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DF20A
User Manuals: Suzuki DF20A Outboard Motor
Manuals and User Guides for Suzuki DF20A Outboard Motor. We have
3
Suzuki DF20A Outboard Motor manuals available for free PDF download: Service Manual, Owner's Manual
Suzuki DF20A Service Manual (261 pages)
Brand:
Suzuki
| Category:
Outboard Motor
| Size: 19 MB
Table of Contents
Table of Contents
2
Lower Unit
2
Precautions
3
General Precautions
3
Precaution for Lower Unit
3
Precautions
5
Precaution for MID Unit
5
Wire / Hose Routing
9
Electrical Component Location
10
Housing and Bracket
11
Precautions
11
Precaution for Housing and Bracket
11
Service Instructions
11
Lower Side Cover Components
11
Lower Side Cover Removal and Installation
12
Tightening Torque
12
Tiller Handle and Handle Bracket Removal and Installation
12
Throttle Control Cable Installation and Adjustment
15
Steering Friction Adjuster Disassembly and Assembly
15
Tiller Handle Components
19
Tiller Handle Disassembly and Assembly
20
Engine Holder / Driveshaft Housing / Mounts Components
22
Engine Holder / Driveshaft Housing / Mounts Disassembly
24
Engine Holder / Driveshaft Housing / Mounts Assembly
25
Engine Holder / Driveshaft Housing / Mounts Related Component Inspection
28
Driveshaft Upper Oil Seal Replacement
29
Clamp / Swivel / Steering Brackets Components
30
Clamp / Swivel / Steering Brackets Disassembly
32
Clamp / Swivel / Steering Brackets Assembly
34
Clamp / Swivel / Steering Brackets Related Components Inspection
37
Important Notice
39
Precautions
40
Precautions for Powerhead
40
Right Hand Rotation Unit
41
Diagnostic Information and Procedures
41
Diagnose Lower Unit Malfunction
41
Service Instructions
42
Lower Unit Components
42
Propeller Removal and Installation
44
Propeller / Nut / Cotter Pin Inspection
44
Lower Unit Removal and Installation
45
Water Pump Removal and Installation
46
Water Pump and Related Items Inspection
48
Lower Unit Disassembly
48
Pinion Bearing Removal and Installation
51
Lower Unit Related Items Inspection
52
Propeller Shaft Oil Seal Replacement
55
Driveshaft Oil Seal Replacement
56
Lower Unit Assembly
56
Lower Unit Gears - Shimming and Adjustment
61
Initial Checking
62
Wire Routing
67
Wiring Diagram
67
Schematic and Routing Diagram
67
Wiring Harness Routing Diagram
69
Engine Control
77
Precautions
77
Precautions on Engine Control Diagnosis
77
General Description
78
Engine Control System Description
78
Engine Control Module (ECM)
81
Caution System Description
85
Self-Diagnostic System Description
87
Fail-Safe System Description
89
Oil Change Reminder System Description
90
Component Location
91
Engine Control System Components / Engine Electrical Device Location
91
Diagnostic Information and Procedures
91
Troubleshooting with Self-Diagnostic Code
91
Self-Diagnostic Code "3 - 4" MAP Sensor
91
Self-Diagnostic Code "1 - 4" Cylinder Temp
92
Troubleshooting
92
Self-Diagnostic Code "2 - 3" IAT Sensor
93
Self-Diagnostic Code "4 - 2" CKP Sensor
94
Self-Diagnostic Code "2 - 4" CMP Sensor
95
Self-Diagnostic Code "2 - 2" Air Intake System
96
Self-Diagnostic Code "3 - 2" MAP Sensor 2
97
Self-Diagnostic Code "4 - 3" Fuel Injector
98
Self-Diagnostic Code "2 - 1" TPS
99
Self-Diagnostic Code "1 - 1" Rectifier
99
Regulator (over Charging)
99
Self-Diagnostic Code "5 - 3" Oil Pressure Switch
100
Troubleshooting Without Self-Diagnostic Code
100
IAC System Troubleshooting
101
Service Instructions
102
How to Use the 26 Pin Test Cord
102
Inspection of the ECM and Its Circuit
103
ECM Removal and Installation
106
Caution Lamp Inspection
106
Precautions for Fuel / Water Hose Routing
108
Fuel Hose Routing
109
Water Hose Routing
112
Engine Electrical Devices
114
Precautions
114
Precaution for Engine Electrical Device
114
General Description
114
Sensor and Switch Description
114
Neutral Switch
116
Failure Symptoms
116
ECM Power Source
117
Component Location
118
Location of Sensor and Switch
118
Service Instructions
118
Resistance Check
118
ECM Power Source Coil Removal and Installation
119
ECM Power Source Coil Peak Voltage
119
Inspection
119
CKP Sensor Peak Voltage Inspection
119
CKP Sensor Removal and Installation
119
Cylinder Temp. Sensor Removal and Installation
120
Cylinder Temp. Sensor Inspection
121
IAT Sensor Removal and Installation
121
IAT Sensor Inspection
121
CMP Sensor Removal and Installation
122
CMP Sensor Inspection
122
MAP Sensor Removal and Installation
123
MAP Sensor Output Voltage Inspection
124
IAC Valve Removal and Installation
125
IAC Valve Inspection
125
TPS Inspection
125
Emergency and Engine Stop Switch Inspection
126
Cylinder Head Cover Removal and Installation
129
Power Unit Mechanical
129
General Description
129
Power Unit Construction Description
129
Diagnostic Information and Procedures
129
Cylinder Compression Check
129
Oil Pressure Check
129
Service Instructions
129
Valve Clearance Inspection
129
Recoil Starter Removal and Installation
129
Air Intake Silencer Case Removal and Installation
131
Intake Manifold and Throttle Body Components
132
Intake Manifold Removal and Installation
133
Throttle Body Removal and Installation
135
Throttle Body Inspection
135
Camshaft Pulley Removal and Installation
135
Power Unit Removal and Installation
136
Camshaft, Rocker Arm and Rocker Arm Shaft Removal and Installation
144
Camshaft, Rocker Arm and Rocker Arm Shaft Inspection
145
Cylinder Head Assembly Components
147
Cylinder Head Removal and Installation
148
Cylinder Head Disassembly and Assembly
149
Cylinder Head Components Inspection and Servicing
151
Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Components
158
Cylinder and Crankshaft Disassembly and Assembly
159
Cylinder, Piston and Piston Ring Inspection and Servicing
167
Cylinder Bore
168
Piston Pin and Conrod Inspection
170
Crank Pin and Conrod Inspection
171
Crankshaft Inspection
173
Crankshaft Main Bearing Inspection
174
Crankshaft Oil Seal Inspection
176
General Description
183
1F-1 Power Unit Cooling System
183
Water Cooling System Description
183
Displacement Type Water Pump Description
183
Schematic and Routing Diagram
184
Cooling Water Circulation Chart
184
Diagnostic Information and Procedures
185
Powerhead Cooling System Diagnosis
185
Thermostat Removal and Installation
185
Service Instructions
185
Thermostat and Related Items Inspection
186
Water Pump Removal and Installation
187
Water Pump Related Item Inspection
187
Water Tube Removal and Installation
187
Water Tube Related Item Inspection
187
Fuel System
188
Precautions
188
Precautions on Fuel System Service
188
General Description
189
Electronic Fuel Injection System Description
189
Fuel Delivery System Components Description
191
High Pressure Fuel Pump Control System Description
193
Air Intake Components Description
194
Idle Air Control System Description
196
Fuel Pressure Inspection
197
Fuel System Diagnosis
199
Fuel Injection System Troubleshooting
200
Service Instructions
201
Fuel Pressure Relief Procedure
201
Fuel Line Removal and Installation
201
Fuel Line Inspection
201
Fuel Leakage Check Procedure
201
Inspection of Fuel Hose Connections
202
Fuel Vapor Separator Removal and Installation
202
Inspection of Fuel Vapor Separator
203
High Pressure Fuel Pump Removal and Installation
203
High Pressure Fuel Pump Inspection
204
Fuel Injector Inspection with Injector in Place
204
Individual Fuel Injector Operating Sound Inspection
205
Fuel Injector Operating Signal Inspection
206
Fuel Injector Removal and Installation
207
Low Pressure Fuel Pump Removal and Installation
209
Low Pressure Fuel Pump Inspection
210
Fuel Tank Construction
211
Fuel Tank Disassembly and Reassembly
211
Fuel Tank Components Inspection
211
Ignition System
213
General Description
213
Ignition System Description
213
Ignition Control Description
214
Component Location
215
Ignition System Components Location
215
Ignition System Symptom Diagnosis
215
Ignition System Troubleshooting
215
Service Instructions
217
Spark Plug Removal and Installation
217
Spark Plug Inspection
217
Ignition Coil Removal and Installation
217
Ignition Coil Inspection
218
Spark Plug Cap Inspection
219
Ignition Coil Primary Peak Voltage Inspection
219
CKP Sensor Inspection
219
ECM Power Source Coil Inspection
219
Emergency and Engine Stop Switch Inspection
219
Starting System
220
General Description
220
Electric Starter System Description
220
Start-In-Gear Protection System Description
220
Component Location
221
Starting System Components Location
221
Diagnostic Information and Procedures
221
Starter System Symptom Diagnosis
221
Starter System Troubleshooting
222
Service Instructions
224
Starter Motor Removal and Installation
224
Starter Motor Test
225
Starter Motor Components
227
Starter Motor Disassembly and Assembly
227
Starter Motor Components Inspection and Servicing
229
Starter Motor Relay Inspection
233
Neutral Switch Inspection
234
Starter Button Inspection
235
Manual Starting System
236
Precautions
236
Precaution for Manual Starting System
236
General Description
236
Service Instructions
237
Recoil Starter Components
237
Recoil Starter Removal and Installation
238
Recoil Starter Disassembly and Assembly
239
Recoil Starter Components Cleaning and Inspection
242
NSI Cable Installation and Adjustment
243
Charging System
244
General Description
244
Charging System Description
244
Battery Requirement Description
245
Component Location
245
Charging System Components Location
245
Charging System Diagnosis
245
Service Instructions
246
Charging System Construction
246
Flywheel Removal and Installation
247
Battery Charge Coil / CKP Sensor / Stator Base Removal and Installation
248
ECM Power Source Coil / Battery Charge Coil / CKP Sensor / Stator Base Removal and Installation
253
Battery Charge Coil Inspection
258
Rectifier / Regulator Removal and Installation
258
Rectifier / Regulator Inspection
259
Battery Relay Inspection
260
Fuse Inspection
261
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Suzuki DF20A Owner's Manual (129 pages)
Brand:
Suzuki
| Category:
Engine
| Size: 2 MB
Table of Contents
English
5
Table of Contents
5
Fuel and Oil
6
Gasoline
6
Filling the Fuel Tank
7
Engine Oil
8
Gear Oil
8
Location of Safety Labels
9
Location of Parts
11
Motor Installation
13
Battery Installation
14
Battery Requirement
14
Battery Installation
15
Use of Electrical Accessories
16
Battery Charge Cutout System
16
Propeller Selection and Installation
17
Propeller Selection
17
Propeller Installation
17
Trim Angle Adjustment
18
Adjustments
18
Steering Tension Adjustment
19
Throttle Tension Adjustment
19
Idle Speed Adjustment
19
Caution System
20
Over-Revolution Caution System
20
Oil Pressure Caution System
21
Cooling Water Caution System
21
Cancellation
23
Oil Change Reminder System
23
System Activation
23
Diagnostic System
23
Operation of Tilting Systems
24
Tilt Lock Lever
24
Tilt up Lock Arm
25
Shallow Water Position
26
Inspection before Boating
28
Break-In
30
Before Attempting to Start the Engine
31
Operation
31
Starting the Engine
33
Emergency Starting
36
Shifting and Speed Control
38
Stopping the Engine
39
Mooring
40
Operation in Shallow Water
40
Operation of Outboard Motor as Auxiliary Propulsion
41
Operation in Freezing Weather
41
Operation in Salt Water
41
Motor Removal and Transporting
42
Motor Removal
42
Motor Transporting
43
Trailering
44
Inspection and Maintenance
45
Maintenance Schedule
45
Spark Plug
47
Breather and Fuel Line
48
Engine Oil
49
Gear Oil
50
Lubrication
51
Corrosion Prevention
52
Battery
52
Engine Oil Filter
53
Fuel Filter
53
Timing Belt
53
Flushing the Water Passages
53
Submerged Motor
55
Storage Procedure
56
Motor Storage
56
Battery Storage
57
After Storage
57
General Information
57
WARRANTIES (for U.S.A)
57
Identification Number Location
57
Emission Control Information
58
Troubleshooting
58
Flowchart of Oil Change Reminder System
60
Specifications
60
Français
65
Carburant
66
Carburant Et Huile
66
Plein du Réservoir de Carburant
67
Huile Pour Engrenages
68
Huile-Moteur
68
Emplacement des Étiquettes de Sécurité
69
Emplacement des Pièces
71
Installation du Moteur
73
Mise en Place de la Batterie
74
Type de Batterie
74
Système de Coupure de la Charge de la Batterie
76
Utilisation D'accessoires Électriques
76
Choix de L'hélice
77
Choix Et Montage de L'hélice
77
Montage de L'hélice
77
Réglage de L'angle D'inclinaison
78
Réglages
78
Réglage de la Rigidité de L'accélérateur
80
Réglage de la Rigidité de la Direction
80
Réglage de Régime de Ralenti
80
Systèmes de Signalisation
81
Système de Signalisation de Vitesse
82
Système Indicateur de Pression D'huile
82
Système D'alarme Eau de Refroidissement
83
Système de Diagnostic
84
Activation du Système
85
Désactivation
85
Système de Rappel de Vidange D'huile
85
Levier de Verrouillage D'inclinaison
86
Utilisation du Système de Relevage
86
Bras de Verrouillage de Relevage
87
Position de Navigation en Eau Peu Profonde
88
Contrôle Avant L'utilisation
90
Rodage
92
Avant D'essayer de Mettre Le Moteur en Marche
93
Utilisation
93
Mise en Marche du Moteur
95
Mise en Marche de Secours
98
Inversion de Marche Et Commande de la Vitesse
101
Amarrage
102
Arrêt du Moteur
102
Précautions À Suivre en Eau de Mer
103
Utilisation en Eau Peu Profonde
103
Utilisation Par Temps Froid
103
Dépose du Moteur
104
Dépose Et Transport du Moteur
104
Utiliser Le Moteur Hors-Bord Comme Force Motrice Auxiliaire
104
Transport du Moteur
105
Remorquage
107
Contrôle Et Entretien
108
Plan D'entretien
108
Bougie
109
Reniflard Et Conduite D'alimentation
111
Huile du Moteur
112
Huile du Carter D'engrenages
113
Graissage
114
Batterie
115
Protection Contre la Corrosion
115
Courroie de Distribution
116
Filtre À Carburant
116
Filtre À Huile Moteur
116
Rinçage des Passages D'eau
117
Moteur Immergé
119
Procédure de Remisage
120
Remisage du Moteur
120
Après Le Remisage
121
Remisage de la Batterie
121
Emplacement des Numéros D'identification
122
Garantie (États-Unis)
122
Informations Concernant la Régulation des Émissions
122
Informations Générales
122
Dépannage
123
Caractéristiques
124
Principe du Système de Rappel de Vidange D'huile
125
Suzuki DF20A Owner's Manual (71 pages)
Brand:
Suzuki
| Category:
Outboard Motor
| Size: 1 MB
Table of Contents
Table of Contents
4
Identification Number Location
5
Fuel and Oil
5
Location of Safety Labels
8
Location of Parts
10
Motor Mounting
15
Battery Installation
16
Use of Electrical Accessories
18
Battery Charge Cutout System (Df9.9Be/15Ae/20Ae)
18
Propeller Selection and Installation
19
Adjustment
20
Caution System
22
Diagnostic System
25
Oil Change Reminder System
25
Operation of Tilting Systems (Df9.9B/9.9Br/15A/15Ar/20A/20Ar)
26
Operation of Tilting Systems (Df9.9Bt/9.9Bth/15Ath/ 20At/20Ath)
29
Inspection before Boating
31
Break-In
32
Operation
33
Motor Removal and Transporting
46
Trailering
48
Inspection and Maintenance
49
Flushing the Water Passages
58
Submerged Motor
60
Storage Procedure
61
After Storage
62
Troubleshooting
62
Specifications
64
Information Regarding Ec - Directive
64
Flowchart of Oil Change Reminder System
65
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