PRE-PRODUCTION
ISSUE
1
FOREWORD
This manual contains an introductory description of GROUP INDEX
the SUZUKI DF150/175 Outboard motors and pro-
cedures for inspection, service and overhaul of their
main components.
GENERAL INFORMATION 1
General knowledge information is not included.
Please read the GENERAL INFORMATION section PERIODIC MAINTENANCE 2
to familiarize yourself with basic information con-
cerning this motor. Read and refer to the other ENGINE CONTROL SYSTEM 3
sections in this manual for information regarding
proper inspection and service procedures.
This manual will help you better understand these
ENGINE ELECTRICAL 4
outboard motors, assisting you in providing your
customers with optimum and quick service. FUEL SYSTEM 5
• This manual has been prepared using the
latest information available at the time of
POWER UNIT 6
publication.
Differences may exist between the content of MID UNIT 7
this manual and the actual outboard motor.
• Illustrations in this manual are used to show
the basic principles of operation and work
POWER TRIM AND TILT 8
procedures and may not represent the actual
outboard motor in exact detail.
LOWER UNIT
[Standard rotation (Right-hand) model] 9
• This manual is intended for use by techni-
cians who already possess the basic knowl- LOWER UNIT
[Counter rotation (Left-hand) model] 10
edge and skills to service SUZUKI outboard
motors.
Persons without such knowledge and skills
WIRE/HOSE ROUTING 11
should not attempt to service SUZUKI out-
board engines by relying on this manual only
and should contact an authorized SUZUKI
outboard motor dealer.
!
Apprentice mechanics or do-it-yourself
mechanics that don’t have the proper tools
and equipment may not be able to properly
perform the services described in this man-
ual.
Improper repair may result in injury to the
mechanic and may render the engine unsafe
for the boat operator and passengers.
NOTE:
This manual is compiled based on 2006 (K6) model.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2005 Marine & Power Products Division
2
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed on the previous page in a
GROUP INDEX. Select the section needed for reference.
3. Holding the manual as shown at the right will allow you to
find the first page of the section easily.
4. The first page of each section contains a table of contents to
easily locate the item and page you need.
COMPONENT PARTS AND IMPORTANT ITEM ILLUSTRATIONS
Under the name of each system or unit, an exploded view is provided with work instructions and other ser-
vice information such as the tightening torque, lubrication and locking agent points.
Example:
1. Flywheel bolt
2. Flywheel 1 118 N·m (11.8 kg-m, 85.5 lb-ft)
3. Dowel pin
4. CKP sensor
5. Bolt
6. CMP sensor 7
7. Bolt
6
2
NOTE:
Clean flywheel and crankshaft
mating surfaces with cleaning
5
3 solvent.
3
SYMBOL
Listed in the table below are the symbols indicating instructions and other important information necessary
for proper servicing. Please note the definition for each symbol. You will find these symbols used throughout
this manual. Refer back to this table if you are not sure of any symbol(s) meanings.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified Apply SUZUKI SILICONE SEAL.
torque.
Apply oil. Use the engine oil unless oth-
Apply THREAD LOCK “1342”.
erwise specified.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKl Apply THREAD LOCK SUPER “1333B”.
MOLY PASTE in a ratio of 1 : 1)
Apply SUZUKI OUTBOARD MOTOR
Measure in DC voltage range.
GEAR OIL.
Apply SUZUKI SUPER GREASE “A”. Measure in resistance range.
Apply SUZUKI MOLY PASTE.
Measure in continuity test range.
99000-25140
Apply SUZUKI WATER RESISTANT
Use peak voltmeter “Stevens CD-77”.
GREASE.
Apply SUZUKI BOND “1104”. Use special tool.
Apply SUZUKI BOND “1207B”.
4
ABBREVIATIONS
Abbreviations used in this service manual are as follows:
BTDC : Before Top Dead Center
CKP : Crankshaft position
CMP : Camshaft position
CTP : Close Throttle position
DC : Direct Current
DOHC : Double Over Head Camshaft
ECM : Engine Control Module
EX (Ex.) : Exhaust
IAC : Idle Air Control
IAT : Intake Air Temperature
IN (In.) : Intake
MAP : Manifold absolute pressure
OCV : Oil control valve
PORT : Port
PTT : Power Trim & Tilt
SPS : Shift Position Sensor
STBD : Starboard
TPS : Throttle Position Sensor
VSV : Vacuum switching valve
VVT : Variable Valve Timing
5
GENERAL INFORMATION 1-1
GENERAL INFORMATION
1
CONTENTS
WARNING/CAUTION/NOTE .........................................................................1- 2
GENERAL PRECAUTIONS ...........................................................................1- 2
IDENTIFICATION NUMBER LOCATION ......................................................1- 4
FUEL AND OIL ..............................................................................................1- 5
GASOLINE RECOMMENDATION .........................................................1- 5
ENGINE OIL ...........................................................................................1- 5
ENGINE BREAK-IN .......................................................................................1- 6
WARM-UP RECOMMENDATION ..........................................................1- 6
THROTTLE RECOMMENDATION .........................................................1- 6
PROPELLERS ...............................................................................................1- 7
POWERHEAD DIRECTION OF ROTATION .................................................1- 8
CYLINDER NUMBER ....................................................................................1- 8
SPECIFICATIONS .........................................................................................1- 9
SERVICE DATA .............................................................................................1-12
TIGHTENING TORQUE .................................................................................1-20
SPECIAL TOOLS ..........................................................................................1-22
MATERIALS REQUIRED ..............................................................................1-26
6
1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.
!
Indicates a potential hazard that could result in death or injury.
"
Indicates a potential hazard that could result in motor damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the
WARNING and CAUTION stated, you must also use good judgment and observe basic mechanical safety
principles.
GENERAL PRECAUTIONS
!
• Proper service and repair procedures are important for the safety of the service mechanic
and the safety and reliability of the outboard motor.
• To avoid eye injury, always wear protective goggles when filing metals, working on a grinder,
or doing other work, which could cause flying material particles.
• When two or more persons work together, pay attention to the safety of each other.
• When it is necessary to run the outboard motor indoors, make sure that exhaust gas is vented
outdoors.
• When testing an outboard motor in the water and on a boat, ensure that the necessary safety
equipment is on board. Such equipment includes: flotation aids for each person, fire extin-
guisher, distress signals, anchor, paddles, bilge pump, first aid kit, emergency starter rope,
etc.
• When working with toxic or flammable materials, make sure that the area you work in is well
ventilated and that you follow all of the material manufacturer’s instructions.
• Never use gasoline as a cleaning solvent.
• To avoid getting burned, do not touch the engine, engine oil or exhaust system during or
shortly after engine operation.
• Oil can be hazardous. Children and pets may be harmed from contact with oil. Keep new and
used oil away from children and pets. To minimize your exposure to oil, wear a long sleeve
shirt and moisture-proof gloves (such as dishwashing gloves) when changing oil. If oil con-
tacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet
with oil. Recycle or properly dispose of used oil.
• After servicing fuel, oil/engine cooling system and exhaust system, check all lines and fit-
tings related to the system for leaks.
• Carefully adhere to the battery handling instructions laid out by the battery supplier.
7
GENERAL INFORMATION 1-3
"
• If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiv-
alent.
• When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order and orientation.
• Be sure to use special tools where instructed.
• Make sure that all parts used in assembly are clean and also lubricated when specified.
• When use of a certain type of lubricant, bond or sealant is specified, be sure to use the speci-
fied type.
• When removing the battery, disconnect the negative cable first and then the positive cable.
When reconnecting the battery, connect the positive cable first and then the negative cable.
• When performing service to electrical parts, if the service procedures do not require using
battery power, disconnect the negative cable at the battery.
• Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending
with smaller diameter. Always tighten from inside to outside diagonally to the specified tight-
ening torque.
• Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, locking nuts,
cotter pins, circlips, and certain other parts as specified, always replace them with new. Also,
before installing these new parts, be sure to remove any left over material from the mating
surfaces.
• Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
• Use a torque wrench to tighten fasteners to the torque values when specified.
• Remove grease or oil from screw/bolt threads unless a lubricant is specified.
• After assembly, check parts for tightness and operation.
• To protect the environment, do not unlawfully dispose of used motor oil, other fluids and bat-
teries.
• To protect the Earth’s natural resources, properly dispose of used motor parts.
8
1-4 GENERAL INFORMATION
IDENTIFICATION NUMBER LOCATION
MODEL, PRE-FIX, SERIAL NUMBER
The MODEL, PRE-FIX and SERIAL NUMBER of motor are
stamped on a plate attached to the clamp bracket.
Example
MODEL
DF 175
17501F
PRE-FIX SERIAL NUMBER
ENGINE SERIAL NUMBER
A second engine serial number plate is pressed into a boss on
the cylinder block.
XXXXXX
1. Serial number plate
