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HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE
LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed on the previous page
in a GROUP INDEX. Select the section needed
for reference.
3. Holding the manual as shown at the right will al-
low you to find the first page of the section easily.
4. The first page of each section lists a table of con-
tents to easily locate the item and page you need.
COMPONENT PARTS AND IMPORTANT ITEM ILLUSTRATIONS
Under the name of each system or unit, an exploded view is provided with work instructions and other
service information such as the tightening torque, lubrication and locking agent points.
Example :
1 Flywheel bolt
2 Washer
3 Key
4 Flywheel
5 CKP sensor
6 Screw
7 Battery charge &
Power source coil
8 Bolt
190 N . m
(19.0 kg-m, 137.5 lb.-ft.)
6
5
8
7
6
1
2
3
4
5
Crankshaft
NOTE:
Clean flywheel and crankshaft mating sur-
faces with cleaning solvent.
3
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Summary of Contents for Suzuki DF25Q
- Page 1 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed on the previous page in a GROUP INDEX. Select the section needed for reference.
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Page 2: How To Use This Manual
HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed on the previous page in a GROUP INDEX. Select the section needed for reference. -
Page 3: General Information
1-16 GENERAL INFORMATION Data Item Unit DF25Q/25QE DF25QR/25T DF30Q/30QE DF30QR/30T ELECTRICAL Degrees at r/min BTDC 5° – 31° BTDC 5° – 29° Ignition timing r/min 6300 Over revolution limiter 6500 Ω 148 – 222 [R – B, W/B – R/W] CKP sensor resistance at 20°C... -
Page 4: Periodic Maintenance
PERIODIC MAINTENANCE 2-7 LUBRICATION Inspect every 50 hours (3 months). Apply Suzuki Water Resistant Grease to the following points. 99000-25160 : Water Resistant Grease Throttle/shift linkage Throttle/shift linkage (QR/T models) (Q/QE models) -
Page 5: Water Pump Impeller
2-18 PERIODIC MAINTENANCE WATER PUMP / WATER PUMP IMPELLER WATER PUMP Inspect every 200 hours (12 months). Inspect case and under panel. Replace If wear, cracks, distortion or corrosion is found. WATER PUMP IMPELLER Replace every 200 hours (12 months). Inspect water pump impeller. - Page 6 3-14 ENGINE CONTROL TESTING OIL PRESSURE CAUTION SYSTEM To check the oil pressure caution circuit, follow the procedure below. NOTE: Before checking the oil pressure caution circuit, make sure the engine oil pressure is within specification. OIL PRESSURE SWITCH 1. Remove the blue/yellow lead wire from the oil pressure switch. 2.
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Page 7: Starter Motor
ELECTRICAL 4-13 STARTER MOTOR REMOVAL Prior to removing starter motor : • Disconnect battery cables from battery. 1. Remove three bolts and flywheel cover. 2. Remove bolt 1 and negative - battery cable 2. 3. Remove starter motor sub cable 3. 4. -
Page 8: Fuel System
FUEL SYSTEM 5-13 THROTTLE CONTROL CABLE Installation and Adjustment 1. Rotate throttle control grip to bring the throttle to full close. 2. Align the match mark a on throttle cam 1 with the center of throttle lever roller 2 and hold this position. 3. -
Page 9: Recoil Starter
RECOIL STARTER 6-3 DISASSEMBLY Because of the coiled tension in the recoil spring, wear safety glasses and hand protection when winding or unwinding this component. 1. Turn the reel 1 clockwise to release the coiled tension in the recoil spring. 2. -
Page 10: Power Unit
POWER UNIT 7-11 TIMING CHAIN / TENSIONER REMOVAL Prior to this service work : • remove the power unit. (see page 7-2 to 7-6) 1 Crankshaft / timing sprocket 2 Timing chain 3 Timing chain guide 4 Timing chain tensioner 5 Timing chain tensioner adjuster 6 Camshaft and timing sprocket 1. - Page 11 POWER UNIT 7-27 Valve stem end deflection If unable to measure valve guide inside diameter, check “Valve stem end deflection”. 09900-20602 : Dial gauge 09900-20701 : Magnetic stand Measure valve stem end deflection as follows: (1) Install valve into valve guide. (2) Position valve head at approx.
- Page 12 7-38 POWER UNIT NOTE: For proper assembly, mark cylinder number on all pistons, conrods, and conrod caps, using quick drying paint. Remove all conrod cap nuts 1 and conrod caps 2. NOTE: To prevent damage to crank pin and cylinder walls, install a piece Guide hose of hose over threads of rod bolts.
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Page 13: Crankshaft Main Bearing
7-50 POWER UNIT CRANKSHAFT MAIN BEARING Upper half Lower half Check bearings for pitting, scratches, wear or damage. If any improper condition is found, replace both upper and lower halves. Always replace both bearing halves, never only one half of a bearing set. - Page 14 MID UNIT 8-21 Remove circlip B and push out tilt cylinder upper rod C. Remove nut 1 from clamp bracket shaft. Remove tilt cylinder lower shaft bolts 2. Slide STBD clamp bracket 3 off clamp bracket shaft. Remove the PTT unit assembly. (T model) Remove the gas assisted tilt cylinder.
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Page 15: Power Trim And Tilt
POWER TRIM AND TILT INSPECTION Armature and Commutator Check for continuity between the commutator and the armature core / shaft. Replace armature if continuity is indicated. 09930-99320 : Digital tester Tester range : (Continuity) Check continuity between the adjacent commutator segments. Replace armature if no continuity is indicated.
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