Suzuki DF 90 - Df140 K2 (02) Model; Specifications _________________________________________ 1

DF140 “K2” (’02) MODEL 11-1
CONTENTS
GENERAL INFORMATION ______________________________________ 11-2
SPECIFICATIONS _________________________________________ 11-2
SERVICE DATA ___________________________________________ 11-4
TIGHTENING TORQUE _____________________________________ 11-11
SPECIAL TOOLS __________________________________________ 11-13
MATERIALS REQUIRED ___________________________________ 11-16
ENGINE CONTROL SYSTEM ____________________________________ 11-17
POWER UNIT _________________________________________________ 11-18
ENGINE OIL COOLER _____________________________________ 11-18
CAMSHAFT ______________________________________________ 11-20
CYLINDER BLOCK ________________________________________ 11-21
PISTON & PISTON RING ___________________________________ 11-21
CRANKSHAFT ___________________________________________ 11-22
CONROD ASSEMBLY ______________________________________ 11-22
MID UNIT ____________________________________________________ 11-23
POWER TRIM AND TILT ________________________________________ 11-25
SERVICE PROCEDURE ____________________________________ 11-25
OIL LEVEL / AIR BLEEDING ________________________________ 11-25
POWER TRIM AND TILT UNIT _______________________________ 11-26
REMOVAL _______________________________________________ 11-26
DISASSEMBLY ___________________________________________ 11-27
CLEANING AND INSPECTING ______________________________ 11-30
REASSEMBLY ____________________________________________ 11-31
PTT MOTOR _____________________________________________ 11-33
INSTALLATION ___________________________________________ 11-37
COMPONENT PARTS ______________________________________ 11-39
OPERATION _____________________________________________ 11-39
LOWER UNIT (Normal rotation model) ____________________________ 11-46
REMOVAL AND INSTALLATION _____________________________ 11-46
DISASSEMBLY ___________________________________________ 11-46
ASSEMBLY ______________________________________________ 11-51
LOWER UNIT GEARS-SHIMMING AND ADJUSTMENT __________ 11-61
COUNTER ROTATION LOWER UNIT (DF140Z) ______________________ 11-66
REMOVAL AND INSTALLATION _____________________________ 11-67
DISASSEMBLY ___________________________________________ 11-67
INSPECTION _____________________________________________ 11-72
ASSEMBLY ______________________________________________ 11-76
LOWER UNIT GEARS-SHIMMING AND ADJUSTMENT
(Counter rotation model) ___________________________________ 11-86
WIRING DIAGRAM _____________________________________________ 11-92
HOSE ROUTING ______________________________________________ 11-93
DF140 “K2” (’02) MODEL
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