Suzuki Marine DF40A, DF50A, DF50AV, DF60A, DF60AV Owner's Manual

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DF40A

DF50A

DF50AV

DF60A

DF60AV

OWNER’S MANUAL

ENGLISH

IMPORTANT



WARNING/



CAUTION/

NOTICE

/

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.



WARNING

Indicates a potential hazard that could result in death or serious injury.



CAUTION

Indicates 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 instructions to make maintenance easier or instructions clearer.

BREAK-IN INFORMATION

FOR YOUR OUTBOARD MOTOR

The first 10 hours are the most important in the life of your engine. Proper operation during this break-in period is essential to help ensure maximum life and performance.

Refer to the BREAK-IN section of this manual for specific break-in recommendations.

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.

• 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 life jacket 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.

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.

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.

FOREWORD

The proper care and maintenance that your outboard motor requires is outlined in this manual. By following these instructions explicitly you will ensure a long trouble-free operating life for your outboard motor. This outboard motor also conforms to the U.S Environmental Protection

Agency emission regulations which apply to new outboard motors. The proper adjustment of engine components is necessary for this outboard motor to comply with the EPA regulations. Therefore, please follow the maintenance instructions closely to ensure emission compliance. Your Suzuki dealer has experienced technicians that are trained to provide your outboard motor with the best possible service with the right tools and equipment.

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 production changes at any time, without notice and without incurring any obligation to make the same or similar changes to outboard motors previously built or sold.

PLEASE PRESERVE NATURE

Protect and preserve your boating waters and their land access. Never pollute the water or land with oil, gas, or other harmful products. For example, make sure you dispose of used gear oil properly following a gear oil change. Also remember not to litter. With a little bit of effort, our boating waters can be enjoyed for many years to come.

Suzuki Motor Corporation believes in conservation and protection of Earth’s natural resources.

To that end, we encourage every outboard motor owner to recycle, trade in, or properly dispose of, as appropriate, used oil and batteries.

TAKE A BOATING SAFETY CLASS

An educated boater will enjoy boating more and will be a safer boater. We recommend that you take a boating safety class.

Classes explaining required and recommended equipment for small boats and offering training in good seamanship are conducted by the U.S.

Coast Guard Auxiliary, the U.S. Power Squadron, and many Red Cross chapters. For information on classes in your area, call toll-free 1-

800-336-BOAT (2628).

Your state’s department of boating and your

Suzuki Marine dealer can supply you with additional information on boating safety and regulations, or you can call the U.S. Coast Guard

Boating Safety Hotline toll-free at 1-800-368-

5647.

California Proposition 65 Warning



WARNING

Engine exhaust, some of its constituents, and certain product components contain or emit chemicals known to the State of

California to cause cancer and birth defects or other reproductive harm.

FUEL AND OIL....................................... 6

GASOLINE ............................................ 6

FILLING THE FUEL TANK ................... 7

ENGINE OIL .......................................... 8

GEAR OIL ............................................. 8

LOCATION OF SAFETY LABELS ..... 9

LOCATION OF PARTS....................... 10

MOTOR INSTALLATION .................. 12

BATTERY INSTALLATION .............. 12

BATTERY REQUIREMENT ................ 12

BATTERY INSTALLATION ................ 13

USE OF ELECTRICAL

ACCESSORIES................................... 14

PROPELLER SELECTION AND

INSTALLATION................................... 14

PROPELLER SELECTION ................. 14

PROPELLER INSTALLATION ........... 15

ADJUSTMENTS.................................... 15

TRIM ANGLE ADJUSTMENT............. 15

TRIM TAB ADJUSTMENT .................. 17

THROTTLE TENSION

ADJUSTMENT .................................... 17

IDLE SPEED ADJUSTMENT.............. 17

SETTING OF TILT UPPER LIMIT

POSITION <DF50AV/60A/60AV> ....... 18

MOTOR COVER FASTENING

ADJUSTMENT .................................... 19

CAUTION SYSTEM ............................. 19

INDICATOR CHECK ........................... 20

OVER-REVOLUTION CAUTION

SYSTEM .............................................. 20

OIL PRESSURE CAUTION

SYSTEM .............................................. 21

COOLING WATER CAUTION

SYSTEM .............................................. 21

BATTERY VOLTAGE CAUTION

SYSTEM .............................................. 23

DIAGNOSTIC SYSTEM ...................... 23

OIL CHANGE REMINDER

SYSTEM................................................. 24

SYSTEM ACTIVATION ....................... 24

CANCELLATION ................................ 24

ENGINE STALLING CAUTION

SYSTEM................................................. 25

OPERATION OF TILTING

SYSTEMS............................................... 25

POWER TRIM AND TILT .................... 25

MANUAL TILTING .............................. 26

TILT LEVER ........................................ 26

INSPECTION BEFORE BOATING ... 27

BREAK-IN ............................................. 29

OPERATION ......................................... 30

BEFORE ATTEMPTING TO START

THE ENGINE....................................... 30

STARTING THE ENGINE ................... 32

EMERGENCY STARTING .................. 34

SHIFTING AND SPEED CONTROL ... 36

STOPPING THE ENGINE ................... 37

MOORING ........................................... 38

OPERATION IN SHALLOW

WATER................................................ 38

OPERATING THE TROLL MODE

(Optional Item) ................................... 38

OPERATION IN SALT WATER .......... 39

OPERATION IN FREEZING

WEATHER........................................... 39

MOTOR REMOVAL AND

TRANSPORTING ................................. 40

MOTOR REMOVAL ............................ 40

MOTOR TRANSPORTING.................. 40

TRAILERING ....................................... 42

INSPECTION AND

MAINTENANCE................................... 43

MAINTENANCE SCHEDULE ............. 43

SPARK PLUG ..................................... 45

BREATHER AND FUEL LINE ............ 47

ENGINE OIL ........................................ 47

GEAR OIL ........................................... 49

LUBRICATION .................................... 50

CORROSION PREVENTION .............. 50

ANODES.............................................. 50

BONDING WIRES ............................... 51

BATTERY............................................ 51

ENGINE OIL FILTER .......................... 52

FUEL FILTER...................................... 52

FLUSHING THE WATER

PASSAGES............................................. 53

SUBMERGED MOTOR ....................... 55

STORAGE PROCEDURE ................... 56

MOTOR STORAGE............................. 56

BATTERY STORAGE ......................... 57

AFTER STORAGE ............................... 57

GENERAL INFORMATION............... 57

WARRANTIES (For U.S.A)................. 57

IDENTIFICATION NUMBER

LOCATION .......................................... 58

EMISSION CONTROL

INFORMATION.................................... 58

TROUBLESHOOTING ........................ 58

SPECIFICATIONS ............................... 60

CHART OF TOTAL OPERATING

HOURS INDICATION ......................... 61

FLOWCHART OF OIL CHANGE

REMINDER SYSTEM.......................... 61

FUEL AND OIL

GASOLINE

Suzuki highly recommends that you use alcohol-free unleaded gasoline whenever possible, with a minimum pump octane rating of 87

((R+M)/2 method). In some areas, the only fuels that are available are oxygenated fuels.

Oxygenated fuels which meet the minimum octane requirement and the requirements described below may be used in your outboard motor without jeopardizing the New Outboard

Motor Limited Warranty.

Gasoline Containing MTBE

Unleaded gasoline containing MTBE (Methyl

Tertiary Butyl Ether) may be used in your outboard motor if the MTBE content is not greater than 15%. This oxygenated fuel does not contain alcohol.

Gasoline/Ethanol Blends

Blends of unleaded gasoline and ethanol (grain alcohol), also known as gasohol, may be used in your outboard motor if the ethanol content is not greater than 10%.

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.

Gasoline/Methanol Blends

Avoid using blends of unleaded gasoline and methanol (wood alcohol) whenever possible.

DO NOT USE fuels containing more than 5% methanol under any circumstances. Fuel system damage or outboard motor performance problems resulting from the use of such fuels are not the responsibility of Suzuki and may not be covered under the New Outboard Motor Limited Warranty.

Fuel containing 5% or less methanol may be suitable for use in your outboard motor if they contain cosolvents and corrosion inhibitors.

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.

NOTE:

Oxygenated fuels are fuels which contain oxygen-carrying additives such as MTBE or alcohol.

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.

Fuel Pump Labeling

In some states, pumps that dispense oxygenated fuels are required to be labeled for the type and percentage of oxygenate, 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 oxygenate 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:

• Be sure that any oxygenated fuel blend you use has octane ratings of at least 87 pump octane ((R+M)/2 method).

• If you are not satisfied with the driveability or fuel economy of your outboard motor when you are using a gasoline/alcohol blend, you should switch back to unleaded gasoline containing no alcohol.

• If engine pinging is experienced, substitute another brand, as there are differences between brands.

• Unleaded gasoline will extend spark plug life.

NOTICE

3. Turn the air-vent screw 1 on top of the fuel tank cap 2 fully counterclockwise to open the vent.

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.

FILLING THE FUEL TANK

To fill the fuel tank:

1. Always stop the engine before refilling the tank.

2. Remove the portable fuel tank from the boat to refill it.



WARNING

NOTE:

VENT SCREW should be CLOSED for transportation and OPEN for OPERATlON and CAP

REMOVAL .

4. Locate the pressure relief tab 3 under the fuel tank cap and turn the cap counterclockwise until the tab engages the first lock.

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 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.

NOTICE

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.

5. Press down on the tab, and release the lock, then rotate the fuel tank cap 1/4 turn. The tab will engage the second lock.

6. Press the tab down again and turn to remove the fuel tank cap.

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.

7. Carefully refill the fuel tank with gasoline.

Do not over fill.

8. Tighten the fuel tank cap until an audible

“click” is heard.

9. Tighten the air-vent screw on top of the fuel tank cap.

API Classification

TEMP.

˚C

˚F

SAE Viscosity Grade

10W–40

10W–30

–20

–4

–10

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.

GEAR OIL

Suzuki recommends the use of SUZUKI

HYPOID GEAR OIL. If it is not available, use

SAE 90 hypoid gear oil which is rated GL-5 under the API classification system.

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.

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.

WARNING AVERTISSEMENT

• To avoid injury, when engine is running, keep your hands, hair, clothing, etc., away from engine.

• See owner’s manual for details.

• Pour éviter toute blessure, quand le moteur est en marche, éloigner les mains, les cheveux, les vêtements, etc. du moteur.

• 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

: Engine start

: Hazard caused by fire

: Hazard caused by laying the

motor on its side

: Hazard caused by rotating parts

LOCATION OF PARTS

Pilot water hole

Flush plug

Anti-cavitation plate

Trim tab

(Anode)

Motor cover

Power trim and tilt

(P.T.T.) switch

(Reverse side)

Engine oil drain plug

Clamp bracket

Anode

Gear oil level plug

Water intake hole

Gear oil drain plug

DF40A/50A/60A

Priming bulb

MONITOR-TACHOMETER FUEL HOSE

Lock-out lever

SIDE MOUNT TYPE

Power trim and tilt (P.T.T.) switch

TOP MOUNT TYPE

Power trim and tilt

(P.T.T.) switch

Remote control handle

Warm-up lever

Ignition key

Emergency stop switch

Remote control handle

Ignition key

Emergency stop switch

Throttle tension adjuster

Free accelerator button

REMOTE CONTROL BOX (Option)

Pilot water hole

Flush plug

Anode

(Reverse side)

Anode

Anti-cavitation plate

Trim tab

DF50AV/60AV

Motor cover

Power trim and tilt

(P.T.T.) switch

(Reverse side)

Engine oil drain plug

Clamp bracket

Anode

Gear oil level plug

Water intake hole

Gear oil drain plug

MOTOR INSTALLATION BATTERY INSTALLATION



WARNING

BATTERY REQUIREMENT

Choose a 12 Volt cranking-type lead acid battery that meets the specifications shown below.

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”.

NOTE:

It is against federal regulations for any marine dealer to service a motor that exceeds the recommended maximum horsepower for your boat.

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.



WARNING

650 Marine Cranking Amps (MCA)/ABYC, or 512 Cold Cranking Amps (CCA)/SAE or 160 Reserve Capacity (RC) Minutes/SAE

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.

• The use of Maintenance-Free, sealed, or Gel-

Cell batteries is not recommended because they may not be compatible with Suzuki’s charging system.

• 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.

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.

BATTERY INSTALLATION

Secure the battery in a dry area of the boat, away from vibration.

To remove the battery, first disconnect the black lead from the negative terminal, then disconnect the red lead from the positive terminal.

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.

Connecting and disconnecting the battery as described above will help minimize the chance of creating an accidental short circuit and sparks.

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.

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

Hexagonnut

Red lead

Hexagonnut

Black lead

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

Hexagon-nut



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.

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.

NOTICE

PROPELLER SELECTION

AND INSTALLATION

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.

USE OF ELECTRICAL ACCESSORIES

The amount of power (12V DC) available for accessories depends on the operating condition of the motor. For getting a detailed information, please inquire of your authorized Suzuki

Marine Dealer.

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.

NOTICE

NOTE:

Use of too much power for electrical accessories under certain operating conditions can cause the battery to discharge.

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:

DF40A

DF50A/50AV

DF60A/60AV

5000 – 6000 r/min. (min –1 )

5300 – 6300 r/min. (min –1 )

If the engine speed is not within this range, consult your authorized Suzuki Marine Dealer to determine which propeller size is best for you.

If you change propellers, be sure to perform the above check again, to confirm that the engine speed under full throttle is within the specified range.

PROPELLER INSTALLATION



WARNING

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:

ADJUSTMENTS

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.

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.

Refer to the POWER TRIM AND TILT section.

If you still cannot achieve good performance, there may be a problem with engine mounting height. Consult your dealer for assistance.

• Trim angle too small (Boat tends to “plow”)

• Trim angle too large (Boat tends to “porpoise”)

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. Align the grooves in the propeller nut with the hole in the shaft, then insert the cotter pin 7 and bend the pin ends over to lock it in place.

To remove the propeller, reverse the above procedure.

• Proper trim angle

Tilt range

Trim range



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.

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.

THROTTLE TENSION ADJUSTMENT

The tension of the remote control handle can be adjusted according to your preference. To increase the tension, turn the adjuster A clockwise. To decrease the tension, turn the adjuster counterclockwise.

To adjust the trim tab:

1. Loosen the bolt A that holds the trim tab in place.

Side mount type

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 rear end of the trim tab toward the starboard side.

NOTE:

Top mount type

When adjusting the tension of the remote control handle, consult your authorized Suzuki

Marine Dealer.

IDLE SPEED ADJUSTMENT

The idle speed has been factory adjusted between 750 – 850 r/min. in neutral.

NOTE:

If idle speed cannot be set within the specified range, contact your authorized Suzuki Marine

Dealer.

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.

SETTING OF TILT UPPER LIMIT POSITION

<DF50AV/60A/60AV>

If the outboard motor contacts the motor well of the boat during full tilt up operation, the upper limit setting should be reset.

Perform this set-up after the current position setting has been canceled, as explained in the following procedure.

5. Press the “UP” side of the PTT switch for three seconds and the buzzer will sound twice briefly indicating the setting has been canceled.

CANCELING THE TILT UPPER POSITION

LIMIT SETTING

1. Turn the ignition key to the “ON” position.

2. Pull out the emergency stop switch lock plate.

PTT switch

6. Return the throttle to the fully closed position.

3. Make sure that remote control handle is in

“NEUTRAL”.

4. Using the throttle only function of the remote control box, move the warm-up lever upward until the caution buzzer sounds one time.

“NEUTRAL”

SETTING THE TILT UPPER POSITION

LIMIT

7. Press the “UP” side of the PTT switch so that the optimum full tilt up position for the boat can be obtained.

8. Using the throttle only function of the remote control box, move the warm-up lever upward until the caution buzzer sounds one time.

9. Press the “UP” side of PTT switch three times within three seconds. The buzzer will sound one time briefly indicating the setting has been accepted.

10. Return the throttle to the fully closed position and install the lock plate on the emergency switch. Operate the full tilt up and full down operations several times by pressing the PTT switch and check that the setting of both the trim lower limit and tilt upper limit are properly set.



WARNING

Setting of the tilt upper limit position 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.

MOTOR COVER FASTENING ADJUST-

MENT

If you feel the motor cover fastening is loose or too tight when locking the levers, adjust as follows:

1. Loosen the bolt 1 .

2. Adjust the position of bracket 2 . To increase the fastening, move the bracket to the direction A . To decrease the fastening, move the bracket to the direction B .

3. Tighten the bolt 1 .

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

Continuing to operate your outboard motor with the Caution System activated can result in severe damage to your outboard motor.

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.

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.

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.

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.

This system must be reset by moving the throttle to the idle position for about one second to restore full engine operation.

NOTICE

If the Caution System is not working properly, you may not be alerted to a condition that can cause damage to your outboard motor.

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 lamps or buzzer may be broken or a failure may exist in the system circuit. Consult your authorized Suzuki marine dealer.

NOTE:

For checking the total motor operating hours, refer to the CHART OF TOTAL OPERATING

HOURS INDICATION on the last page.

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.

Consult your authorized Suzuki marine dealer if the Over-Revolution Caution

System activates for no apparent reason.

OIL PRESSURE CAUTION SYSTEM

This system operates when the engine lubricating oil pressure drops below the correct level.

If this system activates, the red OIL lamp will light and a buzzer will begin a series of beeps.

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.

If you continue to run, the engine will automatically stop 3 minutes after beginning of the above CAUTION system activation.

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.

NOTICE

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.

NOTICE

Operating the engine with the Oil Pressure Caution System activated can result in severe engine damage.

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.

COOLING WATER CAUTION SYSTEM

This system is activated when the cylinder wall temperature is too high due to insufficient water cooling.

If this system activates, stop the engine immediately, if wind and water conditions make it safe to do so.



WARNING

If you attempt to remove or reinstall the motor cover while the engine is running, you may be injured.

NOTE:

The cooling water caution system will not detect high combustion chamber temperature caused by, for example, an oil system malfunction, poor quality fuel, or spark plugs with an incorrect heat range.

If this system activates, the red TEMP lamp will light and the buzzer will begin a series of beeps. 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.

To check the oil level, stop the engine and then remove the motor cover.

If you continue to run, the engine will automatically stop 3 minutes after beginning of the above CAUTION system activation.

Check the oil level and add oil if necessary. If the oil level is correct, consult your authorized

Suzuki Marine Dealer.

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.

NOTICE

Operating the engine with the Cooling

Water Caution System activated can result in severe engine damage.

If the Cooling Water 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.

If the cooling water 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.

NOTE:

Remember that the cooling water caution system cannot detect overheating caused by, for example, an oil system malfunction, poor quality fuel, or incorrect spark plugs.

NOTE:

If the engine is operated beyond the maximum trim position, the water intake holes may be above the water line. In this situation, the cooling water caution system may activate.

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 engine into the water, being sure that water intakes are immersed, and restart it.

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.

NOTE:

If pilot hole water discharge is sufficient, buzzer and TEMP lamp may still operate until engine temperature decreases. Run engine in NEU-

TRAL only until the caution systems are cancelled.

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 beeps.

DIAGNOSTIC SYSTEM

If abnormal conditions exist in any sensor signal being sent 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 cancelled 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

Failure to take proper precautions when inspecting or servicing the battery can be hazardous.

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.

Also incorporated is a fail-safe provision that allows the operation at a restricted speed even under such a failure condition.

NOTE:

• The CHECK ENGINE lamp will light briefly when the ignition key is turned to the “ON” position.

• The failed system can be identified by the mode of the red CHECK ENGINE lamp flashing and buzzer sounding.

This diagnostic code is designed to appear while the ignition key is turned on.

• The buzzer sound with diagnostic system activating will be cancelled by pushing the ignition key in.

NOTICE

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.

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.

Consult your authorized Suzuki marine dealer for repair of the control system.

OIL CHANGE REMINDER

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.)

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.

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.

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.

4. Turn the ignition key to the “OFF” position.

5. Set the plate 1 in the original position.

ENGINE STALLING

CAUTION SYSTEM

OPERATION OF TILTING

SYSTEMS

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.

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.

Side mount type

Top mount type

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.

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 screw A four turns counterclockwise, move the motor to the desired position, then retighten the release screw.

TILT LEVER

The tilt lever is provided so you can support the motor in a tilted position for non-moving engine support.

To set the tilt lever:

1. Tilt the motor all the way up using the power trim and tilt.

2. Pull down the tilt lever as shown in the illustration.

DF50AV/60A/60AV



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.

DF40A/50A

3. Lower the motor using the power trim and tilt, until the motor is supported by the tilt lever.

To release the lever, tilt the motor all the way up using the power trim and tilt, and pull up the tilt lever.



CAUTION

INSPECTION BEFORE

BOATING

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 lever, your hand could be injured.

Keep all persons away from the remote

Power Trim and Tilt switch while you are moving the tilt lever.

NOTICE

Damage can occur if you use the tilt lever other than when the boat is moored or is otherwise stationary.

The tilt lever relieves pressure from the power trim and tilt and should only be used when the boat is stationary. Do not use the tilt lever when trailering your boat and motor. Refer to the TRAILERING section of this manual.



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:

• Check 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 .

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.

To fill the engine with oil:

1. Remove the oil filler cap.

2. Fill with recommended engine oil to the upper level.

2. Pull out the oil dipstick 3 and wipe oil off with a clean cloth.

NOTICE

Running the engine with an excessive amount of oil can damage the engine.

Do not overfill the engine with oil.

NOTE:

If the engine oil is contaminated or discolored, replace with fresh engine oil. Refer to the

ENGINE OIL section.

3. Tighten the oil filler cap securely.

3. Insert the dipstick all the way into the engine, then remove it again.

UPPER LIMIT

LOWER LIMIT

• 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 MAINTENANCE section.

• Make sure that the battery leads are securely connected to the battery terminals.

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.

NOTICE

• Visually check the propeller to make sure it is not damaged.

Failure to follow the break-in procedures described below can result in severe engine damage.

• Make sure the motor is securely mounted to the transom.

Be sure to follow the engine break-in procedures described below.

• Check for proper operation of the Power

Trim and Tilt.

Break-in period : 10 hours

• Check for proper trim angle.

• Make sure you have the boating safety and emergency equipment on board.

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 at high speed without sufficient warm-up may cause severe engine damage such as piston seizure.

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.).

NOTE:

You may throttle up beyond the recommended operating range to plane your boat, then immediately reduce the throttle to the recommended operating range.

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.

OPERATION

BEFORE ATTEMPTING TO START THE

ENGINE

1. Lower the motor into the water.

2. If there is a manual fuel tank air-vent, turn the air-vent screw 1 on top of the fuel tank cap fully counterclockwise to open the vent.

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.

During the last 7 hours of break-in operation, do not operate at wide open throttle for more than 5 minutes at a time.



WARNING

When connecting the fuel hose to the portable fuel tank or motor, the fuel may be under pressure and may spray out around the connector, causing serious injury.

Before connecting the fuel hose, loosen and retighten the fuel tank cap once to relieve the fuel pressure in fuel tank.

For handling the fuel tank cap, refer to the “FUEL AND OIL/FILLING FUEL TANK” section in this manual.

NOTE:

SUZUKI genuine portable fuel tanks have a semi-auto air vent.

3. Make sure that the motor fuel hose and the hose from the boat’s fuel tank are securely attached and clamped.

5. Make sure the lock plate is in place and the emergency stop switch cord is fastened securely to your wrist or appropriate clothing area such as your belt.

Side mount type

Top mount type

4. Make sure the motor is in “NEUTRAL”.

Side mount type

Top mount type



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.

Side mount type:

Make sure the warm-up lever is in the fully closed position.

NOTE:

There is a spare plastic lock plate for temporary use only. Remove it from the cord and place in a safe place on the boat. However, the original cord and lock plate should be replaced as soon as possible.

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.

3. Turn the ignition key to the “ON” position, then observe the monitor-tachometer indication. If nothing abnormal is indicated, then turn the key to the “START” position to start the engine.

After returning the ignition key to “ON” position from “START” one, the starter motor continues to turn for 4 seconds until the engine start.

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.

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.

4. Warm up the engine for about 5 minutes.

NOTICE

If you hold the ignition key at the

“START” position to start the engine, the starter system can be damaged.

Turn the ignition key to the “START” position once and release it to start the engine.

The engine will crank continuously for 4 seconds or until the engine starts.

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

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 authorized Suzuki Marine Dealer.

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.

EMERGENCY STARTING

If you must get the engine running, but are unable to do so because of starter system failure or battery discharge, you can use the emergency starting procedure to start the engine.

NOTE:

If the battery voltage is too low to operate the electric fuel pump, you will not be able to start the engine using the EMERGENCY STARTING procedure because sufficient fuel will not be supplied to the engine.



WARNING

If you touch electrical components when rope-starting the engine, you can get a severe electrical shock.

When rope-starting the engine, be careful not to touch electrical components such as ignition coils or spark plug leads.

1. Make sure that the motor is in “NEUTRAL” and the emergency stop switch lock plate is removed.



WARNING

When you use the emergency starting procedure, the start-in-gear protection system will not work. If the shift lever is not in the “NEUTRAL” position, the boat can start off unexpectedly when the engine is started, throwing occupants or causing an accident.

Make sure that the shift lever is in the

“NEUTRAL” position before attempting to start the motor using the emergency starting procedure.

2. Remove the motor cover.

3. With the ignition key turned off, loosen the screws securing the ring gear cover and remove the ring gear cover.

9. Turn the ignition key to the “ON” position.

10. After following steps for normal starting procedure, pull the emergency starter rope sharply to start the engine. Repeat, if the motor has not started.



WARNING

If you attempt to reinstall the ring gear cover or motor cover after starting the engine you can be injured.

Do not attempt to reinstall the ring gear cover or motor cover after starting the engine.

4. Squeeze the fuel line priming bulb several times until you feel resistance.

5. Put the emergency stop switch lock plate in place.

6. Turn the ignition key to the “ON” position and listen for the electric fuel pump to cycle.

 WARNING

When the engine is running, there are many moving parts that could cause severe personal injury.

NOTE:

The initial fuel pump cycle is for a period of 3 seconds after the ignition key is first turned on.

If you are not sure about fuel pump operation, you may turn the key off, then repeat step #6.

When the engine is running, keep your hands, hair, clothing, etc., away from the engine.

7. With the ignition key turned off, tie a knot in one end of the emergency starter rope located in the tool kit. Tie the other end around the screw-driver handle in the tool kit.

8. Hook the knotted end of the rope in the pulley notch and wind the rope around the pulley in a clockwise direction.

NOTE:

Be sure to have the starter system repaired as soon as possible. You should not continue to use the emergency starting procedure for routine engine starting.

SHIFTING AND SPEED CONTROL

NOTICE

NEUTRAL

32˚ 32˚

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.

FORWARD

REVERSE

NOTE:

Top mount type

Not equipped with a lock-out lever. Exercise care when selecting neutral position.

Top mount type

NEUTRAL

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.

FORWARD

35˚ 35˚

REVERSE

Shifting

To shift into “FORWARD”, squeeze the lock-out lever on the control handle and move the control handle forward to approximate position A , as shown in the illustration.

Speed control

To increase speed after you have shifted into gear, continue moving the control handle forward or rearward.

 WARNING

To shift into “REVERSE”, squeeze the lock-out lever on the control handle and move the control handle rearward to approximate position B , as shown in the illustration.

A detent or notch is present on all Suzuki control boxes to provide a “feel” for positions A , B , and neutral. Always shift quickly and firmly from neutral to position A or B to prevent abnormal wear on the gear and clutch engagement surfaces.

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.

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.



WARNING

Unauthorized use of your boat could lead to an accident or damage to your boat.

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.

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 battery can discharge.

To prevent unauthorized use of your boat, be sure to remove the key and emergency stop switch lock plate when the boat is unattended.

4. After stopping the engine, disconnect the fuel line from the outboard motor if there is a fuel connector.

 WARNING

Side mount type

Top mount type

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.

5. Turn 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 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.

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 LEVER section for details on how to tilt up the motor.

NOTICE

If the motor hits bottom, serious damage can occur.

Do not allow the motor to hit bottom. If the motor does strike bottom, inspect it immediately for damage.

Improperly securing your boat may cause damage to your boat or motor, or other property damage.

OPERATING THE TROLL MODE

(Optional Item)

Trolling speed can be controlled to install the optional Troll Mode switch.

Please contact your authorized Suzuki Marine

Dealer for more information.

Do not allow your motor to rub against quay walls, piers or other boats when the boat is tied up.

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.

To tilt the motor higher than the normal trim angle, use the Power Trim and Tilt switch.



WARNING

NOTE:

To monitor engine speed correctly during the troll mode operation, Suzuki recommends the use of the Suzuki 2-scale Monitor Tachometer.

Usual scale

Trolling mode scale

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.

System Outline

The “Troll Mode System” is activated by pressing the troll mode switch, when the motor is running at in-gear idle speed. By using this system, you can set and maintain a desired engine speed with the control switch in a range from ingear idle speed (approx. 800 rpm) to 1200 rpm.

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.

How to use the Troll Mode

Setting the troll mode:

1. Shift into forward or reverse gear and make sure that the throttle is fully closed (in-gear idle speed).

2. Press the “UP” or “DN” position of the troll mode switch, until you hear one beep.

The REV/TRL (or REV) lamp on the monitor gauge will flash indicating that the motor has been set to the troll mode. The REV/TRL (or

REV) lamp will continue to flash while the motor is in the troll mode.

Cancelling the troll mode:

The troll mode can be cancelled by shifting the remote control lever to the neutral position, or by increasing the engine speed to 3000 rpm or more. In both cases, two short (0.1 sec.) beeps sound when cancelling the troll mode.

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.

Troll mode switch

NOTE:

The troll mode system will not operate if the switch is depressed when the remote control lever is in the neutral position.

Adjusting trolling speed:

• When pressing the “UP” switch, one short beep sounds and the engine speed increases by 50 rpm.

• When pressing the “DN” switch, one short beep sounds and the engine speed decreases by 50 rpm.

NOTE:

• When pressing the “DN” switch at the lower limit of trolling speed, the engine speed will not change and three long (0.8 sec.) beeps will sound.

• When pressing the “UP” switch at the upper limit of trolling speed, the engine speed will not change and three long (0.8 sec.) beeps will sound.

• Shift operation and throttle control remain operational, even in troll mode.

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

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 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.

MOTOR TRANSPORTING

When transporting the motor, place the motor either vertically or horizontally.

Horizontal transport:

1. Drain the engine oil. Refer to the ENGINE

OIL section.

2. Drain the gasoline from the vapor separator as follows:

(1) Fully steer the motor to the starboard side.

(2) Pull the drain hose end 1 out.

(3) Loosen the vapor separator drain screw

2 and drain the gasoline into a suitable container.

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.



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 drain screw and put the drain hose 1 back.

3. Rest the motor on a case protector with the starboard side downwards as shown.

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.



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 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.

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 lever 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 lever 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.

INSPECTION AND MAINTENANCE

NOTICE

MAINTENANCE, REPLACEMENT OR

REPAIR OF EMISSION CONTROL

DEVICES AND SYSTEMS MAY BE PER-

FORMED BY ANY MARINE SI ENGINE

REPAIR ESTABLISHMENT OR INDIVIDUAL

USING ANY PART WHICH HAS BEEN

CERTIFIED UNDER THE PROVISIONS IN

THE CLEAN AIR ACT Sec. 207 (a) (2).

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

Powerhead)

Bonding wires

Battery

* Engine oil filter

Initial 20 hrs.

or 1 month

–

Every 100 hrs.

or 12 months

Every 200 hrs.

or 12 months

Every 300 hrs.

or 36 months

* Low pressure fuel filter

* Idle speed

* Valve lash

* Water pump

* Water pump impeller

* Propeller nut & pin

* Bolts & Nuts

* Thermostat

–

I I

Replace every 400 hours or 2 years.

–

I: Inspect and clean, adjust, lubricate, or replace, if necessary T: Tighten R: Replace

NOTE:

Water-separating fuel filter

Replace the filter element every 12-months (or more frequently if recommended by the filter manufacturer).



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 were established for normal usage of your outboard motor. If your outboard motor is used under severe conditions such as frequent full throttle operation or frequent operation in muddy, silty, sandy, acidic, or shallow water, you may need to perform maintenance more often than indicated in the chart. 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.

SPARK PLUG

Remove the spark plugs as follows:

1. Remove the bolts securing the fuel hose guard A .

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.

Your authorized Suzuki Marine Dealer can determine if the standard spark plug is suitable for your type of motor usage by inspecting the color of the plug’s porcelain center electrode insulator after operation.

2. Remove the bolt securing the ignition coil.

3. Pull out the ignition coil.

4. Loosen and remove the spark plug using the box wrench in the tool bag.

If the plug tends to run hot (usually evidenced by whitening of the insulator or a burnt electrode), stop using your motor immediately as severe engine damage may result. If the plug tends to run cold (usually evidenced by blackening of the insulator or a wet electrode), performance may suffer. Ask your authorized

Suzuki Marine dealer to evaluate either of these problems to determine the cause.

Insulator

Center electrode

Your outboard motor comes equipped with the following “standard” spark plug for normal usage.

Standard spark plug NGK DCPR6E

Ground electrode

Gap

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

15 – 19 N·m

(1.5 – 1.9 kg-m, 10.8 – 13.7 lb-ft)

Rotation angle

New plug

Re-use plug

1/2 – 3/4 of a turn

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.

To maintain a strong spark, you should clean and adjust the plug at the interval shown in the maintenance schedule.

Remove carbon deposits from the spark plug using a small wire brush or spark plug cleaner, and adjust the gap as follows:

Spark plug gap

0.8 – 0.9 mm

(0.031 – 0.035 in.)

If the electrode or insulator is damaged, or if either shows excessive wear, then the spark plug should be replaced.

BREATHER AND FUEL LINE

Inspect the breather and fuel line for leaks, cracks, swelling, or other damage. If the breather and fuel line are damaged in any way, they must be replaced. Consult your authorized

Suzuki Marine Dealer if it is necessary to replace them.

ENGINE OIL



WARNING

Never perform any ENGINE OIL procedure with the motor running, as serious injury can occur.

Fuel line Breather line

The motor must be shut off before any

ENGINE OIL procedures are performed.

NOTICE



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.

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.

3. Place a drain pan under the engine oil drain screw.



CAUTION

7. Check the engine oil level.

The engine oil temperature may be high enough to burn your fingers when the drain plug is loosened.

UPPER LIMIT

Wait until the drain plug is cool enough to touch with bare hands before removing it.

LOWER LIMIT

4. Remove the engine oil drain screw 1 and gasket 2 , then let the engine oil drain.

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.

5. After draining, secure the engine oil drain screw with a new gasket.

NOTICE

A previously-used gasket may leak, resulting in engine damage.

• 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.

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.

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.

Oil capacity: 2.7 L (2.9/2.4 US/Imp. qt.)

Engine oil: SAE (or NMMA FC-W) 10W-40,

10W-30

API (or NMMA FC-W) Classification SG, SH, SJ, SL, SM

GEAR OIL

To check the gear oil level, adjust the engine to an upright position, 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.

Periodic gear oil replacement is essential for long life of your outboard motor.

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 gear oil level plug 1 .

DF50AV/60AV MODEL

Approximately 1050 ml (35.5/37.0 US/lmp oz.) will be required.

4. Reinstall and tighten the gear oil level plug

1 , then quickly reinstall and tighten the gear oil drain plug 2 .

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

DF40A/50A/60A

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.

DF50AV/60AV

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

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 gear oil level hole 1 .

DF40A/50A/60A MODEL

Approximately 610 ml (20.6/21.5 US/lmp oz.) will be required.

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.

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

CORROSION PREVENTION

ANODES

The motor is protected from exterior corrosion by anodes. These anodes control electrolysis and help 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.

In certain areas of the country, the water is unusually harsh on metal. Additional anti-corrosion measures may be helpful under those conditions. Consult your authorized Suzuki Marine

Dealer for details.

Throttle/Shift linkage

Marine-grade water resistant grease

DF60A

Propeller shaft

Swivel bracket

Marine-grade water resistant grease

(Grease Gun)

Steering bracket

NOTE:

Before applying grease through the steering bracket grease nipple, lock the motor in the fully tilted up position.

Your authorized Suzuki Marine Dealer may also have additional recommendations due to regional climate or operating conditions.

Please consult him for advice.

DF40A/50A/50AV/60AV

DF40A/50A/60A

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.

DF50AV/60AV

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 powerhead.

BATTERY

If you are using a maintenance-free battery, inspect the window area according to the instructions on the battery to make sure the battery is in good condition.

If you are not using a maintenance-free battery, the battery fluid level should be checked every

100 hours of operation or 12 months. 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 DIS-

TILLED WATER ONLY until the battery solution level reaches the MAX level line.



WARNING

Battery acid is poisonous and corrosive, and can cause severe injury.

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.



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

ENGINE OIL FILTER

The engine oil filter must be changed by an 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).

FUEL FILTER

The fuel filter must be inspected by authorized

Suzuki Marine Dealer periodically.

Low pressure fuel filter

Inspect low pressure fuel filter at initial 20 hours

(1 month).

Inspect low pressure fuel filter at every 100 hours (12 months).

Replace low pressure fuel filter with a new one at every 400 hours (2 years).

Battery posts, terminals, and related accessories contain lead and lead compounds that may be hazardous.

Wash hands after handling.

NOTICE

If you add diluted sulphuric acid to the battery after it has been initially serviced, you will damage the battery.

NEVER add diluted sulphuric acid to the battery after it has been initially serviced.

Follow the battery manufacturer’s instructions for specific maintenance procedures.

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:

ENGINE RUNNING – Vertical position –

Suzuki recommends that you flush the water passage by using this method.

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.

1. Cover the auxiliary water intake hole 1 with a piece of duct tape. (except DF50AV/60AV model)

To flush the water passages, you must obtain a commercially available engine flush device.



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.



WARNING

2. Install the flushing attachment 2 so that the water intake holes are covered by the rubber cups on the attachment.

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

NEUTRAL. 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.

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.

4. Place the remote control lever in the “NEU-

TRAL” position with the propeller removed and start the motor. As soon as the engine starts, water should spray out of the pilot water hole 3 , indicating proper water pump operation. If no water spray is evident, stop the motor immediately and consult your dealer.

2. Install garden hose directly or by using a hose connector matched to flushing point 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.

5. Allow the engine to run only at idle speed while flushing. 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 and remove the duct tape from the water intake hole.

9. Clean the motor surface and apply a coat of automotive wax on the external finish of the motor.

3. Turn on the water to obtain a good water flow. Flush the engine for about five minutes.

4. Turn off the water.

5. Remove the hose and connector (if used) then reinstall the plug into the flushing port.

6. Leave the motor in a vertical position until the engine is drained completely.

ENGINE NOT RUNNING – Vertical position –

1. Remove the plug A from the flushing port .

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.

SUBMERGED MOTOR

NOTICE

If your motor has been accidentally submerged in water, it must receive a special repair service as soon as possible to prevent corrosion. If possible, have a qualified marine dealer service the engine. If immediate servicing is not available, take the following steps to help protect your motor. In the event that your motor is accidentally submerged, take the following steps:

Severe engine damage may occur if you continue cranking the engine when you encounter friction or resistance.

1. Get the motor out of the water as soon as possible.

2. Remove the motor cover and immediately wash the engine 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 and all filters.



WARNING

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.

7. Have your authorized Suzuki Marine Dealer inspect the engine as soon as possible.

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 one tablespoon of engine oil in through each spark plug hole. Coat the engine inner parts with oil by manually turning the flywheel several times. Don’t use the electric starter, as this may bend the connecting rods.

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 high quality 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. Spray entire powerhead with a rust preventative (not a penetrating oil product).

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. Select an area with constant temperature to avoid corrosion caused by condensation. Do not store next to furnaces, heaters, etc.



WARNING

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.

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. Do not set battery on concrete or earth, as this will accelerate loss of charge.

2. Wash the casing and terminals using fresh water only, then dry with clean cloth.

3. Fully charge the battery. If the battery will be stored for a long period of time, check the specific gravity of the fluid at least once a month and recharge the battery when the charge is 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.

AFTER STORAGE

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.

GENERAL INFORMATION

• 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.)

WARRANTIES (For U.S.A)

The warranties covering your outboard motor are explained in a separate Limited Warranty booklet given to you at the time of sale. Please read this booklet carefully so you can understand your rights and responsibilities.

IDENTIFICATION NUMBER LOCATION

The model and identification numbers of your outboard motor are stamped on a plate attached to the clamp bracket. Record these numbers below for future reference. It is important to know these numbers when you place a parts order or if your motor is stolen.

Model Number:

Identification Number:

EMISSION CONTROL

INFORMATION

NOTICE

• THIS ENGINE IS CERTIFIED TO OPER-

ATE ON UNLEADED GASOLINE OF 87

OCTANE ((R+M)/2 METHOD) OR

GREATER.

• EXHAUST EMISSION CONTROL

SYSTEM:

ECM, MFI

Ignition Key Number:

Spare key

Ignition key number stamped position

TROUBLESHOOTING

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.

4. Inspect the fuse and replace with new fuse if needed.

Main fuse (30A)

FUSE

1. Turn the ignition key to the “off” position.

2. Remove the motor cover.

3. Remove the fuse box cover and pull off the fuse.

Normal fuse Blown fuse

Fuse box cover

Normal fuse Blown fuse

NOTE:

Use the fuse puller at the back of fuse box cover, when the fuse is pulled off and installed.

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.

SPARE

30A

MAI N

RELAY

STARTER

RELAY

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.

Main fuse: 30A

Spare fuse: 30A

Spare fuse: 15A

Starter motor relay fuse: 30A

PTT switch fuse: 15A

Ignition coil/Injector/ECM/IAC fuse: 30A

Fuel pump fuse: 15A

Spare fuse: 30A

SPECIFICATIONS

Item DF40A DF50A/50AV DF60A/60AV

Engine Type

Number of Cylinders

Bore and Stroke

Piston Displacement

Maximum output

Full Throttle Operating Range

Idle speed (in Neutral)

Ignition System

Engine Lubrication

Engine Oil Capacity

Spark Plug

Spark Plug Gap

Valve Lash

4 Stroke

72.5 × 76.0 mm (2.85 × 2.99 in.)

29.4 kW (40PS)

941 cm 3 (57.4 cu. in.)

36.8 kW (50PS) 44.1 kW (60PS)

5000 – 6000 r/min.

(min –1 )

5300 – 6300 r/min. (min

800 ± 50 r/min. (min –1 )

Full-transistor

Trochoid pump pressure lubrication

–1 )

2.7 L (2.9/2.4 US/Imp. qt.)

NGK DCPR6E

0.8 – 0.9 mm (0.031 – 0.035 in.)

IN. : 0.18 – 0.22 mm (0.007 – 0.009 in.)

EX.: 0.28 – 0.32 mm (0.011 – 0.013 in.)

Fuel Type

Minimum Fuel Octane Rating

Power rated in accordance with NMMA procedure.

Alcohol-free unleaded gasoline

87 Pump ((R+M)/2 method)

CHART OF TOTAL OPERATING HOURS INDICATION

Total operating hours

0h-(49h)

50h-

60h-

540h-

550h-

560h-

1040h-

1050h-

1540h-

1550h-

2030h-

2040h or over

MONITOR-TACHOMETER

Needle 1 indication

REV-LIMIT lamp 2 flashing *

500rpm

600rpm

5400rpm

500rpm

1 time

600rpm

5400rpm

500rpm

5400rpm

500rpm

5300rpm

5400rpm

1 time

2 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

NOTE:

This system will activate up to 2100 hour’s operation.

WIRING DIAGRAM

W W W

B/R B/R B/R

SUZUKI

B B B

R/G R/G R/G

R/G R/G R/G R/G R/G R/G

B B B

R/G R/G R/G

B/G

O/Y

Y Y Y

B B B

O/Y

B/G

O/Y

B/G

P/W P/W

G/W

P/W

G/W G/W

Bl/B Bl/B

B Bl/B Bl/B Bl/

G/W G/W G/W

P/W P/W

O/Y O/Y

B/G

O/Y

B/G B/G

B B

Y Y

P/W

B Bl/B

G/W G/W

Bl/B Bl/

G/W

P/W P/W P/W

B Bl/

G/W G/W G/W

Bl/B Bl/B

P/W P/W

Lbl/W

W/Bl W/Bl

Lbl/W

R/W

R/G R/G

R/W

R/G

B B B

O/B O/B

Bl Bl Bl

R/W

O/B

W/B

B/R

O O O

B B B

W/B

R/Y

W/B

P/W P/W

R/Y

P/W

R/Y

W/B

Gr/Y

B/Br

Gr/Y

B/Br B/B

Gr/

B/R B/R

Y Y Y

R R R

O O O

Y/G

R/B

Bl/

G/W

Bl/

O/Y

P/B

R/B

Y/G

Bl/B

O/Y

G/W

P/B

R/B

Y/G

Bl/B

O/Y

G/W

P/B

W W W

V V V

P P P

B/G

W/Y W/Y

B/G

W/Y

B/G

B/W

Br/ Br/Y

B/W

Br/Y

B/W

Y/Bl

Lg/B

B/Bl

P/W

Y/Bl

Lg/B

B/Bl

P/W

Br Br Br

Y/B

G/Y

Y/B Y/B

G/Y

Y/B

G/Y

Y Y Y

Gr Gr Gr

Lbl Lb

B/B

Lbl

B B B

Bl Bl Bl

G G G

P/W

W Bl/W

Lg/W

Bl/W

Lg/W

Bl/R Bl/ Bl/R

R/B

B/G B/G B/G

R/B R/B

W/R

Y/G

P/B

R/B

B/W B/W B/W

R/B R/B

Br Br

Br W/R G

B B B

R R R

W bl/

P/W P/W P/W

Lbl/W Lbl/W Lb Lbl Lbl

P P P

B B B

B/B

B/G B/G B/G

B B

B/Bl B/Bl

W/Y W/Y W/Y

B/W B/W

W/Y W/Y W/Y

R R

Lb Lbl Lbl

W/R W/R W/R

P P P

W/R

Lbl

Y/B Y/B Y/B

Br Br

Y/G Y/G Y/G

B/Bl B/Bl

Prepared by

Outboard Motor Engineering Department

June, 2015

Part No. 99011-88L50-03B

Printed in Japan

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OWNER’S MANUAL

IMPORTANT

WARNING/

CAUTION/

/

CAUTION

BREAK-IN INFORMATION

FOR YOUR OUTBOARD MOTOR

IMPORTANT NOTICE TO OWNERS

FOREWORD

PLEASE PRESERVE NATURE

TAKE A BOATING SAFETY CLASS

TABLE OF CONTENTS

FUEL AND OIL

GASOLINE

FILLING THE FUEL TANK

ENGINE OIL

GEAR OIL

LOCATION OF SAFETY LABELS

LOCATION OF PARTS

MOTOR INSTALLATION BATTERY INSTALLATION

BATTERY REQUIREMENT

BATTERY INSTALLATION

PROPELLER SELECTION

AND INSTALLATION

USE OF ELECTRICAL ACCESSORIES

PROPELLER SELECTION

PROPELLER INSTALLATION

ADJUSTMENTS

TRIM ANGLE ADJUSTMENT

TRIM TAB ADJUSTMENT

THROTTLE TENSION ADJUSTMENT

IDLE SPEED ADJUSTMENT

SETTING OF TILT UPPER LIMIT POSITION

<DF50AV/60A/60AV>

MOTOR COVER FASTENING ADJUST-

MENT

CAUTION SYSTEM

INDICATOR CHECK

OVER-REVOLUTION CAUTION SYSTEM

OIL PRESSURE CAUTION SYSTEM

COOLING WATER CAUTION SYSTEM

BATTERY VOLTAGE CAUTION SYSTEM

DIAGNOSTIC SYSTEM

OIL CHANGE REMINDER

SYSTEM

SYSTEM ACTIVATION

CANCELLATION

ENGINE STALLING

CAUTION SYSTEM

OPERATION OF TILTING

SYSTEMS

POWER TRIM AND TILT

MANUAL TILTING

TILT LEVER

CAUTION

CAUTION

INSPECTION BEFORE

BOATING

BREAK-IN

OPERATION

BEFORE ATTEMPTING TO START THE

ENGINE

STARTING THE ENGINE

EMERGENCY STARTING

SHIFTING AND SPEED CONTROL

STOPPING THE ENGINE

MOORING

OPERATING THE TROLL MODE

(Optional Item)

OPERATION IN SHALLOW WATER

OPERATION IN SALT WATER

OPERATION IN FREEZING WEATHER

MOTOR REMOVAL AND

TRANSPORTING

MOTOR REMOVAL

MOTOR TRANSPORTING

TRAILERING

INSPECTION AND MAINTENANCE

NOTICE