Suzuki df2.5 Service Manual

ADJUSTMENT
If engine idle speed is out of specification, adjust engine speed.
Turn the idle adjustment screw
® clockwise to increase idle
speed or counterclockwise to decrease idle speed.
CARBURETOR
Inspect initially after 20 hours (1 month) and every 100
hours (6 months) thereafter.
Inspect the body, the float chamber, the lever, the linkage, the
connector and the
fuel inlet.
If crack or other damage is found, replace.
IGNITION TIMING
I Inspect every 200 hours (12 months).
NOTE:
Before checking the ignition timing, make sure that the idle
speed is adjusted within the specification.
1. Start and warm up the engine.
2. Attach the timing light cord to the spark plug high-tension
cord.
iMOh 09930-76420: Timing light
3. Check the ignition timing while operating the engine at the
idling speed.
Ignition timing: Approx. BTDC 30°

Suzuki df2.5 Specifications

General

Starting System	Manual
Fuel Tank Capacity	1.0 L
Number of Cylinders	1
Full Throttle Operating Range	5250 - 5750 RPM
Steering	Tiller
Displacement	68 cm3 (4.2 cu.in.)
Max Output	2.5 hp
Weight	13.5 kg
Ignition System	CDI
Bore x Stroke	48 x 38 mm (1.9 x 1.5 in.)

Summary

General Information

Safety Warnings and Precautions

Explains signal words (WARNING, CAUTION, NOTE) and general safety practices for servicing.

Specifications and Technical Data

Details engine specifications, including dimensions, performance, and component data.

Tightening Torque Values

Lists specified torque values for various fasteners used in the outboard motor.

Special Tools for Servicing

Lists specialized tools required for various maintenance procedures.

Periodic Maintenance Procedures

Maintenance Schedule and Chart Overview

Outlines recommended intervals for all periodic service tasks based on operating hours or time.

Engine Oil, Gear Oil, and Lubrication Service

Step-by-step guide for checking and changing engine oil, gear oil, and performing lubrication.

Spark Plug, Valve Clearance, and Idle Speed Service

Covers spark plug inspection/replacement, valve clearance adjustment, and idle speed setting.

Ignition Timing and Fuel System Component Service

Procedures for checking ignition timing and inspecting fuel system components like the carburetor.

Water Pump, Propeller, and Anode Maintenance

Details service intervals and procedures for water pump, propeller, and anode components.

Ignition and Electrical System

Ignition System Overview and Troubleshooting

Describes the ignition system and provides troubleshooting steps for starting issues.

Component Inspection Procedures

Details inspection of igniter unit, spark plug cap, and air gap for proper function.

Flywheel Magneto and Igniter Unit Service

Covers removal and installation of flywheel magneto and igniter unit.

Fuel System Service

Fuel System Safety Precautions

Emphasizes safety measures due to gasoline's flammability and toxicity.

Fuel Line and Carburetor Service Procedures

Procedures for fuel line removal/installation and carburetor disassembly/reassembly.

Fuel Tank and Fuel Cock Maintenance

Covers inspection and installation of the fuel tank and fuel cock assembly.

Recoil Starter Service

Recoil Starter Removal and Disassembly

Step-by-step guide for removing and disassembling the recoil starter assembly.

Recoil Starter Inspection and Reassembly

Covers inspection of recoil starter components and reassembly procedures.

Power Unit Service

Power Unit Removal and Installation Overview

Outlines the procedure for removing and installing the entire power unit.

Cylinder Head, Valve, and Rocker Arm Service

Details removal, installation, and inspection of cylinder head, valves, and rocker arm assemblies.

Piston, Crankshaft, Conrod, and Camshaft Service

Covers disassembly, inspection, and reassembly of core engine internal components.

Thermostat Service Procedures

Instructions for thermostat removal, inspection, and installation.

Mid Unit Service

Driveshaft Housing, Swivel Bracket, and Clamp Bracket Disassembly

Procedures for disassembling mid unit housing, brackets, and related parts.

Mid Unit Component Inspection and Reassembly

Inspection criteria and reassembly steps for mid unit components.

Tiller Handle Removal and Service

Covers removal, disassembly, and reassembly of the tiller handle assembly.

Lower Unit Service

Lower Unit Removal and Disassembly Procedures

Detailed steps for removing and disassembling the lower unit and its components.

Lower Unit Component Inspection Guidelines

Inspection criteria for propeller, gearcase, gears, and shaft components.

Lower Unit Reassembly and Gear Adjustment

Procedures for reassembling the lower unit and adjusting gears, including oil filling.

Gear Shimming and Backlash Adjustment

Critical procedures for adjusting gear backlash and tooth contact patterns for proper gear engagement.

Wire and Hose Routing Diagrams

Hose Routing Diagram and Precautions

Illustrates fuel and breather hose routing with installation cautions.

Wire Routing Diagram and Schematics

Diagrams showing wire routing and the ignition system wiring schematic.

Supplementary Manual - 2008 Model Updates

Foreword and General Information Updates

Introduces the supplementary manual and outlines general information changes for the 2008 model.

Specifications and Service Data Changes

Details updated specifications and service data for the 2008 model.

Periodic Maintenance and Ignition Timing Updates

Notes changes in periodic maintenance schedules and ignition timing for later models.

Fuel System and Carburetor Updates

Covers changes to the fuel pump (US market) and carburetor settings for later models.

Lower Unit and Propeller Shaft Updates

Details design changes in the lower unit and propeller shaft components for later models.

Driveshaft Oil Seals and Wire Routing Updates

Covers replacement of driveshaft oil seals and illustrates updated wire routing for later models.