2009-2010 Suzuki DF70A DF80A DF90A Outboard motor Service Manual

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This is the original Suzuki service manual. Perfect for all maintenance tasks and rebuilds. Includes all specifications as well as step by step service procedures.
Models covered:
DF70A
DF80A
DF90A

Manual Part Number: 99500-87L00-01E

Manual chapters:
General Information
- General Information
- Maintenance and Tune-Up
Power Head
- Precautions
- Engine General Information and Diagnosis
- Engine Electrical Devices
- Power Unit Mechanical
- Power Unit Lubrication
- Power Unit Cooling System
- Fuel System
- Ignition System
- Starting System
- Charging System
Mid Unit
- Precautions
- Housing and Bracket
- Power Trim and Tilt
Lower Unit
- Precautions
- Right Hand Rotation Unit
Wire / Hose Routing
- Precautions
- Wire Routing
- Fuel / Water Hose Routing

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Full list of manual chapters:

COVER
IMPORTANT NOTICE
FOREWORD
TABLE OF CONTENTS
Precautions
    Precautions
        Precautions
            General Precautions
General Information
    General Information
        General Description
            Symbols
            Abbreviations
            Wire Color Symbols
            Warning, Caution and Information Label Locations
            Genuine Parts Description
            Outboard Motor Identification Number Location
            Fuel and Oil Recommendations
            Break-In Procedures
            Propeller Selection Guide
            Battery Requirement
            Powerhead Direction of Rotation Description
        Specifications
            Specifications
            Service Data
            Tightening Torque Specifications
        Special Tools and Equipment
            Recommended Service Material
            Special Tool
    Maintenance and Tune-Up
        Precautions
            Precautions for Maintenance
        General Description
            Recommended Oil and Lubricants
        Scheduled Maintenance
            Periodic Maintenance Schedule Chart
            Lubrication Point
        Service Instructions
            Engine Oil Level Check
            Engine Oil Change and Engine Oil Filter Replacement
            Gear Oil Change
            Spark Plug Removal and Installation
            Spark Plug Inspection and Cleaning
            Tappet Clearance Inspection and Adjustment
            Idle Speed and Idle Air Control (IAC) Duty Inspection
            Ignition Timing Inspection
            Breather Line and Fuel Line Inspection
            Low Pressure Fuel Filter Inspection
            High Pressure Fuel Filter Replacement
            Water Pump and Water Pump Impeller Inspection
            Propeller / Propeller Nut and Cotter Pin Inspection
            Anodes Inspection
            Bonding Wires Inspection
            Battery Inspection
            Bolts and Nuts Inspection
            Oil Pressure Check
            Cylinder Compression Pressure Check
Power Head
    Precautions
        Precautions
            Precautions for Powerhead
    Engine General Information and Diagnosis
        Precautions
            Precautions on Engine Diagnosis
        General Description
            Engine Control System Description
            Engine Control Module (ECM)
            Caution System Description
            Self-Diagnostic System Description
            Fail-Safe System Description
            Operating Hour Indication System Description
            Oil Change Reminder System Description
        Component Location
            Engine Control System Components / Engine Electrical Device Location
        Diagnostic Information and Procedure
            ECM Power and Ground Circuit Check
            Troubleshooting with Self-Diagnostic Code
            Self-Diagnostic Code "3 - 4" MAP Sensor
            Self-Diagnostic Code "1 - 4" Cylinder Temp. Sensor
            Self-Diagnostic Code "2 - 3" IAT Sensor
            Self-Diagnostic Code "4 - 2" CKP Sensor
            Self-Diagnostic Code "2 - 4" CMP Sensor
            Self-Diagnostic Code "2 - 2" Air Intake System
            Self-Diagnostic Code "3 - 2" MAP Sensor 2
            Self-Diagnostic Code "1 - 5" Ex. Manifold Temp. Sensor
            Self-Diagnostic Code "4 - 3" Fuel Injector
            Self-Diagnostic Code "2 - 1" TPS (Throttle Position Sensor)
            Self-Diagnostic Code "1 - 2" Shift Position Sensor
            Self-Diagnostic Code "3 - 3" Neutral Switch
            Self-Diagnostic Code "1 - 1" Rectifier/Regulator (Over Charging)
            Self-Diagnostic Code "5 - 3" Oil Pressure Switch
            Self-Diagnostic Code "3 - 7" Trim Sensor
            Troubleshooting Without Self-Diagnostic Code
            IAC System Troubleshooting
        Service Instructions
            How to Use the 36 Pin Test Cord Set
            Inspection of the ECM and Its Circuit
            ECM Main Relay Inspection
    Engine Electrical Devices
        Precautions
            Precaution for Engine Electrical Device
        General Description
            Sensor and Switch Description
            ECM Power Source Line
        Component Location
            Location of Sensor and Switch
        Service Instructions
            Resistance Check
            Cylinder Temp. Sensor Removal and Installation
            Cylinder Temp. Sensor Inspection
            Ex. Manifold Temp. Sensor Removal and Installation
            Ex. Manifold Temp. Sensor Inspection
            CKP Sensor Removal and Installation
            CKP Sensor Inspection
            IAT Sensor Removal and Installation
            IAT Sensor Inspection
            CMP Sensor Removal and Installation
            CMP Sensor Inspection
            MAP Sensor Removal and Installation
            MAP Sensor Output Voltage Inspection
            IAC Valve Removal and Installation
            IAC Valve Inspection
            TPS Inspection
            Shift Position Sensor Inspection
            Trim Sensor Inspection
    Power Unit Mechanical
        General Description
            Power Unit Construction Description
        Diagnostic Information and Procedures
            Cylinder Compression Check
            Oil Pressure Check
        Service Instructions
            Tappet Clearance Inspection
            Ring Gear Cover Removal and Installation
            Cylinder Head Cover Removal and Installation
            Air Intake Silencer Case Removal and Installation
            Electric Parts Holder Removal and Installation
            Intake Manifold and Throttle Body Components
            Intake Manifold Removal and Installation
            Throttle Body Removal and Installation
            Throttle Body Inspection
            Power Unit Removal and Installation
            Timing Chain, Chain Tensioner and Camshaft Sprockets Components
            Timing Chain, Chain Tensioner and Camshaft Sprockets Removal and Installation
            Timing Chain, Chain Tensioner and Camshaft Sprockets Inspection
            Camshaft, Tappet and shim Removal and Installation
            Camshaft, Tappet and Shim Inspection
            Cylinder Head Assembly Components
            Cylinder Head Removal and Installation
            Cylinder Head Disassembly and Assembly
            Cylinder Head Components Inspection and Servicing
            Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Components
            Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Disassembly and Assembly
            Cylinder, Piston and Piston Ring Inspection and Servicing
            Piston Pin and Conrod Inspection
            Crank Pin and Conrod Bearing Inspection
            Selection of Conrod Bearing
            Crankshaft Inspection
            Crankshaft Main Bearing Inspection
            Crankshaft Drive Gear Inspection
            Crankshaft Oil Seal Inspection
    Power Unit Lubrication
        General Description
            Engine Lubrication Description
        Schematic and Routing Diagram
            Engine Oil Lubrication Chart
        Diagnostic Information and Procedures
            Oil Pressure Check
            Oil Change Reminder System
            Low Oil Pressure Caution System
            Powerhead Lubrication System Diagnosis
        Service Instructions
            Oil Pump Removal and Installation
            Oil Pump Disassembly and Assembly
            Inspection Oil Pump Component Parts
            Oil Pressure Switch Removal and Installation
            Oil Pressure Switch Inspection
            Oil Strainer Removal and Installation
            Oil Strainer Related Parts Inspection
    Power Unit Cooling System
        General Description
            Water Cooling System Description
            Displacement Type Water Pump Description
            Water Pressure Valve Description
        Schematic and Routing Diagram
            Cooling Water Circulation Chart
        Diagnostic Information and Procedures
            Powerhead Cooling System Diagnosis
        Service Instructions
            Thermostat Removal and Installation
            Thermostat Inspection
            Water Pressure Valve Removal and Installation
            Water Pressure Valve Related Item Inspection
            Water Pump Removal and Installation
            Water Pump Related Item Inspection
            Water Tube Removal and Installation
            Water Tube Related Item Inspection
    Fuel System
        Precautions
            Precautions on Fuel System Service
        General Description
            Electronic Fuel Injection System Description
            Fuel Delivery System Components Description
            High Pressure Fuel Pump Control System Description
            Air Intake Components Description
            Idle Air Control System Description
        Diagnostic Information and Procedures
            Fuel Pressure Inspection
            Fuel System Diagnosis
            Fuel Injection System Troubleshooting
        Service Instructions
            Fuel Pressure Relief Procedure
            Fuel Line Removal and Installation
            Fuel Line Inspection
            Fuel Leakage Check Procedure
            Inspection of Fuel Hose Connections
            High Pressure Fuel Pump Operating Sound Inspection
            Fuel Vapor Separator Removal and Installation
            Fuel Vapor Separator Disassembly and Assembly
            Inspection of Fuel Vapor Separator Component Parts
            Fuel Injector Inspection with Injector in place
            Individual Fuel Injector Operating Sound Inspection
            Fuel Injector Operating Signal Inspection
            Fuel Injector Removal and Installation
            Low Pressure Fuel Pump Removal and Installation
            Low Pressure Fuel Pump Inspection
    Ignition System
        General Description
            Ignition System Description
            Ignition Control Description
        Component Location
            Ignition System Components Location
        Diagnostic Information and Procedures
            Ignition System Symptom Diagnosis
            Ignition System Troubleshooting
        Service Instructions
            Spark Plug Removal and Installation
            Spark Plug Inspection
            Ignition Coil Removal and Installation.
            Ignition Coil Inspection
            Ignition Coil Operating Signal Inspection
            CKP Sensor Inspection
            CMP Sensor Inspection
            Ignition Switch Inspection
            ECM Main Relay Inspection
    Starting System
        General Description
            Electric Starter System Description
            Starter Motor Operation Condition Description
            Start-In-Gear Protection System Description
        Component Location
            Starting System Components Location
        Diagnostic Information and Procedures
            Starter System Troubleshooting
        Service Instructions
            Starter Motor Removal and Installation
            Starter Motor Test
            Starter Motor Components
            Starter Motor Disassembly and Assembly
            Starter Motor Components Inspection and Servicing
            Ignition Switch Inspection
            Starter Motor Relay Inspection
            Neutral Switch Inspection
            Emergency Stop Switch Inspection
    Charging System
        General Description
            Charging System Description
            Battery Requirement Description
        Component Location
            Charging System Components Location
        Diagnostic Information and Procedures
            Charging System Diagnosis
        Service Instructions
            Charging System Construction
            Flywheel Removal and Installation
            Battery Charge Coil Removal and Installation
            Battery Charge Coil Inspection
            Rectifier/Regulator Removal and Installation
            Rectifier/Regulator Inspection
            Main Fuse Inspection
Mid Unit
    Precautions
        Precautions
            Precaution for Mid Unit
    Housing and Bracket
        Precautions
            Precaution for Housing and Bracket
        Service Instructions
            Lower Side Cover Components
            Lower Side Cover Removal and Installation
            Engine Holder / Oil Pan / Driveshaft Housing / Mounts Components
            Engine Holder / Oil Pan / Driveshaft Housing / Mounts Disassembly
            Engine Holder / Oil Pan / Driveshaft Housing / Mounts Assembly
            Engine Holder / Oil Pan / Driveshaft Housing / Mounts Related Component Inspection
            Clutch Shaft Bearing and Oil Seal Replacement
            Driveshaft Upper Oil Seal Replacement
            Driven Gear Bearing and Oil Seal Replacement
            Clamp / Swivel / Steering Brackets Components
            Clamp / Swivel / Steering Brackets Disassembly
            Clamp / Swivel / Steering Brackets Assembly
            Clamp / Swivel / Steering Brackets Related Components Inspection
    Power Trim and Tilt
        Precautions
            Precaution for Power Trim and Tilt
        General Description
            Power Trim and Tilt Description
            Principles of Power Trim and Tilt Operation Description
        Schematic and Routing Diagram
            Power Trim and Tilt System Diagram
        Diagnostic Information and Procedures
            Diagnose PTT System Malfunction
        Service Instructions
            Checking PTT Fluid Level
            Air Bleeding from PTT Unit
            Setting of Trim Down Position Limit
            Setting Tilt Up Limit Position
            Power Trim and Tilt Unit Removal and Installation
            Power Trim and Tilt Unit Components
            Power Trim and Tilt Unit Disassembly
            Power Trim and Tilt Unit Reassembly
            Power Trim and Tilt Unit Components Cleaning and Inspecting
            Power Trim and Tilt Motor Removal and Installation
            Power Trim and Tilt Motor Disassembly and Assembly
            PTT Motor Related Items Inspection
            PTT Motor Relay Inspection
            PTT Switch Inspection
Lower Unit
    Precautions
        Precautions
            General Precautions
            Precaution for Lower Unit
    Right Hand Rotation Unit
        Diagnostic Information and Procedures
            Diagnose Lower Unit Malfunction
        Service Instructions
            Lower Unit Components
            Propeller Removal and Installation
            Propeller / Nut / Cotter Pin Inspection
            Lower Unit Removal and Installation
            Water Pump Removal and Installation
            Water Pump and Related Items Inspection
            Lower Unit Disassembly
            Pinion Bearing Removal and Installation
            Lower Unit Related Items Inspection
            Propeller Shaft Oil Seal Replacement
            Driveshaft Oil Seal Replacement
            Lower Unit Assembly
            Trim Tab Adjustment
            Lower Unit Gears - Shimming and Adjustment
Wire / Hose Routing
    Precautions
        Precautions
            Precautions for Wire / Hose Routing
        Component Location
            Electrical Component Location
    Wire Routing
        Schematic and Routing Diagram
            Wiring Diagram
            Wiring Harness Routing Diagram
    Fuel / Water Hose Routing
        Precautions
            Precautions for Fuel / Water Hose Routing
        Schematic and Routing Diagram
            Fuel Hose Routing
            Water Hose Routing