered in PDF format.
Below is just a small sample of information you might find in a typical service manual but it covers everything you will ever need to service your entire motor. Information will differ depending on year and model.
GENERAL INFORMATION
Warning and cautions
General precautions
Identification numbers
Oil and gas recommendations specs
Engine oil specifications
Propellers and powerhead direction of rotations specification
Service data
Torque specs
Tools and materials required and much more
MAINTENANCE
Periodic maintenance schedule
Maintenance chart and intervals
Tune-up procedures
Engine oil, engine oil filter, and gear oil lubrications
Spark plugs, spark plug gap and type
Idle speed, ignition timing
Breather and fuel line, fuel pressure and fuel filter
Water pump, impeller propeller, propeller selection nut and cotter pn, anodes, battery
Fuel mixture check oil pressure, cylinder compression and much more
ENGINE CONTROL SYSTEM
Engine control system structure
Wiring diagram for engine control
Engine control module (ECM) ignition system
Electronic fuel injection
Caution system, overheat warning buzzer low battery voltage
Self-diagnostic system troubleshooting flywheel cpk sensor oil pressure switch and much more
ELECTRICAL
Battery charging system
Electric starter system
Manual starter including inspection removal installation disassemble and assembly
Starter motor, performance test, monitor tachometer and more
FUEL SYSTEM
Precaution on fuel system, fuel line and fuel lines
For Carburetor models you would find carb, float valve, how to tune carburetor, fix carburetor flooding, rebuild carburetor adjusting carb and more
POWER UNIT
Intake manifold, power unit oil pump timing chain
Cylinder head assembly, cylinder crankshaft, piston and pistons, thermostat, water cooling operation
Engine lubrication, piston rings, piston pin and much more
MID UNIT
Engine side cover drive shaft housing and oil pan, swivel bracket, steering bracket, clamp bracket water pressure valve and more
POWER TRIM AND TILT
System wiring diagram, oil level, air bleeding power trim and tilt unit, ptt motor removal, motor relay, ptt switch and more
LOWER UNIT
Pinion bearing, propeller, gear case, gears propeller shaft components, bearing housing, shift rod guide housing, water pump and related items, driveshaft oil deal housing, trim tab, lower unit gears shimming and adjustments and more
WIRE HOSE ROUTING
Wiring diagrams, wire routing fuel water hose routing and more
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