Suzuki DF 60 Manuals

Manuals and User Guides for Suzuki DF 60. We have 1 Suzuki DF 60 manual available for free PDF download: Service Manual

Suzuki DF 60 Service Manual

Suzuki DF 60 Service Manual (283 pages)

For ’03 model

Brand: Suzuki | Category: Outboard Motor | Size: 15.74 MB

Table of Contents

Foreword Group Index

2
- Table of Contents
  2
- General Information
  6
- General Precautions
  6
- Warning / Caution / Note
  6
- Fuel and Oil
  8
  - Gasoline Recommendation
    8
  - Engine Oil
    8
- Identification Number Location
  8
- Engine Break-In
  9
  - Warm-Up Recommendation
    9
  - Throttle Recommendation
    9
- Propellers
  10
- Specifications
  11
- Service Data
  13
- Self-Diagnostic System Indication
  18
- Tightening Torque
  19
- Special Tools
  21
- Materials Required
  24
Periodic Maintenance 2

25
- Periodic Maintenance Schedule
  
  26
  - Periodic Maintenance Chart
    26
- Maintenance and Tune-Up Procedures
  
  27
  - Engine Oil/Engine Oil Filter
    27
  - Gear Oil
    30
  - Lubrication
    31
  - Spark Plug
    32
  - Valve Clearance
    33
  - Timing Belt
    35
  - Idle Speed
    38
  - Ignition Timing
    39
  - Breather and Fuel Line
    40
  - Low Pressure Fuel Filter
    40
  - High Pressure Fuel Filter
    40
  - Water Pump Impeller / Water Pump
    41
  - Propeller Nut and Pin/Propeller
    41
  - Anodes and Bonding Wires
    42
  - Battery
    43
  - Bolts and Nuts
    44
  - Fuel Mixture Check (Ofeedback)
    45
- Oil Pressure
  
  47
- Cylinder Compression
  
  48
Engine Control System

49
- Engine Control System Structure
  50
  - System Structure 1
    50
  - System Structure 2
    51
  - Wiring Diagram for Engine Control
    52
- Components for System Control
  53
  - Engine Control Module (Ecm)
    53
  - Sensor and Switch
    56
- Ignition System
  60
  - Ignition Control System
    60
- Electronic Fuel Injection System
  62
  - Fuel Injection Control System
    62
  - Fuel Delivery System Components
    64
  - Fuel Pump Control System
    67
  - Air Intake Components
    68
  - Idle Air Control System
    69
- Caution System
  71
- Electrical
  74
- Fuel System
  93
  - Removal/Installation
    99
    
    Flywheel/Ckp Sensor/Cmp Sensor
    99
    
    Oil Pressure Switch
    101
Electrical

102
- Battery Charging System
  
  103
  - Outline
    103
  - Inspection
    104
  - Removal/Installation
    105
- Electric Starter System
  
  107
  - Outline
    107
  - Troubleshooting
    108
  - Inspection
    109
  - Starter Motor
    111
- Electric Parts Holder
  
  118
- Monitor-Tachometer
  
  119
Fuel System

120
- Precaution on Fuel System Service
  
  121
  - General Precaution
    121
  - Fuel Pressure Relief Procedure
    121
- Fuel Line
  
  122
  - Removal/Installation
    122
  - Fuel Leakage Check Procedure
    122
  - Fuel Hose Connection
    123
  - Fuel Pressure Inspection
    123
- Fuel Vapor Separator / High Pressure Fuel Pump
  
  125
  - Removal / Installation
    125
  - Disassembly
    126
  - Inspection
    127
  - Reassembly
    128
- Fuel Injector / Delivery Pipe
  
  130
  - Removal
    130
  - Inspection
    130
  - Installation
    131
- Low Pressure Fuel Pump
  
  132
  - Removal / Installation
    132
  - Disassembly / Reassembly
    133
  - Inspection
    134
- Fuel Tank
  
  135
  - Disassembly / Reassembly
    135
  - Inspection
    136
Power Unit

137
- Intake Manifold Assy
  138
  - Removal
    138
  - Installation
    141
- Power Unit
  142
  - Removal
    142
  - Installation
    146
- Cylinder Head Assy
  150
  - Removal
    150
  - Installation
    150
  - Disassembly
    151
  - Inspection / Servicing
    153
  - Reassembly
    162
- Cylinder / Crankshaft / Piston
  164
  - Disassembly
    164
  - Inspection / Servicing
    168
  - Reassembly
    181
- Operation
  187
  - Water Cooling System
    187
  - Engine Lubrication System
    188
MID Unit

189
- Engine Side Cover
  190
  - Removal
    190
  - Installation
    191
- Tiller Handle
  192
  - Removal / Disassembly
    192
- Driveshaft Housing and Oil Pan
  200
  - Removal
    200
  - Inspection
    203
  - Reassembly
    204
- Swivel Bracket, Steering Bracket and Clamp Bracket
  210
  - Removal / Disassembly
    210
  - Inspection
    212
  - Reassembly
    213
Power Trim and Tilt

217
- System Wiring Diagram
  218
- Service Procedure
  219
  - Oil Level
    219
  - Air Bleeding
    219
- Power Trim and Tilt Unit
  220
  - Removal
    220
  - Disassembly
    221
  - Inspection
    223
  - Reassembly
    225
  - Ptt Motor
    226
    
    Ptt Motor Removal
    226
    
    Ptt Motor Disassembly
    227
    
    Ptt Motor Inspection
    228
    
    Ptt Motor Reassembly
    229
    
    Ptt Motor Installation
    230
  - Installation
    231
- Ptt Motor Relay
  233
- Ptt Switch
  234
- Operation
  235
  - Components
    235
  - Principles of Operation
    236
- Lower Unit
  238
Lower Unit

241
- Removal & Disassembly
  242
  - Pinion Bearing
    247
- Pinion Bearing ________________________________________ 9- 7
  249
  - Inspection
    249
    
    Propeller
    249
    
    Gearcase
    249
    
    Gears
    250
    
    Propeller Shaft Components
    250
    
    Propeller Shaft Bearing Housing
    250
    
    Shift Rod Guide Housing Components
    251
    
    Water Pump and Related Items
    251
    
    Driveshaft Oil Seal Housing
    252
    
    Driveshaft
    252
  - Assembly & Installation
    253
  - Lower Unit Gears- Shimming and Adjustment
    263
  - Routing and Diagram
    268
    
    Wire Routing
    269
    
    Fuel Hose Routing
    275
    
    Water Hose Routing
    278
    
    Wiring Diagram
    280

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