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Suzuki DF15 Service Manual

Suzuki DF15
320 pages
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99500-94J01-01E
Printed in Japan
TK
K5, K6, K7, K8
For 2005 model
99500-94J01-01E

Table of Contents

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Suzuki DF15 Specifications

General IconGeneral
Ignition SystemDigital CDI
Number of Cylinders2
Fuel Delivery SystemElectronic Fuel Injection
Maximum Output11.0 kW (15 PS)
Starting SystemElectric or Manual
Oil Capacity1.0 L
Fuel Tank Capacity12 L
Full Throttle Operating Range5000 - 6000 rpm
Alternator12V 6A (Optional)
Trim MethodManual Trim and Tilt
Engine Type4-Stroke SOHC
Weight44 kg
Fuel SystemElectronic Fuel Injection

Summary

General Information

Safety Warnings and Precautions

Covers all warnings, cautions, and general safety guidelines for servicing.

Specifications and Service Data

Contains detailed technical specifications and service limits for engine components.

Tightening Torques

Lists critical torque values for important fasteners during assembly.

Special Tools and Materials Required

Identifies necessary special tools and materials for servicing.

Periodic Maintenance

Maintenance Schedule and Chart

Outlines recommended service intervals and tasks for regular upkeep.

Tune-Up Procedures

Details procedures for engine oil, filters, spark plugs, valves, and carburetor.

Specific Maintenance Checks

Covers spark plug, valve clearance, and timing belt inspection and replacement.

Ignition and Electrical System

Ignition System Operation and Timing Control

Explains the CDI system principles and ignition timing adjustment.

Ignition System Troubleshooting and Inspection

Guides on diagnosing and testing ignition components like coils and CDI unit.

Battery Charging and Starter Motor Systems

Covers the outline, inspection, and troubleshooting of charging and starting circuits.

Caution Systems Overview

Details the over-revolution and low oil pressure warning systems.

Fuel System

Fuel System Safety Precautions

Emphasizes critical safety measures when working with fuel systems.

Fuel Line and Hose Routing

Provides guidelines for proper fuel hose installation and connection.

Carburetor Service and Operation

Covers carburetor removal, disassembly, cleaning, reassembly, and function.

Fuel Pump and Fuel Tank Maintenance

Details procedures for fuel pump service and fuel tank inspection.

Recoil Starter System

Recoil Starter Removal and Disassembly

Step-by-step instructions for removing and taking apart the recoil starter.

Recoil Starter Inspection and Reassembly

Covers inspection of components and the process of reassembling the starter.

Neutral Start Interlock (NSI) System Installation

Details the installation and adjustment of the safety interlock system.

Power Unit Components

Power Unit Removal and Installation Procedures

Outlines the process for removing and reinstalling the main power unit.

Cylinder Head and Camshaft Service

Covers cylinder head assembly, camshaft inspection, and related service.

Crankshaft, Piston, and Connecting Rod Service

Details disassembly, inspection, and service for engine internals.

Valve Train Service and Specifications

Provides service limits and procedures for valves, guides, and springs.

Engine Lubrication and Cooling Systems

Explains the engine oil lubrication chart and cooling system operation.

Mid Unit Components

Engine Side Cover and Tiller Handle Service

Covers removal and installation of side covers and tiller handle assembly.

Driveshaft Housing and Oil Pan Service

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

Steering and Bracket Assembly Service

Explains the service procedures for swivel, steering, and clamp brackets.

Lower Unit Components

Lower Unit Removal and Disassembly Procedures

Step-by-step guide for removing and disassembling the lower unit.

Water Pump and Gearcase Service

Covers inspection and service for water pump and gearcase components.

Gear Shimming and Backlash Adjustment

Details procedures for adjusting gear contact and backlash.

Propeller Shaft Thrust Play Check

Explains how to measure and adjust propeller shaft thrust play.

Wire and Hose Routing

Wiring Diagrams for Different Models

Provides detailed wiring diagrams for various DF models.

Wire Routing Illustrations

Shows correct routing for electrical wiring harnesses and components.

Fuel and Water Hose Routing Guidelines

Illustrates proper routing for fuel and water hoses, including precautions.

DF9.9/15 "K6" (2006) Model Specifics

2006 Model Specifications Overview

Lists key specifications specific to the 2006 model.

2006 Model Service Data Details

Provides service data points relevant to the 2006 model.

Peak Voltage Testing Procedures

Describes how to perform peak voltage tests on ignition system components.

DF9.9/15 "K7" (2007) Model Specifics

2007 Model Specifications Overview

Lists key specifications specific to the 2007 model.

2007 Model Service Data Details

Provides service data points relevant to the 2007 model.

Model Year Changes and Updates

Highlights changes in cylinder head, starter, timing belt, clutch, and pump for the 2007 model.

DF9.9T/TH "K8" (2008) Model Specifics

2008 Model Specifications Overview

Lists key specifications specific to the 2008 model.

2008 Model Service Data Details

Provides service data points relevant to the 2008 model.

Power Tilt System Operation and Wiring

Explains the power tilt system's function and provides wiring diagrams.

PT Motor Disassembly and Inspection

Details the procedures for disassembling and inspecting the PT motor.

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