Suzuki outboard service manuals/ owner's manuals. On this page you can free download Suzuki outboard service manual. Suzuki DF40/ DF50 Service.

Download repair manuals straight to your computer, tablet or smart phone in seconds. All manuals are in pdf format for quick easy download. No special software is required to download a manual. Once downloaded, save the manual to your downloads folder or desktop forever.

Manuals and User Guides for SUZUKI DF 50. We have 2 SUZUKI DF 50 manuals available for free PDF download: Service Manual, Supplemental Service Manual Suzuki DF 50 Service Manual.
Jul 24, 2013 Suzuki Download 1999-2011 Df40 Df50 Service Manual 40/50 Hp. DOWNLOAD HERE. This 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 Suzuki Outboard DF.

Suzuki Outboard Manuals

With high-energy rotations, 2-stage gear reduction, battery-less electronic fuel injection and unparalleled speed and power, Suzuki Outboards help mariners have a truly great experience.

But for the motor to continue running optimally, it is absolutely necessary to maintain and repair it as per the manufacturer’s recommendations.

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This is where a Suzuki Outboard manual comes in.

We have compiled the most comprehensive and in-depth research manual to help everyone from DIY enthusiasts to professionals – with this manual, anyone can understand the mechanism and intricate workings of Suzuki Outboards.

As such, the manual includes everything from the basics to pro-tips for diagnosing, maintaining and servicing your Suzuki Outboard. After all, we’ve got to carry on the legacy of Suzuki’s unprecedented technology.

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Also known as a factory service manual, this is a highly recommended piece of documentation to have on you at all times. It contains a holistic description of the engine with an aim to inform the reader in the best possible manner.

Remember, only when you understand your Outboard’s engine, will you be able to do justice to its maintenance needs.

The manual is fully-illustrated and supported by detailed demos, diagrams, service information, exploded parts view and troubleshooting tips to get you started. Detailed step-by-step procedures follow so that the reader has no difficulty in following the instructions.

As an all-inclusive guide to help you tackle any technical fault or issue, you can expect to find information and maintenance tips on everything; from the fuel delivery system, full throttle operating range, steering, ignition system to engine mounting, gear ratio, gear shift and the exhaust system.

Overall, the Suzuki Outboard Manual is a highly reliable document written by industry experts with helpful tips such as break-in information for your outboard motor to ensure maximum performance.

And the best part is that this manual is available for different models so you can cater to your specific Outboard’s problems. In short, whether you own the 1988 model or have upgraded to the 2015 model, there is a different manual for each.

Simply pay the upfront fees to gain access to the PDF on your mobile or desktop for on-the-go consultation.

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PROPELLERS

An outboard motor is designed to develop its rated power within a specified engine speed range. The maximum rated power delivered by the Suzuki models are shown in your service manual. If the standard propeller fails to meet the above requirement, use another pitch propeller to hold the engine speed within the range specified in your manual propeller selection chart.
Installing a propeller with pitch either too high or too low will cause incorrect maximum engine speed, which may result in severe damage to the motor.

Disassembly of propeller shaft components

1. Slide propeller shaft away from reverse gear housing assembly

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2. Remove horizontal slider and forward gear thrust washer

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3. Remove spring

4. Using special tool, push dog pin shifter.

5. Remove clutch dog shifter propeller shaft.

PROPELLER

• Inspect propeller for bent, chipped or broken blades and replace or repair if necessary.

• Inspect propeller bushing splines for wear or other damage and replace if necessary.

• Inspect propeller bushing for deterioration or slipping and replace if necessary.

PROPELLER SHAFT COMPONENTS

• Inspect horizontal slider and connector pin for excessive wear or other damage. Replace if necessary.

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• Inspect clutch dog shifter for excessive wear, chip or other damage. Replace if necessary.

• Inspect dog pin for bent or other damage. Replace if necessary.

• Inspect propeller shaft / splines for wear, twist or other damage. Replace if necessary.

PROPELLER SHAFT BEARING HOUSING

• Inspect housing for cracks or other damage. Replace if necessary.

• Inspect propeller shaft bearings and reverse gear bearing for pitting, rough or other damage. Replace if necessary.

• Inspect oil seals and O-ring for cuts, nicks or tears.

Replacing propeller shaft oil seal

1. Remove retaining ring

2. Extract oil seals

1 and washer 2.3 using oil seal remover.

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Do not re-use oil seal once removed.

Always use a new oil seal.

3. Apply Water Resistant Grease to inner circumference of housing.

4. Using an oil seal installer, drive two oil seals (one at a time) into housing.

The lipped portion of seal should face towards propeller.

Apply Water Resistant Grease to seal lips.

5. Install washer and retaining ring.

PROPELLER INSTALLATION

1. Install spacer shaft, then slide on propeller

2. Fit spacer specified torque.

1 and propeller stopper 2 onto propeller3.4, washer 5 and nut 6, then tighten nut to

Propeller nut : 55 N.m (5.5 kg-m, 40.0 lb.-ft.)

3. Push cotter pin secure.

PROPELLER SELECTION FOR COUNTER

ROTATION

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For counter-rotation model, newly designed stainless steel propellers are available as follows.

Suzuki highly recommend to use the genuine Suzuki counterrotation propeller for the counter rotation model. In case of twin installation, always use on both engines, the same size normal rotation and counter-rotation propellers.

ENGINE CRANKED, BUT NOT START (OR STOPS SHORTLY AFTER STARTING)
UNSTABLE IDLING / TROLLING (OR ENGINE TENDS TO STALL)

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• Incorrect by-pass air screw adjustment [NOTE3]
• IAC valve failure [NOTE3]
• IAC passage failure (clogged hose, etc.) [NOTE3]
• Spark plug failure
• Ignition coil failure
• ECM failure
• Wire continuity / connection failure
• Failure of high pressure fuel system components :
• Fuel injector (clog, stuck valve, etc.)
• Fuel pressure regulator (incorrect regulated pressure,