This manual contains an introductory description on
SUZUKI Outboard motor DF90/115/140 and proce-
dures for the inspection, service and overhaul of its
main components.
General knowledge information is not included.
Please read the GENERAL INFORMATION sec-
tion to familiarize yourself with basic information
concerning this motor. Read and refer to the other
sections in this manual for information regard-
ing proper inspection and service procedures.
This manual will help you better understand this out-
board motor so that you may provide your custom-
ers with optimum and quick service.
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE CONTROL SYSTEM
ENGINE ELECTRICAL
FUEL SYSTEM
POWER UNIT
MID UNIT
POWER TRIM AND TILT
LOWER UNIT
WIRE / HOSE ROUTING
DF140 “K2” (’02) MODEL
DF90/115 “K2” (’02) MODEL
DF90/115/140 “K3” (’03) MODEL
DF90/115/140 “K4” (’04) MODEL
DF90/115/140 “K5” (’05) MODEL
DF90/115/140 “K6” (’06) MODEL
DF90/115/140 “K7” (’07) MODEL
DF90/115/140 “K8” (’08) MODEL
GROUP INDEX
#
Apprentice mechanics or do-it-yourself me-
chanics that don’t have the proper tools and
equipment may not be able to properly per-
form the services described in this manual.
Improper repair may result in injury to the
mechanic and may render the engine unsafe
for the boat operator and passengers.
FOREWORD
• This manual has been prepared using the lat-
est information available at the time of publi-
cation.
If a modification has been made since then,
differences may exist between the content of
this manual and the actual outboard motor.
• Illustrations in this manual are used to show
the basic principles of operation and work
procedures and may not represent the ac-
tual outboard motor in exact detail.
• This manual is intended for use by technicians
who already possess the basic knowledge and
skills to service SUZUKI outboard motors.
Persons without such knowledge and skills
should not attempt to service an outboard
engine by relying on this manual only.
Instead, please contact your nearby autho-
rized SUZUKI outboard motor dealer.
COPYRIGHT SUZUKI MOTOR CORPORATION 2003
NOTE:
This manual is compiled based on 2001 (K1) model.
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DF100 “K9” (’09) MODEL
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