Suzuki DF15 Outboard Motor Manuals

Manuals and User Guides for Suzuki DF15 Outboard Motor. We have 1 Suzuki DF15 Outboard Motor manual available for free PDF download: Service Manual

Suzuki DF15 Service Manual

Suzuki DF15 Service Manual (320 pages)

Four Stroke Outboard motor

Brand: Suzuki | Category: Outboard Motor | Size: 15.76 MB

Table of Contents

General Information 1

5
- General Information
  2
- Periodic Maintenance
  2
- Ignition and Electrical
  2
  - Fuel System
    2
    
    Lower Unit
    2
    
    Recoil Starter
    2
    
    Component Parts and Important Item Illustrations
    3
    
    Table of Contents
    5
- Warning/Caution/Note
  6
- General Precautions
  6
- Identification Number Location
  8
- Fuel and Oil
  9
  - Gasoline Recommendation
    9
  - Engine Oil
    9
- Engine Break-In
  10
  - Warm-Up Recommendation
    10
  - Throttle Recommendation
    10
- Propellers
  11
- Specifications
  12
- Service Data
  14
- Tightening Torque
  21
- Special Tools
  23
- Materials Required
  26
Periodic Maintenance

27
- Periodic Maintenance Schedule
  28
  - Periodic Maintenance Chart
    28
- Maintenance and Tune-Up Procedures
  29
  - Engine Oil
    29
  - Engine Oil Filter
    30
  - Gear Oil
    31
  - Lubrication
    32
  - Spark Plug
    33
  - Valve Clearance
    34
  - Timing Belt
    36
  - Idle Speed
    39
  - Carburetor
    39
  - Ignition Timing
    40
  - Breather and Fuel Line
    40
  - Fuel Filter
    40
  - Water Pump/Water Pump Impeller
    41
  - Propeller/Nut/Pin
    41
  - Anodes and Bonding Wires
    42
  - Battery
    43
  - Bolts and Nuts
    44
- Oil Pressure
  45
- Cylinder Compression
  47
  - Test Procedure
    47
Ignition and Electrical

48
- Ignition System
  49
  - Principles of Operation
    49
  - Ignition Timing Control
    50
  - Troubleshooting
    51
  - Inspection
    52
  - Removal/Installation
    56
- Caution System
  61
- Battery Charging System
  65
  - Outline
    65
  - Inspection
    66
  - Removal/Installation
    69
- Electric Starter System
  70
  - Outline
    70
  - Troubleshooting
    72
  - Inspection
    73
  - Starter Motor
    76
Fuel System

88
- Fuel Line
  89
  - Removal/Installation
    89
  - Fuel Leakage Check Procedure
    90
  - Fuel Hose Connection
    90
- Precaution on Fuel System Service
  89
  - General Precaution
    89
- Carburetor
  91
  - Removal
    91
  - Installation
    92
  - Disassembly
    93
  - Cleaning & Inspection
    96
  - Reassembly
    98
- Throttle Control
  100
  - Installation/Adjustment
    100
- Fuel Pump
  102
  - Removal/Installation
    102
  - Disassembly/Reassembly
    103
  - Inspection
    104
- Fuel Tank
  105
  - Disassembly/Reassembly
    105
  - Inspection
    106
- Operation
  107
  - Carburetor
    107
Recoil Starter

112
- Removal
  113
- Disassembly
  114
- Inspection
  116
- Reassembly
  117
- Installation
  119
- Neutral Start Interlock (Nsi)
  120
  - Installation/Adjustment
    120
Power Unit

121
- Power Unit
  122
  - Removal
    122
  - Installation
    126
- Cylinder Head Assembly
  129
  - Removal
    129
  - Assembly
    129
  - Disassembly
    130
  - Inspection/Servicing
    132
  - Reassembly
    141
- Cylinder/Crankshaft/Piston
  144
  - Disassembly
    144
  - Inspection/Servicing
    146
  - Reassembly
    157
- Thermostat
  163
  - Removal
    163
  - Inspection
    163
  - Installation
    163
- Operation
  164
  - Water Cooling System
    164
  - Engine Lubrication System
    165
MID Unit

167
- Engine Side Cover
  168
  - Removal
    168
  - Installation
    169
- Tiller Handle
  170
  - Removal
    170
  - Installation
    171
  - Disassembly/Assembly
    172
- Driveshaft Housing and Oil Pan
  173
  - Removal
    173
  - Inspection
    175
  - Reassembly
    176
  - Removal/Disassembly
    179
  - Inspection
    182
  - Reassembly
    183
Lower Unit

187
- Removal & Disassembly
  188
- Pinion Bearing
  192
- Inspection
  194
  - Propeller
    194
  - Gearcase
    194
  - Gears
    194
  - Propeller Shaft Components
    195
  - Propeller Shaft Bearing Housing
    195
  - Shift Cam and Related Items
    196
  - Water Pump and Related Items
    196
  - Water Inlet Housing
    196
  - Driveshaft
    197
- Assembly & Installation
  198
- Lower Unit Gears- Shimming and Adjustment
  207
  - Forward Gear/Pinion Gear
    207
  - Pinion Gear/Reverse Gear
    209
  - Checking Propeller Shaft Thrust Play
    210
Wire/Hose Routing

211
- Wiring Diagram
  212
  - Df9.9/Df15
    212
  - Df9.9E/Df15E
    213
  - Df9.9R/Df15R
    214
- Wire Routing
  215
- Fuel/Water Hose Routing
  221
Df9.9/15 "K6" (2006) Model

223
- Specifications
  224
- Service Data
  226
- Battery Charge Coil
  233
- Neutral Switch Bracket
  233
- Shift Cam Spring Pin, Shift Cam and Shift Rod
  234
Df9.9/15 "K7" (2007) Model

235
- Specifications
  236
- Service Data
  238
- Tightening Torque
  245
- Cam Shaft Pulley Bolt
  246
- Cylinder Head, Recoil Starter Assy and Timing Belt Cover
  246
- Clutch Notch Lever
  247
- Oil Pan Gasket
  247
- Water Pump and Gearcase
  248
Df9.9T/Th "K8" (2008) Model

250
- Specifications
  251
- Service Data
  253
- Tightening Torque
  260
- Cylinder/Crankshaft Bearing
  261
- Power Tilt
  262
  - Service Procedure
    263
  - Air Bleeding
    263
  - Power Tilt Unit
    264
- Pt Motor Relay
  275
- Pt Switch
  276
- Operation
  277
- Wiring Diagram
  284
- Wire Routing
  286
  - Outboard Motor
    294
Df9.9T/Th/Df15 (Serial No. 110001 and Later) Foreword

295
- General Information
  296
  - Specifications (Df9.9T/Th)
    296
  - Service Data (Df9.9T/Th)
    300
  - Service Data (Df15)
    307
  - Special Tools
    314
- Periodic Maintenance
  315
  - Maintenance and Tune-Up Procedures
    315
  - Cylinder Compression
    316
- Ignition and Electrical
  317
  - Ignition System
    317
- Power Unit
  318
  - Cylinder Head
    318

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