2006-2014 Suzuki DF2.5 Outboard Motor Service Manual

Comprehensive service manual covering the Suzuki DF2.5 Outboard Motor, detailing procedures, parts diagrams, and specifications. Ref: 99501-97J00-01E.

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Document Details

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Document Number / Seller:
31803 / Dennis Thomas
File Size:
17.91 MB
File Type:
PDF
Language:
English
Pages:
204
Printable:
Yes
Category:
Outboard Motor
Last updated / verified
Jan 5, 2026

Models Covered & Key Technical Specifications

Suzuki DF2.5 Outboard Motor Service Manual (2006-2014) Suzuki DF2.5 Outboard Motor (99501-97J00-01E) | 204-Page Guide – OEM Specs Information-Suite

  • System Assembly Gap: 0.05 mm for valve stem to valve guide clearance.
  • Maximum Load Capacity: 9.0 compression ratio established for optimal engine performance.
  • Measured Thermal Envelope: 48-52 °C (118-126 °F) signifies the standard thermostat operating temperature.
  • Published Ignition Timing: BTDC 30° determines the ignition advance timing.
  • Authorized Fastening Values: 13 N-m is the cylinder head bolt torque specified for secure assembly.
  • Technical Running Clearance: 0.020-0.060 mm signifies the piston ring to groove clearance Range.

Professional Workshop Service Manual & Technical Specifications

Suzuki DF2.5 Outboard Motor Service Manual: 2006-2014 | OEM Specs Information-Suite

Engine-Type: 4-stroke OHV // Assembly-Group: Power Head / Lower Unit Logic // Operational-Scope: Complete Service Procedures.

Assessment-Element Parameters Calibration-Spec
Cylinder Head Distortion 0.05 mm (0.002 in) N/A
Valve Clearance 0.13-0.17 mm (0.005-0.007 in) N/A
Piston Ring End Gap 0.15-0.35 mm (0.006-0.014 in) N/A
Conrod Big End Oil Clearance 0.015-0.035 mm (0.0006-0.0014 in) N/A
Spark Plug Gap 0.6-0.7 mm (0.024-0.028 in) N/A
Idle Speed 1900 ± 100 r/min N/A

Cataloging major assemblies into sections covering General Information, Specifications, Service Data, Periodic Maintenance, Ignition and Electrical systems, Fuel System, Carburetors, and Lower Unit components. This manual documents essential torque specifications for [component] to ensure proper pressure slip prevention.

Drivetrain specifications are addressed in detail, including gear ratios and drive line impact protection. Reassembly procedures are specified for all major components, ensuring correct installation. Service intervals are documented clearly for regular maintenance. Component locations are identified for ease of access during disassembly and reassembly. Service procedures are documented for various systems including ignition, fuel, and lubrication.

This structured, detailed manual provides comprehensive information for the maintenance and repair of your Suzuki DF2.5 Outboard Motor.

FAQ

Specify the lubrication **requirements** for the propeller shaft. keyboard_arrow_down

Water Resistant Grease is applied to the propeller shaft and its components, specifically to the oil seal lips and the splines. Suzuki Part Number 99000-25161 is recommended for this application.

What is the **exact** compression pressure testing procedure? keyboard_arrow_down

960-1400 kPa (9.6-14.0 kg/cm², 137-199 psi) is the cylinder compression range. The test involves removing the spark plug, installing a compression gauge, and cranking the engine with the throttle wide open.

Calculate the **specific** torque for the flywheel nut. keyboard_arrow_down

45 N-m (4.5 kg-m, 32.5 lb-ft) is the specified torque for the flywheel nut, crucial for securing the flywheel magneto during reassembly.

What values are **designated** for the valve spring free length? keyboard_arrow_down

The standard valve spring free length is 22.42 mm (0.883 in), with a service limit of 21.52 mm (0.847 in). Measurements should be taken with a Vernier caliper.

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This service manual is a must-have for any Suzuki DF2.5 owner. The instructions are clear and easy to follow. I was able to troubleshoot issues quickly. Plus, the download process was seamless, and I received the link in my email almost instantly!