Suzuki DF150AP, DF175AP, DF200, DF200AP, DF225, DF250 Owner's Manual
The Suzuki DF175AP is a powerful and reliable outboard motor that is designed for a variety of boating applications. It features a four-stroke, fuel-injected engine with a displacement of 175 cubic inches. The DF175AP is equipped with a number of advanced features such as a digital ignition system, a lean-burn engine management system, and a multi-point fuel injection system. These features help to improve fuel efficiency and performance. The DF175AP also features Suzuki's exclusive Lean Burn Control System, which helps to reduce fuel consumption and emissions. The DF175AP is available with a variety of propeller options to match your specific boating needs.
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DF200
DF225
DF250
OWNER’S MANUAL
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EN
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ENGLISH
1
IMPORTANT
WARNING/
CAUTION/
NOTICE
WARNING
CAUTION
/
NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING ,
CAUTION , NOTICE and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.
Indicates a potential hazard that could result in death or serious injury.
I ndicates a potential hazard that could result in minor or moderate injury.
NOTICE
Indicates a potential hazard that could result in damage to the motor or boat.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
This symbol appears in various locations on your Suzuki product to refer you to important information in the owner’s manual.
IMPORTANT NOTICE TO
OWNERS
WARNING
Failure to take the proper precautions may increase the risk of death or severe injury to you and your passengers.
2
• Prior to first-time use of your outboard motor, familiarize yourself thoroughly with the contents of this owner’s manual. Be aware of all outboard motor features and all safety and maintenance requirements.
• Inspect the boat and motor before each trip.
See the INSPECTION BEFORE BOATING section for important items.
• Become thoroughly familiar with all operating and handling characteristics of your boat and motor. Practice at low and moderate speeds until you are competent at handling the boat and motor. Do not attempt to operate at maximum performance until you are completely familiar with all of these characteristics.
• Carry boating safety and emergency equipment. This important equipment includes; flotation aids for each person (plus one throwable buoyant cushion in any boat 16 feet or longer), fire extinguisher, sound signaling device, visual distress signals, anchor, bilge pump, bucket, compass, emergency starter rope, extra fuel and oil, first aid kit, flashlight, food and water, mirror, paddles, tool kit, and transistor radio.
Be sure you are carrying the equipment appropriate for your trip before launching.
• Never start the engine or let it run indoors or where there is little or no ventilation.
Exhaust gas contains carbon monoxide, a gas that is colorless and odorless and can cause death or severe injury.
• Instruct your passengers on how to operate the boat, how to deal with emergencies, and how to operate safety and emergency equipment.
• Do not hold onto the motor cover or any other parts of your outboard motor while getting on or off your boat.
• Ensure that everyone wears a PFD (Personal Flotation Device) on board.
• Never operate the boat while under the influence of alcohol or other drugs.
• Distribute all weight load evenly in the boat.
• Have all scheduled maintenance performed.
Consult your authorized Suzuki marine dealer as required.
• Do not modify or remove any outboard motor standard equipment. To do so may make the motor unsafe to use.
• Learn and obey all applicable navigation rules.
• Pay attention to all weather forecasts. Do not set out if weather is unsettled.
• Use extreme caution when purchasing replacement parts or accessories. Suzuki strongly recommends that you use only genuine Suzuki replacement parts/accessories or their equivalent. Inappropriate or poor quality replacement parts or accessories can create unsafe operating conditions.
FOREWORD
• Never remove the flywheel cover (except for when emergency starting).
NOTE:
Mounting radio transceiver or navigational equipment antennae too close to the engine cowling can cause electrical noise interference.
Suzuki recommends that antennae be mounted at least one meter (40 inches) away from the engine cowling.
Thank you for choosing a Suzuki outboard motor. Please read this manual carefully and review it from time to time. It contains important information on safety, operation, and maintenance. A thorough understanding of the information presented in this manual will help you experience safe, enjoyable boating.
This manual should be considered a permanent part of the outboard motor and should remain with the outboard motor when resold or otherwise transferred to a new owner or operator. Please read this manual carefully before operating your new Suzuki and review the manual from time to time. It contains important information on safety, operation, and maintenance.
All information in this manual is based on the latest product information available at the time of publication. Due to improvements or other changes, there may be discrepancies between this manual and your outboard motor. Suzuki reserves the right to make changes at any time without notice.
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TABLE OF CONTENTS
IDENTIFICATION NUMBER
LOCATION.............................................. 5
FUEL AND OIL....................................... 5
LOCATION OF SAFETY LABELS ..... 8
LOCATION OF PARTS......................... 9
MOTOR MOUNTING.......................... 10
BATTERY INSTALLATION .............. 10
USE OF ELECTRICAL
ACCESSORIES ..................................... 12
PROPELLER SELECTION AND
INSTALLATION................................... 13
ADJUSTMENT...................................... 14
CAUTION SYSTEM ............................. 16
DIAGNOSTIC SYSTEM ...................... 19
OIL CHANGE REMINDER
SYSTEM................................................. 20
ENGINE STALLING CAUTION
SYSTEM................................................. 20
WATER IN FUEL ALERT
SYSTEM................................................. 20
OPERATION OF TILTING
SYSTEMS............................................... 21
INSPECTION BEFORE BOATING ... 23
BREAK-IN ............................................. 25
OPERATION ......................................... 26
MOTOR REMOVAL AND
TRANSPORTING ................................. 31
TRAILERING........................................ 33
INSPECTION AND
MAINTENANCE................................... 34
FLUSHING THE WATER
PASSAGES............................................. 45
SUBMERGED MOTOR ....................... 47
STORAGE PROCEDURE ................... 48
AFTER STORAGE ............................... 49
TROUBLESHOOTING ........................ 49
SPECIFICATIONS ............................... 51
INFORMATION REGARDING
EC – DIRECTIVE ................................. 51
CHART OF TOTAL OPERATING
HOURS INDICATION ......................... 52
FLOWCHART OF OIL CHANGE
REMINDER SYSTEM.......................... 52
4
IDENTIFICATION
NUMBER LOCATION
The model and identification numbers of your outboard motor are stamped on a plate attached to the clamp bracket. It is important to know these numbers when you place a parts order or if your motor is stolen.
Suzuki recommends that you install a waterseparating fuel filter assembly between your boat’s fuel tank(s) and outboard motor(s). Fuel filtration systems of this type will help prevent water that may be present in your boat’s fuel tank(s) from contaminating your motor’s electronic fuel injection system. Water contamination can cause poor engine performance and can also cause damage to the electronic fuel injection system components.
Your Authorized Suzuki Marine Dealer can provide you advice about water-separating fuel filter systems and installation.
Gasoline/Ethanol Blends
Blends of unleaded gasoline and ethanol (grain alcohol), also known as “GASOHOL”, are commercially available in some areas. Blends of this type may be used in your outboard motor if they are no more than 10% ethanol. Make sure this gasoline-ethanol blend has octane ratings no lower than those recommended for gasoline.
Use the recommended gasoline which conforms to the following labels.
FUEL AND OIL
GASOLINE
Suzuki highly recommends that you use alcohol-free unleaded gasoline whenever possible, with a minimum octane rating of 91 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane content may be used, provided the guidelines that follow are met.
NOTICE
Use of leaded gasoline can cause engine damage. Use of improper or poor quality fuel can affect performance and may damage your motor and fuel system.
Use only unleaded gasoline. Do not use fuel having lower than the recommended octane, or fuel that may be stale or contaminated by dirt/water etc. or
78RB0900*
Pump Labeling for Gasoline/Alcohol
Blends
In some states, pumps that dispense gasoline/ alcohol blends are required to be labeled for the type and percentage of alcohol content, and whether important additives are present. Such labels may provide enough information for you to determine if a particular blend of fuel meets the requirements listed above. In other states, pumps may not be clearly labeled as to the content or type of alcohol and additives. If you are not sure that the fuel you intend to use meets these requirements, check with the service station operator or the fuel suppliers.
NOTE:
Oxygenated fuels are fuels which contain oxygen-carrying additives such as alcohol.
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NOTE:
If you are not satisfied with the operation or fuel economy of your outboard motor when you are using gasoline/alcohol blends, you should switch back to unleaded gasoline containing no alcohol.
Be sure that any gasoline/alcohol blend you use has octane ratings of at least 91 octane
(Research method).
If engine pinging is experienced, substitute another brand as there are differences between brands.
Unleaded gasoline will extend spark plug life.
WARNING
Gasoline is extremely flammable and toxic. It can cause a fire and can be hazardous to people and pets.
ENGINE OIL
NOTICE
Use of poor quality engine oil can adversely affect engine performance and life.
Suzuki recommends that you use Suzuki
Marine 4-Cycle Engine Oil or its equivalent.
Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil.
Suzuki recommends the use of SAE 10W-40 or
10W-30 SUZUKI MARINE 4-CYCLE ENGINE
OIL. If SUZUKI MARINE 4-CYCLE ENGINE
OIL is not available, select a NMMA certified
FC-W oil or good quality 4-cycle motor oil from the following chart according to the average temperatures in your area.
Always take the following precautions when refueling:
• Never permit anyone other than an adult to refill the fuel tank.
• If you use a portable fuel tank, always stop the motor and remove the fuel tank from the boat to refill it.
• Do not fill the fuel tank all the way to the top or fuel may overflow when it expands due to heating by the sun.
• Be careful not to spill fuel. If you do, wipe it up immediately.
• Do not smoke, and keep away from open flames and sparks.
API Classification
SG
SH
SJ
SL
SM
TEMP.
˚C
˚F
SAE Viscosity Grade
10W–40
10W–30
–20
–4
–10
14
0
32
10
50
20
68
30
86
40
104
NOTE:
In very cold weather (below 5°C (41°F)), use
SAE (or NMMA FC-W) 5W-30 for easier starting and smooth operation.
NOTICE
Gasoline kept in the fuel tank for long periods of time will produce varnish and gum, which can damage the engine.
Always use fresh gasoline.
NOTICE
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Fuels containing alcohol can cause paint damage, which is not covered under the New
Outboard Motor Limited Warranty.
Be careful not to spill fuel containing alcohol while refueling. If fuel is spilled, wipe it up immediately.
GEAR OIL
Suzuki recommends the use of SUZUKI OUT-
BOARD MOTOR GEAR OIL. If it is not available, use SAE 90 hypoid gear oil which is rated
GL-5 under the API classification system.
7
LOCATION OF SAFETY LABELS
Read and follow all of the labels on your outboard motor or fuel tank. Make sure you understand all of the labels.
Keep the labels on your outboard motor or fuel tank. Do not remove them for any reason.
8
WARNING AVERTISSEMENT
• Fuel can leak creating a fire hazard if you lay motor on its side. Drain fuel completely from vapor separator or carburetor before laying motor on its side.
• See owner’s manual for details.
• Le carburent risque de fuir et de présenter un danger d’incendie si le moteur est placé sur le côté.
Vidanger entièrement le carburant du séparateur de vapeurs ou du carburateur avant de procéder.
• Pour plus de détail, voir le manuel du propriétaire.
Label symbol meanings
These symbols mean as follows;
: General warning symbol
(Caution or Warning)
: Read owner ’ s manual carefully
: Remote control lever/gear shift
lever operation-two direction;
Forward/Neutral/Reverse
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: Engine start
: Hazard caused by fire
: Hazard caused by laying the
motor on its side
LOCATION OF PARTS
Motor cover
Power trim and tilt
(P.T.T.) switch
Pilot water hole
(Reverse side)
MONITOR-TACHOMETER
Clamp bracket
Anode
Anode
Air vent hole plug
Gear oil level plug
Gear oil drain plug
Lock-out lever
Power trim and tilt (P.T.T.) switch
Remote control handle
Warm-up lever
Ignition key
Emergency stop switch
Flush plug
Engine oil drain plug
Anti-cavitation plate
Trim tab
Water intake hole
Throttle tension adjuster
REMOTE CONTROL BOX
Priming bulb
FUEL LINE
9
MOTOR MOUNTING BATTERY INSTALLATION
WARNING
BATTERY REQUIREMENT
Overpowering your boat can be hazardous.
Excessive horsepower will have an adverse effect on hull safety and may cause operating/ handling difficulties. The boat may also sustain stress and hull damage.
Never install an outboard motor with horsepower exceeding the manufacturer’s recommended maximum horsepower listed on the boat’s “Certification Plate”. Contact your authorized Suzuki marine dealer if you are unable to locate the hull “Certificate Plate”.
Suzuki strongly recommends that you have your outboard motor, controls and gauges installed by an authorized Suzuki Marine
Dealer. He has the tools, the facilities and the know-how.
WARNING
Failure to have your outboard motor and associated controls and gauges properly installed can result in personal injury or damage.
Suzuki strongly recommends that you have your outboard motor, controls and gauges installed by your authorized Suzuki marine dealer. He has the tools, the facilities, and the know-how to do the job correctly.
850 Marine Cranking Amps (MCA)/ABYC, or 670 Cold Cranking Amps (CCA)/SAE or 180 Reserve Capacity (RC) Minutes/SAE or 12 Volt 100 AH
NOTE:
• The specifications listed above are the minimum battery rating requirements for starting the engine.
• Additional electrical loads from the boat will require larger capacity batteries. Consult your Suzuki dealer to determine the proper battery sizing for your boat and engine combination.
• Dual-purpose (Cranking/Deep-cycle) batteries can be used if they meet the minimum specifications listed above (MCA, CCA, or
RC).
• Do not use a Deep Cycle battery for the main cranking battery.
• When connecting batteries in parallel, they must be of the same type, capacity, manufacturer, and of similar age. When replacement is necessary, they should be replaced as a set. Consult your Suzuki dealer for proper battery installation information.
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BATTERY INSTALLATION
Secure the battery in a dry area of the boat, away from vibration.
NOTE:
• It is recommended that the battery be installed in an enclosed battery case.
• When connecting batteries, hexagon-nuts must be used to secure battery leads to battery posts.
To hook up the battery, first connect the red lead from the motor to the positive battery terminal, then connect the black lead to the negative battery terminal.
Red lead
Sub battery cable
Black lead
Hexagon-nut
To remove the battery, first disconnect the black lead from the negative terminal, then disconnect the red lead from the positive terminal.
Suzuki recommends that you install the terminal cap on the positive battery terminal to prevent an accidental short circuit of battery terminals.
If a terminal cap is required, contact your authorized Suzuki marine dealer.
WARNING
If you place the battery near the fuel tank, a spark from the battery may ignite the gasoline, causing a fire and/or an explosion.
Do not place the fuel tank in the same compartment/area as the battery.
WARNING
Batteries produce flammable hydrogen gas and may explode if they are near flames or sparks.
Never smoke or cause sparks when working near the battery. Keep the battery away from open flames. To avoid creating a spark when charging the battery, connect the battery charger cables to the proper terminals before turning the charger on.
WARNING
Battery acid is poisonous and corrosive. It can cause severe injury and can damage painted surfaces.
Avoid contact with eyes, skin, clothing, and painted surfaces. If battery acid comes in contact with any of these, flush immediately with large amounts of water. If acid contacts the eyes or skin, get immediate medical attention.
NOTICE
The electrical system or its components may be damaged if proper battery precautions are not followed.
• Be sure to attach battery leads correctly.
• Do not disconnect battery leads from the battery while the engine is running.
11
SUB BATTERY CABLE
The sub battery cable 1 is used to supply voltage to the engine control system. In the midst of the cable, a 15A fuse 2 is provided to protect the control circuit.
If the sub battery cable is not correctly connected to the battery, engine cannot be started.
USE OF ELECTRICAL
ACCESSORIES
The amount of power (DC12V) available for accessories, however, depends on the operating condition of the motor. For getting a detailed information, please inquire of your authorized
Suzuki Marine Dealer.
NOTE:
Use of too much power for electrical accessories under certain operating conditions can cause the battery to discharge.
12
PROPELLER SELECTION
AND INSTALLATION
PROPELLER INSTALLATION
WARNING
PROPELLER SELECTION
It is essential to use a propeller on your outboard motor that is properly matched to your boat’s operating characteristics. The speed of the engine when you operate your boat at full throttle depends on the propeller you use.
Excessive engine speed can seriously damage the motor, while low engine speed at full throttle will adversely affect the performance. Your operating load will also affect propeller selection. Smaller loads generally require largerpitch propellers; larger loads generally require smaller-pitch propellers. Your authorized Suzuki
Marine Dealer will assist you in selecting a suitable propeller for your boat.
Failure to take proper precautions when installing or removing the propeller can result in severe personal injury.
When installing or removing the propeller:
• Always shift into “Neutral” and remove the emergency stop switch lock plate so that the motor cannot be started accidentally.
• Wear gloves to protect hands, and “lock” the propeller by placing a block of wood between the blades and the anti-cavitation plate.
To install a propeller on your outboard motor, use the following procedure:
NOTICE
Installing a propeller with either too much or too little pitch will cause incorrect maximum engine speed, which may result in severe damage to the motor.
Ask your authorized Suzuki marine dealer to assist you in selecting a suitable propeller for your boat.
You can determine if your propeller is appropriate for use with your boat by using a tachometer to measure engine speed when operating your boat at full throttle, under minimum load conditions. If you are using an appropriate propeller, the engine speed will be within the following range:
Full throttle operating range
DF200
DF225
DF250
5000 – 6000 r/min. (min
5000 – 6000 r/min. (min
–1 )
–1 )
5500 – 6100 r/min. (min –1 )
1. Coat the propeller shaft splines 1 liberally with Suzuki water resistant grease to help prevent corrosion.
2. Place the stopper 2 on the shaft.
3. Align the propeller 3 with the propeller shaft splines and slide the propeller onto the shaft.
4. Place the spacer 4 and washer 5 on the shaft.
5. Install the propeller nut 6 and tighten it with a torque wrench to 50 – 60 N·m (5.0 – 6.0
kg-m/36.0 – 43.5 lb-ft).
6. Insert the cotter pin 7 and bend it so that it can’t come off.
To remove the propeller, reverse the above procedure.
If the engine speed is not within this range, consult your authorized Suzuki Marine Dealer to determine which propeller size is best for you.
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ADJUSTMENT
TRIM ANGLE ADJUSTMENT
To help maintain steering stability and good performance, always maintain the proper trim angle as shown in the illustration. The appropriate trim angle varies depending on the combination of the boat, engine, and propeller, as well as operating conditions.
• Trim angle too small (Boat tends to “plow”)
• Trim angle too large (Boat tends to “porpoise”)
• Proper trim angle
WARNING
Trim angle greatly affects steering stability. If the trim angle is too small, the boat may
“plow” or “bow steer”. If the trim angle is too large, the boat may “chine walk” from side to side or “porpoise” up and down. These conditions, which result in loss of steering control, can cause occupants to be thrown overboard.
Always maintain proper trim angle based on the combination of your boat, engine, and propeller, as well as operating conditions.
WARNING
When the motor is tilted beyond the maximum trim position, the swivel bracket will not have side support from the clamp bracket and the tilt system will be unable to cushion the engine if the lower unit strikes an obstruction.
This could lead to occupant injury.
Do not operate the engine above 1500 r/min or operate the boat in a planing attitude with the motor tilted beyond the maximum trim position.
NOTICE
If you operate the boat with the motor trimmed beyond the maximum trim position, the water intake holes may be above the water line, causing severe engine damage due to overheating.
Never operate the boat with the motor trimmed beyond the maximum trim position.
Tilt range
Trim range
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Make a test run in the boat to determine if the trim angle needs to be adjusted. Adjust the trim angle using the Power Trim and Tilt system. If necessary, you can change the limit of downward travel that can be achieved using the
Power Trim and Tilt by moving the tilt pin to another position.
TRIM TAB ADJUSTMENT
This adjustment is used to compensate for the possible tendency of your boat to veer slightly to port or starboard. This tendency could be due to such things as propeller torque, motor mounting position, etc.
While operating your boat with the motor adjusted to the proper trim angle, observe the position of the needle on the TRIM GAUGE provided as optional part. When making future trim angle adjustment, use the TRIM GAUGE as a guide.
To adjust the trim tab:
1. Loosen the bolt A that holds the trim tab in place.
(Optional part)
2. If the boat tends to veer to port, move the rear end of the trim tab toward the port side.
If the boat tends to veer to starboard, move the starboard side.
3. Tighten the bolt that holds the trim tab in place.
After adjusting the trim tab, check to see if the boat still tends to veer to one side. If necessary, readjust the trim tab.
15
THROTTLE TENSION ADJUSTMENT
The tension of the remote control handle can be adjusted according to your preference. To increase the tension, turn the throttle tension adjuster A clockwise. To decrease the tension, turn the adjuster counterclockwise.
CAUTION SYSTEM
The caution systems are designed to alert you to certain situations which may cause damage to your outboard motor.
NOTICE
Your outboard motor may become damaged if you rely on the Caution System to alert you to any malfunction that may occur or to give you an indication of the need for maintenance.
To avoid damage to your outboard motor, regularly inspect and maintain it.
NOTICE
IDLE SPEED ADJUSTMENT
The idle speed has been factory adjusted between 600 – 700 r/min in neutral.
Continuing to operate your outboard motor with the Caution System activated can result in severe damage to your outboard motor.
NOTE:
If idle speed cannot be set within the specified range, contact your authorized Suzuki Marine
Dealer.
If the Caution System activates while you are operating your outboard motor, stop the motor as soon as possible and correct the problem or consult your authorized Suzuki marine dealer for assistance.
MOTOR COVER FASTENING
ADJUSTMENT
If you feel motor cover fastening is loose or too tight when locking the levers, adjust as follows:
1. Loosen the bolts 1 , 2 and 3 .
2. Adjust the position of brackets 4 , 5 and 6 .
To increase the fastening, move the brackets to the direction A . To decrease the fastening, move the brackets to the direction B .
3. Tighten the bolts.
Motor cover
INDICATOR CHECK
Each time the ignition key is turned to the “ON” position, four lamps – the REV LIMIT 1 , the
OIL 2 , the TEMP 3 and the CHECK ENGINE
4 in the monitor-tachometer will light briefly and the buzzer will also sound for the first two seconds, regardless of the motor conditions.
For the next three seconds, the monitortachometer will indicate the total motor operating hours by means of the lamp flashing and needle indicating.
After this brief check period, the monitortachometer will return to their stand-by mode and will only respond to motor conditions requiring a caution alert.
16
NOTICE
If the Over-Revolution Caution System activates at recommended maximum throttle and you are sure that the propeller pitch is sufficient and there are no factors like “over-trimming” or “ventilation”, there may be a problem with the Over-Revolution Caution
System.
NOTICE
Consult your authorized Suzuki marine dealer if the Over-Revolution Caution System activates for no apparent reason.
If the Caution System is not working properly, you may not be alerted to a condition that can cause damage to your outboard motor.
OIL PRESSURE CAUTION SYSTEM
This system operates when the engine lubricating oil pressure drops below the correct level.
If any of the four lamps does not come on or the buzzer does not sound when the ignition key is turned to the “ON” position, the lamp or buzzer may be broken or a failure may exist in the system circuit. Consult your authorized
Suzuki marine dealer.
If this system activates, the red OIL lamp will light and a buzzer will begin a series of beep. In addition, when this system is activated at 1000 r/min. or higher, engine speed will automatically be reduced to approximately 1000 r/min. with
REV LIMIT lamp lit.
NOTE:
For checking the total motor operating hours, refer to the CHART OF TOTAL OPERATING
HOURS INDICATION on the last page.
If you continue to run, the engine will automatically stop 3 minutes after beginning of the above CAUTION system activation.
OVER-REVOLUTION CAUTION SYSTEM
This system is activated when engine speed exceeds maximum recommended speed for more than 10 seconds.
If this system activates, engine speed will automatically be reduced to approximately
3000 r/min. with red REV LIMIT lamp lit.
NOTE:
In case that the engine is automatically stopped due to the CAUTION system, the engine can be started again.
However the CAUTION system will repeatedly activate until eliminating the cause.
This system must be reset by moving the throttle to the idle position for about one second to restore full engine operation.
If this system activates, stop the engine immediately, if wind and water conditions make it safe to do so.
17
WARNING
If you attempt to remove or reinstall the motor cover while the engine is running, you may be injured.
To check the oil level, stop the engine and then remove the motor cover.
Check the oil level and add oil if necessary. If the oil level is correct, consult your authorized
Suzuki Marine Dealer.
NOTICE
NOTE:
In case that the engine is automatically stopped due to the CAUTION system, the engine can be started again.
However the CAUTION system will repeatedly activate until eliminating the cause.
Your engine may become severely damaged If you rely on the Oil Pressure Caution System to indicate the need to add engine oil.
Check the engine oil level periodically and add oil as necessary.
If the overheat caution system activates when operating, reduce engine speed immediately and check if water is being discharged from the pilot water hole. If no water is seen, follow the procedures outlined below.
NOTICE
Operating the engine with the Oil Pressure
Caution System activated can result in severe engine damage.
Water and wind conditions permitting, stop the engine, tilt it out of the water and remove any debris like seaweed, plastic bags or sand that may have blocked the water intakes.
Lower the motor into the water, being sure that water intakes are immersed, and restart it.
If the Oil Pressure Caution System activates, stop the engine as soon as possible and add engine oil, if necessary, or otherwise correct the problem.
OVERHEAT CAUTION SYSTEM
This system is activated when the cylinder wall temperature is too high due to insufficient water cooling.
If this system activates, the red TEMP lamp will light and a buzzer will begin a series of beep. In addition, when this system is activated at 3000 r/min. or higher, engine speed will automatically be reduced to approximately 3000 r/min. with
REV LIMIT lamp lit.
Check (A) that water discharges from the pilot hole and (B) that the red TEMP lamp is no longer lit.
Be aware that the red TEMP lamp may light again if engine temperature rises abnormally. If either of the above situations arises, your authorized Suzuki Marine Dealer must be consulted as soon as possible.
NOTICE
Operating the engine with the overheat caution system activated can result in severe engine damage.
If you continue to run, the engine will automatically stop 3 minutes after beginning of the above CAUTION system activation.
If the overheat caution system activates, stop the engine as soon as possible, wind and water conditions permitting, and inspect the engine according to the above instructions.
Consult your authorized Suzuki marine dealer if you cannot correct the problem.
18
BATTERY VOLTAGE CAUTION SYSTEM
This system is activated when the battery voltage deficiency which could impair your motor’s performance occurs.
If this system activates, the red CHECK
ENGINE lamp will light and buzzer will begin a series of beep.
DIAGNOSTIC SYSTEM
If abnormal conditions exist in any sensor signal being input to the control unit, the self-diagnostic system warns of the abnormal condition.
If this system activates, the red CHECK
ENGINE lamp will flash and a buzzer will sound.
This system will be canceled automatically when the battery voltage restores to the proper voltage level. Refrain from using any electrical equipment such as P.T.T. system, hydraulic trim tabs, hydraulic jack plate, etc.
WARNING
Also incorporated is a fail-safe provision that allows the operation at a restricted speed even under such a failure condition.
The failed system can be identified by the mode of the lamp flashing and buzzer sounding.
The diagnostic code is designed to appear when the ignition key is turned on.
Failure to take proper precautions when inspecting or servicing the battery can be hazardous.
NOTICE
Do not attempt to inspect or service the battery without first reading the warnings, cautions, and instructions in the “BATTERY
INSTALLATION” section of this manual.
If the diagnostic system activates while you are operating your outboard motor, there is an abnormal condition in one of the sensor signals of the control system.
NOTE:
• A marginal battery may have enough power to start your engine, yet may still cause this caution system to activate whenever engine or boat accessory use places a high current demand on the battery.
• If this caution system activates continuously, even after you have stopped using engine or boat accessories, contact your authorized
Suzuki Marine Dealer.
Consult your authorized Suzuki marine dealer for repair of the control system.
NOTE:
The buzzer sound with diagnostic system activating will be canceled by pushing the ignition key in.
19
OIL CHANGE REMINDER
SYSTEM
ENGINE STALLING
CAUTION SYSTEM
This system informs the operator of the time for replacing engine oil on the basis of the maintenance schedule.
The system is designed to register the total operating hours of the outboard motor and function its operation when the preprogrammed hours have reached.
(Refer to the INSPECTION AND MAINTE-
NANCE section and the last page.)
This system informs the operator when the motor stalls while it is operating.
When the engine stalls for any reason, the caution buzzer sounds three times.
WATER IN FUEL ALERT
SYSTEM
SYSTEM ACTIVATION
When the total operating hours have reached the preprogrammed hours, the OIL lamp will flash. If the engine is not running, the buzzer will begin a series of double beeps additionally.
This indication will repeat until you cancel the system activation.
This engine is equipped with an integral fuel filter/water separator and associated alert system.
The alert system will activate if water separated from the fuel exceeds a specific volume.
CANCELLATION
1. Turn the ignition key to the “ON” position.
2. Pull out the emergency stop switch plate 1 .
3. Pull up the emergency stop switch knob 2 three times in 10 seconds. A short beep will be heard if the cancellation is successfully finished.
If this system activates, the red REV-LIMIT lamp will flash and a buzzer will begin a series of double beeps when the engine is in neutral only.
4. Turn the ignition key to the “OFF” position.
5. Set the plate 1 in the original position.
If this system activates, stop the engine immediately, if wind and water conditions are safe to do so, and check the fuel filter/water separator for water. Or consult your authorized Suzuki marine dealer.
NOTE:
• Canceling of the system activation is possible regardless of whether or not the engine oil has been replaced. Once the system has operated, however, Suzuki strongly recommends that the engine oil be replaced before canceling the system activation.
• Even if the engine oil has been replaced with the system not operating, it is still necessary to perform the cancellation.
For inspection and cleaning of the fuel filter, refer to the LOW PRESSURE FUEL FILTER in the INSPECTION AND MAINTENANCE section.
20
OPERATION OF TILTING
SYSTEMS
POWER TRIM AND TILT
The “Power Trim and Tilt” is operated by pressing the switch. To tilt the motor up, press the upper part of the switch. To tilt the motor down, press the lower part of the switch.
TILT LIMITER CAM
If the outboard motor contacts the motor well of the boat while tilting, adjust the tilt limiter cam to limit maximum tilt position.
1. Place the motor in the normal running position.
2. Rotate the tilt limiter cam:
To reduce the amount of tilt, move the tab A of cam upward.
To increase the amount of tilt, move the tab
A of cam downward.
UP
DOWN
UP
DOWN
WARNING
The power trim and tilt (PTT) switch can be accidentally activated when the ignition key is off, resulting in injury.
Keep all persons away from the outboard motor to help prevent accidental activation of the PTT system.
3. To check your adjustment, tilt the motor fully up to check for motor contact.
Adjust further if necessary.
Return the motor to the normal running position for each adjustment, and repeat your check after each adjustment.
WARNING
Adjusting the tilt limiter cam will not prevent the outboard motor from tilting fully up and contacting the motor well if the motor’s lower unit hits an object at high speed. Such tilting could damage your motor and boat and injure boat occupants.
Keep all occupants away from the motor when operating at high speed.
21
MANUAL TILTING
If you are unable to tilt the motor using the
“Power Trim and Tilt” because of an electrical problem or some other problem, you can move the motor manually. To tilt the motor up or down, turn the manual release valve A two turns counterclockwise, move the motor to the desired position, then retighten the release screw.
3. Lower the motor by pressing the Power Trim and Tilt “DOWN” switch, until the motor is supported by the Tilt Bracket.
4. Continue to operate the Power Trim and Tilt
“DOWN” switch until the trim rods are completely retracted.
NOTICE
CAUTION
The motor is very heavy. When you tilt it manually, you could injure your back or slip and fall causing injury.
When you tilt the motor manually, ensure that your grip and footing are secure and that you are able to support the weight of the engine.
TILT BRACKET
The Tilt Bracket is provided so you can support the motor in a tilted position for non-moving engine support.
To set the Tilt Bracket:
1. Tilt the motor all the way up by pressing the
Power Trim and Tilt “UP” switch.
2. Pull down the Tilt Bracket as shown in the illustration.
If you do not retract the trim rams completely when mooring, they may become deteriorated or corroded.
Be sure to retract the trim rams completely when mooring.
To release the Tilt Lever, tilt the motor all the way up using the Power Trim and Tilt “UP” switch, and pull up the Tilt Lever.
CAUTION
The remote Power Trim and Tilt switch will work when the ignition switch is off. If someone activates the switch while you are moving the tilt bracket, your hand could be injured.
Keep all persons away from the remote Power
Trim and Tilt switch while you are moving the tilt bracket.
22
NOTICE
Damage can occur if you use the tilt bracket other than when the boat is moored or is otherwise stationary.
The tilt bracket relieves pressure from the power trim and tilt and should only be used when the boat is stationary. Do not use the tilt bracket when trailering your boat and motor.
Refer to the TRAILERING section of this manual.
INSPECTION BEFORE
BOATING
WARNING
Failure to inspect your boat and motor before beginning a trip can be hazardous.
Before boating, always perform the inspections described in this section.
It is important to make sure that your boat and motor are in good condition and that you are properly prepared for an emergency.
Always perform the following checks before you begin boating:
• Make sure that you have enough fuel for the intended run.
• Check the level of engine oil in the sump.
NOTICE
Running the engine with an insufficient amount of oil can cause serious engine damage.
Always check the oil level before each trip and add oil if necessary.
To check the oil level:
NOTE:
To avoid an incorrect assessment of engine oil level, check the level only when the engine has cooled.
1. Place the motor in a vertical position, then remove the motor cover 1 by unlocking the lever 2 and 3 .
23
2. Pull out the oil dipstick and wipe oil off with a clean cloth.
To fill the engine oil:
1. Remove the oil filler cap.
2. Fill the recommended engine oil to the upper level.
NOTE:
If the engine oil is contaminated or discolored, replace with fresh engine oil (Refer to the
INSPECTION AND MAINTENANCE/ENGINE
OIL section).
3. Insert the dipstick all the way into the engine, then remove it again.
NOTICE
Running the engine with an excessive amount of oil can damage the engine.
Do not overfill the engine with oil.
24
UPPER LIMIT
LOWER LIMIT
The oil on the dipstick should be between the upper and lower limits shown on the dipstick. If the oil level indication is near the lower limit, add enough oil to raise the level to the upper limit.
3. Tighten the oil filler cap securely.
• Check the battery solution level.
The level should be kept between the MAX and the MIN level lines at all times. If the level drops below the MIN level line, refer to the INSPECTION AND MAINTENANCE section.
• Make sure that the battery leads are securely connected to the battery terminals.
• Visually check the propeller to make sure it is not damaged.
• Make sure that the motor is securely mounted to the transom.
• Check for proper operation of the Power
Trim and Tilt.
• Make sure that the tilt pin is securely installed in the proper position.
• Make sure you have the boating safety and emergency equipment on board.
• Make sure that the emergency stop switch operates properly.
• Make sure the obstacle is not attached to water intake hole.
BREAK-IN
Proper operation during this break-in period will help ensure maximum life and performance from your engine. The following guidelines will explain proper break-in procedures.
NOTE:
You may throttle up beyond the recommended operating range to plane your boat, then immediately reduce the throttle to the recommended operating range.
NOTICE
Failure to follow the break-in procedures described below can result in severe engine damage.
Be sure to follow the engine break-in procedures described below.
Break-in period : 10 hours
2. For the next 1 hour:
Safe boating conditions permitting, operate the engine in gear at 4000 r/min. or at threequarter throttle. Avoid running the engine at full throttle.
3. Remaining 7 hours:
Safe boating conditions permitting, operate the engine in gear at desired engine speed.
You may occasionally use full throttle; however do not operate the engine continuously at full throttle for more than 5 minutes at any time.
Break-in procedure
1. For the initial 2 hours:
Allow sufficient idling time (about 5 minutes) for the engine to warm up after cold engine starting.
NOTICE
Running continuously at full throttle for more than 5 minutes at a time during the last 7 hours of break-in operation may cause severe engine damage such as seizure.
NOTICE
Running at high speed without sufficient warm-up may cause severe engine damage such as piston seizure.
During the last 7 hours of break-in operation, do not operate at wide open throttle for more than 5 minutes at a time.
Always allow sufficient idling time (5 minutes) for the engine to warm-up before running at high speed.
After warming up, run the engine at idling speed or the lowest in-gear speed for about
15 minutes.
During the remaining 1 hour and 45 minutes, if safe boating conditions permit, operate the engine in gear at less than 1/2 (half) throttle
(3000 r/min.).
25
OPERATION
BEFORE ATTEMPTING TO START THE
ENGINE
1. The motor has been lowered into the water.
2. Make sure that the motor fuel hose and the hose from the boat’s fuel tank are securely attached and clamped.
4. Make sure that the motor is in “NEUTRAL”.
5. Make sure the lock plate is in place and attach the emergency stop switch cord to a part of your body.
3. Ensure that the boat fuel tank is correctly vented and that any in-line filters are free of dirt etc. If fuel tank filler cap has a manual vent, be sure that it is fully open.
26
WARNING
1. Squeeze the fuel line priming bulb several times until you feel resistance.
Failure to properly attach the emergency stop switch cord or to take proper precautions to help ensure that the emergency stop switch works as intended may result in serious injury or death to the operator or passengers.
Always take the following precautions:
• Make sure that the emergency stop switch cord is fastened securely to the operator’s wrist or to an appropriate clothing area (belt etc.).
• Ensure that no obstructions impede or restrict emergency stop switch operation.
• Be careful not to pull the stop switch cord or knock out the lock plate during normal operation. The motor will stop abruptly, and the loss of forward motion may unexpectedly throw occupants forward.
2. Make sure that the warm-up lever is in the fully closed position.
NOTE:
A spare plastic lock plate is provided for temporary use only. Remove it from the cord and place it in a safe place on board your boat. If you lose or break the emergency stop switch cord/lock plate assembly, replace it as soon as possible so that you can resume normal use of the emergency stop switch.
3. Turn the ignition key to the “ON” position.
4. Turn the ignition key to the “START” position.
STARTING THE ENGINE
WARNING
Exhaust gas contains carbon monoxide, a dangerous gas that is difficult to detect because it is colorless and odorless. Breathing carbon monoxide can cause death or severe injury.
Never start the engine or let it run indoors or where there is little or no ventilation.
NOTE:
If the emergency stop switch lock plate is not in position, the starter motor cannot operate.
NOTICE
If you turn the ignition key to the “START” position for more than 5 seconds, the starter system could be damaged.
Never turn the ignition key to the “START” position for more than 5 seconds.
27
NOTE:
The continuous operating time of the starter motor is set at five seconds.
When this time is exceeded, the starter motor will automatically stop.
If the motor stops, wait about ten seconds for the motor to cool down and try again.
NOTICE
If the OIL lamp remains lit while operating the outboard, the oil level may be low enough to damage the engine.
Stop the engine and check the oil level.
5. Warm up the engine for about 5 minutes.
NOTICE
NOTICE
Never operate your outboard motor when there is no water coming out of the pilot water hole, or severe damage can result.
After starting the engine, check to make sure that there is water coming out of the pilot water hole.
WARNING
Operating the boat when the emergency stop switch is not operating properly can be hazardous.
Before starting off, check to make sure that the emergency stop switch operates properly.
Operating the engine at high RPM or “wide open throttle” immediately after starting the engine without allowing the engine to warm up may cause engine failure.
Always allow the engine to warm up sufficiently before operating it at high speeds.
Cooling water check
As soon as the engine starts, water should spray out of the pilot water hole 1 , indicating that the water pump and cooling system are working properly. If you notice that water does not spray out of the pilot water hole, stop the engine as soon as possible and consult your
Suzuki Marine Dealer.
SHIFTING AND SPEED CONTROL
NOTICE
Severe engine damage may occur if (a) engine speed is not allowed to return to idle and boat speed is not reduced when shifting from
“FORWARD” to “REVERSE” or from
“REVERSE” to “FORWARD”, or (b) care is not taken when operating the boat in reverse.
Always allow the engine speed to return to idle before shifting. Exercise caution and use minimal speed when operating the boat in reverse. Be sure the handle/shift lever is in the desired position before accelerating.
NOTICE
If you shift gears when the engine is not running, the shifting mechanism can be damaged.
Avoid shifting gears when the engine is not running.
28
Shifting
To shift into “FORWARD”, squeeze the lock-out lever on the control handle and move the control handle forward to approximately position A , as shown in the illustration.
STOPPING THE ENGINE
NOTE:
When it is necessary to stop the engine in an emergency, pull the emergency stop switch lock plate out of the emergency stop switch by pulling the emergency stop switch cord.
To shift into “REVERSE”, squeeze the lock-out lever on the control handle and move the control handle rearward to approximately position
B , as shown in the illustration.
NEUTRAL
To stop the engine:
1. Shift into “NEUTRAL”.
2. After operating at full throttle, cool off the engine a few minutes by allowing it to idle or troll at low speed.
32˚ 32˚
REVERSE
FORWARD
Speed Control
To increase speed after you have shifted into gear, continue moving the control handle forward or rearward.
WARNING
3. Turn the ignition key to the “OFF” position.
Always leave the ignition key in the “OFF” position when the motor is not running, or the battery can discharge.
Since the same handle is used for shifting and speed control it is possible to move the handle past the detent and engage the throttle.
This can cause the boat to move suddenly resulting in personal injury or property damage.
You must be careful not to move the control handle too far forward or rearward when shifting.
NOTICE
If the ignition key is left ON when the engine is not running, the battery will discharge.
Always turn the ignition key OFF when the engine is not running.
29
WARNING
Unauthorized use of your boat could lead to an accident or damage to your boat.
To prevent unauthorized use of your boat, be sure to remove the key and emergency stop switch lock plate when the boat is unattended.
OPERATION IN SHALLOW WATER
When operating your boat in shallow water, it may be necessary to tilt the motor higher than the normal trim angle. When you tilt the motor beyond the normal trim angle, however, you should only operate the boat at slow speeds.
After returning to deep water, be sure to lower the motor to the normal trim angle.
WARNING
4. After stopping the engine, disconnect the fuel line from the outboard motor if there is a fuel connector.
WARNING
If you leave the motor stopped for a long period of time with the fuel line connected, fuel can leak out.
Disconnect the fuel line from fuel tank, if there is a fuel connector, whenever you leave the motor stopped for a long period of time.
When the motor is beyond the maximum trim position, the swivel bracket will not have side support from the clamp bracket and the tilt system will be unable to cushion the engine if the lower unit strikes an obstruction. This could lead to occupant injury. In addition, beyond the maximum trim position, the water intake holes may be above the water line, which can result in severe engine damage from overheating.
Do not operate the engine above 1500 r/min or operate the boat in a planning attitude with the engine beyond the maximum trim position.
5. Twist the air-vent screw on the fuel tank cap clockwise to shut the vent (if equipped).
NOTE:
To make sure that the emergency stop switch operates properly, stop the engine occasionally by pulling out the lock plate, while operating the engine at idling speed.
NOTICE
If the motor hits bottom, serious damage can occur.
MOORING
The motor should be tilted up out of the water when you moor the boat in shallow water or if the motor will not be used for some time, to protect it from damage by underwater obstacles at low tide or corrosion from salt water.
Refer to the TILT BRACKET section for details on how to tilt up the motor.
NOTICE
Do not allow the motor to hit bottom. If the motor does strike bottom, inspect it immediately for damage.
OPERATION IN SALT WATER
After operating the motor in salt water, you should flush the water passages with clean, fresh water as outlined in the FLUSHING THE
WATER PASSAGES section. If you do not flush the water passages, salt can corrode the motor and shorten its life.
Improperly securing your boat may cause damage to your boat or motor, or other property damage.
Do not allow your motor to rub against quay walls, piers or other boats when the boat is tied up.
30
OPERATION IN FREEZING WEATHER
When operating your outboard motor in freezing temperatures, you should keep the lower unit submerged in the water at all times.
When taking motor out of the water, stand it up in a vertical position until the cooling system drains completely.
NOTICE
MOTOR REMOVAL AND
TRANSPORTING
MOTOR REMOVAL
If it is necessary to remove the outboard motor from your boat, we recommend that you ask your authorized Suzuki Marine Dealer to do the work for you.
If you leave your outboard motor out of the water in freezing temperatures with water still in the cooling system, the water can freeze and expand, causing severe damage to the motor.
When your outboard is in the water in freezing temperatures, keep the lower unit submerged in the water at all times. When the motor is stored out of the water in freezing temperatures stand it up in the vertical position so that the cooling system drains completely.
MOTOR TRANSPORTING
When transporting the motor, place the motor either vertically or horizontally.
Vertical transport:
Attach the motor to the carrier by securing clamp bracket with two sets of transom bolt and nut.
Never use display stand for transportation of the motor.
Horizontal transport:
1. Drain the engine oil. Refer to the ENGINE
OIL section.
2. Drain the gasoline from the vapor separator
1 as follows:
(1) Remove the motor cover.
(2) Pull the drain hose end 2 out.
31
(3) Loosen the vapor separator drain screw 3 and drain the gasoline into a suitable container.
WARNING
Gasoline is extremely flammable and toxic. It can cause a fire and can be hazardous to people and pets.
Use a proper, safe container to store any gasoline drained from the outboard motor. Keep gasoline away from sparks, flames, people, and pets.
(4) After draining, retighten the vapor separator drain screw 3 , and then put the drain hose back.
3. Rest the motor on a case protector with the port side downwards as shown.
WARNING
Spilled fuel or fuel vapor can cause a fire and is hazardous to health.
Always take the following precautions:
• Drain the fuel from the fuel line and fuel vapor separator before transporting the boat/outboard motor and before removing the motor from the boat.
• DO NOT lay motor on its side without draining fuel.
• Keep the motor away from open flames or sparks.
• Wipe up spilled fuel immediately.
NOTICE
If spilled gasoline is just left on painted surface, it may cause a stain or discoloration of the surface coating.
Wipe off any spilled gasoline immediately with a soft cloth etc.
NOTICE
If you are not careful when resting the outboard on its side and do not take proper precautions such as first draining the engine oil and cooling water completely, damage can occur. Engine oil may enter the cylinder from the sump, water may enter the cylinder through the exhaust port, or the outer casings may be damaged.
Always drain the engine oil and cooling water completely before laying the motor on its side, and be careful laying the motor down.
NOTICE
If you let the lower unit of your outboard sit higher than the power head during transporting or storing, water may trickle into the power head, causing damage to the engine.
Never let the lower unit sit higher than the power head when transporting or storing your outboard.
32
TRAILERING
When trailering your boat with the motor attached, keep the motor in the normal operating position unless there is not enough ground clearance. If you need more ground clearance, trailer the motor in a tilted position using a transom saver bar or similar device to support the weight of the motor.
NOTICE
If you use the tilt bracket to hold the motor in the fully tilted up position when trailering the boat, towing motion or poor road surfaces may cause unexpected tilt lock release, resulting in damage to the motor and the tilt lock mechanism.
Never use the tilt bracket to hold the motor in the fully tilted up position when trailering the boat. Use a transom saver bar or similar device to support the weight of the motor.
33
INSPECTION AND MAINTENANCE
MAINTENANCE SCHEDULE
It is important to inspect and maintain your outboard motor regularly. Follow the chart below.
At each interval, be sure to perform the indicated service. Maintenance intervals should be judged by number of hours or number of months, whichever comes first.
WARNING
Exhaust gas contains carbon monoxide, a dangerous gas that is difficult to detect because it is colorless and odorless. Breathing carbon monoxide can cause death or severe injury.
Never start the engine or let it run indoors or where there is little or no ventilation.
Interval
Item to be serviced
Spark plug
Breather & Fuel line
Engine oil
Gear oil
Lubrication
Anodes (external)
* Anodes (internal cylinder block/cylinder head)
Bonding wire
Battery
* Engine oil filter
Initial 20 hrs.
or 1 month
R
I
I
I
R
Every 100 hrs.
or every
12 months
R
R
I
I
I
I
I
Every 200 hrs.
or every
12 months
Low pressure fuel filter
I
I
I
R
I
I
R
I
Replace every 400 hours or every 2 years.
* Low pressure fuel pump filter
* High pressure fuel filter
* Idle speed
* Valve clearance (lash)
* Water pump
* Water pump impeller
* Propeller nut & pin
* Bolts & Nuts
* Thermostat
I
I
T
Replace every 1000 hours.
Replace every 1000 hours.
I
T
I
I
I
I
I: Inspect and clean, adjust, lubricate, or replace, if necessary T: Tighten R: Replace
Every 300 hrs.
or every
36 months
I
R
NOTE:
Water-separating fuel filter
Replace the filter element every 12-months (or more frequently if recommended by the filter manufacturer).
34
WARNING
Improper maintenance or failure to perform recommended maintenance can be hazardous. Poor maintenance or lack of maintenance increases the chance of an accident or equipment damage.
Be sure to have maintenance performed according to the schedule in the above chart.
Suzuki recommends that only your authorized
Suzuki marine dealer or a qualified service mechanic perform maintenance on those items in the chart above which are marked with an asterisk (*). You may perform maintenance on the unmarked items by referring to the instructions in this section if you have mechanical experience. If you are not sure whether you can successfully complete any of the unmarked maintenance jobs, ask your authorized Suzuki marine dealer to do the maintenance for you.
WARNING
The safety of you and your passengers depends on how well you maintain your outboard motor.
Follow all inspection and maintenance instructions carefully. If you do not have prior mechanical experience, do not attempt to perform maintenance on your outboard motor.
You could be injured or may damage the motor.
NOTICE
The maintenance intervals in the chart are designed for normal usage of your outboard motor. If your outboard motor is used under severe conditions as outlined below, you may need to perform maintenance more often than indicated in the chart.
• Frequent full throttle operation
• Prolonged continuous operation at the maximum speed
• Prolonged continuous operation at idling speed or trolling speed
• Frequent operation in muddy, silty, sandy, acidic or shallow water
• Operation without appropriate warmup
• Frequent abrupt acceleration and deceleration
• Frequent shift operation
Failure to perform maintenance more frequently could result in damage.
Consult your authorized Suzuki marine dealer regarding appropriate maintenance intervals for your usage conditions. When replacing parts on your outboard motor, Suzuki strongly recommends that you use genuine Suzuki parts or their equivalent.
TOOL KIT
A tool kit is provided with your outboard motor.
Keep the kit on board your boat and make sure that all of the items provided remain in the kit.
The tool kit contains the following items:
1 Tool bag
2 8 mm Box wrench
3 8 × 10 mm Box wrench
4 16 mm Box wrench
5 Combination screw driver
6 Screwdriver handle
7 Pliers
8 Hexagon wrench 8 mm
9 Engine oil drain plug gasket (spare)
35
SPARK PLUG
Remove the spark plugs as follows:
1. Remove the bolt securing the ignition coil.
2. Pull out the ignition coil.
3. Loosen and remove the spark plug using the box wrench in the tool bag.
Your outboard motor comes equipped with the following “standard” spark plug for normal usage.
NGK BKR6E Standard
NOTICE
Non-resistor types of spark plugs will interfere with the function of the electronic ignition, causing misfiring, or causing problems with other electronic boat equipment and accessories.
Use ONLY resistor type spark plugs in your outboard motor.
A normally operating spark plug is very lightbrown in color. If the standard plug is not suitable for your operating, consult your authorized
Suzuki Marine Dealer.
NOTICE
Use of improper spark plugs or improperly tightening spark plugs can cause severe engine damage.
• Do not experiment with other spark plug brands unless you can determine that they are directly equivalent to the specified brand, or you may experience engine damage which will not be covered under warranty. Note that aftermarket cross-reference charts may not be accurate.
• To install a spark plug; seat it as far as possible by hand, then use a wrench to tighten it to either the recommended torque setting or the specified rotation angle.
Tightening torque
25 – 29 N·m
(2.5 – 2.9 kg-m, 18.0 – 21.0 lb-ft)
Rotation angle
New plug 1/2 – 3/4 of a turn
Re-use plug 1/12 – 1/8 of a turn
• Do not overtighten or cross-thread a spark plug, as this will damage the aluminum threads of the cylinder head.
36
To maintain a strong spark, you should clean and adjust the plugs at the intervals shown in the maintenance chart. Remove carbon deposits from the spark plugs using a small wire brush or spark plug cleaner, and adjust the gap according to the following chart:
BREATHER AND FUEL LINE
Inspect the breather and fuel line for leaks, cracks, swelling, or other damage. If the breather and fuel line is damaged in any way, it must be replaced. Consult your authorized
Suzuki Marine Dealer if it is necessary to replace them.
Spark plug gap
0.7 – 0.8 mm
(0.028 – 0.031 in.) Breather line
Breather line
Fuel line
1. Excessive wear 2. Breakage 3. Melting
4. Erosion 5. Yellow deposits 6. Oxidation
NOTE:
If the spark plug condition is found as shown in the illustration above, ensure it is replaced with new one. Otherwise, it will cause difficulty in starting the engine, increase fuel consumption, and result in engine troubles.
WARNING
Fuel leakage can contribute to an explosion or fire, resulting in serious personal injury.
Have your authorized Suzuki Marine Dealer replace the fuel line if there is any evidence of leaking, cracking or swelling.
37
ENGINE OIL
WARNING
3. Place a drain pan under the engine oil drain screw.
CAUTION
Never perform any ENGINE OIL procedure with the motor running, as serious injury can occur.
The motor must be shut off before any
ENGINE OIL procedures are performed.
NOTICE
The engine oil temperature may be high enough to burn your fingers when the drain plug is loosened.
Wait until the drain plug is cool enough to touch with bare hands before removing it.
4. Remove the engine oil drain screw 1 and gasket 2 , then let the engine oil drain.
Extended trolling can reduce oil life. Your engine may be damaged if you do not change engine oil more frequently under this type of use.
Change your engine oil more frequently if your engine is used for extended trolling.
Engine oil change
The oil should be changed when engine is warm so that the oil will drain thoroughly from the engine.
To change the engine oil:
1. Place the motor in a vertical position and remove the motor cover.
2. Remove the oil filler cap.
5. After draining, secure the engine oil drain screw with a new gasket.
NOTICE
A previously-used gasket may leak, resulting in engine damage.
Do not re-use gaskets. Be sure to always use new gaskets.
NOTE:
There are spare gaskets in the tool bag.
6. Fill with recommended engine oil to the upper level.
Oil capacity: 8.0 L
38
7. Check the engine oil level.
GEAR OIL
To check the gear oil level, remove the gear oil level plug 1 and look into the hole. The oil level should be at the bottom edge of the hole. If the oil level is low, add the specified gear oil until the level reaches the bottom edge of the hole.
Then, reinstall and tighten the plug.
UPPER LIMIT
LOWER LIMIT
NOTE:
To avoid incorrect measurement of engine oil level, check oil level only when the engine has cooled.
8. Reinstall the oil filler cap.
WARNING
Engine oil can cause injury to people or pets.
Repeated, prolonged contact with used engine oil may cause skin cancer. Even brief contact with used oil may irritate skin.
To change the gear oil:
1. Make sure the motor is in an upright position. Place a drain pan under the lower casing.
2. Remove the gear oil drain plug 2 , then remove the air vent hole plug 3 .
• Keep new and used oil away from children and pets.
• Wear a long-sleeve shirt and waterproof gloves when handling oil.
• Wash with soap if oil contacts your skin.
• Launder any clothing or rags that are wet with oil.
NOTE:
Recycle or properly dispose of used engine oil.
Do not throw it in the trash, or pour it on the ground, down a drain, or into the water.
3. After the oil has drained completely, inject the specified gear oil into the gear oil drain hole 2 until it just starts to come out of the air vent hole 3 . Approximately 1.1 L (1.2/1.0
US/lmp. qt.) of oil will be required.
NOTE:
The oil level plug and the air vent hole plug are different from the oil drain plug.
The magnet is installed in the drain plug.
Clean the magnet if there is a metal powder on it.
Do not make a mistake in their positions when install them.
4. Reinstall and tighten the air vent hole plug
3 , then quickly reinstall and tighten the gear oil drain plug 2 .
39
NOTE:
To avoid insufficient injection of gear oil, check the gear oil level 10 minutes after doing the procedure in the step 4. If the oil level is low, slowly inject the gear oil into the gear oil level hole 1 up to the correct level.
WARNING
LOW PRESSURE FUEL FILTER
The low pressure fuel filter must be replaced by an authorized Suzuki Marine Dealer periodically.
Replace low pressure fuel filter at every 400 hours (2 years).
WARNING
Gear oil can cause injury to people or pets.
Repeated, prolonged contact with used gear oil may cause skin cancer. Even brief contact with used oil may irritate skin.
• Keep new and used oil away from children and pets.
• Wear a long-sleeve shirt and waterproof gloves when handling oil.
• Wash with soap if oil contacts your skin.
• Launder any clothing or rags that are wet with oil.
Gasoline is extremely flammable and toxic. It can cause a fire and can be hazardous to people and pets.
Always take the following precautions when servicing the fuel filter:
• Stop the motor before cleaning the fuel filter.
• Be careful not to spill fuel. If you do, wipe it up immediately.
• Do not smoke, and keep away from open flames and sparks.
WARNING NOTE:
Recycle or properly dispose of used gear oil.
Do not throw it in the trash, or pour it on the ground, down a drain, or into the water.
NOTICE
Cleaning solvent is toxic and an irritant, and can cause injury to people and pets.
Keep solvent away from children and pets.
Dispose of solvent properly when you are finished.
If fishing line wraps around the rotating propeller shaft, the propeller shaft oil seal can become damaged and can allow water to enter the gear case causing severe damage.
If the gear oil has a milky color, it is contaminated with water. Immediately contact your authorized Suzuki marine dealer for advice.
Do not operate your outboard until the oil is changed and the cause of the contamination is corrected.
Inspect and clean the fuel filter as follows:
1. Turn the engine off and allow it to cool.
2. Make sure that the ignition key is in the OFF position.
3. Remove the bolts 1 securing the fuel filter cap 2 in place.
40
NOTICE
7. Drain the fuel and water in the filter cup into a suitable container.
Improperly loosening the filter cup can cause sensor lead wire damage.
NOTICE
• Be careful not to twist the sensor lead wire when removing the filter cup.
• Disconnect the lead wire connector before removing the filter cup.
If spilled gasoline is just left on painted surface, it may cause a stain or discoloration of the surface coating.
Wipe off any spilled gasoline immediately with a soft cloth etc.
4. Push the connector lock tab “a”, then disconnect the water sensor lead wire connector
3 .
8. Pull out the filter element 5 . Inspect the filter element 5 , O-ring 6 and seal ring 7 for damage. If they are damaged, replace them.
“a”
5. Place a rag under the filter before removal to catch any spilled fuel.
6. Separate the filter cup 4 from the cap 2 by turning the filter cup counterclockwise.
9. Wash the filter element with clean solvent and dry it.
10. Reinstall the seal ring and filter element in their original positions.
11. Verify that the O-ring is in place in the top of the filter cup and screw the filter cup back into place.
12. Connect the water sensor lead wire connector 3 .
13. Reinstall the fuel filter with the attaching bolts.
14. Restart the engine and check that there are no leaks around the fuel filter.
NOTE:
If any water exists in the fuel filter cup, remove the cup and drain the water. Always dispose of excess fuel safely. For questions, consult your authorized Suzuki Marine Dealer.
41
LUBRICATION
Proper lubrication is important for the safe, smooth operation and long life of each working part of your outboard motor. The following chart shows the lubrication points of your motor and the recommended lubricant:
LOCATION LUBRICANT
Throttle/Shift linkage
Propeller shaft
Marine-grade water resistant grease
Swivel bracket
Marine-grade water resistant grease
(Grease Gun)
Trim ram pad
DF200 transaom “L”
Steering bracket
Mount oil seal cover
NOTE:
Before applying grease through the steering bracket grease nipple, lock the motor in the fully tilted up position.
42
Use a hand operated grease gun and follow the steps below when servicing the grease nipple
A on the mount oil seal cover.
1. Turn the engine off and allow it to cool.
2. Inject approximately 10 grams of grease at initial 20 hours.
Inject approximately 5 grams of grease at every 100 hours (12 months).
ANODES AND BONDING WIRES
Anodes
The motor is protected from exterior corrosion by anodes. These pieces of anodes control electrolysis and prevent corrosion. The anodes will corrode in place of the parts they are protecting. You should periodically inspect each of the anodes and replace them when 2/3 of the metal has corroded away.
Upper mount seal
NOTICE
Using a hydraulic or air powered grease gun to service the grease nipple A on the mount oil seal cover may cause damage to the oil seal.
Do not use powered grease guns when servicing grease nipple A on the mount oil seal cover.
NOTE:
If grease will not inject into the fitting, consult your Authorized Suzuki Marine Dealer.
NOTICE
If anodes are not properly maintained, underwater aluminum surfaces (such as the lower unit) will suffer galvanic corrosion damage.
• Periodically inspect anodes to make sure they have not become detached.
• Do not paint anodes, as this will render them ineffective.
• Periodically clean anodes with a wire brush to remove any coating which might decrease their protective ability.
NOTE:
Consult your authorized Suzuki Marine Dealer for inspection and replacement of internal anodes attached to the cylinder block/cylinder head.
43
Bonding wires
Bonding wires are used to electrically connect the engine components so they exist in a common ground circuit. This allows them to be protected against electrolysis by the anodes.
These wires and their terminals should be checked periodically to be sure they have not been damaged.
WARNING
If you are not careful when checking or servicing the battery, you can cause a short circuit, which could result in an explosion, fire, or circuit damage.
Disconnect the negative (black) cable when checking or servicing the battery. Be careful not to allow a metal tool or other metal object to touch the battery’s positive terminal and the motor at the same time.
WARNING
Battery posts, terminals, and related accessories contain lead and lead compounds that may be hazardous.
Wash hands after handling.
NOTICE
BATTERY
The battery solution level must be kept between the MAX and the MIN level lines at all times. If the level drops below the MIN level line, add
DISTILLED WATER ONLY until the battery solution level reaches the MAX level line.
WARNING
Battery acid is poisonous and corrosive, and can cause severe injury.
NEVER add diluted sulphuric acid to the battery after it has been initially serviced. Follow the battery manufacturer’s instructions for specific maintenance procedures.
ENGINE OIL FILTER
The engine oil filter must be changed by authorized Suzuki Marine Dealer periodically.
Replace engine oil filter with a new one at initial
20 hours (1 month).
Replace engine oil filter with a new one at every
200 hours (12 months).
Avoid contact with eyes, skin, clothing, and painted surfaces. If battery acid comes in contact with any of these, flush immediately with large amounts of water. If acid contacts the eyes or skin, get immediate medical attention.
If you add diluted sulphuric acid to the battery after it has been initially serviced, you will damage the battery.
44
FLUSHING THE WATER
PASSAGES
NOTICE
After operation in muddy, brackish, or salt water, you should flush the water passages and motor surface with clean, fresh water.
If you do not flush the water passages, salt can corrode the motor and shorten its life. Flush the water passages as follows.
Severe engine damage can occur in as little as
15 seconds if the engine is started without supplying water to the cooling system.
Never start the motor without supplying water to the cooling system.
ENGINE RUNNING – Vertical position –
Suzuki recommends that you flush the water passages by using this method.
To flush the water passages, you must obtain a commercially available engine flush device.
WARNING
1. Make sure that the motor is stopped.
2. Install the flushing attachment 1 so that the water intake holes are covered by the rubber cups on the attachment.
3. Connect a garden hose to the flushing attachment and turn on the water to obtain enough flow so that plenty of excess water is flowing out from around the rubber cups on the attachment.
Exhaust gas contains carbon monoxide, a dangerous gas that is difficult to detect because it is colorless and odorless. Breathing carbon monoxide can cause death or severe injury.
Never start the engine or let it run indoors or where there is little or no ventilation.
WARNING
Failure to take proper precautions when flushing the water passages can be hazardous.
When flushing the water passages, always take the following precautions:
• Make sure that the engine remains in NEU-
TRAL. If shifted into gear, the propeller shaft will turn and could cause severe personal injury.
• Make sure the motor is properly clamped to a secure stand or boat, and remain in attendance until flushing is completed.
• Keep children and pets away from the area, and stay clear of all moving parts.
4. Place the remote control handle in the
“NEUTRAL” position with the propeller removed, start the motor and allow it to run at idle.
5. Readjust the water flow, if necessary, so that there is still plenty of excess water flowing out from around the rubber cups.
6. Allow the water to continue circulating for a few minutes.
7. Stop the motor, then turn off the water.
8. Remove the flushing attachment from the water intake hole.
9. Clean the motor surface and apply a coat of automotive wax on the external finish of the motor.
45
ENGINE NOT RUNNING
– Vertical position –
1. Make sure that the motor is stopped.
2. Remove one of the plug A or C from the two flushing port .
4. Turn on the water to obtain a good water flow. Flush the engine for about five minutes.
5. Turn off the water.
6. Remove the hose and connector (if used) then reinstall the plug into the flushing port.
7. Leave the motor in a vertical position until the engine is drained completely.
ENGINE NOT RUNNING
– Full tilt up position –
1. Raise the engine to the full tilt up position.
2. Follow the “ENGINE NOT RUNNING – Vertical position” instructions.
DO NOT RUN ENGINE IN THE FULL TILT
UP POSITION.
3. Lower the motor to a vertical position until the engine is drained completely.
3. Install garden hose by using a hose connector matched to flushing port thread B .
Thread B : 0.75 – 11.5 NHR (American standard hose coupling threads for garden hose applications.)
NOTE:
The hose connector (flushing attachment) matched to the flushing point thread B is included in the crate parts.
46
SUBMERGED MOTOR
A motor that has been accidentally submerged in water must be overhauled as soon as possible to prevent corrosion. In the event that your motor is accidentally submerged, take the following steps:
1. Get the motor out of the water as soon as possible.
2. Wash it thoroughly with fresh water to completely remove all salt, mud, and seaweed.
3. Remove the spark plugs. Drain the water from the cylinders through the spark plug holes by manually turning the flywheel several times.
4. Check if any water is evident in the engine oil. If water is seen, remove the oil drain plug and drain the oil. After draining, tighten the oil drain plug.
5. Drain the fuel line.
WARNING
7. Take the motor to your authorized Suzuki
Marine Dealer as soon as possible to be overhauled.
NOTICE
If the fuel supply is contaminated with water, engine damage may occur.
If the boat’s fuel tank filler and vent were submerged, inspect the fuel supply to make sure it is not contaminated with water.
Gasoline is extremely flammable and toxic. It can cause a fire and can be hazardous to people and pets.
Keep flames and sparks away from gasoline.
Dispose of unwanted fuel properly.
6. Pour engine oil into the engine through the spark plug holes. Coat the engine inner parts with oil by manually turning the flywheel several times.
NOTICE
Severe engine damage may occur if you continue cranking the engine when you encounter friction or resistance.
If you encounter friction or resistance while cranking the engine, stop at once and do not attempt to start the engine until you find and correct the problem.
47
STORAGE PROCEDURE
MOTOR STORAGE
When storing your motor for a long period of time (for example, at the end of the boating season), it is recommended that you take your motor to your authorized Suzuki Marine Dealer.
However, if you choose to prepare the motor for storage yourself, follow the procedure outlined below:
1. Change the gear oil as outlined in the GEAR
OIL section.
2. Change the engine oil as outlined in the
ENGINE OIL section.
3. Fill a fuel stabilizer to the fuel tank according to the instructions on the stabilizer can.
4. Flush the water passages in the motor thoroughly. Refer to the FLUSHING THE
WATER PASSAGES (Engine running) section.
5. Readjust the water flow, run the engine at about 1500 r/min in neutral for five minutes to distribute the stabilized fuel through the engine.
6. Stop the engine. Then turn off the water and disconnect the flushing attachment.
7. Lubricate all other specified parts. Refer to the LUBRICATION section.
8. Apply a coat of automotive wax on the external finish of the motor. If paint damage is evident, apply touch up paint before waxing.
9. Store the motor in an upright position in a dry, well-ventilated area.
WARNING
BATTERY STORAGE
1. When the outboard motor will not be used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reusing it.
2. If the battery will be stored for a long period of time, check the specific gravity of the battery solution at least once a month and recharge the battery when low.
WARNING
Failure to take proper precautions when charging the battery can be hazardous. Batteries produce explosive vapors that can ignite. Battery acid is poisonous and corrosive, and can cause severe injury.
• Do not smoke and keep battery away from open flames and sparks.
• To avoid creating a spark when charging the battery, connect the battery charger cables to the proper terminals before turning the charger on.
• Handle the battery with extreme care and avoid skin contact with battery acid.
• Wear proper protective clothing (Safety glasses, gloves, etc.)
When the engine is running, there are many moving parts that could cause severe personal injury.
When the engine is running, keep your hands, hair, clothing, etc., away from the engine.
NOTICE
Severe engine damage can occur in as little as
15 seconds if the engine is started without supplying water to the cooling system.
Never start the motor without supplying water to the cooling system.
48
AFTER STORAGE TROUBLESHOOTING
When taking your motor out of storage, follow the procedure below to return it to operating condition:
1. Thoroughly clean the spark plugs. Replace them if necessary.
2. Check the gear-case oil level and if necessary, add gear oil according to the procedure outlined in the GEAR OIL section.
3. Lubricate all moving parts according to the
LUBRICATION section.
4. Check the engine oil level.
5. Clean the motor and wax the painted surfaces.
6. Recharge the battery before installing it.
This troubleshooting guide is provided to help you find the cause of common complaints.
NOTICE
Failure to troubleshoot a problem correctly can damage your outboard motor. Improper repairs or adjustments may damage the outboard motor instead or fixing it. Such damage may not be covered under warranty.
If you are not sure about the proper action to correct a problem, consult your Suzuki marine dealer.
Starter motor will not operate:
• Shift lever is not in NEUTRAL.
• Fuse is blown out.
• Emergency stop switch lock plate is not in position.
Engine will not start (hard to start):
• Fuel tank is empty.
• Fuel hose is not properly connected to engine.
• Fuel hose is kinked or pinched.
• Spark plug is fouled.
Engine idles unstably or stalls:
• Fuel hose is kinked or pinched.
• Spark plug is fouled.
Engine speed will not increase (Engine power is low):
• Engine is overloaded.
• Caution/Diagnosis system is activated.
• Propeller is damaged.
• Propeller is not properly matched to loads.
Engine vibrates excessively:
• Engine mounting bolts or clamp screws are loose.
• Foreign object (seaweed etc.) is tangled on propeller.
• Propeller is damaged.
Engine overheats:
• Cooling water intake(s) are blocked.
• Engine is overloaded.
• Propeller is not properly matched to loads.
49
FUSE
1. Turn the ignition key to the “off” position.
2. Remove the motor cover and electric parts holder cover.
5. Inspect the fuse and replace with new fuse if needed.
Main fuse (60A)
Electric parts holder cover
Normal fuse
Sub fuse (30A)
Blown fuse
3. Remove the fuse cover and pull off the fuse.
Spare fuse
Main fuse
Sub fuse/
Fuse case
4. Remove the sub battery cable fuse.
Spare fuse
Sub battery cable fuse case
Sub battery cable fuse
Normal fuse Blown fuse
NOTE:
If a fuse is blown, try to determine the root cause and correct it.
If the cause is not corrected, the fuse may be blown again.
WARNING
If you replace a blown fuse with a fuse having a different amperage rating or with a substitute such as aluminum foil or a wire, extensive electrical system damage and a fire may result.
Always replace a blown fuse with a fuse of the same type and rating.
NOTICE
If a new fuse blows in a short time after installation, you may have a major electrical system problem.
Consult your SUZUKI marine dealer.
50
SPECIFICATIONS
Item
Engine Type
Number of Cylinders
Bore and Stroke
Piston Displacement
Maximum output
Full Throttle Operating Range
Ignition System
Engine Lubrication
Engine Oil Capacity
Gear Oil Capacity
Spark Plug
Spark Plug Gap
Valve Clearance (Lash)
Fuel Type
Minimum Fuel Octane Rating
DF200 DF225 DF250
4 Stroke
6
95.0 × 85.0 mm
(3.74 × 3.35 in.)
3 614 cm 3
(220.5 cu. in.)
147.1 kW (200PS) 165.5 kW (225PS) 183.9 kW (250PS)
5 000 – 6 000 r/min. (min –1 )
Full-transistor
Trochoid pump pressure lubrication
8.0 L (8.5/7.0 US/Imp. qt.)
5 500 – 6 100 r/min. (min –1 )
1.1 L (1.2/1.0 US/Imp. qt.)
NGK BKR6E
0.7 – 0.8 mm (0.028 – 0.031 in.)
IN. : 0.23 – 0.27 mm (0.009 – 0.011 in.)
EX.: 0.33 – 0.37 mm (0.013 – 0.015 in.)
Alcohol-free unleaded gasoline
91 (Research method)
INFORMATION REGARDING EC – DIRECTIVE
(For European countries)
Sound Pressure Level
Regulation
2013 / 53 / EU
Sound pressure level limit
75 dB(A)
Sound pressure level is measured according to ISO 14509-1:2008.
51
CHART OF TOTAL OPERATING HOURS INDICATION
Total operating hours
0 h- (49 h)
50 h-
60 h-
540 h-
550 h-
560 h-
:
:
1040 h-
1050 h-
:
:
:
:
1540 h-
1550 h-
:
:
MONITOR-TACHOMETER
Needle 1 indication
REV-LIMIT lamp 2 flashing *
No No
500 r/min No
600 r/min
:
:
5400 r/min
500 r/min
600 r/min
:
:
5400 r/min
500 r/min
:
:
5400 r/min
500 r/min
:
:
2030 h5300 r/min
2040 h or over 5400 r/min
No
:
:
No
1 time
1 time
:
:
1 time
2 times
:
:
2 times
3 times
:
:
3 times
3 times
*: One flashing is corresponded to 500 hours.
FLOWCHART OF OIL CHANGE REMINDER SYSTEM
Action
Starting operation
(*1) (*4)
Indication
(*2)
Cancellation
(*4)
Indication
(*3)
Cancellation
(*4)
Indication
(*3)
Cancellation
(*4)
Indication Cancellation
Repeat
*1: Lapse of initial 20 hour’s operation
*2: Lapse of 80 hour’s operation
*3: Lapse of 100 hour’s operation
*4: When performing cancellation before system activation
52
WIRING DIAGRAM
DF200T/Z
Bl/B P/W G/W
Bl/B P/W G/W
O/Y Gr
Dg
Y/G
W
R
W/R
P
Lbl
Lbl
P
W/R
B/Y Gr
B R
B/R Gr
B Bl
O/Y O/Y O/Y
Y Y
Gr Gr Gr
B B
B
W/R
P/B
Y/G
B
Gr
W
Dg
Bl
W/R
P/B
Y/G
B
Gr
W
Dg
Bl
Gr
W
P/B
W
W
W/R
W
W/R
R
B
Y/R
B/Br
Lg/R
R/W
O
R/Y
W/B
W/G
V/W
Lg/W
R/B
O
Dg
R/Bl
Br
Gr
B/Bl
Br/Y
B
B/Y
B
Bl/B
G/W
Bl/W
W/Bl
O/B
R/G
O/Bl
Gr/Y
O/Y
Y
Bl
P/B
Bl/R
P/Bl
W
R
B
G/R
Lg/B
Y/Bl
Bl
Lg
Bl/Y
B/R
G/Y
B
P/W
Y/B
B/W
R/G R/G
B
R/G
B
R/G
IG
OFF
STAR
FREE
PUSH
Br Br
R/Bl
B
Bl
G
B
Bl
G
B
W/Y W/Y
B
Lbl
Lbl Lbl
Lbl
R
P/Bl
B/W
Bl
Y
B
Y/G
Br
R
W
B
B B
DF225T/Z
Bl/B P/W G/W
Bl/B P/W G/W
O/Y Gr
Dg
Y/G
W
R
W/R
P
Lbl
Lbl
P
W/R
B/Y Gr
B R
B/R Gr
B Bl
O/Y O/Y O/Y
Y Y
Gr Gr Gr
B B
B
W/R
P/B
Y/G
B
Gr
W
Dg
Bl
W/R
P/B
Y/G
B
Gr
W
Dg
Bl
W
P/B
Gr
W
W
W/R
W
W/R
R
B
Lg/B
Y/Bl
G/R
W
R
P/Bl
Bl/R
P/B
Y
O/Y
Bl
Br
Gr
Br/Y
B/Bl
R/B
O
R/Bl
Dg
V/W
Lg/W
Y/R
B/Br
Lg/R
R/W
O
R/Y
W/B
W/G
Bl/B
G/W
B
B
B/Y
Bl/W
B/W
Bl/Y
B
B/R
G/Y
P/W
Y/B
Bl
Lg
Gr/R
R/G
W/Bl
O/B
O/Bl
Gr/Y
R/G R/G
B
R/G
B
R/G
IG
OFF
STAR
FREE
PUSH
Br Br
R/Bl
B
Bl
G
B
Bl
G
B
W/Y
W/Y
B
Lbl
Lbl Lbl
Lbl
R
P/Bl
B/W
Bl
Y
B
Y/G
Br
R
W
B
B B
DF250T/Z
Bl/B P/W G/W
Bl/B P/W G/W
O/Y Gr
W
R
Y/G
Dg
W/R
P
Lbl
Lbl
P
W/R
B/Y Gr
B R
B/R Gr
B Bl
Y Y
O/Y O/Y O/Y
Gr Gr Gr
B B
B
Gr
W
Dg
Bl
Y/G
B
W/R
P/B
Gr
W
Dg
Bl
Y/G
B
W/R
P/B
Gr
W
P/B
W
W
W/R
W
W/R
B
R
B/R
G/Y
B
P/W
Bl
Lg
Bl/Y
Gr/R
R/G
Y/B
B/W
W/Bl
O/B
O/Bl
Gr/Y
Br/W
W
R
O/G
G/R
P/Bl
P/B
Y
Bl/R
O/Y
Bl
Lg/B
B/O
B
B
B/Y
Bl/B
G/W
Bl/W
Br/R
Lg/R
Y/R
B/Br
R/W
O
R/Y
W/B
W/G
Br
Gr
Br/Y
O
B/Bl
R/B
Y/Bl
Lg/W
V/W
R/Bl
Dg
R/G R/G
B
R/G
B
R/G
IG
OFF
STAR
FREE
PUSH
Br Br
R/Bl
B
Bl
G
B
Bl
G
B
W/Y W/Y
B
Lbl
Lbl Lbl
Lbl
R
P/Bl
B/W
Bl
Y
B
Y/G
Br
R
W
B
B B
If you cannot find your local language in this owner’s manual please contact your Suzuki Marine dealer.
English
Si vous ne trouvez pas la langue que vous cherchez dans ce manuel du propriétaire, contactez vote concessionnaire marine Suzuki local.
French
Se il presente manuale non include la vostra lingua, entrare in contatto con un rivenditore di prodotti marini Suzuki.
Italian
Wenn Sie Ihre Landessprache in dieser Bedienungsanleitung nicht finden können, setzen Sie sich bitte mit Ihrem Suzuki-Marine-Händler in Verbindung.
German
Si no puede encontrar su idioma local en este manual del propietario, póngase en contacto con su proveedor Suzuki Marine.
Spanish
Kontakta din återförsäljare av Suzukis marinprodukter, om du inte hittar ditt lokala språk i denna bruksanvisning.
Swedish
Hvis du ikke finner ditt språk i denne bruksanvisningen ber vi deg vennligst om å kontakte din Suzuki
Marine forhandler.
Norwegian
Jos omaa kieltäsi ei löydy näistä käyttöohjeista, pyydämme ottamaan yhteyttä Suzuki Marine -jälleenmyyjään.
Finnish
Als uw taal in deze gebruikshandleiding niet te vinden is, neemt u dan alstublieft contact op met uw
Suzuki Marine dealer.
Dutch
Se você não puder encontrar o seu idioma neste manual do proprietário, entre em contato com o seu revendedor marítimo Suzuki.
Portuguese
Kontakt venligst din Suzuki Marine forhandler, hvis du ikke kan finde dit sprog i denne vejledning.
Danish
Pokud v tomto návodu na použití, nenaleznete Váš mate ř ský jazyk, obra ť te se prosím, na Vašeho obchodního zástupce Suzuki Marine.
Czech
W przypadku, gdy niniejsza instrukcja obs ł ugi u ż ytkownika nie zawiera tekstu w Pa ń stwa j ę zyku, uprzejmie prosimy skontaktowa ć si ę z dealerem Suzuki Marine.
Polish
Kui te ei leia sellest kasutusjuhendist oma kohalikku keelt, pöörduge palun kohaliku Suzuki Marine edasimüüja poole.
Estonian
Ако в този наръчник на потребителя не откривате Вашият език , моля обърнете се към регионалният дилър на Suzuki Marine.
Bulgarian
Jeigu šioje naudotojo instrukcijoje negalite surasti informacijos reikiama kalba, prašome kreiptis į
„Suzuki Marine“ bendrov ė s atstov ą .
Lithuanian
V prípade, že sa v tejto príru č ke majite ľ a nenachádza jazyková verzia Vašej krajiny, skontaktujte sa s
Vaším distribútorom Suzuki Marine.
Slovak
Č e v priro č niku za lastnika ne najdete svojega lokalnega jezika, se prosimo obrnite na predstavnika podjetja Suzuki Marine.
Slovene
Dac ă nu pute ţ i g ă si limba dumneavoastr ă în acest manual, v ă rug ă m s ă contacta ţ i distribuitorul Suzuki
Marine.
Rumanian
Ja J ū s neatrodat savu viet ē jo valodu šaj ā lietot ā ja rokasgr ā mat ā , l ū dzu kontakt ē jaties ar savu Suzuki
Marine p ā rst ā vi.
Latvian
Amennyiben e kézikönyvben az Ön országában beszélt nyelv szerinti útmutató nem elérhet ő , kérjük lépjen kapcsolatba a Suzuki Marine helyi kereskedelmi képvisel ő jével.
Hungarian
Εάν δεν μπορείτε να βρείτε την τοπική σας γλώσσα σε αυτό το εγχειρίδιο ιδιοκτήτη παρακαλούμε να έλθετε σε
επαφή με την αντιπροσωπία της Suzuki Marine.
Greek
Ako ne možete prona ć i Vaš jezik u ovom priru č niku, molimo kontaktirajte Vašeg lokalnog predstavnika programa Suzuki Marine.
Hrvatski
Prepared by
August, 2018
Part No. 99011-93JG0-054
Printed in Japan
© COPYRIGHT SUZUKI MOTOR CORPORATION 2018

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Key features
- 175 cubic inches displacement
- Four-stroke engine
- Fuel-injected
- Digital ignition system
- Lean-burn engine management system
- Multi-point fuel injection system
- Lean Burn Control System