Suzuki DF 140 Four Stroke Manuals

Manuals and User Guides for Suzuki DF 140 Four Stroke. We have 1 Suzuki DF 140 Four Stroke manual available for free PDF download: Service Manual

Suzuki DF 140 Four Stroke Service Manual (616 pages)

Brand: Suzuki | Category: Outboard Motor | Size: 9.77 MB

General Information 1

5
- Engine Control System
  2
  - Fuel System
    2
    
    Product View and Components
    3
    
    How to Use this Manual
    3
    
    Symbol Description
    4
    
    Table of Contents
    5
- General Information
  2
- Warning / Caution / Note
  6
- General Precautions
  6
- Identification Number Location
  8
- Fuel and Oil
  8
  - Gasoline Recommendation
    8
  - Engine Oil
    8
- Engine Break-In
  9
- Propellers
  10
- Powerhead Direction of Rotation
  10
- Specifications
  11
  - General Specification
    12
- Service Data
  13
  - Self-Diagnostic System Indication
    19
- Tightening Torque
  20
- Special Tools
  22
- Materials Required
  25
Periodic Maintenance 2

26
- Periodic Maintenance Schedule
  
  27
  - Periodic Maintenance Chart
    27
- Maintenance and Tune-Up Procedures
  
  28
  - Engine Oil / Engine Oil Filter
    28
  - Engine Oil Change/Engine Oil Filterreplacement
    29
  - Gear Oil
    31
  - Lubrication
    32
  - Spark Plug
    33
  - Tappet Clearance
    34
  - Idle Speed
    39
  - Ignition Timing
    40
  - Breather and Fuel Line
    41
  - Low Pressure Fuel Filter
    41
  - High Pressure Fuel Filter
    42
  - Water Pump / Water Pump Impeller
    42
  - Propeller / Nut / Cotter Pin
    42
  - Anodes and Bonding Wires
    43
  - Battery
    44
  - Bolt and Nuts
    45
  - Feedback)
    45
- Oil Pressure
  
  46
- 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
  - Ecm Connector / Terminals Layout
    54
  - Ecm Internal Structure
    55
  - 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
- 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
  81
- O 2 Feedback System
  82
- Inspection
  83
  - Precaution on System Inspection
    83
  - 44-Pin Test Cord
    83
  - Inspection for Ecm Circuit Voltage
    84
  - Inspection for Resistance
    86
  - Component Inspections
    87
- Troubleshooting
  93
- Removal / Installation
  99
  - Flywheel
    99
  - Ckp Sensor / Cmp Sensor
    99
  - Oil Pressure Switch
    102
Electrical

103
- Battery Charging System
  
  104
  - Outline
    104
  - Inspection
    105
  - Removal / Installation
    107
- Electric Starter System
  
  109
  - Outline
    109
  - Troubleshooting
    111
  - Inspection
    112
  - Starter Motor
    114
    
    Disassembly
    115
    
    Inspection & Servicing
    118
    
    Assembly
    123
    
    Performance Test
    124
- Monitor-Tachometer
  
  126
  - Inspection
    126
- Erectric Parts Holder
  
  127
Fuel System

128
- Removal / Installation
  128
- Precaution on Fuel System Service
  
  129
  - General Precaution
    129
  - Fuel Pressure Relief Procedure
    130
- Removal / Installation
  
  131
- Fuel Line ______________________________________________ 5-4
  
  131
  - Fuel Leakage Check Procedure
    131
  - Fuel Hose Connection
    132
  - Fuel Pressure Inspection
    132
- Fuel Vapor Separator / High Pressure Fuel Pump
  
  134
  - Removal / Installation
    134
  - Disassembly
    135
  - Inspection
    136
  - Assembly
    137
- Fuel Injector
  
  139
  - Inspection
    139
  - Removal
    139
  - Installation
    140
- Low Pressure Fuel Pump
  
  141
  - Removal / Installation
    141
  - Disassembly / Reassembly
    142
  - Inspection
    143
- Fuel Tank
  
  144
  - Disassembly / Reassembly
    144
  - Inspection
    145
Power Unit

146
- Intake Manifold Assembly
  
  147
  - Removal
    147
  - Installation
    149
- Power Unit
  
  150
  - Removal
    150
  - Installation
    154
- Oil Pump
  
  157
  - Removal
    157
  - Inspection
    157
  - Installation
    158
- Timing Chain / Tensioner
  
  159
  - Removal
    159
  - Inspection
    161
  - Installation
    162
- Cylinder Head Assembly
  
  165
  - Removal
    165
  - Installation
    166
  - Disassembly
    169
  - Inspection / Servicing
    170
  - Reassembly
    183
- Cylinder / Crankshaft / Piston
  
  185
  - Disassembly
    185
  - Inspection / Servicing
    188
  - Reassembly
    202
- Thermostat
  
  208
- Operation
  
  209
  - Water Cooling System
    209
  - Engine Lubrication System
    210
- Removal / Inspection / Installation
  
  209
MID Unit

211
- Engine Side Cover
  
  212
  - Removal
    212
  - Installation
    212
- Driveshaft Housing and Oil Pan
  
  213
  - Removal
    213
  - Inspection
    215
  - Assembly
    217
- Swivel Bracket, Steering Bracket and Clamp Bracket
  
  223
  - Removal
    223
  - Inspection
    225
  - Reassembly
    226
- Clamp Bracket ________________________________________ 7-13
  
  223
- Water Pressure Valve
  
  230
Power Trim and Tilt

231
- System Wiring Diagram
  
  232
- Service Procedure
  
  233
  - Oil Level
    233
  - Air Bleeding
    233
- Power Trim and Tilt Unit
  
  234
  - Removal
    234
  - Disassembly
    235
  - Inspection
    237
  - Reassembly
    239
  - Ptt Motor
    240
    
    Ptt Motor Removal
    240
    
    Ptt Motor Disassembly
    241
    
    Ptt Motor Inspection
    242
    
    Ptt Motor Assembly
    243
    
    Ptt Motor Installation
    244
  - Installation
    245
- Ptt Motor Relay
  
  247
- Ptt Switch
  
  248
- Operation
  
  249
  - Components
    249
  - Principles of Operation
    250
Lower Unit

255
- Removal & Disassembly
  
  256
- Pinion Bearing
  
  261
- Inspection
  
  263
  - Propeller
    263
  - Gearcase
    263
  - Gears
    264
  - Propeller Shaft Components
    264
  - Propeller Shaft Bearing Housing
    264
  - Shift Rod Guide Housing Components
    265
  - Water Pump and Related Items
    265
  - Driveshaft Oil Seal Housing
    266
  - Driveshaft
    266
- Assembly & Installation
  
  267
- Trim Tab
  
  277
- Lower Unit Gears-Shimming and Adjustment
  
  278
Df140 "K2" ('02) Model

294
- Specifications _________________________________________ 1
  294
- General Information
  295
  - Specifications
    295
  - Service Data
    297
  - Tightening Torque
    304
  - Special Tools
    306
  - Materials Required
    309
- Engine Control System
  310
- Power Unit
  311
  - Engine Oil Cooler
    311
  - Camshaft
    313
  - Cylinder Block
    314
  - Piston & Piston Ring
    314
  - Crankshaft
    315
  - Conrod Assembly
    315
- MID Unit
  316
- Power Trim and Tilt
  318
  - Service Procedure
    318
  - Oil Level / Air Bleeding
    318
  - Power Trim and Tilt Unit
    319
  - Removal
    319
  - Disassembly
    320
  - Cleaning and Inspecting
    323
  - Reassembly
    324
  - Ptt Motor
    326
  - Installation
    330
  - Component Parts
    332
  - Operation
    332
- LOWER UNIT (Normal Rotation Model)
  339
  - Removal and Installation
    339
  - Disassembly
    339
  - Assembly
    344
  - Lower Unit Gears-Shimming and Adjustment
    354
- Counter Rotation Lower Unit (Df140Z)
  359
  - Removal and Installation
    360
  - Disassembly
    360
  - Inspection
    365
  - Assembly
    369
  - LOWER UNIT GEARS-SHIMMING and ADJUSTMENT (Counter Rotation Model)
    379
- Wiring Diagram
  385
- Hose Routing
  386
Df90/115 "K2" ('02) Model

387
- Specifications
  388
- Service Data
  390
- Tightening Torque
  397
- Materials Required
  398
- Fuel/Water Hose Routing
  399
- Conrod Assy and Bearing
  402
- Crank Pin and Conrod Bearing
  402
- Over-Revolution Caution System
  402
- Camshaft and Tappet Shim
  403
- Crankshaft and Flywheel
  403
- Engine Holder Gasket
  404
- Engine Holder Bolt
  405
- Upper Mount Front Nut
  405
- Clutch Linkage
  406
Df90/115/140 "K3" (2003) Model

407
- Service Data (Df140(W)T/140Z) __________________________ 13-13
  
  426
- Service Data (Df90T/115(W)T) ___________________________ 13-6
  
  426
  - Tightening Torque
    426
  - Ecm
    427
  - Ecm Main Relay and Starter Motor Relay
    427
  - Battery Charge Coil
    428
  - Rectifier & Regulator
    428
  - Exhaust Camshaft (for Df115 Only)
    429
  - Remote Control Cable Holder
    429
  - Cylinder Head Instllation
    430
  - Crankcase to Cylinder Instllation
    431
  - Upper Mount
    432
  - Drive Shaft
    432
  - Propeller Shaft Bearing Housing
    432
  - Df115W and Df140W
    433
    
    Exhaust Valve
    433
    
    Water Pump Case
    433
    
    Ecm
    433
  - Wiring Diagram
    434
  - Wire Routing
    435
  - Water Hose Routing
    437
Df90/115/140 "K4" ('04) Model

438
- Specifications (Df90T/115T/115Wt)
  439
- Specifications (Df140T/140Wt/140Z)
  441
- Service Data (Df90/115)
  443
- Service Data (Df140)
  450
- Cylinder Block
  457
- Rectifier & Regulator
  457
- Temperature Sensor
  457
- Electric Parts Holder
  458
- P.t.t. Motor
  458
- Power Trim & Tilt (P.t.t.) Relay
  458
- Clamp Bracket Shaft
  459
- Swivel Bracket
  459
- Tilt Limit Switch System
  459
- Driveshaft
  460
- Pinion Gear Back up Shim
  460
- Port Clamp Bracket
  460
- Lower Unit Gears-Shimming and Adjustment
  461
- Wiring Diagram
  462
Df90/115/140 "K5" (2005) Model

463
- Specifications (Df90T/115T/115Wt)
  464
- Specifications (Df140T/140Wt/140Z/140Wz)
  466
- Service Data (Df90T/115T/115Wt)
  468
- Service Data (Df140T/140Wt/140Z/140Wz)
  475
- Engine Wiring Harness
  482
- Safety Relay System
  482
- Ecm
  483
- Sub-Battery Cable
  483
- Remote Control Box and Remote Control Wire
  484
- Piston Oil Ring
  486
- Tensioner Adjuster
  486
- Tilt Limit Switch Cover
  486
- Engin Holder
  487
- Upper and Lower Mount
  487
- Transom Bolt
  488
- Wire/Hose Routing
  489
- Wiring Diagram
  492
Df90/115/140 "K6" (2006) Model

493
- Specifications (Df90T/115T/115Wt)
  494
- Specifications (Df140T/140Wt/140Z/140Wz)
  496
- Service Data (Df90T/115T/115Wt)
  498
- Service Data (Df140T/140Wt/140Z/140Wz)
  505
- Tightening Torque
  513
  - Periodic Maintenance Schedule
    513
  - Ecm
    514
  - Neutral Switch
    514
  - Fuel Filter
    514
  - Delivery Pipe
    515
  - Oil Strainer
    515
  - OIL COOLER (for DF140)
    515
  - Engine Holder and Cylinder Block
    516
  - Cltuch Link
    517
  - Swivel Bracket Bushing Grease Path
    517
  - CLAMP BRACKET (for DF90 and DF115)
    519
  - Swivel Bracket
    520
  - Steering Bracket
    521
  - Upper Mount
    521
  - Water Pump
    523
  - Water Pump Tube
    524
  - Exhaust Seal Rubber
    524
  - Shift Rod Guide Housing
    525
  - Shift Rod, Shifter Yoke and Horizontal Slider
    526
  - Drive Shaft
    526
  - Propeller Shaft and Connector Pin
    527
  - Forward Gear and Clutch Dog
    527
  - Wiring/Hose Routing
    529
  - Wiring Diagram
    531
Df90/115/140 "K7" (2007) Model

532
- Specifications (Df90T/115T/115Wt)
  533
- Specifications (Df140T/140Wt/140Z/140Wz)
  535
- Service Data (Df90T/115T/115Wt)
  537
- Service Data (Df140T/140Wt/140Z/140Wz)
  544
- Periodic Maintenance Schedule
  551
- Ecm
  552
- Fuel Hose, Cable Grommet and Front Panel
  552
- Pinion/Gear Set
  554
Df90/115/140 "K8" (2008) Model

555
- Specifications (Df90T/115T/115Wt)
  556
- Specifications (Df140T/140Wt/140Z/140Wz)
  558
- Service Data (Df90T/115T/115Wt)
  560
- Service Data (Df140T/140Wt/140Z/140Wz)
  567
- Periodic Maintenance
  574
  - Idle Speed
    574
- Engine Control System
  576
  - Ecm
    576
  - Wiring Harness
    576
- Digital Gauge System
  577
  - Digital Gauge
    577
  - Modification of Harness Connection
    578
  - Digital Gauge and Related Parts Connection
    578
  - Set-Up of Tachometer
    580
  - Tachometer-Monitor
    581
  - Tachometer Display Indication
    582
- Engine Holder
  583
- Wiring Diagram
  584
- Wire Routing
  585
  - General Information
    588
    
    Specifications
    588
    
    Service Data
    590
    
    Special Tools
    599
    
    Materials Required
    603
  - Engine Control
    604
    
    Ecm
    604
  - Wire/Hose Routing
    606
    
    Wiring Diagram
    606
    
    Wire Routing
    607
    
    Fuel/Water Hose Routing
    611

Suzuki Categories

Motorcycle Automobile Motorcycle Accessories Offroad Vehicle Musical Instrument

More Suzuki Manuals

Suzuki DF 140 Four Stroke Manuals

Suzuki DF 140 Four Stroke Service Manual (616 pages)

Table of Contents

General Information 1

Periodic Maintenance 2

Periodic Maintenance Schedule

Maintenance and Tune-Up Procedures

Oil Pressure

Cylinder Compression

Engine Control System

Electrical

Battery Charging System

Electric Starter System

Monitor-Tachometer

Erectric Parts Holder

Fuel System

Precaution on Fuel System Service

Removal / Installation

Fuel Line ______________________________________________ 5-4

Fuel Vapor Separator / High Pressure Fuel Pump

Fuel Injector

Low Pressure Fuel Pump

Fuel Tank

Power Unit

Intake Manifold Assembly

Power Unit

Oil Pump

Timing Chain / Tensioner

Cylinder Head Assembly

Cylinder / Crankshaft / Piston

Thermostat

Operation

Removal / Inspection / Installation

MID Unit

Engine Side Cover

Driveshaft Housing and Oil Pan

Swivel Bracket, Steering Bracket and Clamp Bracket

Clamp Bracket ________________________________________ 7-13

Water Pressure Valve

Power Trim and Tilt

System Wiring Diagram

Service Procedure

Power Trim and Tilt Unit

Ptt Motor Relay

Ptt Switch

Operation

Lower Unit

Removal & Disassembly

Pinion Bearing

Inspection

Assembly & Installation

Trim Tab

Lower Unit Gears-Shimming and Adjustment

Df140 "K2" ('02) Model

Df90/115 "K2" ('02) Model

Df90/115/140 "K3" (2003) Model

Service Data (Df140(W)T/140Z) __________________________ 13-13

Service Data (Df90T/115(W)T) ___________________________ 13-6

Df90/115/140 "K4" ('04) Model

Df90/115/140 "K5" (2005) Model

Df90/115/140 "K6" (2006) Model

Df90/115/140 "K7" (2007) Model

Df90/115/140 "K8" (2008) Model

Related Products

Suzuki Categories