DOWNLOAD Suzuki Outboard Repair Manual 1979-2015

Suzuki Outboard Repair Manual

DOWNLOAD a Suzuki outboard repair manual instantly. A Suzuki outboard repair manual is a book of instructions, detailing the action of mending or fixing the boat motor back to factory specifications. The downloadable handbook covers every aspect of repair, from basic maintenance to complete engine overhaul, and restoration.

 A download Suzuki repair manual, also known as a service manual, repair guide or workshop manual,  is no different from a repair book you’d buy in stores, except this book is digitally delivered straight to your computer in seconds. It contains a main index page or table of contents, general information chapter, powerhead chapter, mid unit chapter, lower unit chapter, wiring and hose routing chapter, fuel system chapter, maintenance chapter, electrical chapter, and in some cases supplemental manuals.

Download Online Factory Service Repair manual PDF

All Suzuki repair manuals contain pictures, illustrations, parts diagrams, critical specifications, and most importantly, a troubleshooting guide to help a mechanic trace faults within the engine’s mechanical or electrical system. A troubleshooting guide is especially helpful for those who are unsure what’s causing the boat motor to work improperly.

All Suzuki outboard repair manuals contain step-by-step repair procedures. These procedures consist of part removal, part disassembly, part inspection, part cleaning, reassembly and installation. Depending on the part in question, the manual may also contain testing procedures to determine if the part is faulty. The following is a small example of chapters and subjects covered in a Suzuki outboard repair manual (actual subjects may differ depending on year and model outboard):

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

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

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

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

  • Removal and inspection
  • Disassembly and cleaning
  • Assembly and installation
  • Pinion bearing
  • Propeller
  • Gear case
  • Gears
  • Propeller shaft components
  • Propeller shaft bearing housing
  • Shift rod guide housing components
  • Water pump and related items
  • Driveshaft oil seal housing
  • Driveshaft
  • 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.

A downloadable repair manual isn’t much different then a manual you’d buy in a store. In fact, some would say it’s more convenient than the traditional paperback book. First, a paperback is very expensive. Secondly, it often gets greasy when using it during repair procedures. However, with a downloadable manual you can print specific pages or repair procedures and throw it away when the repair work is done. Also, a download manual has clickable chapters and a searchable index allowing the mechanic to locate the needed procedures immediately.

A downloadable repair manual is also much easier to obtain as compared to rare paperback versions. You can get a download Suzuki repair manual in just seconds. And you can download it to your phone, tablet or computer without the need for special software. Downloadable manuals are in simple PDF file format, which is an electronic image of text or text and graphics that looks like a printed book and can be viewed, printed, and electronically transmitted.

25 Comments

    • Suzuki 2-stroke outboard repair manual DT models for 1977 1978 1980 1979 1981 1982 1984 1983 1986 1985 1988 1987 1989 1992 1990 1991 1993 1992 1995 1994 1996 1995 1998 1997 2000 1999 2001 2002.

      1977-1985 Suzuki DT2 (2.2 hp)
      1979-1984 Suzuki DT3.5 (3.5 hp)
      1978-1998 Suzuki DT4 (4 hp)
      1977 Suzuki DT4.5 (4.5 hp)
      1978-1983, 1999-2002 Suzuki DT5 (5 hp)
      1984-2002 Suzuki DT6 (6 hp)
      1977-1979 Suzuki DT7.5 (7.5 hp)
      1980-1987 Suzuki DT8 (8 hp)
      1977-1979 Suzuki DT9.9 (9.9 hp)
      1977-1979 Suzuki DT14 (14 hp)
      1983-1997 Suzuki DT16 (16 hp)
      1977-1988 Suzuki DT20 (20 hp)
      1977-1988 Suzuki DT25 (25 hp)
      1979-1982 Suzuki DT28 (28 hp)
      1983-1987 Suzuki DT30 (30 hp)
      1980-1982, 1987-1989 DT35 (35 hp)
      1980-1998 Suzuki DT40 (40 hp)
      1981-1992 Suzuki DT48 (48 hp)
      1977-1984, 1985-1992 Suzuki DT50 (50 hp)
      1985-1987, 1988-1992 Suzuki DT55 (55 hp)
      1983-1984, 1985-1992 Suzuki DT60 (60 hp)
      1978-1982, 1985-1987, 1988-1992 Suzuki DT65 (65 hp)
      1983-1987 Suzuki DT75 (75 hp)
      1979-1987 Suzuki DT85 (85 hp)
      1989-1997 Suzuki DT90 (90 hp)
      1989-1999, 2001 Suzuki DT100 (100 hp)
      1981-1985 Suzuki DT115 (115 hp)
      1981-1985 Suzuki DT140 (140 hp)

    • The following years cover the DF manuals, 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014. The following manuals are available for instant download for these models:

      1999-2011 Suzuki DF40 DF50 (40HP 50HP) Repair Manual
      2000-2003 Suzuki DF25 DF30 (25HP 50HP) Repair Manual
      2001-2009 Suzuki DF115 DF140 (115HP 140HP) Repair Manual
      2001-2009 Suzuki DF90 DF100 (90HP 100HP) Repair Manual
      2002-2005 Suzuki DF4 DF5 DF6 (4HP 5HP 6HP) Repair Manual
      2002-2011 Suzuki DF4 DF5 (4 HP 5 HP) Repair Manual
      2003-2007 Suzuki DF60 DF70 (60HP 70HP) Repair Manual
      2003-2011 Suzuki DF9.9 DF15 (9.9HP 15HP) Repair Manual
      2004-2007 Suzuki DF25 DF30 (25 HP 30 HP) Repair Manual
      2004-2011 Suzuki DF200 DF225 DF250 (200HP 225HP 250HP) Repair Manual
      2006-2011 Suzuki DF150 DF175 (150HP 175HP) Repair Manual
      2006-2014 Suzuki DF2.5 (2.5HP) Repair Manual
      2009-2011 Suzuki DF70 DF80 (70HP 80HP) Repair Manual
      2009-2011 Suzuki DF90 (90HP) Repair Manual
      2010-2014 Suzuki DF8 (8 hp) DF9.9 (9.9 hp) Service Manual
      2012-2013 Suzuki DF15 (15hp) DF20 (20 hp) Service Manual
      2007-2013 Suzuki DF300 (300hp 300 hp) Service manual

  1. hi i am looking for a repair manual for a 2015 suzuki df25a any assistance would be greatfully appreciated

  2. I am looking for a manual for a Suzuki Model DT 15 serial Number 01503-013979
    manufactured in 2009. Can you assist??

  3. I am trying to locate a manual for a 1986 DT25. I am having trouble and I am looking to troubleshoot it before just buying parts.

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