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DF 60
Suzuki DF 60 Service Manual
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LOWER UNIT 9-13
55 N·m
(5.5 kg-m, 40.0 lb-ft)
Shift rod guide housing
Bolt
O-ring
Dust seal
W
asher
O-ring
O-ring
W
asher
Circlip
Pin
Spring
Shift rod spring collar
Shift rod
Magneto
Magneto holder
Pin
Pin
Clutch cam
Detent ball
Spring
Plate
Shift rod guide
Grommet
W
ater pump case
Pin
Bolt
Key
W
ater pump impeller
Pump case under panel
Gasket
Exhaust seal
Exhaust seal plate
Union
Hose
Nipple
Gearcase
Bolt
Bolt
Pin
Anode
W
asher
Bolt
T
rim tab
Bolt
Screw
W
ater filter PORT
W
ater filter STBD
ASSEMBL
Y & INST
ALLA
TION
Assembly & installation are re
verse order of remov
al & disassembly with the special attention to the f
ollowing
steps.
252
254
Table of Contents
Foreword Group Index
2
Table of Contents
2
General Information
6
General Precautions
6
Warning / Caution / Note
6
Fuel and Oil
8
Gasoline Recommendation
8
Engine Oil
8
Identification Number Location
8
Engine Break-In
9
Warm-Up Recommendation
9
Throttle Recommendation
9
Propellers
10
Specifications
11
Service Data
13
Self-Diagnostic System Indication
18
Tightening Torque
19
Special Tools
21
Materials Required
24
Periodic Maintenance 2
25
Periodic Maintenance Schedule
26
Periodic Maintenance Chart
26
Maintenance and Tune-Up Procedures
27
Engine Oil/Engine Oil Filter
27
Gear Oil
30
Lubrication
31
Spark Plug
32
Valve Clearance
33
Timing Belt
35
Idle Speed
38
Ignition Timing
39
Breather and Fuel Line
40
Low Pressure Fuel Filter
40
High Pressure Fuel Filter
40
Water Pump Impeller / Water Pump
41
Propeller Nut and Pin/Propeller
41
Anodes and Bonding Wires
42
Battery
43
Bolts and Nuts
44
Fuel Mixture Check (Ofeedback)
45
Oil Pressure
47
Cylinder Compression
48
Engine Control System
49
Engine Control System Structure
50
System Structure 1
50
System Structure 2
51
Wiring Diagram for Engine Control
52
Components for System Control
53
Engine Control Module (Ecm)
53
Sensor and Switch
56
Ignition System
60
Ignition Control System
60
Electronic Fuel Injection System
62
Fuel Injection Control System
62
Fuel Delivery System Components
64
Fuel Pump Control System
67
Air Intake Components
68
Idle Air Control System
69
Caution System
71
Over-Revolution Caution System
71
Low Oil Pressure Caution System
72
Overheat Caution System
73
Low Battery Voltage Caution System
74
Electrical
74
Self-Diagnostic System
75
Priority/Code/Pattern for Self-Diagnostic System Operation
75
Condition for Self-Diagnostic System Operation
77
Fail-Safe System
78
Pre-Programmed Value for Fail-Safe System
78
Operating Hour Indication System
79
Oil Change Reminder System
80
Start-In-Gear Protection System
82
O 2 Feedback System
83
Inspection
84
Precaution on System Inspection
84
44-Pin Test Cord
84
Inspection for Ecm Circuit Voltage
85
Inspection for Resistance
87
Component Inspections
88
Troubleshooting
93
Fuel System
93
Removal/Installation
99
Flywheel/Ckp Sensor/Cmp Sensor
99
Oil Pressure Switch
101
Electrical
102
Battery Charging System
103
Outline
103
Inspection
104
Removal/Installation
105
Electric Starter System
107
Outline
107
Troubleshooting
108
Inspection
109
Starter Motor
111
Electric Parts Holder
118
Monitor-Tachometer
119
Fuel System
120
Precaution on Fuel System Service
121
General Precaution
121
Fuel Pressure Relief Procedure
121
Fuel Line
122
Removal/Installation
122
Fuel Leakage Check Procedure
122
Fuel Hose Connection
123
Fuel Pressure Inspection
123
Fuel Vapor Separator / High Pressure Fuel Pump
125
Removal / Installation
125
Disassembly
126
Inspection
127
Reassembly
128
Fuel Injector / Delivery Pipe
130
Removal
130
Inspection
130
Installation
131
Low Pressure Fuel Pump
132
Removal / Installation
132
Disassembly / Reassembly
133
Inspection
134
Fuel Tank
135
Disassembly / Reassembly
135
Inspection
136
Power Unit
137
Intake Manifold Assy
138
Removal
138
Installation
141
Power Unit
142
Removal
142
Installation
146
Cylinder Head Assy
150
Removal
150
Installation
150
Disassembly
151
Inspection / Servicing
153
Reassembly
162
Cylinder / Crankshaft / Piston
164
Disassembly
164
Inspection / Servicing
168
Reassembly
181
Operation
187
Water Cooling System
187
Engine Lubrication System
188
MID Unit
189
Engine Side Cover
190
Removal
190
Installation
191
Tiller Handle
192
Removal / Disassembly
192
Driveshaft Housing and Oil Pan
200
Removal
200
Inspection
203
Reassembly
204
Swivel Bracket, Steering Bracket and Clamp Bracket
210
Removal / Disassembly
210
Inspection
212
Reassembly
213
Power Trim and Tilt
217
System Wiring Diagram
218
Service Procedure
219
Oil Level
219
Air Bleeding
219
Power Trim and Tilt Unit
220
Removal
220
Disassembly
221
Inspection
223
Reassembly
225
Ptt Motor
226
Ptt Motor Removal
226
Ptt Motor Disassembly
227
Ptt Motor Inspection
228
Ptt Motor Reassembly
229
Ptt Motor Installation
230
Installation
231
Ptt Motor Relay
233
Ptt Switch
234
Operation
235
Components
235
Principles of Operation
236
Lower Unit
238
Lower Unit
241
Removal & Disassembly
242
Pinion Bearing
247
Pinion Bearing ________________________________________ 9- 7
249
Inspection
249
Propeller
249
Gearcase
249
Gears
250
Propeller Shaft Components
250
Propeller Shaft Bearing Housing
250
Shift Rod Guide Housing Components
251
Water Pump and Related Items
251
Driveshaft Oil Seal Housing
252
Driveshaft
252
Assembly & Installation
253
Lower Unit Gears- Shimming and Adjustment
263
Routing and Diagram
268
Wire Routing
269
Fuel Hose Routing
275
Water Hose Routing
278
Wiring Diagram
280
5
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Suzuki DF 60 Specifications
General
Brand
Suzuki
Model
DF 60
Category
Outboard Motor
Language
English
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