Df140 service manual

After adjusting all gear positions, measure the propeller shaft thrust play. If not within the following specification, a shim adjustment is required.

Use only the propeller shaft thrust shim to adjust thrust play. If the measurement is more than the specification, increase the propeller shaft thrust shim thickness. If the measurement is less than the specification, reduce the propeller shaft thrust shim thickness.

Engine stalls when engaging gear Propeller shaft bearings damaged, lacking lubrication or seized. Engaging gear s has no effect on propulsion Clutch out of adjustment. Engaging gear s has no effect on propulsion Driveshaft broken or splines damaged. Engaging gear s has no effect on propulsion Chipped or worn dog clutches. Engaging gear s has no effect on propulsion Propeller not secured correctly fallen off. Inspection or retighten. Loss of power. Assuming engine is OK.

Propeller bush slipping Replace. Bent or worn propeller. Repair or replace. Engine shakes the boat Failed propeller bush. Engine shakes the boat Bent driveshaft or propeller shaft. Engine shakes the boat Damaged propeller. Clutch will not engage or disengage Seized shift rod. Clutch will not engage or disengage Clutch shaft and clutch rod have become detached.

Clutch will not engage or disengage Problem at control box end. Inspection or replace. Lower Unit Components 1. Oil seal cover 2. Oil seal 3. Bolt 4. Shift rod guide housing 5. O-ring 6. Shift rod 7. Magnet 8. Shifter yoke 9. Pin Horizontal slider Bush Water pump case Bolt Dowel pin Key Water pump case sealing Inner sleeve Water pump impeller Under panel Gasket Exhaust seal rubber Exhaust seal plate Union Hose Nipple Gearcase Anode Washer Trim tab Screw Water filter PORT Driveshaft 2.

Bolt 3. Driveshaft oil seal housing 4. Oil seal 5. Oil seal 6. Shim 7. Bearing 8. O-ring 9. Driveshaft collar Plug Pinion bearing Ring Oil seal protector Oil seal Bearing Propeller shaft bearing housing O-ring Shim Thrust washer Backup shim Forward gear thrust bearing Forward gear Pinion gear Pinion nut Reverse gear Reverse gear retainer Thrust bearing Reverse gear bearing housing Spacer Small detent ball Spring Large detent bell Dog pin Connector pin Clutch dog shifter Dog spring Propeller shaft Stopper Propeller bush Propeller nut Cotter pin : Nm 12 kgf-m, Remove cotter pin 1 from propeller nut and remove propeller nut 2.

Remove washer 3 , spacer 4 , propeller 5 and stopper 6 from the propeller shaft. Installation Coat the propeller shaft splines liberally with Suzuki water resistant grease. Fit spacer 3 , washer 4 and nut 5 , then tighten nut to specified torque. Push cotter pin 6 through nut and shaft, then bend to secure.

Removal Failure to take proper precautions when removing or installing the lower unit can result in severe personal injury. Remove bolt and trim tab 1. Remove seven bolts 2 and separate gearcase 3 from driveshaft housing. Installation Apply clutch rod splines with Water Resistant Grease, then install clutch rod 1 by aligning clutch rod splines with splines in clutch shaft.

Insert two dowel pins 3. Apply water resistant grease to driveshaft and shift rod splines. Apply Suzuki silicone seal to seven gearcase bolts and tighten them to specified torque. Removal Remove the lower unit. Loosen four bolts 1 , then remove water pump case 2. Remove impeller 3 , impeller key 4 , under panel 5 and dowel pins 6. Keep impeller key 4 for reuse and discard the gasket. Remove inner sleeve 7 , sealing 8.

To facilitate the removal of inner sleeve from pump case, warm up the entire case using a heater like hair dryer Installation Place the dowel pins 1 , gasket 2 and under panel 3 into position.

Place the sealing 7 into groove of the pump case 6. Install inner sleeve 8 into the pump case, ensuring that projection of inner sleeve and groove of pump case are aligned. Install the pump case assembly 9 while rotating driveshaft clockwise to flex the impeller vanes in the correct direction.

Securely tighten the four pump case bolts 10 to the specified torque. Inspect the following parts. Inspect impeller. Replace if vanes are cut, torn, wornor other abnormal conditions. Inspect pump case. Replace if cracked, distorted or other abnormal conditions are noted.

Remove the lower unit. Remove the propeller. Remove the water pump and related parts. Place a drain pan under oil drain plug.

Remove oil drain plug 1 first then oil level plug 2 and allow gear oil to drain. Inspect oil for water, contaminates or metal. Remove the bolts 3 and shift rod guide housing assembly 4.

Remove two bolts 5 securing the propeller shaft bearing housing to the gearcase. Using special tools, pull out the propeller shaft bearing housing. Remove the propeller shaft and bearing housing assembly 6. Special tool A : — Sliding hammer B : — Propeller shaft remover Hold the pinion nut securely, then fit special tool to the driveshaft and loosen the pinion nut. Remove pinion nut 7. Special tool C : — Driveshaft holder Remove the four bolts securing driveshaft oil seal housing 8 , then remove oil seal housing and pinion gear shim.

Lift out driveshaft assembly 9. Remove driveshaft collar 10 from driveshaft If necessary. Remove the pinion gear Remove reverse gear 12 with reverse gear retainer 13 and thrust bearing Remove the reverse gear 12 from reverse gear retainer Remove the bearing thrust washer 15 and back-up shim Remove the reverse gear bearing housing 17 and dowel pin To disassemble propeller shaft components, refer to following.

Remove horizontal slider 29 and spacer Remove the spring 31 from the clutch dog shifter Special tool D : — Shift lock pin remover f Remove the clutch dog shifter 32 and connector pin 34 from propeller shaft. To disassemble shift rod components, refer to following.

Removal and Installation Tools To remove the pinion bearing from the gearcase, use the following special tools. Place the attachment D inside the pinion bearing. Insert the removal shaft A into attachment D. Thread sliding hammer E into top of removal shaft A.

Put wood block under pinion bearing. Drive the pinion bearing out downwards by striking top of shaft A with sliding hammer E. Pinion bearing 2. Place the installer shaft A with pinion bearing on end of installer shaft into the gearcase.

Secure the plate B by tightening the bolt C. Thread the sliding hammer E into the top of the installer shaft A. Assemble the lower unit. Gearcase Inspect the gearcase. Replace if cracked, damaged or other abnormal conditions are noted. Replace gears if damaged, worn or other abnormal conditions are noted. Inspect forward gear thrust bearing. Replace if cracked or damaged.

Visually check each bearings. Replace if pitted, noisy or rough. Propeller Shaft Components Inspect horizontal slider and connector pin. Replace if wear, damage or other abnormal condition. Inspect detent balls.

Research method. However, blends of unleaded Suzuki engineers have delivered a pair of outboards that offer great fuel economy without sacrificing on performance and employ advanced technologies that Suzuki has pioneered over the last decade.

Please read your Owner's Manual carefully. Remember, boating and alcohol or other drugs don't mix. Suzuki encourages you to operate your boat safely and with respect for the marine environment. Specifications, appearances We're now offering complete maintenance kits on a range of Suzuki outboards. Each kit has the complete range of. Suzuki Genuine Parts required for servicing Suzuki outboards according to the periodical maintenance schedule as detailed in the owner's manual.

This outboard motor has been designed and produced utilizing Suzuki's most modern technology. The finest product, however, cannot perform properly unless it is correctly assembled and serviced. This set-up manual has been produced to aid you in properly assembling and servicing this outboard motor. Important note: Always wear a lifejacket when boating and a kill cord when operating an outboard.

Feedback from our Take a few minutes to Magnetic-type gauge Steuerbord verteilen. Kenntnisse und Einrichtungen. Suzuki's four-stroke outboards, the DF and DF, are the product of Compact Outboards. Along with creating clean-running outboards, another important goal that Suzuki engineers set for the DF series was to create a compact outboard.

With the Please read your owner's manual carefully. Normal service and regular maintenance procedures necessitated by normal usage, such as outboard tuning, We are your one-stop location for Genuine Yamaha, Kawasaki, Suzuki, This Installation and Owner's Manual contains all the information that you and others will Refer to page 44 for correct torque specifications.

Figure 6. Figure 8.