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Suzuki DF 25 Service Manual

Suzuki DF 25
285 pages
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99500 89J02 01E
99500-89J02-01E
1

Table of Contents

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Suzuki DF 25 Specifications

General IconGeneral
Ignition SystemDigital CDI
Engine MountingShear Mount
Maximum Output25 hp
Starting SystemElectric
SteeringTiller
Trim MethodManual
Shaft Length381 mm / 508 mm
ExhaustThrough propeller hub

Summary

GENERAL INFORMATION

WARNINGS AND PRECAUTIONS

Important warnings, cautions, and general safety precautions for servicing the outboard motor.

FUEL AND OIL RECOMMENDATIONS

Recommended gasoline and engine oil types, classifications, and viscosity ratings.

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE AND CHART

Recommended intervals for servicing based on hours or months of operation.

ENGINE OIL AND FILTER MAINTENANCE

Procedures for checking, changing, and replacing engine oil and oil filters.

VALVE CLEARANCE ADJUSTMENT

Procedure for checking and adjusting valve clearance.

ENGINE CONTROL SYSTEM

TESTING IGNITION SYSTEM

Troubleshooting steps for ignition system issues.

ELECTRICAL SYSTEM

ELECTRIC STARTER SYSTEM TROUBLESHOOTING

Diagnostic flowchart for electric starter system issues.

STARTER MOTOR INSPECTION

Procedures for removing, inspecting, and installing the starter motor.

FUEL SYSTEM

PRECAUTIONS ON FUEL SYSTEM SERVICE

Safety precautions when servicing the fuel system.

CARBURETOR REMOVAL AND INSTALLATION

Steps for removing and installing carburetors.

RECOIL STARTER SERVICE

NEUTRAL START INTERLOCK (NSI) INSTALLATION

Procedure for installing and adjusting the neutral start interlock system.

POWER UNIT SERVICE

POWER UNIT REMOVAL PROCEDURE

Steps for safely removing the power unit from the engine.

CYLINDER HEAD ASSEMBLY SERVICE

Procedures for removing and assembling the cylinder head.

VALVE AND VALVE GUIDE SERVICE

Procedures for measuring and servicing valve and valve guide clearances.

PISTON AND PISTON RING INSPECTION

Inspection of pistons and piston rings for wear and damage.

CRANKSHAFT AND CONROD INSPECTION

Inspection of crankshaft and conrod components for wear and damage.

MID UNIT SERVICE

GAS ASSISTED TILT CYLINDER SERVICE

Procedures for removing, inspecting, and installing the gas assisted tilt cylinder.

LOWER UNIT GEARS SHIMMING AND ADJUSTMENT

Adjusting gear contact and backlash using shims.

POWER TRIM AND TILT SYSTEM

SERVICE PROCEDURES: OIL LEVEL AND AIR BLEEDING

Procedures for checking oil level and bleeding air from the PTT system.

PTT MOTOR SERVICE

Procedures for removing, disassembling, inspecting, and assembling the PTT motor.

LOWER UNIT SERVICE

REMOVAL & DISASSEMBLY

Steps for removing and disassembling the lower unit.

ASSEMBLY & INSTALLATION

Steps for assembling and installing the lower unit components.

GEAR BACKLASH AND TOOTH CONTACT ADJUSTMENT

Procedures for adjusting gear backlash and tooth contact pattern.

DF25/30 "K3" (2003) MODEL SPECIFICATIONS

FUEL AND OIL SPECIFICATIONS

Specifications for fuel type, engine oil, and gear oil.

ENGINE CONTROL AND ELECTRICAL SPECIFICATIONS

Specifications for ignition system, CDI unit, and electrical components.

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