Suzuki Periodic Maintenance Schedule

ferret30 · Posted: Fri Nov 04, 2011 1:21 pm Post subject:

Where do you get the service manual? I looked on ebay and all the printed manuals seemed to be for older models (i.e. pre-2000) and the newer manuals were all PDFs on CD, and they don't specify years.

If it's legal for sellers to sell copied CDs of the service manual, the manual's probably available for download somewhere, right?

So, anyone have tips on where to get the manual for a 2006 Suzuki DF90?

Matt Gurnsey · Posted: Fri Nov 04, 2011 3:37 pm Post subject:

Your friendly neighborhood Suzuki dealer should be able to download late model Service Manuals from Suzuki for you and save it to CD or Flash Drive.

This has just been made available recently by Suzuki. Yamaha has had this available for quite some time.

Your dealer may charge a reasonable fee for the time involved and or storage media.

@ C · Posted: Fri Nov 04, 2011 3:54 pm Post subject:

I have a pdf of the 90/100/115/140 manual if anyone wants it.
Just let me know.
Bill

Falco · Posted: Thu Dec 22, 2011 6:17 pm Post subject:

You may be able to get the service manual from Brown's Point and I second the other posting as to them being the best place to get parts. The manual I have is outstanding and I have done all my own service for 7 years and 800+ hours on my twin DF40s. They still purr like kittens. The water pump should be serviced (Suzuki makes a kit) every 200 hours but double check this for your particular model. It is super simple to do. Do not overtorque the water pump housing nuts (5 ft-lbs is not much at all). I learned about this after twisting off one of the studs.

joeC · Posted: Thu Dec 22, 2011 6:39 pm Post subject: Impeller

I always change mine at about 100 hrs. They are cheap and easy to replace. The impellors do get trashed very easy if you run in dirty or sandy water. they take at most no mecanical expertiste or knowlege to replace.I have run boats for years and it is all bad to have a bad water pump. In the years I have run boats outboards with no water pumps just low water pickups and even these have issues All C-brats should learn to change a water pump it is easy especially if it is not to old. If it it old replace the housing and the seals under the housing. otherwise just the impellor.
Joe

Tug · Posted: Thu Dec 22, 2011 7:48 pm Post subject:

I just got my Water Pump Repair Kit from Brown's Point Marine, was less than $50.00. I bought the kit just in case i needed the seal also.

Winter project is to clean this room,this used to be my spare room but now it looks more like a Marine Supply Depot. Tug

Falco · Posted: Thu Dec 22, 2011 10:06 pm Post subject:

Storage Wars! I'll give you $250 for the whole room!

On the impellor replacement, be sure and turn the drive shaft clockwise as you drop the water pump housing on to orient the impellor vanes properly.

rogerar · Posted: Fri Dec 23, 2011 5:12 am Post subject:

How about the Valve Adjustment-fairly easy, but requires Suzuki special tool. My DF 115 manual says check and adjust every 200 hrs.
Roger

Falco · Posted: Fri Dec 23, 2011 8:13 am Post subject:

Yes, the tappet clearance check and adjustment is pretty straightforward but is the most challenging regular maintenance task at 200 hour intervals. Or I should say making any necessary adjustments (by changing out tappet shims) is the most challenging. Checking tappet clearances (the space between cam and shim) is comparatively easy.

The "tool" you need is actually a set of small metal brackets, one for the intake valves and one for the exhaust valves that hold a valve open where a tappet shim needs to be replaced. They are horribly expensive ($100) for what they are, but you save a ton on service labor...

Follow the instructions in the official Suzi shop manual and go slow. Be sure and use a torque wrench. Note that if a tappet is out of spec, you will need to remove the shim (get a small magnet for this) and measure its thickness with a micrometer, then reinstall it, calculate the new shim thickness needed (per table in service manual), order the replacement shim then install it. If you plan to use the boat before installing the replacement shim, you should install a new valve cover gasket set (outer rim gasket AND spark plug hole gaskets). Use another new gasket set when you swap out the old shim(s) with the new one(s). Obviously it's cheaper to just wait to use the boat until after you've received and installed the replacement shim(s). I just mention this because replacing that gasket set everytime you open the cover is important. Also - be sure to use the official Suzi silicone on the valve cover as indicated in the service manual. It's good stuff and the tube lasts forever.

It all sounds somewhat complicated, but it's not. These engines are incredibly well engineered and laid out. Have fun!

rogerar · Posted: Fri Dec 23, 2011 6:33 pm Post subject:

Great advice. They actually make a chart to write down all the valve clearances as you check them, a great way to stay organized and keep records of wear. I'll try to scan a copy on here so you can download it.
Merry Xmas!
Roger

Tug · Posted: Tue Apr 24, 2012 12:13 pm Post subject:

Replaced my impeller last week.I had planned on trying to do the job myself but the dealer said it would not be expensive to replace. It only cost me $ 59.33 to have it done at the shop and it only took a few hours to do. Good price. I placed something over my signature, just to be on the safe side.Tug

http://i1201.photobucket.com/albums/bb355/Tug7/100_0651.jpg