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Suzuki DF 60 Service Manual

Suzuki DF 60
283 pages
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99500-99E10-01E
For ’03 model –

Table of Contents

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Suzuki DF 60 Specifications

General IconGeneral
Cylinders3
SteeringRemote
Starting SystemElectric
Max Power Output60 hp
Trim MethodPower Trim and Tilt
Engine Type4-stroke
Displacement941 cc
Fuel Delivery SystemSequential Multi Point Fuel Injection
Maximum Output60 HP
Full Throttle Operating Range5, 300 - 6, 300 rpm
Recommended FuelUnleaded gasoline
ExhaustThrough propeller hub
Cooling SystemWater-cooled
Warranty3-year limited warranty

Summary

Foreword

How to Use This Manual

Component Parts and Important Item Illustrations

Explains how components and important items are illustrated with details.

Symbol

General Information

Warning, Caution, and Note

Explains the meaning and importance of warning, caution, and note signals.

General Precautions

Provides essential safety guidelines and precautions for servicing the outboard motor.

Fuel and Oil

Covers recommendations for gasoline and engine oil specifications for the motor.

Specifications

Lists detailed technical specifications for the outboard motor models.

Service Data

Provides essential service data and measurement limits for various engine components.

Tightening Torque

Specifies torque values for important fasteners required during assembly and service.

Special Tools

Lists specialized tools required for performing specific maintenance and repair tasks.

Periodic Maintenance

Periodic Maintenance Schedule

Details the recommended intervals for periodic service work based on hours or months.

Periodic Maintenance Chart

A table outlining service items and intervals for inspection, tightening, or replacement.

Engine Oil / Engine Oil Filter

Covers procedures for checking, changing, and replacing engine oil and filter.

Gear Oil

Outlines the procedure for changing and filling the gear oil in the lower unit.

Valve Clearance

Explains how to check and adjust valve clearance for proper engine operation.

Cylinder Compression

Explains the procedure for measuring cylinder compression and interpreting results.

Engine Control System

Engine Control System Structure

Describes the overall structure and components of the engine control system.

Wiring Diagram for Engine Control

A comprehensive wiring diagram showing all connections within the engine control system.

Ignition System

Describes the transistorized electronic ignition system.

Electronic Fuel Injection System

Covers the electronic fuel injection system, its components, and control.

Caution System

Details the four caution systems that alert the operator to engine abnormalities.

Self-Diagnostic System

Alerts the operator to abnormalities via lamp flashing and buzzer sounds.

Troubleshooting

Provides a guide to troubleshooting engine control system issues based on diagnostic codes.

Electrical

Battery Charging System

Explains the operation and components of the battery charging system.

Electric Starter System

Details the electric starter system circuit and its components.

Starter Motor

Covers inspection, disassembly, and reassembly of the starter motor.

Monitor-Tachometer

Explains the inspection of the monitor-tachometer and its lamps.

Fuel System

Precaution on Fuel System Service

Covers general precautions for servicing the fuel system, emphasizing safety.

Fuel Line

Details procedures for removing, installing, and checking fuel lines for leakage.

Fuel Vapor Separator / High Pressure Fuel Pump

Covers removal, installation, disassembly, inspection, and reassembly of the fuel vapor separator and high-pressure pump.

Fuel Injector / Delivery Pipe

Details removal, inspection, and installation procedures for fuel injectors and delivery pipes.

Low Pressure Fuel Pump

Covers removal, installation, disassembly, inspection, and reassembly of the low-pressure fuel pump.

Fuel Pressure Inspection

Details the procedure for inspecting fuel pressure using special tools.

Power Unit

Intake Manifold Assy

Covers removal and installation of the intake manifold assembly.

Power Unit

Details the removal and installation of the entire power unit.

Cylinder Head Assy

Covers removal, installation, disassembly, inspection, and reassembly of the cylinder head assembly.

Cylinder / Crankshaft / Piston

Details disassembly, inspection, and reassembly of cylinder, crankshaft, and piston components.

Valve / Valve Guide

Details measuring clearance between valve guide and stem, and stem end deflection.

Valve Guide Replacement

Provides steps for replacing valve guides, with precautions.

Tightening Torque

Specifies torque values for cylinder head bolts and other fasteners.

Special Tools

Lists specialized tools for camshaft measurement.

Mid Unit

Engine Side Cover

Covers removal and installation of the engine side cover.

Tiller Handle

Details removal, disassembly, reassembly, and installation of the tiller handle.

Driveshaft Housing and Oil Pan

Covers removal, inspection, and reassembly of the driveshaft housing and oil pan.

Swivel Bracket, Steering Bracket and Clamp Bracket

Details removal, disassembly, inspection, and reassembly of these bracket components.

Lubrication

Details applying water-resistant grease through grease nipples after reassembly.

Power Trim and Tilt

System Wiring Diagram

Provides the system wiring diagram for the power trim and tilt.

Service Procedure

Covers checking oil level and performing air bleeding for the PTT system.

Power Trim and Tilt Unit

Step-by-step instructions for removing the power trim and tilt unit.

PTT Motor

Covers removal, disassembly, inspection, reassembly, and installation of the PTT motor.

Principles of Operation

Explains the operating principles of the trim/tilt UP and DOWN circuits.

Lower Unit

Removal & Disassembly

Step-by-step instructions for removing and disassembling the lower unit, including gearcase separation.

Pinion Bearing

Details removal and installation of the pinion bearing.

Inspection

General note on replacing components with wear or damage, and washing metal parts.

Assembly & Installation

Provides an exploded view and parts list for lower unit assembly.

Gear Oil

Instructs on filling gearcase with specified gear oil.

Trim Tab Adjustment

Details adjusting the trim tab to counteract steering pull.

Pinion Gear Back-up Shim Adjustment

Details adjusting the pinion gear back-up shim for proper clearance.

Checking Driveshaft Thrust Play

Measures driveshaft thrust play after obtaining optimum tooth contact.

Checking Propeller Shaft Thrust Play

Measures propeller shaft thrust play and requires shim adjustment.

Leakage Check

Details checking for oil leakage by applying air pressure.

Routing and Diagram

Wire Routing

Illustrates routing for various wire harnesses and cables, with notes on ground points.

Fuel Hose Routing

Illustrates the correct routing for fuel hoses, with precautions.

Wiring Diagram

Presents the complete wiring diagram for the outboard motor, including wire colors.

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