EasyManua.ls Logo

Suzuki DF 90 Service Manual

Suzuki DF 90
616 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
99500-90J07-01E
TK
99500-90J07-03E
Printed in Japan
K1 K2 K3 K4 K5 K6 K7 K8 K9

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Suzuki DF 90 and is the answer not in the manual?

Suzuki DF 90 Specifications

General IconGeneral
SteeringRemote
Starting SystemElectric
Number of Cylinders4
Trim MethodPower Trim and Tilt
Full Throttle Operating Range5, 500 - 6, 300 rpm
Fuel SystemMulti-point sequential electronic fuel injection
Ignition SystemFully-transistorized
ExhaustThrough Prop Hub Exhaust
Shaft Length508 mm (20 in), 635 mm (25 in)
Fuel TypeUnleaded gasoline (87 octane or higher)

Summary

FOREWORD

GENERAL INFORMATION

Introduces motor components and procedures.

SPECIFICATIONS

Lists key technical specifications for the outboard motors.

SERVICE DATA

Details essential service specifications and limits for maintenance.

TIGHTENING TORQUE

Crucial torque values for important fasteners during assembly.

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR

Guidance on navigating the manual to find specific information.

COMPONENT PARTS AND IMPORTANT ITEM ILLUSTRATIONS

Exploded views and service details for various components.

SYMBOL

SYMBOL DEFINITION

Explanation of symbols used in the manual for servicing instructions.

GENERAL INFORMATION

WARNING / CAUTION / NOTE

Highlights critical safety information and special notes.

GENERAL PRECAUTIONS

Outlines essential safety procedures for servicing.

SERVICE DATA

Key operational and maintenance specifications and tolerances.

SPECIAL TOOLS

Lists specialized tools required for specific service procedures.

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

Recommended intervals for all periodic service work.

MAINTENANCE AND TUNE-UP PROCEDURES

Step-by{' '}by{' '}step procedures for maintenance and tune-ups.

ENGINE OIL / ENGINE OIL FILTER

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

OIL PRESSURE

Procedure for testing engine oil pressure and troubleshooting.

ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM STRUCTURE

Overview of the system's input, control, and output components.

SENSOR AND SWITCH

Explains the function and operation of various engine sensors and switches.

ELECTRONIC FUEL INJECTION SYSTEM

Details the speed-density, multi-point, sequential electronic fuel injection system.

TROUBLESHOOTING

Diagnostic flowcharts for identifying and resolving system issues.

ELECTRICAL

BATTERY CHARGING SYSTEM

Overview of the circuit components and function for charging the battery.

ELECTRIC STARTER SYSTEM

Description of the starting circuit components and their electrical connections.

STARTER MOTOR

Details on starter motor removal, installation, disassembly, and inspection.

INSPECTION & SERVICING

Procedures for inspecting and servicing starter motor components.

FUEL SYSTEM

PRECAUTION ON FUEL SYSTEM SERVICE

Essential safety precautions when working on the fuel system.

FUEL PRESSURE RELIEF PROCEDURE

Steps to safely relieve fuel pressure before component removal.

FUEL VAPOR SEPARATOR / HIGH PRESSURE FUEL PUMP

Procedures for removal, disassembly, inspection, and assembly.

FUEL INJECTOR

Procedures for inspecting, removing, and installing fuel injectors.

POWER UNIT

INTAKE MANIFOLD ASSEMBLY

Procedures for removing and installing the intake manifold assembly.

CYLINDER HEAD ASSEMBLY

Procedures for removing, installing, disassembling, and inspecting the cylinder head.

CYLINDER / CRANKSHAFT / PISTON

Procedures for disassembling, inspecting, and reassembling engine core components.

VALVE / VALVE GUIDE

Specifications and procedures for inspecting valve and valve guide dimensions.

MID UNIT

DRIVESHAFT HOUSING AND OIL PAN

Procedures for removing, inspecting, and assembling the driveshaft housing and oil pan.

SWIVEL BRACKET, STEERING BRACKET AND CLAMP BRACKET

Procedures for removing, inspecting, and reassembling steering components.

INSPECTION

Inspection of bushings, oil seals, shafts, and brackets for wear or damage.

POWER TRIM AND TILT

SERVICE PROCEDURE

Procedures for checking oil level and performing air bleeding.

PTT MOTOR

Procedures for PTT motor removal, disassembly, inspection, and assembly.

PRINCIPLES OF OPERATION

Detailed explanation of the hydraulic circuits for trim/tilt operation.

LOWER UNIT

REMOVAL & DISASSEMBLY

Procedures for removing and disassembling the lower unit.

PINION BEARING

Procedures for removing and installing the pinion bearing.

INSPECTION

Inspection of propeller, gearcase, and bearings for damage.

LOWER UNIT GEARS-SHIMMING AND ADJUSTMENT

Procedures for shimming and adjusting gears for correct contact and backlash.

WIRE / HOSE ROUTING

WIRING DIAGRAM

Comprehensive electrical diagram showing all connections.

WIRE ROUTING

Diagrams illustrating the proper routing of electrical harnesses and wires.

FUEL / WATER HOSE ROUTING

Diagrams illustrating the correct routing of fuel and water hoses.

Related product manuals