DOWNLOAD Suzuki Outboard Repair Manual 1979-2015

Suzuki Outboard Repair Manual

Download a Suzuki outboard repair manual instantly. A downloadable Suzuki boat motor repair manual, also termed Suzuki outboard online factory service manual (FSM) or Suzuki engine workshop manual, is a digitally transmitted handbook giving instructions on how to overhaul, service or restore the motor back to working order.

The digital instruction book contains a wealth of how-to guides developed by the manufacturer that outline everything from flushing the engine to complete engine overhaul.

Download Online Factory Service Repair manual PDF

Suzuki repair manuals are written or printed publications consisting of pages on how to fix or mend the complete outboard motor to factory specifications. Each manual begins with a cover page and a preface, which is an introduction to a book.

A table-of-contents, or main chapters, outline a list of titles to the main parts of the Suzuki repair manual. Each chapter is broken-down into subchapters, which describe things like component specifications and step-by-step repair procedures.

Here is a list of main chapters and subchapters often found in a Suzuki outboard repair manual. Keep in mind that actual information in a Suzuki outboard repair manual will depend on the year and model of the outboard engine.   

GENERAL INFORMATION

  • General precautions
  • Identification numbers and locations
  • Fuel and oil recommendations
  • Engine break-in
  • Warm-up and throttle recommendations
  • Propellers
  • Specifications
  • Service data
  • Torque specs

PERIODIC MAINTENANCE

  • Maintenance chart
  • Maintenance and tune-up procedures
    • Engine oil filter and engine oil
    • Gear oil
    • Lubrication
    • Spark plug
    • Valve clearance
    • Timing belt
    • Idle speed
    • Ignition timing
    • Breather hose and fuel line
    • Low pressure fuel filter
    • High pressure fuel filter
    • Water pump implore and water pump
    • Propeller nut and pin
    • Propeller
    • Anodes and bonding wires
    • Battery
    • Bolts and nuts
    • Fuel mixture check
  • Oil pressure
  • Cylinder compression

ENGINE CONTROL SYSTEM

  • Overheating caution system
  • Fuel pump control system
  • Engine control system structure
  • Sensors and switches
  • Self-diagnostic system
  • Operating hour indication system
  • O2 feedback system
  • Ignition system
  • Low oil pressure caution system
  • Engine control module (ECM)
  • Idle air control system
  • Fail-safe system
  • Electronic fuel injection system
  • Low battery voltage caution system
  • Caution system
  • Component inspections
  • oil pressure switch
  • Over-revolution caution system
  • Start-in-gear protection system
  • Flywheel, CKP, CMP sensor
  • Fuel delivery system
  • Oil change reminder system
  • Troubleshooting
  • Components for system control

ELECTRICAL

  • Battery charging system
  • Electric starter system
  • Manual starter system
  • Starter motor
  • Electrical parts holder
  • Monitors-tachometer

FUEL SYSTEM

  • Removal and inspection
  • Disassembly and cleaning
  • Assembly and installation
    • Fuel hose connections
    • Precaution on fuel system service
    • Fuel vapor separator
    • Low pressure fuel pump
    • Fuel leakage check
    • Fuel pressure inspections
    • Fuel tank
    • Fuel injector and delivery pipe
    • High pressure fuel pump
    • Fuel line
    • Fuel pressure relief procedure

POWER UNIT

  • Removal and inspection
  • Disassembly and cleaning
  • Assembly and installation
    • Intake manifold
    • Power unit
    • Cylinder head
    • Cylinder, crankshaft, piston
    • Water cooling system
    • Engine lubrication system

MID UNIT

  • Removal and inspection
  • Disassembly and cleaning
  • Assembly and installation
    • Engine side cover
    • Tiller handle
    • Driveshaft hosing
    • Oil pan
    • Swivel bracket
    • Steering bracket
    • Clamp bracket

POWER TRIM AND TILT

  • Removal and inspection
  • Disassembly and cleaning
  • Assembly and installation
    • System wiring diagram
    • Oil level and air bleeding
    • Power trim and tilt unit
    • PTT motor
    • PTT motor relay
    • Principles of operation

LOWER UNIT

  • Propeller shaft components
  • Gears
  • Assembly and installation
  • Driveshaft oil seal housing
  • Propeller
  • Disassembly and cleaning
  • Pinion bearing
  • Propeller shaft bearing housing
  • Removal and inspection
  • Driveshaft
  • Gear case
  • Water pump and related items
  • Shift rod guide housing components
  • Lower unit gears shimming, adjustment

HOSE ROUTING AND DIAGRAMS

  • Wiring routing
  • Fuel hose routing
  • Water hose routing
  • Wiring diagram
Suzuki Outboard Service Manual
Example of what a downloadable digital repair manual looks like.
Suzuki Outboard Service Manual
Example of what a digitally delivered repair manual looks like.

Suzuki repair manuals are aimed mainly at professional marine technicians but enough information is given in the book for do-it-yourself enthusiasts and backyard mechanics that lack basic mechanical theory. However, complicated repair jobs should be left to licensed professional garage.

A Suzuki outboard repair manual contains part removal, inspection, cleaning, assembly and reinstallation procedures. Pictures, diagrams and illustrations are strewn throughout the manual to help the mechanic rectify any problem.

Sometimes a mechanic cannot locate the source of the problem. The good news: Suzuki repair manuals contain advanced troubleshooting guides to help you trace and correct faults stemming from the electronic or mechanical system, including the fuel system. For example, the troubleshooting section shows you fix and diagnose:

  • Engine will not start
  • Engine is hard to start or stalls soon after starting
  • Engine idles rough
  • Engine idles high or low
  • Engine stalls
  • Poor acceleration
  • Engine will not turn off
  • Engine overheating
  • Poor engine performance
  • Hard shifting
  • Charging issues
  • Limited engine speed

What does a Suzuki repair manual look like?

A downloadable Suzuki repair manual appears identical to that of a repair book you would get at a marine parts store, dealership or licensed repair shop. The benefits of a digital repair manual over a paperback manual is convince and functionality.

You can download a repair manual instantly, which means you get it now, rather than waiting weeks for it to arrive in the mail. You can print out specific pages from the manual and avoid getting a costly paperback book all greasy.

The Suzuki download manual has clickable chapters and subchapters which are designed to help you located information quickly. The manual also has a search feature built into it. This allows you to search the document using specific words located in the document.

How to obtain a Suzuki repair manual?

To acquire a Suzuki repair manual for your outboard engine, click on the download link on this page. Next select the year and model repair manual, click on the link, and the manual will be electrically transmitted directly to your computer, tablet or e-reader within seconds.

All Suzuki repair manuals are in simple PDF format, which stands for Portable Document Format. The file format provides an electronic image of the printed book.

Since all modern electronic devices (computers, smartphones and e-readers) are already preinstalled with the software needed to download and view the manual, you won’t need to download any additional software to view the book. In fact, once you download the manual, you can save it to your device forever.

So what are you waiting for? Download a Suzuki outboard repair manual instantly and fix your problems now!

Which Suzuki repair manuals are available for instant download?

YEAR MODEL NAME HORSEPOWER SERVICE MANUAL #
1977-2002 DT2.2 thru DT140 2.2hp thru 140hp N/A
1996-2002 DF9.9 DF14 9.9hp, 15hp N/A
1997-1998 DF40 DF50 40hp, 50hp N/A
1997-1999 DF25 DF30 25hp, 30hp N/A
1997-2000 DF60 DF70 60hp, 70hp N/A
1999-2004 DF40T DF50T 40hp, 50hp 99500-87J00-01E
2005 DF40T DF40QH DF50T DF50TH 40hp, 50hp 99501-87J40-01E
2006-2007 DF40T DF40QH DF50T DF50TH 40 hp, 50 hp 99501-87J50-01E
2008-2011 DF40QH DF50QH 40 hp, 50 hp 99501-87J00-01E
2000-2011 DF25Q DF25QE DF25QR DF25T 25 hp 99500-89J02-01E
2008-2012 DF25 DF25E DF25R 25hp N/A
2000-2003 DF30Q DF30QE DF30R DF30T 30 hp 99500-89J02-0E1
2001-2008 DF90T DF115T DF115W DF115WT 90hp 115hp 99500-90J07-03E
2002 DF140T DF140Z 140hp 99500-90J07-03E
2009 DF100T DF100WT 100hp 99500-90J07-03E
2002-2011 DF4 DF5 DF6 4hp 5hp 6hp 99500-91J02-01E
2003-2011 DF60T DF70W DF70T DF70WTH 60hp 70hp
2003-2005 DF9.9 DF9.9A DF9.9E DF9.9AE 9.9hp 99500-93E10-01E
2003-2005 DF9.9R DF9.9AR DF15 DF15A 9.9 hp 15hp 99500-93E01-01E
2003-2007 DF15E DF15AE DF15R DF15AR 15 hp 99500-93E01-01E
2006-2014 DF2.5 2.5hp 99500-97Joo-0E1
2008-2011 DF9.9T DF9.9TH 9.9hp 99501-94Joo-01E
2012-2013+ DF15A DF15AE DF20A DF2oAE 15hp 20hp 99500-89L00-01E
2014-2015+ DF25A DF25AE DF25AR DF25Q 25hp 99500-94710-01E
2014-2015+ DF25AQE DF25ATH DF25AT 25 hp 99500-94710-01E
2010-2013 DF60AT DF60TH 60 hp N/A
2010-2012 DF40AT DF40AQH DF50AT 40hp 50hp 99501-88L00-01E
2010-2013 DF50ATH 50hp 99501-88L10-01E
2009-2013 DF70AT DF80AT DF90AT 70hp 80hp 90hp N/A
2013-2014+ DF100AT DF115AT DF115AZ 100 hp 115 hp 99500-92J00-01E
2014+ DF140AT DF140AZ 140hp 99500-92J00-01E
2006-2010 DF150T DF150Z DF175T DF175Z 150hp 175hp N/A
2008-2010 DF150WT DF150WZ 150 hp 99501-96J10-01E
2004-2011 DF200 DF200T DF225T DF250T 200hp 225hp 250hp N/A
2006-2007 DF200WT DF225WT 200 hp 225 hp 99501-93J10-01E
2008 DF250 DF250S 250 hp N/A
2009-2011 DF200T(E01) DF200Z(E01) 200hp N/A
2007-2011 DF300 DF300T DF300Z 300hp N/A
2012-2013 DF300AP 300 hp 99501-98J40-01E
2010-2014 DF8 DF8A DF8AE DF8AR 8hp N/A
2010-2014 DF9.9A DF9.9AE DF9.9AR 9.9hp N/A

4 Comments

    • The following years and models are available for suzuki 2-stroke DT motors 1977 1989 1979 1982 1981 1983 1982 1985 1985 1987 1986 1989 1988 1991 1990 1993 1992 1994 1995 1997 1996 1998 1999 2002 2001.

      1977-1985 DT2 (2.2 hp)
      1979-1984 DT3.5 (3.5 hp)
      1978-1998 Suzuki DT4 (4 hp)
      1977 DT4.5 (4.5 hp)
      1978-1983, 1999-2002 DT5 (5 hp)
      1984-2002 Suzuki DT6 (6 hp)
      1977-1979 DT7.5 (7.5 hp)
      1980-1987 Suzuki DT8 (8 hp)
      1977-1979 DT9.9 (9.9 hp)
      1977-1979 Suzuki DT14 (14 hp)
      1983-1997 DT16 (16 hp)
      1977-1988 Suzuki DT20 (20 hp)
      1977-1988 DT25 (25 hp)
      1979-1982 DT28 (28 hp)
      1983-1987 Suzuki DT30 (30 hp)
      1980-1982, 1987-1989 DT35 (35 hp)
      1980-1998 DT40 (40 hp)
      1981-1992 Suzuki DT48 (48 hp)
      1977-1984, 1985-1992 DT50
      1985-1987, 1988-1992 DT55 (55 hp)
      1983-1984, 1985-1992 DT60
      1978-1982, 1985-1987, 1988-1992 Suzuki DT65 (65 hp)
      1983-1987 DT75 (75 hp)
      1979-1987 DT85 (85 hp)
      1989-1997 DT90
      1989-1999, 2001 DT100
      1981-1985 Suzuki DT115
      1981-1985 DT140

  1. Need a Manual for a 1999 DF70 4 stroke so I can figure out the engine hours of motor 07001F-971629 four-stroke

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