2001-2009 Suzuki DF90, DF100, DF115, DF140 Outboard Motor Service Manual

Suzuki DF90/100/115/140 outboard motor troubleshooting and repair reference, covering engine and electrical systems. Documents part numbers and procedures. PN 99500-90J07-03E

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Document Details

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Document Number / Seller:
29820 / Edward Crawford
File Size:
42.87 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Outboard Motor
Last updated / verified
Mar 23, 2025

Models Covered & Key Technical Specifications

2001-2009 Suzuki DF90, DF100, DF115, DF140 Outboard Motor Service Manual

Technical reference for DF90/DF100/DF115/DF140 outboard motors, covering engine and electrical systems. Documents part numbers and procedures. PN 99500-90J07-03E.

  • Engine Type: 4-stroke DOHC
  • Number of Cylinders: 4
  • Engine Oil Viscosity: SAE 10W-40
  • Maximum Output: 66.2 kW (90 PS) for DF90T / 84.6 kW (115 PS) for DF115T
  • Ignition System: Fully transistorized, electronic microcomputer timing advanced type
  • Fuel Delivery: Speed-density, multi-point, sequential, electronic fuel injection

Professional Workshop Service Manual & Technical Specifications

Multi-System Maintenance Technical Manual: Outboard Motor Precision Diagnostics: Suzuki DF90, DF100, DF115, DF140 Outboard Motor (2001-2009) Procedure-Database

System-Identifier: DF90, DF100, DF115, DF140 // Technical-Scope: Engine, Electrical, Fuel System, Power Unit, Troubleshooting // System-Identifier: Outboard Motor

Assessment-Parameter Value Validation-Data
Engine Type 4-stroke DOHC N/A
Fuel Delivery Electronic Fuel Injection Multi-point Sequential
Ignition System Transistorized Electronic Microcomputer Timing
Cooling System Water Cooled Standard
Lubrication System Wet Sump Trochoid Pump
Starting System Electric Standard

Technical content addresses:

Maintenance and Tune-Up Procedures: Covering periodic maintenance requirements for engine oil, filters, gear oil, lubrication, spark plugs, tappet clearance, idle speed, ignition timing, fuel lines, water pump, anodes, battery, bolts, and nuts.

Electrical Systems: Details on battery charging, starter motor, monitor-tachometer, electric parts holder, ignition system, electronic fuel injection, fuel delivery components, fuel pump, fuel injectors, fuel tank, and oil pressure switches.

Power Unit Components: Procedures for intake manifold, power unit, oil pump, timing chain, cylinder head, cylinder/crankshaft/piston, thermostat, water cooling, and engine lubrication systems.

Troubleshooting: Diagnostic codes and flowcharts for common issues like no-start conditions, unstable idling, and electrical system faults.

Component Inspections: In-depth inspection procedures for various engine components including camshafts, valves, pistons, rings, crankshaft, and bearings.

This manual documents torque specifications for various components to ensure proper rotational loosening prevention.

FAQ

Reference the **specified** tool requirements for camshaft installation. keyboard_arrow_down

Camshaft installation requires specific tools like a Crankshaft holder (09911-49910), Dial gauge (09900-20602), and Magnetic stand (09900-20701) for precise measurement and alignment.

What are the **essential** electrical values for checking the ignition coil resistance? keyboard_arrow_down

Primary ignition coil resistance should be between 1.9 – 2.5 Ω, while secondary coil resistance ranges from 18–34 kΩ for No. 2&3 and 19–36 kΩ for No. 1&4.

Specify the **correct** piston ring groove width for the 2nd ring. keyboard_arrow_down

The standard piston ring groove width for the 2nd ring is 1.51 – 1.53 mm (0.059 – 0.060 in.).

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Reviews (4)

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Very detailed and easy to follow. The manual covers all aspects of maintenance well. Downloading was hassle-free, and assistance via email was prompt and helpful.
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I was impressed by how thorough this manual is. The troubleshooting section was particularly helpful. The download process was smooth, and I received the email link quickly.
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Excellent manual with clear visuals. It has everything you need for maintenance. Customer support was responsive when I had questions about the download. A+ service!
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This manual is a lifesaver! The detailed instructions and diagrams made my maintenance tasks so much easier. Highly recommend!