Suzuki DF 40 Manuals

Manuals and User Guides for Suzuki DF 40. We have 3 Suzuki DF 40 manuals available for free PDF download: Service Manual, Supplemental Service Manual

Suzuki DF 40 Service Manual

Suzuki DF 40 Service Manual (405 pages)

Four Stroke

Brand: Suzuki | Category: Outboard Motor | Size: 10.42 MB

Table of Contents

General Information 1

5
- Component Parts and Important Item Illustrations
  3
- Table of Contents
  5
- Warning/Caution/Note
  6
- General Precautions
  6
  - General Information
    6
- Identification Number Location
  8
- Fuel and Oil
  8
  - Gasoline Recommendation
    8
  - Engine Oil
    8
- Engine Break-In
  9
- Propellers
  10
- Specifications
  11
- Service Data
  13
  - General Information
    15
  - Starter Motor
    18
  - Self-Diagnostic System Indication
    19
- Tightening Torque
  20
- Special Tools
  22
- Materials Required
  25
Periodic Maintenance 2

26
- Periodic Maintenance Schedule
  
  27
  - Periodic Maintenance Chart
    27
- Maintenance and Tune-Up Procedures
  
  28
  - Engine Oil / Engine Oil Filter
    28
  - Engine Oil Change/Engine Oil Filterreplacement
    29
  - Gear Oil
    31
  - Lubrication
    32
  - Spark Plug
    33
  - Tappet Clearance
    34
  - Idle Speed
    40
  - Ignition Timing
    41
  - Breather and Fuel Line
    42
  - Low Pressure Fuel Filter
    42
  - High Pressure Fuel Filter
    43
  - Water Pump / Water Pump Impeller
    43
  - Propeller / Nut / Cotter Pin
    43
  - Anodes and Bonding Wires
    44
  - Battery
    45
  - Bolt and Nuts
    46
  - Fuel Mixture Check (Ofeedback)
    47
- Oil Pressure
  
  52
- Cylinder Compression
  
  54
Engine Control System

55
- Engine Control System Structure
  56
  - System Structure 1
    56
  - System Structure 2
    57
  - Wiring Diagram for Engine Control
    58
  - Engine Control System
    58
- Components for System Control
  59
  - Engine Control Module (Ecm)
    59
  - Ecm Connectors / Terminals Layout
    60
  - Ecm Internal Structure
    61
  - Sensor and Switch
    62
- Ignition System
  66
  - Ignition Control System
    66
- Electronic Fuel Injection System
  68
- Caution System
  77
  - Over-Revolution Caution System
    77
  - Low Oil Pressure Caution System
    78
  - Overheat Caution
    79
  - Electrical
    80
  - Low Battery Voltage Caution System
    80
- Self-Diagnostic System
  81
  - Priority / Code / Pattern for Self-Diagnostic System Operation
    81
  - Condition for Self-Diagnostic System Operation
    83
- Fail-Safe System
  84
  - Pre-Programmed Value for Fail-Safe System
    84
- Operating Hour Indication System
  85
- Start-In-Gear Protection System
  86
- O 2 Feedback System
  87
- Inspection
  88
- Troubleshooting
  96
  - Fuel System
    96
- Removal / Installation
  102
  - Flywheel / Ckp Sensor / Cmp Sensor
    102
  - Oil Pressure Switch
    105
Electrical

106
- Battery Charging System
  
  107
  - Outline
    107
  - Removal / Installation
    110
- Electric Starter System
  
  112
  - Outline
    112
  - Troubleshooting
    113
  - Inspection
    114
  - Starting Motor
    117
- Monitor-Tachometer
  
  123
  - Inspection
    123
Fuel System

124
- Precaution on Fuel System Service
  
  125
  - General Precaution
    125
  - Fuel Pressure Relief Procedure
    126
- Fuel Line
  
  127
  - Removal / Installation
    127
  - Fuel Leakage Check Procedure
    127
  - Fuel Hose Connection
    128
  - Fuel Pressure Inspection
    129
- Fuel Vapor Separator / High Pressure Fuel Pump
  
  131
  - Removal / Installation
    131
  - Disassembly
    132
  - Inspection
    133
  - Assembly
    135
- Fuel Injector
  
  136
  - Inspection
    136
  - Removal
    136
  - Installation
    137
- Low Pressure Fuel Pump
  
  138
  - Removal / Installation
    138
  - Disassembly / Reassembly
    139
  - Inspection
    140
- Fuel Tank
  
  141
  - Disassembly / Reassembly
    141
- Inspection
  
  142
Power Unit

143
- Intake Manifold Assembly
  
  144
  - Removal
    144
  - Installation
    145
- Power Unit
  
  146
  - Removal
    146
  - Installation
    150
- Oil Pump / Case
  
  153
  - Removal
    153
  - Disassembly
    153
  - Inspection
    154
  - Measuring Pump Components
    154
  - Assembly
    155
  - Installation
    155
- Timing Chain / Tensioner
  
  158
  - Removal
    158
  - Inspection
    160
  - Installation
    161
- Cylinder Head Assembly
  
  164
  - Removal
    164
  - Assembly
    164
  - Disassembly
    167
  - Inspection / Servicing
    168
  - Reassembly
    181
- Cylinder / Crankshaft / Piston
  
  183
  - Disassembly
    183
  - Inspection / Servicing
    186
  - Reassembly
    200
- Thermostat
  
  207
- Operation
  
  208
  - Water Cooling System
    208
  - Engine Lubrication System
    209
Power Trim and Tilt

210
- System Wiring Diagram
  
  211
- Service Procedure
  
  212
  - Oil Level
    212
  - Air Bleeding
    212
- Power Trim and Tilt Unit
  
  213
  - Removal
    213
  - Disassembly
    214
  - Cleaning and Inspecting
    216
  - Reassembly
    218
  - Ptt Motor
    220
  - Installation
    224
- Ptt Motor Relay
  
  226
- Ptt Switch
  
  227
- Operation
  
  228
  - Components
    228
  - Principles of Operation
    229
Lower Unit

234
- Removal & Disassembly
  
  235
- Pinion Bearing
  
  239
- Inspection
  
  241
  - Propeller
    241
  - Gearcase
    241
  - Gear
    242
  - Propeller Shaft Components
    242
  - Propeller Shaft Bearing Housing
    242
  - Shift Rod and Shift Cam
    243
  - Water Pump and Related Items
    243
  - Driveshaft Bearing Housing
    244
  - Driveshaft
    245
- Assembly & Installation
  
  246
- Trim Tab
  
  256
- Lower Unit Gears-Shimming and Adjustment
  
  257
  - Wiring Diagram
    263
  - Fuel / Water Hose Routing
    269
Df40150 "K5" (2005) Model .

273
- Specifications (Df50Wtidf50Wqh)
  274
- Service Data
  278
- Tightening Torque
  285
- Flywheel MAGNETO and CRANKSHAFT
  286
- Over-Revolution Caution System
  286
- Safety Relay System
  286
- Battery Charging System
  287
- Electric Starter System
  289
- Assembly
  303
- Remote Control Box & Remote Control Wire
  306
- Cylinder Head
  307
- Upper Oil Seal Housing
  307
- Upper Mount
  308
- Lower Mount
  309
- Clamp Bracket Shaft
  310
- Ptt Motor Relay
  311
- Swivel Bracket Bush
  311
- Tiller Handle Assy
  311
- Driveshaftidriveshaft Bearing Housing
  313
- Gearcase Magnet
  314
- Shift Rod Guide
  314
- Water Pump Case
  314
- Propeller Shaft Bearing
  315
- Wiring Diagram
  316
Df40/50 "K6" (2006) Model

326
- Specifications (Df40T/Df40Qh/Df50T/Df50Th)
  327
- Specifications (Df50Wt/Df50Wqh)
  329
- Service Data
  331
- Periodic Maintenance Schedule
  338
- Ecm
  339
- Fuel Filter
  339
- Iac Hose
  339
- Intake Manifold
  340
- Piston
  341
- Water Pump Case under Gasket
  341
- Wiring Diagram
  342
- Fuel Hose Routing
  345
Df40/50 "K7" (2007) Model

348
- Specifications (Df40T/Df40Qh/Df50T/Df50Th)
  349
- Specifications (Df50Wt/Df50Wqh)
  351
- Service Data
  353
- Tightening Torque
  360
- Periodic Maintenance Schedule
  361
- Ecm
  362
- Silencer
  362
- Tiller Handle (Df40Qh, Df50Qh and Df50Wqh)
  363
- Clutch Dog Shifter and Return Spring
  365
- Clutch Shaft Arm and Clutch Shaft Side Arm
  365
- Detent Spring and Shift Cam
  365
- Engine Side Cover
  366
Forward

370
- General Information
  
  372
  - Warning/Caution/Note
    372
  - General Precautions
    372
- Specifications
  
  374
  - Lower Unit
    375
- Service Data
  
  376
- Tightening Torque
  
  382
- Special Tools
  
  384
- Materials Required
  
  387
- Wiring Diagram
  
  388
- Engine Control System
  
  389
- MID Unit
  
  391
  - Tiller Handle
    391
    
    Removal
    391
    
    Disassembly
    392
    
    Assembly
    395
    
    Installation
    396
  - Tilt Aid System
    401
    
    Removal
    401
    
    Inspection
    402
    
    Installation
    403

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Suzuki DF 40 Supplemental Service Manual

Suzuki DF 40 Supplemental Service Manual (20 pages)

Brand: Suzuki | Category: Outboard Motor | Size: 0.59 MB

Table of Contents

Table of Contents
2
Specifications
3
Service Data
5
Ecm Main Relay
10
Exhaust Manifold Temperature Sensor and Cylinder Temperature Sensor
10
Cylinder Block
11
Buzzer
11
Neutral Switch Bracket
12
Under Oil Seal Housing
12
Forward Gear Thrust Washer
12
Exhaust Cam Shaft
13
Wiring Diagrams
14
Wire Routing
15

Suzuki DF 40 Service Manual

Suzuki DF 40 Service Manual (8 pages)

Brand: Suzuki | Category: Outboard Motor | Size: 0.43 MB

Table of Contents

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