Suzuki DF300 Manuals

Suzuki DF300 Manuals

Manuals and User Guides for Suzuki DF300. We have 1 Suzuki DF300 manual available for free PDF download: Service Manual

Suzuki DF300 Service Manual

Suzuki DF300 Service Manual (593 pages)

Brand: Suzuki | Category: Outboard Motor | Size: 59.07 MB

Table of Contents

General Information 1

6
- Table of Contents
  6
- Warning/Caution/Note
  7
- General Precautions
  7
- Identification Number Location
  9
- Fuel and Oil
  10
  - Gasoline Recommendation
    10
  - Engine Oil
    10
- Engine Break-In
  11
  - Warm-Up Recommendation
    11
  - Throttle Recommendation
    11
- Propellers
  12
- Powerhead Direction of Rotation
  13
- Suzuki Precision Control System
  13
- Cylinder Number
  13
- Specifications
  14
- Service Data
  17
- Tightening Torque
  24
- Special Tools
  26
- Materials Required
  30
Periodic Maintenance

31
- Periodic Maintenance Schedule
  32
  - Periodic Maintenance Chart
    32
- Maintenance and Tune-Up Procedures
  33
  - Engine Oil/Engine Oil Filter
    33
  - Gear Oil
    36
  - Lubrication
    37
  - Spark Plug
    38
  - Tappet Clearance
    39
  - Idle Speed
    46
  - Ignition Timing
    47
  - Fuel Line
    48
  - Low Pressure Fuel Filter
    49
  - High Pressure Fuel Filter
    49
  - Pcv System
    50
  - Low Pressure Fuel Pump Filter
    51
  - Water Pump/Water Pump Impeller
    51
  - Propeller/Nut/Cotter Pin
    51
  - Anodes
    52
  - Bonding Wires
    53
  - Battery
    54
  - Bolts and Nuts
    55
- Oil Pressure
  56
- Cylinder Compression
  58
Engine Control System

60
- Engine Control System Structure
  
  61
- Components for System Control
  
  63
- Ignition System
  
  84
  - Ignition Control System
    85
  - Specifications
    85
- Electronic Fuel Injection System
  
  87
- VVT (Variable Valve Timing) SYSTEM
  
  98
- Electronic Shift System
  
  100
  - Outline
    100
  - Operation
    100
- Tachometer Monitor
  
  101
  - Digital Display Screen
    101
- Caution System
  
  102
  - Over-Revolution Caution System
    103
  - Low Oil Pressure Caution System
    103
  - Overheat Caution
    104
  - Low Battery Voltage Caution System
    105
  - Check Control Unit Communication Caution
    105
  - Check Second Station Caution
    106
  - Check Throttle System Caution
    106
  - Check Shift Control Caution
    107
- Self-Diagnostic System
  
  108
  - Code for Self-Diagnostic System Operation
    108
  - Condition for Self-Diagnostic System Operation
    110
- Fail-Safe System
  
  112
  - Pre-Programmed Value for Fail-Safe System
    112
- Oil Change Reminder System
  
  114
- Start-In-Gear Protection System
  
  115
- Inspection
  
  116
  - Precaution on System Inspection
    116
  - 26-Pin & 34-Pin Test Cord
    117
  - Inspection for Ecm Circuit Voltage
    118
  - Inspection for Bcm Circuit Voltage
    122
  - Inspection for Resistance
    125
  - Component Inspections
    126
  - Switch Panel
    148
- Removal/Installation
  
  151
  - Flywheel
    151
  - Ckp Sensor
    153
  - Cmp Sensor
    154
  - Oil Pressure Switch
    154
  - OCV (Oil Control Valve)
    155
  - Electronic Throttle Body Assembly
    156
- Clutch Link Rod
  
  158
- Troubleshooting
  
  159
Engine Electrical

172
- Battery Charging System
  173
  - Outline
    173
  - Inspection
    175
  - Removal/Installation
    181
- Electric Starter System
  183
  - Outline
    183
  - Troubleshooting
    185
  - Inspection
    186
  - Starter Motor
    189
- Electric Parts Holder
  201
  - Removal
    201
  - Installation
    203
Fuel System

204
- Precautions When Servicing Fuel System
  205
  - General Precaution
    205
  - Fuel Pressure Relief Procedure
    206
- Fuel Line
  207
  - Removal/Installation
    207
  - Fuel Leakage Check Procedure
    207
  - Fuel Hose Connection
    208
  - Fuel Pressure Inspection
    208
- Low Pressure Fuel Pump/Fuel Vapor Separator Set
  210
  - Removal
    210
  - Fuel System Diagram
    212
  - Inspection
    213
  - Installation
    213
- Fuel Vapor Separator/High Pressure Fuel Pump
  214
  - Removal and Disassembly
    214
  - Inspection
    216
  - Assembly
    218
- Evaporation Purge System
  220
  - System Inspection
    220
  - Purge Valve
    220
- Fuel Injector
  222
  - Inspection
    222
  - Removal
    223
  - Installation
    224
- Low Pressure Fuel Pump
  226
  - Inspection
    226
- Low Pressure Fuel Filter/Fuel Hose
  227
  - Inspection
    227
Power Unit

228
- Ring Gear Cover and Air Intake Silencer Case
  229
  - Removal
    229
  - Installation
    229
- Cylinder Head Cover
  230
  - Removal
    230
  - Installation
    232
- Intake Collector Assembly
  234
  - Removal
    234
  - Installation
    236
- Power Unit
  238
  - Removal
    238
  - Installation
    244
- Oil Pump
  249
  - Removal
    249
  - Disassembly
    250
  - Inspection
    251
  - Measuring Pump Components
    251
  - Assembly
    252
  - Installation
    253
- Timing Chain
  254
  - Removal
    254
  - Inspection
    258
  - Installation
    260
- Cylinder Head Assembly
  267
  - Removal
    267
  - Assembly
    269
  - Disassembly
    274
  - Inspection/Servicing
    275
  - Reassembly
    285
- Cylinder/Crankshaft/Piston
  287
  - Disassembly
    287
  - Inspection/Servicing
    290
  - Reassembly
    302
- Thermostat
  309
  - Removal
    309
  - Inspection
    309
  - Installation
    310
- Operation
  311
  - Engine Lubrication System
    311
  - Water Cooling System
    313
  - Pcv System
    314
MID Unit

315
- Engine Side Cover
  316
  - Removal
    316
  - Installation
    316
- Driveshaft Housing and Oil Pan
  317
  - Removal
    317
  - Inspection
    323
  - Assembly
    326
- Swivel Bracket, Steering Bracket and Clamp Bracket
  333
  - Removal
    333
  - Inspection
    336
  - Reassembly
    337
- Water Pressure Valve
  342
  - Removal
    342
  - Inspection
    342
  - Installation
    342
Power Trim and Tilt

343
- System Wiring Diagram
  344
- Service Procedure
  345
  - Oil Level
    345
  - Air Bleeding
    345
- Power Trim and Tilt Unit
  346
  - Removal
    346
  - Disassembly
    348
  - Cleaning and Inspecting
    351
  - Reassembly
    353
  - Ptt Motor
    357
    
    Removal
    357
    
    Disassembly
    357
    
    Inspection
    358
    
    Assembly
    359
    
    Installation
    361
- Ptt Motor Relay
  363
- Ptt Switch
  364
- Tilt Limit Switch
  364
- Operation
  365
  - Component Parts
    365
  - Principles of Operation
    365
Lower Unit [Standard Rotation (Right-Hand) Model]

372
- Removal & Disassembly
  373
- Inspection
  380
  - Propeller
    380
  - Gearcase
    380
  - Gears/Bearing
    380
  - Propeller Shaft Components
    381
  - Propeller Shaft Bearing Housing
    381
  - Shift Rod Guide Housing Components
    382
  - Water Pump and Related Items
    383
  - Driveshaft Oil Seal Housing
    383
  - Driveshaft
    384
- Assembly & Installation
  385
- Trim Tab
  397
- Lower Unit Gears- Shimming and Adjustment
  398
Lower Unit [Counter Rotation (Left-Hand) Model]

405
- Removal & Disassembly
  406
- Inspection
  414
  - Propeller
    414
  - Gearcase
    414
  - Gears/Bearing
    415
  - Forward Gear Bearing/Thrust Bearing
    415
  - Propeller Shaft Components
    415
  - Propeller Shaft Bearing Housing
    416
  - Shift Rod Guide Housing Components
    417
  - Water Pump and Related Items
    417
  - Driveshaft Oil Seal Housing
    418
  - Driveshaft
    418
- Assembly & Installation
  419
- Trim Tab
  433
- Lower Unit Gears- Shimming and Adjustment
  434
Wire/Hose Routing

441
- Wiring Diagram
  
  442
- Df300
  
  442
  - For Single Engine
    442
  - For Single Engine and Dual Station
    444
  - For Multiple Engine
    445
  - For Multiple Engine and Dual Station
    446
- Wiring
  
  448
  - Single Engine, Single Station
    448
  - Single Engine, Dual Stations
    449
  - Twin Engines, Single Station
    450
  - Twin Engines, Dual Stations
    451
  - Triple Engines, Single Station
    452
  - Triple Engines, Dual Stations
    453
- Wire Routing
  
  454
- Fuel/Water Hose Routing
  
  460
- Fuel Hose Routing
  
  460
- Water Hose Routing
  
  464
Section 12

467
- Specifications
  471
  - Service Data
    471
  - Engine Control
    478
    
    Ecm
    478
    
    Shift Learning
    478
  - MID Unit
    480
    
    Shift Actuator Holder
    480
  - Power Unit
    481
    
    Crankcase
    481
    
    Collector Cover
    481
    
    FUEL HOSE (Fuel Tank to Low Pressure Fuel Filter)
    482
    
    Water Hose
    482
  - Lower Unit
    483
    
    Propeller Shaft/Forward Thrust Washer
    483
    
    Clutch Dog Shifter
    483
Section 13

485
- Service Data
  489
- Ecm
  496
  - Ecm
    496
    
    Wiring Harness
    496
  - Engine Control
    496
  - Power Unit
    499
    
    Camshaft
    499
  - Wiring Diagram
    500
Section 14

504
- Service Data
  508
- Engine Control
  515
  - Ecm
    515
  - Ckp Sensor
    515
- General Information
  515
  - Identification Number Location
    515
- Power Unit
  516
  - Piston
    516
- Power Trim and Tilt
  517
  - Mooring
    517
- Lower Unit
  518
  - Connector Pin
    518
- Wire Routing
  519
(30002F-110001 -, 30002Z-110001 -) Foreword

521
- Specifications
  522
- Service Data
  525
- Materials Required
  532
- Special Tools
  532
- Periodic Maintenance
  533
  - Maintenance and Tune-Up Procedures
    533
- Engine Control System
  535
  - Engine Control System Structure
    535
  - Components for System Control
    537
  - Ignition System
    543
  - Electronic Fuel Injection System
    544
  - Inch/2 Inch Gauge
    546
  - Caution System
    547
  - Water in Fuel Alart System
    554
  - Oil Change Reminder System
    555
  - Self-Diagnostic System
    556
  - Fail-Safe System
    561
  - Inspection
    563
  - O 2 Sensor
    569
  - Troubleshooting
    570
- Fuel System
  571
  - Low Pressure Fuel Filter
    571
- Power Unit
  572
  - Cylinder
    572
- Power Trim and Tilt
  574
  - Setting of Trim down Position Limit
    574
- Wire/Hose Routing
  576
  - Wiring Diagram
    576
  - Wiring
    582
  - Wire Routing
    588

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