2009-2010 Suzuki DF70A DF80A DF90A Outboard motor Service Manual
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- 2009 2012 Suzuki DF70A 90A Service Manual
This is the original Suzuki service manual. Perfect for all maintenance tasks and rebuilds. Includes all specifications as well as step by step service procedures.
Models covered:
DF70A
DF80A
DF90A
Manual Part Number: 99500-87L00-01E
Manual chapters:
General Information
- General Information
- Maintenance and Tune-Up
Power Head
- Precautions
- Engine General Information and Diagnosis
- Engine Electrical Devices
- Power Unit Mechanical
- Power Unit Lubrication
- Power Unit Cooling System
- Fuel System
- Ignition System
- Starting System
- Charging System
Mid Unit
- Precautions
- Housing and Bracket
- Power Trim and Tilt
Lower Unit
- Precautions
- Right Hand Rotation Unit
Wire / Hose Routing
- Precautions
- Wire Routing
- Fuel / Water Hose Routing
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Full list of manual chapters:
COVER
IMPORTANT NOTICE
FOREWORD
TABLE OF CONTENTS
Precautions
Precautions
Precautions
General Precautions
General Information
General Information
General Description
Symbols
Abbreviations
Wire Color Symbols
Warning, Caution and Information Label Locations
Genuine Parts Description
Outboard Motor Identification Number Location
Fuel and Oil Recommendations
Break-In Procedures
Propeller Selection Guide
Battery Requirement
Powerhead Direction of Rotation Description
Specifications
Specifications
Service Data
Tightening Torque Specifications
Special Tools and Equipment
Recommended Service Material
Special Tool
Maintenance and Tune-Up
Precautions
Precautions for Maintenance
General Description
Recommended Oil and Lubricants
Scheduled Maintenance
Periodic Maintenance Schedule Chart
Lubrication Point
Service Instructions
Engine Oil Level Check
Engine Oil Change and Engine Oil Filter Replacement
Gear Oil Change
Spark Plug Removal and Installation
Spark Plug Inspection and Cleaning
Tappet Clearance Inspection and Adjustment
Idle Speed and Idle Air Control (IAC) Duty Inspection
Ignition Timing Inspection
Breather Line and Fuel Line Inspection
Low Pressure Fuel Filter Inspection
High Pressure Fuel Filter Replacement
Water Pump and Water Pump Impeller Inspection
Propeller / Propeller Nut and Cotter Pin Inspection
Anodes Inspection
Bonding Wires Inspection
Battery Inspection
Bolts and Nuts Inspection
Oil Pressure Check
Cylinder Compression Pressure Check
Power Head
Precautions
Precautions
Precautions for Powerhead
Engine General Information and Diagnosis
Precautions
Precautions on Engine Diagnosis
General Description
Engine Control System Description
Engine Control Module (ECM)
Caution System Description
Self-Diagnostic System Description
Fail-Safe System Description
Operating Hour Indication System Description
Oil Change Reminder System Description
Component Location
Engine Control System Components / Engine Electrical Device Location
Diagnostic Information and Procedure
ECM Power and Ground Circuit Check
Troubleshooting with Self-Diagnostic Code
Self-Diagnostic Code "3 - 4" MAP Sensor
Self-Diagnostic Code "1 - 4" Cylinder Temp. Sensor
Self-Diagnostic Code "2 - 3" IAT Sensor
Self-Diagnostic Code "4 - 2" CKP Sensor
Self-Diagnostic Code "2 - 4" CMP Sensor
Self-Diagnostic Code "2 - 2" Air Intake System
Self-Diagnostic Code "3 - 2" MAP Sensor 2
Self-Diagnostic Code "1 - 5" Ex. Manifold Temp. Sensor
Self-Diagnostic Code "4 - 3" Fuel Injector
Self-Diagnostic Code "2 - 1" TPS (Throttle Position Sensor)
Self-Diagnostic Code "1 - 2" Shift Position Sensor
Self-Diagnostic Code "3 - 3" Neutral Switch
Self-Diagnostic Code "1 - 1" Rectifier/Regulator (Over Charging)
Self-Diagnostic Code "5 - 3" Oil Pressure Switch
Self-Diagnostic Code "3 - 7" Trim Sensor
Troubleshooting Without Self-Diagnostic Code
IAC System Troubleshooting
Service Instructions
How to Use the 36 Pin Test Cord Set
Inspection of the ECM and Its Circuit
ECM Main Relay Inspection
Engine Electrical Devices
Precautions
Precaution for Engine Electrical Device
General Description
Sensor and Switch Description
ECM Power Source Line
Component Location
Location of Sensor and Switch
Service Instructions
Resistance Check
Cylinder Temp. Sensor Removal and Installation
Cylinder Temp. Sensor Inspection
Ex. Manifold Temp. Sensor Removal and Installation
Ex. Manifold Temp. Sensor Inspection
CKP Sensor Removal and Installation
CKP Sensor Inspection
IAT Sensor Removal and Installation
IAT Sensor Inspection
CMP Sensor Removal and Installation
CMP Sensor Inspection
MAP Sensor Removal and Installation
MAP Sensor Output Voltage Inspection
IAC Valve Removal and Installation
IAC Valve Inspection
TPS Inspection
Shift Position Sensor Inspection
Trim Sensor Inspection
Power Unit Mechanical
General Description
Power Unit Construction Description
Diagnostic Information and Procedures
Cylinder Compression Check
Oil Pressure Check
Service Instructions
Tappet Clearance Inspection
Ring Gear Cover Removal and Installation
Cylinder Head Cover Removal and Installation
Air Intake Silencer Case Removal and Installation
Electric Parts Holder Removal and Installation
Intake Manifold and Throttle Body Components
Intake Manifold Removal and Installation
Throttle Body Removal and Installation
Throttle Body Inspection
Power Unit Removal and Installation
Timing Chain, Chain Tensioner and Camshaft Sprockets Components
Timing Chain, Chain Tensioner and Camshaft Sprockets Removal and Installation
Timing Chain, Chain Tensioner and Camshaft Sprockets Inspection
Camshaft, Tappet and shim Removal and Installation
Camshaft, Tappet and Shim Inspection
Cylinder Head Assembly Components
Cylinder Head Removal and Installation
Cylinder Head Disassembly and Assembly
Cylinder Head Components Inspection and Servicing
Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Components
Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Disassembly and Assembly
Cylinder, Piston and Piston Ring Inspection and Servicing
Piston Pin and Conrod Inspection
Crank Pin and Conrod Bearing Inspection
Selection of Conrod Bearing
Crankshaft Inspection
Crankshaft Main Bearing Inspection
Crankshaft Drive Gear Inspection
Crankshaft Oil Seal Inspection
Power Unit Lubrication
General Description
Engine Lubrication Description
Schematic and Routing Diagram
Engine Oil Lubrication Chart
Diagnostic Information and Procedures
Oil Pressure Check
Oil Change Reminder System
Low Oil Pressure Caution System
Powerhead Lubrication System Diagnosis
Service Instructions
Oil Pump Removal and Installation
Oil Pump Disassembly and Assembly
Inspection Oil Pump Component Parts
Oil Pressure Switch Removal and Installation
Oil Pressure Switch Inspection
Oil Strainer Removal and Installation
Oil Strainer Related Parts Inspection
Power Unit Cooling System
General Description
Water Cooling System Description
Displacement Type Water Pump Description
Water Pressure Valve Description
Schematic and Routing Diagram
Cooling Water Circulation Chart
Diagnostic Information and Procedures
Powerhead Cooling System Diagnosis
Service Instructions
Thermostat Removal and Installation
Thermostat Inspection
Water Pressure Valve Removal and Installation
Water Pressure Valve Related Item Inspection
Water Pump Removal and Installation
Water Pump Related Item Inspection
Water Tube Removal and Installation
Water Tube Related Item Inspection
Fuel System
Precautions
Precautions on Fuel System Service
General Description
Electronic Fuel Injection System Description
Fuel Delivery System Components Description
High Pressure Fuel Pump Control System Description
Air Intake Components Description
Idle Air Control System Description
Diagnostic Information and Procedures
Fuel Pressure Inspection
Fuel System Diagnosis
Fuel Injection System Troubleshooting
Service Instructions
Fuel Pressure Relief Procedure
Fuel Line Removal and Installation
Fuel Line Inspection
Fuel Leakage Check Procedure
Inspection of Fuel Hose Connections
High Pressure Fuel Pump Operating Sound Inspection
Fuel Vapor Separator Removal and Installation
Fuel Vapor Separator Disassembly and Assembly
Inspection of Fuel Vapor Separator Component Parts
Fuel Injector Inspection with Injector in place
Individual Fuel Injector Operating Sound Inspection
Fuel Injector Operating Signal Inspection
Fuel Injector Removal and Installation
Low Pressure Fuel Pump Removal and Installation
Low Pressure Fuel Pump Inspection
Ignition System
General Description
Ignition System Description
Ignition Control Description
Component Location
Ignition System Components Location
Diagnostic Information and Procedures
Ignition System Symptom Diagnosis
Ignition System Troubleshooting
Service Instructions
Spark Plug Removal and Installation
Spark Plug Inspection
Ignition Coil Removal and Installation.
Ignition Coil Inspection
Ignition Coil Operating Signal Inspection
CKP Sensor Inspection
CMP Sensor Inspection
Ignition Switch Inspection
ECM Main Relay Inspection
Starting System
General Description
Electric Starter System Description
Starter Motor Operation Condition Description
Start-In-Gear Protection System Description
Component Location
Starting System Components Location
Diagnostic Information and Procedures
Starter System Troubleshooting
Service Instructions
Starter Motor Removal and Installation
Starter Motor Test
Starter Motor Components
Starter Motor Disassembly and Assembly
Starter Motor Components Inspection and Servicing
Ignition Switch Inspection
Starter Motor Relay Inspection
Neutral Switch Inspection
Emergency Stop Switch Inspection
Charging System
General Description
Charging System Description
Battery Requirement Description
Component Location
Charging System Components Location
Diagnostic Information and Procedures
Charging System Diagnosis
Service Instructions
Charging System Construction
Flywheel Removal and Installation
Battery Charge Coil Removal and Installation
Battery Charge Coil Inspection
Rectifier/Regulator Removal and Installation
Rectifier/Regulator Inspection
Main Fuse Inspection
Mid Unit
Precautions
Precautions
Precaution for Mid Unit
Housing and Bracket
Precautions
Precaution for Housing and Bracket
Service Instructions
Lower Side Cover Components
Lower Side Cover Removal and Installation
Engine Holder / Oil Pan / Driveshaft Housing / Mounts Components
Engine Holder / Oil Pan / Driveshaft Housing / Mounts Disassembly
Engine Holder / Oil Pan / Driveshaft Housing / Mounts Assembly
Engine Holder / Oil Pan / Driveshaft Housing / Mounts Related Component Inspection
Clutch Shaft Bearing and Oil Seal Replacement
Driveshaft Upper Oil Seal Replacement
Driven Gear Bearing and Oil Seal Replacement
Clamp / Swivel / Steering Brackets Components
Clamp / Swivel / Steering Brackets Disassembly
Clamp / Swivel / Steering Brackets Assembly
Clamp / Swivel / Steering Brackets Related Components Inspection
Power Trim and Tilt
Precautions
Precaution for Power Trim and Tilt
General Description
Power Trim and Tilt Description
Principles of Power Trim and Tilt Operation Description
Schematic and Routing Diagram
Power Trim and Tilt System Diagram
Diagnostic Information and Procedures
Diagnose PTT System Malfunction
Service Instructions
Checking PTT Fluid Level
Air Bleeding from PTT Unit
Setting of Trim Down Position Limit
Setting Tilt Up Limit Position
Power Trim and Tilt Unit Removal and Installation
Power Trim and Tilt Unit Components
Power Trim and Tilt Unit Disassembly
Power Trim and Tilt Unit Reassembly
Power Trim and Tilt Unit Components Cleaning and Inspecting
Power Trim and Tilt Motor Removal and Installation
Power Trim and Tilt Motor Disassembly and Assembly
PTT Motor Related Items Inspection
PTT Motor Relay Inspection
PTT Switch Inspection
Lower Unit
Precautions
Precautions
General Precautions
Precaution for Lower Unit
Right Hand Rotation Unit
Diagnostic Information and Procedures
Diagnose Lower Unit Malfunction
Service Instructions
Lower Unit Components
Propeller Removal and Installation
Propeller / Nut / Cotter Pin Inspection
Lower Unit Removal and Installation
Water Pump Removal and Installation
Water Pump and Related Items Inspection
Lower Unit Disassembly
Pinion Bearing Removal and Installation
Lower Unit Related Items Inspection
Propeller Shaft Oil Seal Replacement
Driveshaft Oil Seal Replacement
Lower Unit Assembly
Trim Tab Adjustment
Lower Unit Gears - Shimming and Adjustment
Wire / Hose Routing
Precautions
Precautions
Precautions for Wire / Hose Routing
Component Location
Electrical Component Location
Wire Routing
Schematic and Routing Diagram
Wiring Diagram
Wiring Harness Routing Diagram
Fuel / Water Hose Routing
Precautions
Precautions for Fuel / Water Hose Routing
Schematic and Routing Diagram
Fuel Hose Routing
Water Hose Routing