Suzuki DF2.5 Service Manual
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Suzuki DF2.5 Service Manual

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  • Page 145 OUTBOARD MOTOR For 2008 model SUPPLEMENTARY SERVICE MANUAL 9 9 5 0 1 - 9 7 J 0 0 - 0 1 E...
  • Page 146 Please read and thoroughly familiarize yourself with this information before using it for your ser- vice activities. NOTE: • Use this supplement with the following service manual: DF2.5 Service Manual (P/no, 99500-97J0 • -01E) • This Supplementary Service Manual describes the modification for 2008 Model. CONTENTS GENERAL INFORMATION ..............2 SPECIFICATIONS................

  • Page 147: General Information

    2 DF2.5 “K8” (’08) MODEL GENERAL INFORMATION * SPECIFICATIONS * These specifications are subject to change without notice. Data Item Unit DF2.5 PRE-FIX 00251F DIMENSIONS & WEIGHT Overall length mm (in) 437 (17.2): with tiller handle raised (front to back)
  • Page 148 NMMA FC-W classification : SE, SF, SG, SH, SJ • Viscosity rating : SAE 10W-40 or NMMA FC-W 10W-40 Engine oil amounts 0.38 (0.40/0.33) (US/lmp. qt) Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil amounts 60 (2.0/2.1) (US/lmp. oz) BRACKET Trim angle Degrees 6 –...

  • Page 149: Service Data

    4 DF2.5 “K8” (’08) MODEL * SERVICE DATA * These service data are subject to change without notice. Data Item Unit DF2.5 POWER HEAD Recommended operating r/min 5 250 – 5 750 range Idle speed r/min 1 900 ± 100 (in-gear: approx. 1 500) * Cylinder compression 960 –...
  • Page 150 DF2.5 “K8” (’08) MODEL 5 Data Item Unit DF2.5 VALVE/VALVE GUIDE Valve diameter mm (in) 20.0 (0.79) mm (in) 18.0 (0.71) Valve mm (in) 0.13 – 0.17 (0.005 – 0.007) clearance (Cold engine EX STD mm (in) 0.13 – 0.17 (0.005 – 0.007)
  • Page 151 6 DF2.5 “K8” (’08) MODEL Data Item Unit DF2.5 CYLINDER/PISTON/PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) Piston to cylinder mm (in) 0.018 – 0.033 (0.0007 – 0.0013) clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 48.000 – 48.015 (1.8898 – 1.8904)
  • Page 152 DF2.5 “K8” (’08) MODEL 7 Data Item Unit DF2.5 CRANKSHAFT/CONROD Conrod small end mm (in) 12.006 – 12.014 (0.4727 – 0.4730) inside diameter Limit mm (in) 12.040 (0.4740) Conrod big end mm (in) 0.015 – 0.035 (0.0006 – 0.0014) oil clearance...

  • Page 153: Tightening Torque

    8 DF2.5 “K8” (’08) MODEL TIGHTENING TORQUE Tightening torque – Important fasteners THREAD TIGHTENING TORQUE ITEM DIAMETER N·m kg-m lb-ft Cylinder head cover bolt 5 mm Cylinder head bolt 6 mm Crankcase bolt 6 mm Conrod cap bolt 5 mm...

  • Page 154: Engine Serial Number

    DF2.5 “K8” (’08) MODEL 9 ENGINE SERIAL NUMBER The engine serial number starts from the following six-figure number located after the model pre-fix. 880001 MODEL PRE-FIX Serial number MID UNIT SWIVEL BRACKET ’08 model parts The swivel bracket assembly has been changed from right-left division type to front-rear division type.
  • Page 155 10 DF2.5 “K8” (’08) MODEL ’08 model Consisting parts 8 N . m 0.8 kg-m 6.0 lb-ft 10 N . m 1.0 kg-m 7.0 lb-ft 10 N . m 1.0 kg-m 7.0 lb-ft 2 N . m 0.2 kg-m 1.5 lb-ft 8 N .

  • Page 156: Lower Unit

    DF2.5 “K8” (’08) MODEL 11 LOWER UNIT WATER PUMP IMPELLER INSTALLATION Before installing the impeller, apply Water Resistant grease to the inner surface of impeller. So that the impeller will not stick to the driveshaft. 99000-25160: SUZUKI WATER RESISTANT GREASE...
  • Page 157 Prepared by Service Department July, 2007 Manual No.99501-97J00-01E Printed in Japan...
  • Page 158 Printed in Japan...
  • Page 182 Applicable model and effective serial number: 00252F-410001 and later Use this supplement with the following service manuals: DF2.5 Service Manual (P/no., 99500-97J01-01E) DF2.5 Supplementary Service Manual (P/no., 99501-97J20-01E) 9 9 5 0 1 - 9 7 J 3 0 - 0 1 E...
  • Page 183 DF2.5 (Serial No. 410001 and later) 1 DF2.5 (Serial No. 410001 and later) FOREWORD This supplementary service manual describes the outline, technical data and servicing proce- dures for the following models. Please read and thoroughly familiarize yourself with this information before using it for your ser- vice activities.

  • Page 184: General Information

    2 DF2.5 (Serial No. 410001 and later) GENERAL INFORMATION * SPECIFICATIONS * These specifications are subject to change without notice. Data Item Unit DF2.5 PRE-FIX 00252F DIMENSIONS & WEIGHT Overall length mm (in) 437 (17.2): with tiller handle raised (front to back)
  • Page 185 DF2.5 (Serial No. 410001 and later) 3 Data Item Unit DF2.5 (P03) DF2.5 (P01) FUEL & OIL Fuel Suzuki highly recommends the use alcohol-free unleaded gas- oline with a minimum pump octane rating of 87 (R/2 + M/2 method) or 91 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane content may be used.

  • Page 186: Service Data

    4 DF2.5 (Serial No. 410001 and later) * SERVICE DATA * These service data are subject to change without notice. Data Item Unit DF2.5 POWER HEAD Recommended operating r/min 5 250 – 5 750 range Idle speed r/min 1 900 ± 100 (in-gear: approx. 1 500) * Cylinder compression 960 –...
  • Page 187 DF2.5 (Serial No. 410001 and later) 5 Data Item Unit DF2.5 CYLINDER HEAD/CAMSHAFT Cylinder head Limit mm (in) 0.05 (0.002) distortion mm (in) 28.480 – 28.680 (1.1213 – 1.1291) height Limit mm (in) 28.180 (1.1094) Rocker arm shaft mm (in) 4.015 –...
  • Page 188 6 DF2.5 (Serial No. 410001 and later) Data Item Unit DF2.5 VALVE/VALVE GUIDE Valve diameter mm (in) 20.0 (0.79) mm (in) 18.0 (0.71) Valve mm (in) 0.13 – 0.17 (0.005 – 0.007) clearance (Cold engine EX STD mm (in) 0.13 – 0.17 (0.005 – 0.007)
  • Page 189 DF2.5 (Serial No. 410001 and later) 7 Data Item Unit DF2.5 CYLINDER/PISTON/PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) Piston to cylinder mm (in) 0.018 – 0.033 (0.0007 – 0.0013) clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 48.000 –...
  • Page 190 8 DF2.5 (Serial No. 410001 and later) Data Item Unit DF2.5 CRANKSHAFT/CONROD Conrod small end mm (in) 12.006 – 12.014 (0.4727 – 0.4730) inside diameter Limit mm (in) 12.040 (0.4740) Conrod big end mm (in) 0.020 – 0.040 (0.0008 – 0.0016)
  • Page 191 DF2.5 (Serial No. 410001 and later) 9 Data Item Unit DF2.5 LOWER UNIT Preliminary gear shim & thrust washer Pinion gear backup shim mm (in) 2.0 (0.08) Forward gear backup mm (in) 0.5 (0.02) shim Propeller shaft reverse mm (in) 1.8 (0.07)

  • Page 192: Periodic Maintenance

    10 DF2.5 (Serial No. 410001 and later) PERIODIC MAINTENANCE • The interval of maintenance schedule has been changed as follows. “Every 50 hrs or 3 months” has not been adopted any longer. “Every 100 hrs or 6 months” has been changed to “Every 100 hrs or 12 months”.

  • Page 193: Maintenance And Tune-Up Procedures

    DF2.5 (Serial No. 410001 and later) 11 MAINTENANCE AND TUNE-UP PROCEDURES IGNITION TIMING OUTLINE Ignition timing has been changed. Inspect every 200 hours (12 months). NOTE: Before checking the ignition timing, make sure that the idle speed is adjusted within the specification.

  • Page 194: Thermostat

    For all markets except for US market See the DF2.5 Service Manual, page 6-38. For US market 1. Remove the recoil starter assembly. (See the DF2.5 Service Manual, page 5-2.) 2. Remove the two bolts 1 securing fuel pump 2.
  • Page 195 DF2.5 (Serial No. 410001 and later) 13 INSPECTION For all markets If salt deposits, corrosion, wear or other damage is found, clean or replace the thermostat. Thermostat operation Check the thermostat operating temperature as follows. 1. Insert a length of thread between the thermostat valve/body and suspend the thermostat in a container filled with water.
  • Page 196 14 DF2.5 (Serial No. 410001 and later) 3. Install the gasket 2 and the thermostat cover 3 to the cylin- der block and secure with the two bolts 4. 4. Install the two nuts 6 to the fuel pump bracket 5.

  • Page 197: Ignition And Electrical

    DF2.5 (Serial No. 410001 and later) 15 IGNITION AND ELECTRICAL OUTLINE For all markets except for US market The advance angle range of ignition timing has been changed as follows. Ignition timing: BTDC 10° at 2000 r/min – BTDC 31° at 4000 r/min In accordance with this change, the igniter unit has been changed.

  • Page 198: Carburetor (For All Markets Except For Us Market)

    16 DF2.5 (Serial No. 410001 and later) CARBURETOR (For all markets except for US market) OUTLINE The carburetor setting has been changed. Type Walbro LMJ-57 I.D mark LMJ-57 Main jet 62 (no change) Main air jet Pilot jet Pilot air jet...

  • Page 199: Fuel Tank And Fuel Cock (For All Markets Except For Us Market)

    DF2.5 (Serial No. 410001 and later) 17 FUEL TANK AND FUEL COCK (For all markets except for US market) OUTLINE The related parts for fuel tank installation have been changed as follows. • The fuel tank has been changed in shape.
  • Page 200 18 DF2.5 (Serial No. 410001 and later) REMOVAL 1. Remove the motor cover. 2. Remove the recoil starter assembly 1. (See the DF2.5 Ser- vice Manual, page 5-2.) 3. Turn the fuel cock lever 2 “OFF” position and tighten the air vent screw on the fuel filler cap.
  • Page 201 DF2.5 (Serial No. 410001 and later) 19 6. Loosen the screw 6. Remove the fuel cock 4 from the fuel tank 5. 7. Drain all fuel from the tank. INSPECTION Fuel cock Check the filter. If clogged or damaged is found, clean the filter or replace the fuel cock assy.
  • Page 202 • Place the fuel tank bracket 1 in position. • Install the fuel tank 2 and the recoil starter 3. • Check the fuel hose routing. (See the DF2.5 Service Manual, page 9-2.) • Check for fuel leakage. (See the DF2.5 Service Manual, page...
  • Page 203 Prepared by Outboard Motor Engineering Department June, 2013 Manual No.99501-97J30-01E Printed in Japan...
  • Page 204 Printed in Japan...

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