Suzuki DF175 Four Stroke Service manual

The Suzuki DF175 Four Stroke is a powerful, reliable, and fuel-efficient outboard motor ideal for a variety of boating activities. Designed with a left-hand rotation powerhead and a standard rotation propeller, it offers smooth and efficient performance. With its 4-stroke DOHC engine, multi-point sequential electronic fuel injection system, and water-cooled design, this motor provides exceptional power and durability. The DF175 is equipped with a range of advanced features, including a self-diagnostic system for troubleshooting, and offers a maximum tilt angle of 74 degrees.

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PRE-PRODUCTION
ISSUE
1
GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE CONTROL SYSTEM 3
ENGINE ELECTRICAL 4
FUEL SYSTEM 5
POWER UNIT 6
MID UNIT 7
POWER TRIM AND TILT 8
LOWER UNIT
[Standard rotation (Right-hand) model] 9
LOWER UNIT
[Counter rotation (Left-hand) model] 10
WIRE/HOSE ROUTING 11
© COPYRIGHT SUZUKI MOTOR CORPORATION 2005 Marine & Power Products Division
FOREWORD
This manual contains an introductory description of
the SUZUKI DF150/175 Outboard motors and pro-
cedures for inspection, service and overhaul of their
main components.
General knowledge information is not included.
Please read the GENERAL INFORMATION section
to familiarize yourself with basic information con-
cerning this motor. Read and refer to the other
sections in this manual for information regarding
proper inspection and service procedures.
This manual will help you better understand these
outboard motors, assisting you in providing your
customers with optimum and quick service.
!
NOTE:
This manual is compiled based on 2006 (K6) model.
• This manual has been prepared using the
latest information available at the time of
publication.
Differences may exist between the content of
this manual and the actual outboard motor.
• Illustrations in this manual are used to show
the basic principles of operation and work
procedures and may not represent the actual
outboard motor in exact detail.
• This manual is intended for use by techni-
cians who already possess the basic knowl-
edge and skills to service SUZUKI outboard
motors.
Persons without such knowledge and skills
should not attempt to service SUZUKI out-
board engines by relying on this manual only
and should contact an authorized SUZUKI
outboard motor dealer.
Apprentice mechanics or do-it-yourself
mechanics that don’t have the proper tools
and equipment may not be able to properly
perform the services described in this man-
ual.
Improper repair may result in injury to the
mechanic and may render the engine unsafe
for the boat operator and passengers.2
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed on the previous page in a
GROUP INDEX. Select the section needed for reference.
3. Holding the manual as shown at the right will allow you to
find the first page of the section easily.
4. The first page of each section contains a table of contents to
easily locate the item and page you need.
COMPONENT PARTS AND IMPORTANT ITEM ILLUSTRATIONS
Under the name of each system or unit, an exploded view is provided with work instructions and other ser-
vice information such as the tightening torque, lubrication and locking agent points.
Example:
5
4
3
2 6
1 118 N·m (11.8 kg-m, 85.5 lb-ft)
1. Flywheel bolt
2. Flywheel
3. Dowel pin
4. CKP sensor
5. Bolt
6. CMP sensor
7. Bolt
NOTE:
Clean flywheel and crankshaft
mating surfaces with cleaning
solvent.
7
3
SYMBOL
Listed in the table below are the symbols indicating instructions and other important information necessary
for proper servicing. Please note the definition for each symbol. You will find these symbols used throughout
this manual. Refer back to this table if you are not sure of any symbol(s) meanings.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply SUZUKI SILICONE SEAL.
Apply oil. Use the engine oil unless oth-
erwise specified. Apply THREAD LOCK “1342”.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKl
MOLY PASTE in a ratio of 1 : 1)
Apply THREAD LOCK SUPER “1333B”.
Apply SUZUKI OUTBOARD MOTOR
GEAR OIL. Measure in DC voltage range.
Apply SUZUKI SUPER GREASE “A”. Measure in resistance range.
Apply SUZUKI MOLY PASTE.
99000-25140 Measure in continuity test range.
Apply SUZUKI WATER RESISTANT
GREASE. Use peak voltmeter “Stevens CD-77”.
Apply SUZUKI BOND “1104”. Use special tool.
Apply SUZUKI BOND “1207B”.4
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Key features

  • 4-stroke DOHC engine
  • Multi-point fuel injection
  • Water-cooled
  • Left-hand rotation powerhead
  • Standard rotation propeller
  • Self-diagnostic system
  • 74 degree tilt angle

Frequently asked questions

Suzuki recommends alcohol-free unleaded gasoline with a minimum pump octane rating of 87 or 91. Blends of unleaded gasoline and alcohol with equivalent octane content may be used.

Use oils that are rated SE, SF, SG, SH, or SJ under the API classification system or NMMA FC-W classification system. The viscosity rating should be SAE (or NMMA FC-W) 10W-40.

The recommended operating range is 5,500 - 6,100 RPM.
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