2002-2011 Suzuki Outboard Service Manual DF4 DF5 4/5 HP DF

This service repair manual is for the Suzuki DF4 & DF5 (4 HP & 5 HP) Outboard engine for the 2002-2011 model years.

The manual describes the service procedures for the complete outboard. Following the Maintenance Schedule recommendations is crucial to ensure the engine operates at its peak. Performing scheduled maintenance compensates for the initial wear during the motor's life.

All chapters in the service manuals apply to the entire engine and illustrate detailed step-by-step procedures for removal & installation of components.

Most 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 use book, just like any book you would buy in a store, except this book is delivered instantly upon purchase. No special software is required as this manual works on all computers. The manual is in PDF format and delivered in PDF format.

• 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
• MAINTENANCE
  • Periodic maintenance schedule
  • Maintenance chart and intervals
  • Tune-up procedures
  • Engine oil, engine oil filter, and gear oil lubrication
  • 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
  • Fuel hose, gas leakage check procedure
  • Fuel pressure inspection fuel vapor high-pressure fuel pump
  • Fuel injector fuel tank
  • For Carburetor models: 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, gearcase, 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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