Suzuki DF90T Manuals

Manuals and User Guides for Suzuki DF90T. We have 1 Suzuki DF90T manual available for free PDF download: Service Manual

Suzuki DF90T Service Manual (616 pages)

Brand: Suzuki | Category: Outboard Motor | Size: 9.77 MB

General Information 1

5
- Engine Control System
  2
  - Fuel System
    2
    
    Product View and Components
    3
    
    How to Use this Manual
    3
    
    Symbol Description
    4
    
    Table of Contents
    5
- General Information
  2
- Warning / Caution / Note
  6
- General Precautions
  6
- Identification Number Location
  8
- Fuel and Oil
  8
  - Gasoline Recommendation
    8
  - Engine Oil
    8
- Engine Break-In
  9
- Propellers
  10
- Powerhead Direction of Rotation
  10
- Specifications
  11
  - General Specification
    12
- Service Data
  13
  - 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
    39
  - Ignition Timing
    40
  - Breather and Fuel Line
    41
  - Low Pressure Fuel Filter
    41
  - High Pressure Fuel Filter
    42
  - Water Pump / Water Pump Impeller
    42
  - Propeller / Nut / Cotter Pin
    42
  - Anodes and Bonding Wires
    43
  - Battery
    44
  - Bolt and Nuts
    45
  - Feedback)
    45
- Oil Pressure
  
  46
- 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
  - Ecm Connector / Terminals Layout
    54
  - Ecm Internal Structure
    55
  - 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
- Self-Diagnostic System
  75
  - Priority / Code / Pattern for Self-Diagnostic System Operation
    75
  - Condition for Self-Diagnostic System Operation
    77
- Fail-Safe System
  78
  - Pre-Programmed Value for Fail-Safe System
    78
- Operating Hour Indication System
  79
- Oil Change Reminder System
  80
- Start-In-Gear Protection System
  81
- O 2 Feedback System
  82
- Inspection
  83
  - Precaution on System Inspection
    83
  - 44-Pin Test Cord
    83
  - Inspection for Ecm Circuit Voltage
    84
  - Inspection for Resistance
    86
  - Component Inspections
    87
- Troubleshooting
  93
- Removal / Installation
  99
  - Flywheel
    99
  - Ckp Sensor / Cmp Sensor
    99
  - Oil Pressure Switch
    102
Electrical

103
- Battery Charging System
  
  104
  - Outline
    104
  - Inspection
    105
  - Removal / Installation
    107
- Electric Starter System
  
  109
  - Outline
    109
  - Troubleshooting
    111
  - Inspection
    112
  - Starter Motor
    114
    
    Disassembly
    115
    
    Inspection & Servicing
    118
    
    Assembly
    123
    
    Performance Test
    124
- Monitor-Tachometer
  
  126
  - Inspection
    126
- Erectric Parts Holder
  
  127
Fuel System

128
- Removal / Installation
  128
- Precaution on Fuel System Service
  
  129
  - General Precaution
    129
  - Fuel Pressure Relief Procedure
    130
- Removal / Installation
  
  131
- Fuel Line ______________________________________________ 5-4
  
  131
  - Fuel Leakage Check Procedure
    131
  - Fuel Hose Connection
    132
  - Fuel Pressure Inspection
    132
- Fuel Vapor Separator / High Pressure Fuel Pump
  
  134
  - Removal / Installation
    134
  - Disassembly
    135
  - Inspection
    136
  - Assembly
    137
- Fuel Injector
  
  139
  - Inspection
    139
  - Removal
    139
  - Installation
    140
- Low Pressure Fuel Pump
  
  141
  - Removal / Installation
    141
  - Disassembly / Reassembly
    142
  - Inspection
    143
- Fuel Tank
  
  144
  - Disassembly / Reassembly
    144
  - Inspection
    145
Power Unit

146
- Intake Manifold Assembly
  
  147
  - Removal
    147
  - Installation
    149
- Power Unit
  
  150
  - Removal
    150
  - Installation
    154
- Oil Pump
  
  157
  - Removal
    157
  - Inspection
    157
  - Installation
    158
- Timing Chain / Tensioner
  
  159
  - Removal
    159
  - Inspection
    161
  - Installation
    162
- Cylinder Head Assembly
  
  165
  - Removal
    165
  - Installation
    166
  - Disassembly
    169
  - Inspection / Servicing
    170
  - Reassembly
    183
- Cylinder / Crankshaft / Piston
  
  185
  - Disassembly
    185
  - Inspection / Servicing
    188
  - Reassembly
    202
- Thermostat
  
  208
- Operation
  
  209
  - Water Cooling System
    209
  - Engine Lubrication System
    210
- Removal / Inspection / Installation
  
  209
MID Unit

211
- Engine Side Cover
  
  212
  - Removal
    212
  - Installation
    212
- Driveshaft Housing and Oil Pan
  
  213
  - Removal
    213
  - Inspection
    215
  - Assembly
    217
- Swivel Bracket, Steering Bracket and Clamp Bracket
  
  223
  - Removal
    223
  - Inspection
    225
  - Reassembly
    226
- Clamp Bracket ________________________________________ 7-13
  
  223
- Water Pressure Valve
  
  230
Power Trim and Tilt

231
- System Wiring Diagram
  
  232
- Service Procedure
  
  233
  - Oil Level
    233
  - Air Bleeding
    233
- Power Trim and Tilt Unit
  
  234
  - Removal
    234
  - Disassembly
    235
  - Inspection
    237
  - Reassembly
    239
  - Ptt Motor
    240
    
    Ptt Motor Removal
    240
    
    Ptt Motor Disassembly
    241
    
    Ptt Motor Inspection
    242
    
    Ptt Motor Assembly
    243
    
    Ptt Motor Installation
    244
  - Installation
    245
- Ptt Motor Relay
  
  247
- Ptt Switch
  
  248
- Operation
  
  249
  - Components
    249
  - Principles of Operation
    250
Lower Unit

255
- Removal & Disassembly
  
  256
- Pinion Bearing
  
  261
- Inspection
  
  263
  - Propeller
    263
  - Gearcase
    263
  - Gears
    264
  - Propeller Shaft Components
    264
  - Propeller Shaft Bearing Housing
    264
  - Shift Rod Guide Housing Components
    265
  - Water Pump and Related Items
    265
  - Driveshaft Oil Seal Housing
    266
  - Driveshaft
    266
- Assembly & Installation
  
  267
- Trim Tab
  
  277
- Lower Unit Gears-Shimming and Adjustment
  
  278
Df140 "K2" ('02) Model

294
- Specifications _________________________________________ 1
  294
- General Information
  295
  - Specifications
    295
  - Service Data
    297
  - Tightening Torque
    304
  - Special Tools
    306
  - Materials Required
    309
- Engine Control System
  310
- Power Unit
  311
  - Engine Oil Cooler
    311
  - Camshaft
    313
  - Cylinder Block
    314
  - Piston & Piston Ring
    314
  - Crankshaft
    315
  - Conrod Assembly
    315
- MID Unit
  316
- Power Trim and Tilt
  318
  - Service Procedure
    318
  - Oil Level / Air Bleeding
    318
  - Power Trim and Tilt Unit
    319
  - Removal
    319
  - Disassembly
    320
  - Cleaning and Inspecting
    323
  - Reassembly
    324
  - Ptt Motor
    326
  - Installation
    330
  - Component Parts
    332
  - Operation
    332
- LOWER UNIT (Normal Rotation Model)
  339
  - Removal and Installation
    339
  - Disassembly
    339
  - Assembly
    344
  - Lower Unit Gears-Shimming and Adjustment
    354
- Counter Rotation Lower Unit (Df140Z)
  359
  - Removal and Installation
    360
  - Disassembly
    360
  - Inspection
    365
  - Assembly
    369
  - LOWER UNIT GEARS-SHIMMING and ADJUSTMENT (Counter Rotation Model)
    379
- Wiring Diagram
  385
- Hose Routing
  386
Df90/115 "K2" ('02) Model

387
- Specifications
  388
- Service Data
  390
- Tightening Torque
  397
- Materials Required
  398
- Fuel/Water Hose Routing
  399
- Conrod Assy and Bearing
  402
- Crank Pin and Conrod Bearing
  402
- Over-Revolution Caution System
  402
- Camshaft and Tappet Shim
  403
- Crankshaft and Flywheel
  403
- Engine Holder Gasket
  404
- Engine Holder Bolt
  405
- Upper Mount Front Nut
  405
- Clutch Linkage
  406
Df90/115/140 "K3" (2003) Model

407
- Service Data (Df140(W)T/140Z) __________________________ 13-13
  
  426
- Service Data (Df90T/115(W)T) ___________________________ 13-6
  
  426
  - Tightening Torque
    426
  - Ecm
    427
  - Ecm Main Relay and Starter Motor Relay
    427
  - Battery Charge Coil
    428
  - Rectifier & Regulator
    428
  - Exhaust Camshaft (for Df115 Only)
    429
  - Remote Control Cable Holder
    429
  - Cylinder Head Instllation
    430
  - Crankcase to Cylinder Instllation
    431
  - Upper Mount
    432
  - Drive Shaft
    432
  - Propeller Shaft Bearing Housing
    432
  - Df115W and Df140W
    433
    
    Exhaust Valve
    433
    
    Water Pump Case
    433
    
    Ecm
    433
  - Wiring Diagram
    434
  - Wire Routing
    435
  - Water Hose Routing
    437
Df90/115/140 "K4" ('04) Model

438
- Specifications (Df90T/115T/115Wt)
  439
- Specifications (Df140T/140Wt/140Z)
  441
- Service Data (Df90/115)
  443
- Service Data (Df140)
  450
- Cylinder Block
  457
- Rectifier & Regulator
  457
- Temperature Sensor
  457
- Electric Parts Holder
  458
- P.t.t. Motor
  458
- Power Trim & Tilt (P.t.t.) Relay
  458
- Clamp Bracket Shaft
  459
- Swivel Bracket
  459
- Tilt Limit Switch System
  459
- Driveshaft
  460
- Pinion Gear Back up Shim
  460
- Port Clamp Bracket
  460
- Lower Unit Gears-Shimming and Adjustment
  461
- Wiring Diagram
  462
Df90/115/140 "K5" (2005) Model

463
- Specifications (Df90T/115T/115Wt)
  464
- Specifications (Df140T/140Wt/140Z/140Wz)
  466
- Service Data (Df90T/115T/115Wt)
  468
- Service Data (Df140T/140Wt/140Z/140Wz)
  475
- Engine Wiring Harness
  482
- Safety Relay System
  482
- Ecm
  483
- Sub-Battery Cable
  483
- Remote Control Box and Remote Control Wire
  484
- Piston Oil Ring
  486
- Tensioner Adjuster
  486
- Tilt Limit Switch Cover
  486
- Engin Holder
  487
- Upper and Lower Mount
  487
- Transom Bolt
  488
- Wire/Hose Routing
  489
- Wiring Diagram
  492
Df90/115/140 "K6" (2006) Model

493
- Specifications (Df90T/115T/115Wt)
  494
- Specifications (Df140T/140Wt/140Z/140Wz)
  496
- Service Data (Df90T/115T/115Wt)
  498
- Service Data (Df140T/140Wt/140Z/140Wz)
  505
- Tightening Torque
  513
  - Periodic Maintenance Schedule
    513
  - Ecm
    514
  - Neutral Switch
    514
  - Fuel Filter
    514
  - Delivery Pipe
    515
  - Oil Strainer
    515
  - OIL COOLER (for DF140)
    515
  - Engine Holder and Cylinder Block
    516
  - Cltuch Link
    517
  - Swivel Bracket Bushing Grease Path
    517
  - CLAMP BRACKET (for DF90 and DF115)
    519
  - Swivel Bracket
    520
  - Steering Bracket
    521
  - Upper Mount
    521
  - Water Pump
    523
  - Water Pump Tube
    524
  - Exhaust Seal Rubber
    524
  - Shift Rod Guide Housing
    525
  - Shift Rod, Shifter Yoke and Horizontal Slider
    526
  - Drive Shaft
    526
  - Propeller Shaft and Connector Pin
    527
  - Forward Gear and Clutch Dog
    527
  - Wiring/Hose Routing
    529
  - Wiring Diagram
    531
Df90/115/140 "K7" (2007) Model

532
- Specifications (Df90T/115T/115Wt)
  533
- Specifications (Df140T/140Wt/140Z/140Wz)
  535
- Service Data (Df90T/115T/115Wt)
  537
- Service Data (Df140T/140Wt/140Z/140Wz)
  544
- Periodic Maintenance Schedule
  551
- Ecm
  552
- Fuel Hose, Cable Grommet and Front Panel
  552
- Pinion/Gear Set
  554
Df90/115/140 "K8" (2008) Model

555
- Specifications (Df90T/115T/115Wt)
  556
- Specifications (Df140T/140Wt/140Z/140Wz)
  558
- Service Data (Df90T/115T/115Wt)
  560
- Service Data (Df140T/140Wt/140Z/140Wz)
  567
- Periodic Maintenance
  574
  - Idle Speed
    574
- Engine Control System
  576
  - Ecm
    576
  - Wiring Harness
    576
- Digital Gauge System
  577
  - Digital Gauge
    577
  - Modification of Harness Connection
    578
  - Digital Gauge and Related Parts Connection
    578
  - Set-Up of Tachometer
    580
  - Tachometer-Monitor
    581
  - Tachometer Display Indication
    582
- Engine Holder
  583
- Wiring Diagram
  584
- Wire Routing
  585
  - General Information
    588
    
    Specifications
    588
    
    Service Data
    590
    
    Special Tools
    599
    
    Materials Required
    603
  - Engine Control
    604
    
    Ecm
    604
  - Wire/Hose Routing
    606
    
    Wiring Diagram
    606
    
    Wire Routing
    607
    
    Fuel/Water Hose Routing
    611

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Suzuki DF90T Manuals

Suzuki DF90T Service Manual (616 pages)

Table of Contents

General Information 1

Periodic Maintenance 2

Periodic Maintenance Schedule

Maintenance and Tune-Up Procedures

Oil Pressure

Cylinder Compression

Engine Control System

Electrical

Battery Charging System

Electric Starter System

Monitor-Tachometer

Erectric Parts Holder

Fuel System

Precaution on Fuel System Service

Removal / Installation

Fuel Line ______________________________________________ 5-4

Fuel Vapor Separator / High Pressure Fuel Pump

Fuel Injector

Low Pressure Fuel Pump

Fuel Tank

Power Unit

Intake Manifold Assembly

Power Unit

Oil Pump

Timing Chain / Tensioner

Cylinder Head Assembly

Cylinder / Crankshaft / Piston

Thermostat

Operation

Removal / Inspection / Installation

MID Unit

Engine Side Cover

Driveshaft Housing and Oil Pan

Swivel Bracket, Steering Bracket and Clamp Bracket

Clamp Bracket ________________________________________ 7-13

Water Pressure Valve

Power Trim and Tilt

System Wiring Diagram

Service Procedure

Power Trim and Tilt Unit

Ptt Motor Relay

Ptt Switch

Operation

Lower Unit

Removal & Disassembly

Pinion Bearing

Inspection

Assembly & Installation

Trim Tab

Lower Unit Gears-Shimming and Adjustment

Df140 "K2" ('02) Model

Df90/115 "K2" ('02) Model

Df90/115/140 "K3" (2003) Model

Service Data (Df140(W)T/140Z) __________________________ 13-13

Service Data (Df90T/115(W)T) ___________________________ 13-6

Df90/115/140 "K4" ('04) Model

Df90/115/140 "K5" (2005) Model

Df90/115/140 "K6" (2006) Model

Df90/115/140 "K7" (2007) Model

Df90/115/140 "K8" (2008) Model

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