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Outboard Motor
DF 25
Suzuki DF 25 Service Manual
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8-2 MID UNIT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
ENGINE SIDE CO
VER
REMO
V
AL
Remov
e f
our (4) screws
1
and PORT side co
v
er
2
.
Remov
e two (2) screws
3
and STBD side cov
er
4
.
INST
ALLA
TION
Installation is re
v
erse order of remov
al.
1.
Side cov
er STBD
2.
Side cov
er PORT
3.
F
ront panel
4.
Screw
5.
Hook
6.
Screw
7.
Cushion
8.
F
ront panel brac
ket
9.
Bolt
10.
Bolt
11.
Bolt
12.
Bolt
13.
Protector
14.
Screw
15.
Plug
16.
Rear hook le
ver
17.
Bush
18.
W
asher
19.
W
ave w
asher
20.
Engine cov
er hook
21.
Bolt
180
182
Table of Contents
Foreword Group Index
2
Table of Contents
2
Component Parts and Important Item Illustrations
3
How to Use this Manual
3
General Information
5
General Information
6
General Precautions
6
Identification Number Location
8
Fuel and Oil
8
Engine Oil
8
Gasoline Recommendation
8
Engine Break-In
9
Propellers
10
Specifications
11
Service Data
15
Tightening Torque
22
Special Tools
24
Materials Required
27
Warning/Caution/Note
6
Periodic Maintenance 2
28
Periodic Maintenance Schedule
29
Periodic Maintenance Chart
29
Engine Oil / Engine Oil Filter
30
Engine Oil Level Check
30
Engine Oil Change/Filter Replacement
31
Gear Oil
33
Lubrication
34
Spark Plug
35
Valve Clearance
36
Idle Speed
38
Carburetor
40
External Check
40
Synchronizing Throttle Valves
40
Dashpot Adjustment
42
Breather and Fuel Line
44
Fuel Filter
44
Ignition Timing
44
Propeller / Nut / Cotter Pin
45
Water Pump / Water Pump Impeller
45
Anodes and Bonding Wires
46
Battery
47
Bolts and Nuts
48
Maintenance and Tune-Up Procedures
30
Oil Pressure
49
Cylinder Compression
51
Engine Control System
52
Ignition System
53
Function and Failure Symptoms
53
System Components
53
Principles of Operation
55
Ignition Timing Control
56
Testing Ignition System
57
Ignition Troubleshooting
57
Checking Coil Resistance
58
Checking Coil / CDI Unit Output
60
Engine Stop & Emergency Stop Switch
62
Caution Systems
63
Over Revolution Caution System
63
Low Oil Pressure Caution System
64
Overheat Caution System
64
Testing Oil Pressure Caution System
65
Cylinder Temperature Sensor
66
Removal / Installation
67
Flywheel / Battery Charge & Power Source Coil / Ckp Sensor
67
Oil Pressure Switch
70
Electrical
71
Battery Charging System
72
Outline
72
Inspection
73
Removal / Installation
75
Electric Starter System
77
Outline
77
Troubleshooting
78
Inspection
80
Starter Motor
83
Fuel System
89
Fuel Line
90
Removal / Installation
90
Fuel Leakage Check Procedure
91
Fuel Hose Connection
91
Recoil Starter
92
General Precaution
90
Precaution on Fuel System Service
90
Carburetors
92
Removal
92
Installation
94
Disassembly
95
Cleaning & Inspection
96
Reassembly
97
Throttle Control
99
Throttle Link
99
Throttle Control Cable
101
Fuel Pump
102
Removal / Installation
102
Disassembly / Reassembly
103
Inspection
104
Fuel Tank
105
Disassembly / Reassembly
105
Inspection
106
Operation
107
Carburetor
107
Accelerator Pump System
108
Recoil Starter
109
Removal
110
Disassembly
111
Inspection
113
Reassembly
114
Installation
116
Neutral Start Interlock (Nsi)
117
Installation/Adjustment
117
Power Unit
118
Power Unit
119
Removal
119
Iinstallation
124
Timing Chain / Tensioner
128
Removal
128
Inspection
130
Installation
131
Cylinder Head Assembly
134
Removal
134
Assembly
134
Disassembly
136
Inspection / Servicing
138
Reassembly
151
Cylinder / Crankshaft / Piston
154
Disassembly
154
Inspection / Servicing
157
Reassembly
171
Thermostat
177
Operation
178
Water Cooling System
178
Engine Lubrication System
179
MID Unit
180
Engine Side Cover
181
Installation
181
Removal
181
Tiller Handle / Handle Bracket
182
Removal
182
Installation
183
Tiller Handle Disassembly / Assembly
183
Gas Assisted Tilt Cylinder
184
Removal
184
Inspection
185
Installation
186
Driveshaft Housing and Oil Pan
188
Removal
188
Inspection
191
Assembly
193
Swivel Bracket, Steering Bracket and Clamp Bracket
199
Removal
199
Inspection
201
Reassembly
202
Power Trim and Tilt
206
System Wiring Diagram
207
Service Procedure
208
Oil Level
208
Air Bleeding
208
Power Trim and Tilt Unit
209
Removal
209
Ptt Motor
210
Removal
210
Motor Disassembly
211
Inspection
212
Motor Assembly
213
Reassembly
214
Installation
215
Ptt Motor Relay
217
Ptt Switch
218
Operation
219
Components
219
Principles of Operation
220
Lower Unit
222
Lower Unit
225
Removal & Disassembly
226
Pinion Bearing
230
Inspection
232
Propeller
232
Gearcase
232
Gear
233
Propeller Shaft Components
233
Propeller Shaft Bearing Housing
233
Shift Rod and Shift Cam
234
Water Pump and Related Items
234
Driveshaft Bearing Housing
235
Driveshaft
235
Assembly & Installation
236
Trim Tab
246
Lower Unit Gears-Shimming and Adjustment
247
Wire / Hose Routing
252
Specifications
270
Service Data
274
Engine Control and Electrical
281
Wire Routing
283
5
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Suzuki DF 25 Specifications
General
Brand
Suzuki
Model
DF 25
Category
Outboard Motor
Language
English
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