DF70A EN

DF80A
DF90A
OWNER’S MANUAL

ENGLISH

1
IMPORTANT • Inspect the boat and motor before each
 WARNING/  CAUTION/ NOTICE/ NOTE trip. See the INSPECTION BEFORE
Please read this manual and follow its instruc- BOATING section for important items.
tions carefully. To emphasize special informa- • Become thoroughly familiar with all
tion, the symbol  and the words WARNING, operating and handling characteristics
CAUTION, NOTICE and NOTE have special of your boat and motor. Practice at low
meanings. Pay special attention to the mes- and moderate speeds until you are
sages highlighted by these signal words. competent at handling the boat and
motor. Do no attempt to operate at maxi-
 WARNING
mum performance until you are com-
Indicates a potential hazard that could pletely familiar with all of these
result in death or serious injury. characteristics.
• Carry boating safety and emergency
 CAUTION equipment. This important equipment
includes; flotation aids for each person
Indicates a potential hazard that could (plus one throwable buoyant cushion in
result in minor or moderate injury. any boat 16 feet or longer), fire extin-
guisher, sound signaling device, visual
NOTICE distress signals, anchor, bilge pump,
bucket, compass, emergency starter Prepared by
Indicates a potential hazard that could rope, extra fuel and oil, first aid kit,
result in damage to the motor or boat. flashlight, food and water, mirror, pad-
dles, tool kit, and transistor radio. Be
NOTE:
sure you are carrying the equipment
Indicates special instructions to make mainte-
nance easier or instructions clearer.
appropriate for your trip before launch- Outboard Motor Engineering Department
ing.
• Never start the engine or let it run
BREAK-IN INFORMATION indoors or where there is little or no
FOR YOUR OUTBOARD MOTOR May, 2010
ventilation. Exhaust gas contains car-
The first 10 hours are the most important in the bon monoxide, a gas that is colorless Part No. 99011-87L02-03A
life of your engine. Proper operation during this and odorless and can cause death or Printed in Japan
break-in period is essential to help ensure max-
severe injury.
imum life and performance.
Refer to the BREAK-IN section of this manual
• Instruct your passengers on how to
operate the boat, how to deal with © COPYRIGHT SUZUKI MOTOR CORPORATION 2010
for specific break-in recommendations.
emergencies, and how to operate
IMPORTANT NOTICE TO OWNERS safety and emergency equipment.
• Do not hold onto the motor cover or
 WARNING any other parts of your outboard motor
while getting on or off your boat.
• Ensure that everyone wears a life jacket
Failure to take the proper precautions on board.
may increase the risk of death or severe • Never operate the boat while under the
injury to you and your passengers. influence of alcohol or other drugs.
• Distribute all weight load evenly in the
• Prior to first-time use of your outboard boat.
motor, familiarize yourself thoroughly • Have all scheduled maintenance per-
with the contents of this owner’s man- formed. Consult your authorized
ual. Be aware of all outboard motor fea- Suzuki marine dealer as required.
tures and all safety and maintenance
requirements.
 • Do not modify or remove any outboard FOREWORD
motor standard equipment. To do so
may make the motor unsafe to use. The proper care and maintenance that your
• Learn and obey all applicable naviga- outboard motor requires is outlined in this man-
tion rules. ual. By following these instructions explicitly you
• Pay attention to all weather forecasts. will ensure a long trouble-free operating life for
Do not set out if weather is unsettled. your outboard motor. This outboard motor also
conforms to the U.S Environmental Protection
• Use extreme caution when purchasing
Agency emission regulations which apply to
replacement parts or accessories. new outboard motors. The proper adjustment of
Suzuki strongly recommends that you engine components is necessary for this out-
use only genuine Suzuki replacement board motor to comply with the EPA regula-
parts/accessories or their equivalent. tions. Therefore, please follow the maintenance
Inappropriate or poor quality replace- instructions closely to ensure emission compli-
ment parts or accessories can create ance. Your Suzuki dealer has experienced tech-
unsafe operating conditions. nicians that are trained to provide your outboard
motor with the best possible service with the
NOTE: right tools and equipment.
Mounting radio transceiver or navigational
equipment antennae too close to the engine All information in this manual is based on the
cowling can cause electrical noise interference. latest product information available at the time
Suzuki recommends that antennae be mounted of publication. Due to improvements or other
at least one meter (40 inches) away from the changes, there may be discrepancies between
engine cowling. this manual and your outboard motor. Suzuki
reserves the right to make production changes
at any time, without notice and without incurring
This manual should be considered a per- any obligation to make the same or similar
manent part of the outboard motor and changes to outboard motor previously built or
should remain with the outboard motor sold.
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 infor-
mation on safety, operation, and mainte-
nance.

1
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 conserva-

tion and protection of Earth’s natural resources.

To that end, we encourage every outboard

motor owner to recycle, trade in, or properly dis-
pose 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 Squad-
ron, and many Red Cross chapters. For infor-
mation 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 addi-
tional information on boating safety and regula-
tions, 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.

2
TABLE OF CONTENTS OPERATION ......................................... 27
BEFORE ATTEMPTING TO START
THE ENGINE....................................... 27
FUEL AND OIL....................................... 4 STARTING THE ENGINE ................... 28
GASOLINE ............................................ 4
EMERGENCY STARTING .................. 29
ENGINE OIL .......................................... 5
SHIFTING AND SPEED CONTROL ... 31
GEAR OIL ............................................. 5
STOPPING THE ENGINE ................... 32
LOCATION OF SAFETY LABELS ..... 6 MOORING ........................................... 33
LOCATION OF PARTS......................... 8 OPERATION IN SHALLOW
MOTOR INSTALLATION .................... 9 WATER................................................ 34
BATTERY INSTALLATION ................ 9 OPERATION IN SALT WATER .......... 34
BATTERY REQUIREMENT .................. 9 OPERATION IN FREEZING
BATTERY INSTALLATION ................ 10 WEATHER........................................... 34
USE OF ELECTRICAL MOTOR REMOVAL AND
ACCESSORIES................................... 11 TRANSPORTING ................................. 35
PROPELLER SELECTION AND MOTOR REMOVAL ............................ 35
INSTALLATION................................... 11 MOTOR TRANSPORTING.................. 35
PROPELLER SELECTION ................. 11 TRAILERING ....................................... 36
PROPELLER INSTALLATION ........... 12 INSPECTION AND
ADJUSTMENTS.................................... 12 MAINTENANCE................................... 37
TRIM ANGLE ADJUSTMENT............. 12 MAINTENANCE SCHEDULE ............. 37
TRIM TAB ADJUSTMENT .................. 13 SPARK PLUG ..................................... 39
THROTTLE TENSION BREATHER AND FUEL LINE ............ 40
ADJUSTMENT .................................... 14 ENGINE OIL ........................................ 41
IDLE SPEED ADJUSTMENT.............. 14 GEAR OIL ........................................... 42
SETTING OF TILT UPPER LIMIT LUBRICATION .................................... 43
POSITION............................................ 14 CORROSION PREVENTION .............. 44
MOTOR COVER FASTENING ANODES.............................................. 44
15
ADJUSTMENT .................................... BONDING WIRES ............................... 45
CAUTION SYSTEM ............................. 16 BATTERY............................................ 45
INDICATOR CHECK ........................... 16 ENGINE OIL FILTER .......................... 46
OVER-REVOLUTION CAUTION FUEL FILTER...................................... 46
SYSTEM .............................................. 17 FLUSHING THE WATER
OIL PRESSURE CAUTION PASSAGES............................................. 46
SYSTEM .............................................. 17 SUBMERGED MOTOR ....................... 49
COOLING WATER CAUTION STORAGE PROCEDURE ................... 50
SYSTEM .............................................. 18 MOTOR STORAGE............................. 50
BATTERY VOLTAGE CAUTION BATTERY STORAGE ......................... 51
SYSTEM ..............................................19
AFTER STORAGE ............................... 51
DIAGNOSTIC SYSTEM ...................... 20
GENERAL INFORMATION............... 51
OIL CHANGE REMINDER WARRANTIES (For U.S.A)................. 51
SYSTEM................................................. 20 IDENTIFICATION NUMBER
SYSTEM ACTIVATION ....................... 20 LOCATION .......................................... 52
CANCELLATION ................................ 20
EMISSION CONTROL
ENGINE STALLING CAUTION INFORMATION.................................... 52
SYSTEM................................................. 21
TROUBLESHOOTING ........................ 52
OPERATION OF TILTING
SYSTEMS............................................... 22 SPECIFICATIONS ............................... 54
POWER TRIM AND TILT .................... 22 CHART OF TOTAL OPERATING
MANUAL TILTING .............................. 22 HOURS INDICATION ......................... 55
TILT LEVER ........................................ 23 FLOWCHART OF OIL CHANGE
INSPECTION BEFORE BOATING ... 24 REMINDER SYSTEM.......................... 55
BREAK-IN ............................................. 26 WIRING DIAGRAM ............................ 56

3
FUEL AND OIL Gasoline Containing MTBE
Unleaded gasoline containing MTBE (Methyl
GASOLINE Tertiary Butyl Ether) may be used in your out-
Suzuki highly recommends that you use alco- board motor if the MTBE content is not greater
hol-free unleaded gasoline whenever possible, than 15%. This oxygenated fuel does not con-
with a minimum pump octane rating of 87 tain alcohol.
((R+M)/2 method). In some areas, the only
fuels that are available are oxygenated fuels. Gasoline/Ethanol Blends
Oxygenated fuels which meet the minimum Blends of unleaded gasoline and ethanol (grain
octane requirement and the requirements alcohol), also known as gasohol, may be used
described below may be used in your outboard in your outboard motor if the ethanol content is
motor without jeopardizing the New Outboard not greater than 10%.
Motor Limited Warranty.
Gasoline/Methanol Blends
Avoid using blends of unleaded gasoline and
NOTICE methanol (wood alcohol) whenever possible.
DO NOT USE fuels containing more than 5%
Use of leaded gasoline can cause engine methanol under any circumstances. Fuel sys-
tem damage or outboard motor performance
damage. Use of improper or poor quality
problems resulting from the use of such fuels
fuel can affect performance and may are not the responsibility of Suzuki and may not
damage your motor and fuel system. be covered under the New Outboard Motor Lim-
ited Warranty.
Use only unleaded gasoline. Do not use
Fuel containing 5% or less methanol may be
fuel having lower than the recommended suitable for use in your outboard motor if they
octane, or fuel that may be stale or con- contain cosolvents and corrosion inhibitors.
taminated by dirt/water etc.
Fuel Pump Labeling
NOTE: In some states, pumps that dispense oxygen-
Oxygenated fuels are fuels which contain oxy- ated fuels are required to be labeled for the type
gen-carrying additives such as MTBE or alco- and percentage of oxygenate, and whether
hol. important additives are present. Such labels
may provide enough information for you to
Suzuki recommends that you install a water- determine if a particular blend of fuel meets the
separating fuel filter assembly between your requirements listed above. In other states,
boat’s fuel tank(s) and outboard motor(s). Fuel pumps may not be clearly labeled as to the con-
filtration systems of this type will help prevent tent or type of oxygenate and additives. If you
water that may be present in your boat’s fuel are not sure that the fuel you intend to use
tank(s) from contaminating your motor’s elec- meets these requirements, check with the ser-
tronic fuel injection system. Water contamina- vice station operator or the fuel suppliers.
tion can cause poor engine performance and
can also cause damage to the electronic fuel NOTE:
injection system components. • Be sure that any oxygenated fuel blend you
Your Authorized Suzuki Marine Dealer can pro- use has octane ratings of at least 87 pump
vide you advice about water-separating fuel fil- octane ((R+M)/2 method).
ter systems and installation. • 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 con-
taining no alcohol.

4
• If engine pinging is experienced, substitute ENGINE OIL
another brand, as there are differences
between brands. NOTICE
• Unleaded gasoline will extend spark plug life.

Use of poor quality engine oil can

 WARNING adversely affect engine performance and
life.
Gasoline is extremely flammable and
toxic. It can cause a fire and can be haz- Suzuki recommends that you use Suzuki
ardous to people and pets. Marine 4-Cycle Engine Oil or its equiva-
lent.
Always take the following precautions
when refueling: Oil quality is a major contributor to your
• Never permit anyone other than an engine’s performance and life. Always select
adult to refill the fuel tank. good quality engine oil.
• If you use a portable fuel tank, always Suzuki recommends the use of SAE 10W-40
SUZUKI MARINE 4-CYCLE ENGINE OIL. If
stop the motor and remove the fuel
SUZUKI MARINE 4-CYCLE ENGINE OIL is not
tank from the boat to refill it. available, select a NMMA certified FC-W oil or
• Do not fill the fuel tank all the way to good quality 4-cycle motor oil from the following
the top or fuel may overflow when it chart according to the average temperatures in
expands due to heating by the sun. your area.
• Be careful not to spill fuel. If you do,
API Classification SAE Viscosity Grade
wipe it up immediately.
• Do not smoke, and keep away from SG
10W–40
SH
open flames and sparks. SJ
SL
10W–30
SM
NOTICE ˚C –20 –10 0 10 20 30 40
TEMP.
˚F –4 14 32 50 68 86 104

Gasoline kept in the fuel tank for long

periods of time will produce varnish and NOTE:
In very cold weather (below 5°C (41°F), use
gum, which can damage the engine.
SAE (or NMMA FC-W) 5W-30 for easier start-
ing and smooth operation.
Always use fresh gasoline.

NOTICE GEAR OIL

Suzuki recommends the use of SUZUKI
HYPOID GEAR OIL. If it is not available, use
Fuels containing alcohol can cause paint SAE 90 hypoid gear oil which is rated GL-5
damage, which is not covered under the under the API classification system.
New Outboard Motor Limited Warranty.

Be careful not to spill fuel containing

alcohol while refueling. If fuel is spilled,
wipe it up immediately.

5
LOCATION OF SAFETY LABELS
Read and follow all of the labels on your out- Keep the labels on your outboard motor or fuel
board motor or fuel tank. Make sure you under- tank. Do not remove them for any reason.
stand all of the labels.

6
7
LOCATION OF PARTS

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

Flush plug

Pilot water hole

TRANSOM X TYPE

Clamp bracket
Engine oil drain plug
Anode

Anode Anti-cavitation
plate

Water intake hole

Gear oil level plug

Gear oil drain plug

SIDE MOUNT TYPE

Power trim and tilt (P.T.T.)
switch MONITOR-TACHOMETER PRIMING BULB
Remote control handle
Lock-out Warm-up lever
lever Ignition key
Emergency TOP MOUNT TYPE
stop switch
Power trim and tilt
(P.T.T.) switch
Ignition key
Remote control
handle
Throttle tension adjuster

Emergency
stop switch

Free accelerator button

REMOTE CONTROL BOX (Option)

8
MOTOR INSTALLATION BATTERY INSTALLATION
BATTERY REQUIREMENT
 WARNING Choose a 12 Volt cranking-type lead acid bat-
tery that meets the specifications shown below.
Overpowering your boat can be hazard-
650 Marine Cranking Amps (MCA)/ABYC,
ous. Excessive horsepower will have an or 512 Cold Cranking Amps (CCA)/SAE
adverse effect on hull safety and may or 160 Reserve Capacity (RC) Minutes/SAE
cause operating/handling difficulties. The
boat may also sustain stress and hull NOTE:
damage. • The specifications listed above are the mini-
mum battery rating requirements for starting
Never install an outboard motor with the engine.
horsepower exceeding the manufac- • Additional electrical loads from the boat will
turer’s recommended maximum horse- require larger capacity batteries. Consult
power listed on the boat’s “Certification your Suzuki dealer to determine the proper
Plate”. Contact your authorized Suzuki battery sizing for your boat and engine com-
marine dealer if you are unable to locate bination.
the hull “Certificate Plate”. • Dual-purpose (Cranking/Deep-cycle) batter-
ies can be used if they meet the minimum
specifications listed above (MCA, CCA, or
NOTE:
RC).
It is against federal regulations for any marine
dealer to service a motor that exceeds the rec- • Do not use a Deep Cycle battery for the main
ommended maximum horsepower for your cranking battery.
boat. • The use of Maintenance-Free, sealed, or Gel-
Cell batteries is not recommended because
Suzuki strongly recommends that you have they may not be compatible with Suzuki’s
your outboard motor, controls and gauges charging system.
installed by your authorized Suzuki Marine • When connecting batteries in parallel, they
Dealer. He has the tools, the facilities and the must be of the same type, capacity, manufac-
know-how. turer, and of similar age. When replacement
is necessary, they should be replaced as a
 WARNING 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.

9
BATTERY INSTALLATION To remove the battery, first disconnect the black
Secure the battery in a dry area of the boat, lead from the negative terminal, then discon-
away from vibration. nect the red lead from the positive terminal.

NOTE: Connecting and disconnecting the battery as

• It is recommended that the battery be described above will help minimize the chance
installed in an enclosed battery case. of creating an accidental short circuit and
• When connecting batteries, hexagon-nuts sparks.
must be used to secure battery leads to bat-
tery posts.  WARNING

To hook up the battery, first connect the red

lead from the motor to the positive battery ter- Batteries produce flammable hydrogen
minal, then connect the black lead to the nega- gas and may explode if they are near
tive battery terminal. flames or sparks.

Never smoke or cause sparks when work-

Hexagon- Hexagon- ing near the battery. Keep the battery
nut nut away from open flames. To avoid creating
Red lead Black a spark when charging the battery, con-
lead nect the battery charger cables to the
proper terminals before turning the
charger on.

 WARNING

Battery acid is poisonous and corrosive.

It can cause severe injury and can dam-
age 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.
Hexagon-nut
NOTICE

The electrical system or its components

 WARNING may be damaged if proper battery pre-
cautions are not followed.
If you place the battery near the fuel tank,
a spark from the battery may ignite the • Be sure to attach battery leads cor-
gasoline, causing a fire and/or an explo- rectly.
sion. • Do not disconnect battery leads from
the battery while the engine is running.
Do not place the fuel tank in the same
compartment/area as the battery.
10
USE OF ELECTRICAL ACCESSORIES PROPELLER SELECTION
The amount of power (DC12V) available for
accessories depends on the operating condi- AND INSTALLATION
tion of the motor. For getting a detailed informa-
tion, please inquire of your authorized Suzuki PROPELLER SELECTION
Marine Dealer. It is essential to use a propeller on your out-
board motor that is properly matched to your
NOTE: boat’s operating characteristics. The speed of
Use of too much power for electrical accesso- the engine when you operate your boat at full
ries under certain operating conditions can throttle depends on the propeller you use.
cause the battery to discharge. 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 selec-
tion. Smaller loads generally require larger-
pitch propellers; larger loads generally require
smaller-pitch propellers. Your authorized Suzuki
Marine Dealer will assist you in selecting a suit-
able propeller for your boat.

NOTICE

Installing a propeller with either too much

or too little pitch will cause incorrect
maximum engine speed, which may
result in severe damage to the motor.

Ask your authorized Suzuki marine

dealer to assist you in selecting a suit-
able propeller for your boat.

You can determine if your propeller is appropri-

ate for use with your boat by using a tachome-
ter to measure engine speed when operating
your boat at full throttle, under minimum load
conditions. If you are using an appropriate pro-
peller, the engine speed will be within the fol-
lowing range:

DF70 5000 – 6000 r/min. (min–1)

DF80 5000 – 6000 r/min. (min–1)
DF90 5500 – 6300 r/min. (min–1)

If the engine speed is not within this range, con-

sult 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.

11
PROPELLER INSTALLATION ADJUSTMENTS
 WARNING TRIM ANGLE ADJUSTMENT
To help maintain steering stability and good
performance, always maintain the proper trim
Failure to take proper precautions when angle as shown in the illustration. The appropri-
installing or removing the propeller can ate trim angle varies depending on the combi-
result in severe personal injury. nation of the boat, engine, and propeller, as well
as operating conditions.
When installing or removing the propeller:
• Always shift into “Neutral” and remove Make a test run in the boat to determine if the
the emergency stop switch lock plate trim angle needs to be adjusted. Adjust the trim
so that the motor cannot be started angle using the Power Trim and Tilt system.
accidentally. Refer to the POWER TRIM AND TILT section.
• Wear gloves to protect hands, and
If you still cannot achieve good performance,
“lock” the propeller by placing a block there may be a problem with engine mounting
of wood between the blades and the height. Consult your dealer for assistance.
anti-cavitation plate.

To install a propeller on your outboard motor,

use the following procedure:

• 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. • Proper trim angle
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 pro-

cedure.

12
 NOTICE

If you operate the boat with the motor

trimmed beyond the maximum trim posi-
tion, the water intake holes may be above
the water line, causing severe engine
damage due to overheating.
Tilt range
Never operate the boat with the motor
trimmed beyond the maximum trim posi-
Trim range
tion.

TRIM TAB ADJUSTMENT

 WARNING This adjustment is used to compensate for the
possible tendency of your boat to veer slightly
to port or starboard. This tendency could be
Trim angle greatly affects steering stabil- due to such things as propeller torque, motor
ity. If the trim angle is too small, the boat mounting position, etc.
may “plow” or “bow steer”. If the trim
angle is too large, the boat may “chine To adjust the trim tab:
walk” from side to side or “porpoise” up 1. Loosen the bolt A that holds the trim tab in
and down. These conditions, which result place.
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 condi-
tions.

 WARNING

When the motor is tilted beyond the maxi-

mum 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 atti-
tude with the motor tilted beyond the
maximum trim position.

13
2. If the boat tends to veer to port, move the IDLE SPEED ADJUSTMENT
rear end of the trim tab toward the port side.
If the boat tends to veer to starboard, move The idle speed has been factory adjusted
the rear end of the trim tab toward the star- between 650 – 750 r/min. in neutral.
board side.
NOTE:
If idle speed cannot be set within the specified
range, contact your authorized Suzuki Marine
Dealer.

SETTING OF TILT UPPER LIMIT POSITION

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.

CANCELING THE TILT UPPER POSITION

LIMIT SETTING
3. Tighten the bolt that holds the trim tab in
1. Turn the ignition key to the “ON” position.
place.
2. Pull out the emergency stop switch lock
plate.
After adjusting the trim tab, check to see if the
boat still tends to veer to one side. If necessary,
readjust the trim tab.

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 clock-
wise. To decrease the tension, turn the adjuster
counterclockwise.

Side mount
type

3. Make sure that remote control handle is in

“NEUTRAL”.

Side mount Top mount

type type

“NEUTRAL” “NEUTRAL”

NOTE:
Top mount type
When adjusting the tension of the remote con-
trol handle, consult your authorized Suzuki
Marine Dealer.

14
4. Top mount type 12. Press the “UP” side of PTT switch three
Using the throttle only function of the remote times within three seconds. The buzzer will
control box, move the control handle forward sound one time briefly indicating the setting
until the caution buzzer sounds one time. has been accepted.
Side mount type 13. Return the throttle to the fully closed posi-
Using the throttle only function of the remote tion and install the lock plate on the emer-
control box, move the warm-up lever upward gency switch. Operate the full tilt up and full
until the caution buzzer sounds one time. down operations several times by pressing
the PTT switch and check that the setting of
both the trim lower limit and tilt upper limit
Side mount Top mount are properly set.
type type
 WARNING
UP
UP
Setting of the tilt upper limit position will
not prevent the outboard motor from tilt-
ing fully up and contacting the motor well
if the motor’s lower unit hits an object at
high speed. Such tilting could damage
PTT switch PTT switch your motor and boat and injure the boat
occupants.
5. Press the “UP” side of the PTT switch for
three seconds and the buzzer will sound
Keep all occupants away from the motor
twice briefly indicating the setting has been when operating at high speed.
canceled.
6. Return the throttle to the fully closed posi-
MOTOR COVER FASTENING ADJUST-
tion.
MENT
If you feel motor cover fastening is loose or too
SETTING THE TILT UPPER POSITION tight when locking the levers, adjust as follows:
LIMIT
7. Press the “UP” side of the PTT switch so 1. Loosen the bolt 1.
that the optimum full tilt up position for the 2. Adjust the position of bracket 2.
boat can be obtained. To increase the fastening, move the brackets
8. Turn the ignition key to the “ON” position. to the direction A. To decrease the fasten-
9. Pull out the emergency stop switch lock ing, move the brackets to the direction B.
plate. 3. Tighten the bolt.
10. Make sure that remote control handle is in
“NEUTRAL”.
11. Top mount type
Using the throttle only function of the
remote control box, move the control handle
forward until the caution buzzer sounds one
time.
Side mount type
Using the throttle only function of the
remote control box, move the warm-up lever
upward until the caution buzzer sounds one
time.

15
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 dam-

aged 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.
NOTICE
To avoid damage to your outboard motor,
regularly inspect and maintain it.
If the Caution System is not working
NOTICE properly, you may not be alerted to a con-
dition that can cause damage to your out-
board motor.
Continuing to operate your outboard
motor with the Caution System activated If any of the four lamps does not come on
can result in severe damage to your out- or the buzzer does not sound when the
board motor. ignition key is turned to the “ON” posi-
tion, the lamps or buzzer may be broken
If the Caution System activates while you or a failure may exist in the system cir-
are operating your outboard motor, stop cuit. Consult your authorized Suzuki
the motor as soon as possible and cor- marine dealer.
rect the problem or consult your autho-
rized Suzuki marine dealer for NOTE:
assistance. For checking the total motor operating hours,
refer to the CHART OF TOTAL OPERATING
INDICATOR CHECK HOURS INDICATION on the last page.
Each time the ignition key is turned to the “ON”
position, four lamps – the REV LIMIT 1, the
OIL 2, the TEMP 3 and the CHECK ENGINE
4 in the monitor-tachometer will light briefly
and the buzzer will also sound for the first two
seconds, regardless of the motor conditions.
For the next three seconds, the monitor-
tachometer will indicate the total motor operat-
ing hours by means of the lamp flashing and
needle indicating.
After this brief check period, the monitor-
tachometer will return to their stand-by mode
and will only respond to motor conditions
requiring a caution alert.

16
OVER-REVOLUTION CAUTION SYSTEM OIL PRESSURE CAUTION SYSTEM
This system is activated when engine speed This system operates when the engine lubricat-
exceeds maximum recommended speed for ing oil pressure drops below the correct level.
more than 10 seconds. If this system activates, the red OIL lamp will
If this system activates, engine speed will auto- light and a buzzer will begin a series of beep. In
matically be reduced to approximately 3000 addition, when this system is activated at 1000
r/min. with red REV LIMIT lamp lit. 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 automati-
cally 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.

This system must be reset by moving the throt-

tle to the idle position for about one second to
restore full engine operation.

NOTICE

If the Over-Revolution Caution System

activates at recommended maximum
throttle and you are sure that the propel-
ler pitch is sufficient and there are no fac-
tors like “over-trimming” or “ventilation”,
there may be a problem with the Over- If this system activates, stop the engine imme-
Revolution Caution System. diately, if wind and water conditions make it safe
to do so.
Consult your authorized Suzuki marine
dealer if the Over-Revolution Caution  WARNING
System activates for no apparent reason.
If you attempt to remove or reinstall the
motor cover while the engine is running,
you may be injured.

To check the oil level, stop the engine and

then remove the motor cover.

Check the oil level and add oil if necessary. If

the oil level is correct, consult your authorized
Suzuki Marine Dealer.

17
 COOLING WATER CAUTION SYSTEM
NOTICE This system is activated when the cylinder wall
temperature is too high due to insufficient water
cooling.
Your engine may become severely dam-
aged If you rely on the Oil Pressure Cau- NOTE:
tion System to indicate the need to add The cooling water caution system will not detect
engine oil. high combustion chamber temperature caused
by, for example, an oil system malfunction, poor
Check the engine oil level periodically quality fuel, or spark plugs with an incorrect
and add oil as necessary. heat range.

If this system activates, the red TEMP lamp will

NOTICE light and the buzzer will begin a series of beep.
In addition, when this system is activated at
3000 r/min. or higher, engine speed will auto-
Operating the engine with the Oil Pres-
matically be reduced to approximately 3000
sure Caution System activated can result r/min. with REV LIMIT lamp lit.
in severe engine damage.
If you continue to run, the engine will automati-
cally stop 3 minutes after beginning of the
If the Oil Pressure Caution System acti-
above CAUTION system activation.
vates, stop the engine as soon as possi-
ble and add engine oil, if necessary, or NOTE:
otherwise correct the problem. 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.

If the cooling water caution system activates

when operating, reduce engine speed immedi-
ately and check if water is being discharged
from the pilot water hole. If no water is seen, fol-
low the procedures outlined below.

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.

18
Check (A) that water discharges from the pilot BATTERY VOLTAGE CAUTION SYSTEM
hole and (B) that the red TEMP lamp is no
longer lit. This system is activated when the battery volt-
Be aware that the red TEMP lamp may light age deficiency which could impair your motor’s
again if engine temperature rises abnormally. If performance occurs.
either of the above situations arises, consult
your authorized Suzuki Marine Dealer as soon If this system activates, the red CHECK
as possible. ENGINE lamp will light and buzzer will begin a
series of beep.
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 can-
celled.

NOTICE

Operating the engine with the Cooling

Water Caution System activated can
result in severe engine damage.

If the Cooling Water Caution System acti- This system will be canceled automatically
vates, stop the engine as soon as possi- when the battery voltage restores to the proper
voltage level. Refrain from using any electrical
ble, wind and water conditions
equipment such as P.T.T. system, hydraulic trim
permitting, and inspect the engine tabs, hydraulic jack plate, etc.
according to the above instructions. Con-
sult your authorized Suzuki marine dealer
 WARNING
if you cannot correct the problem.

NOTE: Failure to take proper precautions when

Remember that the cooling water caution sys- inspecting or servicing the battery can be
tem cannot detect overheating caused by, for hazardous.
example, an oil system malfunction, poor qual-
ity fuel, or incorrect spark plugs. Do not attempt to inspect or service the
battery without first reading the warn-
NOTE:
If the engine is operated beyond the maximum ings, cautions, and instructions in the
trim position, the water intake holes may be “BATTERY INSTALLATION” section of
above the water line. In this situation, the cool- this manual.
ing water caution system may activate.
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.

19
DIAGNOSTIC SYSTEM OIL CHANGE REMINDER
If abnormal conditions exist in any sensor sig-
SYSTEM
nal being sent to the control unit, the self-diag-
This system informs the operator of the time for
nostic system warns of the abnormal condition.
replacing engine oil on the basis of the mainte-
nance schedule.
If this system activates, the red CHECK
The system is designed to register the total
ENGINE lamp will flash and a buzzer will
operating hours of the outboard motor and
sound.
function its operation when the preprogrammed
hours have reached.
(Refer to the INSPECTION AND MAINTE-
NANCE section and the last page.)

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.

Also incorporated is a fail-safe provision that CANCELLATION

allows the operation at a restricted speed even
1. Turn the ignition key to the “ON” position.
under such a failure condition.
2. Pull out the emergency stop switch plate 1.
3. Pull up the emergency stop switch knob 2
NOTE:
three times in 10 seconds. A short beep will
• The CHECK ENGINE lamp will light briefly
be heard if the cancellation is successfully
when the ignition key is turned to the “ON” finished.
position.
• The failed system can be identified by the
mode of the red CHECK ENGINE lamp flash-
ing 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 canceled by pushing the
ignition key in.

NOTICE

If the diagnostic system activates while

you are operating your outboard motor, 4. Turn the ignition key to the “OFF” position.
there is an abnormal condition in one of 5. Set the plate 1 in the original position.
the sensor signals of the control system.

Consult your authorized Suzuki marine

dealer for repair of the control system.

20
NOTE: ENGINE STALLING
• Canceling of the system activation is possible
regardless of whether or not the engine oil
CAUTION SYSTEM
has been replaced. Once the system has
This system informs the operator when the
operated, however, Suzuki strongly recom-
motor stalls while it is operating.
mends that the engine oil be replaced before When the engine stalls for any reason, the cau-
canceling the system activation. tion buzzer sounds twice briefly.
• Even if the engine oil has been replaced with
the system not operating, it is still necessary
to perform the cancellation.

21
OPERATION OF TILTING MANUAL TILTING
SYSTEMS If you are unable to tilt the motor using the
“Power Trim and Tilt” because of an electrical
POWER TRIM AND TILT problem or some other problem, you can move
the motor manually. To tilt the motor up or
The “Power Trim and Tilt” is operated by press- down, turn the manual release screw A two
ing the switch. To tilt the motor up, press the turns counterclockwise, move the motor to the
upper part of the switch. To tilt the motor down, desired position, then retighten the release
press the lower part of the switch. screw.

Side mount Top mount

type type

UP
UP OPEN

CLOSE

DOWN

DOWN

 CAUTION

UP The motor is very heavy. When you tilt it

manually, you could injure your back or
DOWN
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.

 WARNING

The power trim and tilt (PTT) switch can

be accidentally activated when the igni-
tion key is off, resulting in injury.

Keep all persons away from the outboard

motor to help prevent accidental activa-
tion of the PTT system.

22
TILT LEVER
NOTICE
The Tilt Lever is provided so you can support
the motor in a tilted position for non-moving
Damage can occur if you use the tilt lever
engine support.
other than when the boat is moored or is
To set the Tilt Lever: otherwise stationary.
1. Tilt the motor all the way up using the Power
Trim and Tilt. The tilt lever relieves pressure from the
2. Pull down the Tilt Lever as shown in the illus- power trim and tilt and should only be
tration. used when the boat is stationary. Do not
use the tilt lever when trailering your boat
and motor. Refer to the TRAILERING sec-
tion of this manual.

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

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.

23
INSPECTION BEFORE 1. Place the motor in a vertical position,
then remove the motor cover by unlocking
BOATING the lever 1 and 2.

 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
2. Pull out the oil dipstick and wipe oil off
begin boating:
with a clean cloth.
• 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. NOTE:
If the engine oil is contaminated or discol-
To check the oil level: ored, replace with fresh engine oil. Refer to
the ENGINE OIL section.
NOTE:
To avoid an incorrect assessment of engine 3. Insert the dipstick all the way into the
oil level, check the level only when the engine, then remove it again.
engine has cooled.

UPPER LIMIT

LOWER LIMIT

24
 The oil on the dipstick should be between • Check the battery solution level.
the upper and lower limits shown on the The level should be kept between the MAX
dipstick. If the oil level indication is near and the MIN level lines at all times. If the
the lower limit, add enough oil to raise the level drops below the MIN level line, refer
level to the upper limit. to MAINTENANCE section.

To fill the engine with oil: • Make sure that the battery leads are
securely connected to the battery termi-
1. Remove the oil filler cap. nals.
2. Fill with recommended engine oil to the
upper level. • Visually check the propeller to make sure
it is not damaged.

• Make sure the motor is securely mounted

to the transom.

• Check for proper operation of the Power

Trim and Tilt.

• Check for proper trim angle.

• Make sure you have the boating safety

and emergency equipment on board.

NOTICE

Running the engine with an excessive

amount of oil can damage the engine.

Do not overfill the engine with oil.

3. Tighten the oil filler cap securely.

25
BREAK-IN 2. For the next 1 hour:
Safe boating conditions permitting, operate
Proper operation during this break-in period will the engine in gear at 4000 r/min. or at three-
help ensure maximum life and performance quarter throttle. Avoid running the engine at
from your engine. The following guidelines will full throttle.
explain proper break-in procedures. 3. Remaining 7 hours:
Safe boating conditions permitting, operate
NOTICE the engine in gear at desired engine speed.
You may occasionally use full throttle; how-
ever do not operate the engine continuously
Failure to follow the break-in procedures at full throttle for more than 5 minutes at any
described below can result in severe time.
engine damage.
NOTICE
Be sure to follow the engine break-in pro-
cedures described below. Running continuously at full throttle for
more than 5 minutes at a time during the
Break-in period: 10 hours last 7 hours of break-in operation may
cause severe engine damage such as sei-
Break-in procedure zure.
1. For the initial 2 hours:
Allow sufficient idling time (about 5 minutes) During the last 7 hours of break-in opera-
for the engine to warm up after cold engine tion, do not operate at wide open throttle
starting. for more than 5 minutes at a time.

NOTICE

Running at high speed without sufficient

warm-up may cause severe engine dam-
age such as piston seizure.

Always allow sufficient idling time (5 min-

utes) 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 imme-
diately reduce the throttle to the recommended
operating range.

26
OPERATION Side mount Top mount
type type
BEFORE ATTEMPTING TO START THE
ENGINE
1. Lower the motor into the water.
2. Make sure that the motor fuel hose and the
hose from the boat’s fuel tank are securely
attached and clamped.

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

Side mount Top mount

type type
 WARNING

Failure to properly attach the emergency

stop switch cord or to take proper pre-
cautions to help ensure that the emer-
gency stop switch works as intended may
result in serious injury or death to the
operator or passengers.

Always take the following precautions:

4. Make sure the lock plate is in place and the • Make sure that the emergency stop
emergency stop switch cord is fastened switch cord is fastened securely to the
securely to your wrist or appropriate clothing operator’s wrist or to an appropriate
area such as your belt.
clothing area (belt etc.).
• Ensure that no obstructions impede or
restrict emergency stop switch opera-
tion.
• 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 occu-
pants forward.

27
NOTE: 2. Side mount type:
There is a spare plastic lock plate for temporary Make sure the warm-up lever is in the fully
use only. Remove it from the cord and place in closed position.
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 indica-
Never start the engine or let it run indoors tion. If nothing abnormal is indicated, then
turn the key to the “START” position to start
or where there is little or no ventilation. the engine.

NOTE: After returning the ignition key to “ON” posi-

If the emergency stop switch lock plate is not in tion from “START” one, starter motor con-
position, the starter motor cannot operate. tinue to turn for 4 seconds until engine start.

1. Squeeze the fuel line priming bulb several

times until you feel resistance.

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” posi-

tion once and release it to start the
engine.
The engine will crank continuously for 4
seconds or until the engine starts.

28
 NOTICE  WARNING

If the OIL lamp remains lit while operating Operating the boat when the emergency
the outboard, the oil level may be low stop switch is not operating properly can
enough to damage the engine. be hazardous.

Stop the engine and check the oil level. Before starting off, check to make sure
that the emergency stop switch operates
NOTE: properly.
If the engine fails to start after 5 seconds, wait
10 seconds and try again.
EMERGENCY STARTING
4. Warm up the engine for about 5 minutes. If you must get the engine running, but are
unable to do so because of starter system fail-
Cooling water check ure or battery discharge, you can use the emer-
As soon as the engine starts, water should gency starting procedure to start the engine.
spray out of the pilot water hole 1, indicating
that the water pump and cooling system are NOTE:
working properly. If you notice that water does If the battery voltage is too low to operate the
not spray out of the pilot water hole, stop the electric fuel pump, you will not be able to start
engine as soon as possible and consult your the engine using the EMERGENCY STARTING
authorized Suzuki Marine Dealer. 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”

NOTICE and the emergency stop switch lock plate is
removed.

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.

29
 7. With the ignition key turned off, tie a knot in
 WARNING one end of the emergency starter rope
located in the tool kit. Tie the other end
When you use the emergency starting around the screw-driver handle in the tool
procedure, the start-in-gear protection kit.
8. Hook the knotted end of the rope in the pul-
system will not work. If the shift lever is
ley notch and wind the rope around the pul-
not in the “NEUTRAL” position, the boat ley in a counterclockwise direction.
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. Loosen the four bolts securing the ring gear
cover. Remove the ring gear cover.

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

10. After following steps for normal starting pro-
cedure, 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.
4. Squeeze the fuel line priming bulb several
times until you feel resistance. Do not attempt to reinstall the ring gear
5. Put the emergency stop switch lock plate in cover or motor cover after starting the
place. engine.
6. Turn the ignition key to the “ON” position and
listen for the electric fuel pump to cycle.
 WARNING
NOTE:
The initial fuel pump cycle is for a period of 3 When the engine is running, there are
seconds after the ignition key is first turned on.
many moving parts that could cause
If you are not sure about fuel pump operation,
you may turn the key off, then repeat step #6.
severe personal injury.

When the engine is running, keep your

hands, hair, clothing, etc., away from the
engine.

30
NOTE: Shifting
Be sure to have the starter system repaired as To shift into “FORWARD”, squeeze the lock-out
soon as possible. You should not continue to lever on the control handle and move the con-
use the emergency starting procedure for rou- trol handle forward to approximate position A,
tine engine starting. as shown in the illustration.

To shift into “REVERSE”, squeeze the lock-out

SHIFTING AND SPEED CONTROL lever on the control handle and move the con-
trol handle rearward to approximate position B,
NOTICE as shown in the illustration.

A detent or notch is present on all Suzuki con-

Severe engine damage may occur if (a) trol boxes to provide a “feel” for positions A, B,
engine speed is not allowed to return to and neutral. Always shift quickly and firmly from
idle and boat speed is not reduced when neutral to position A or B to prevent abnormal
shifting from “FORWARD” to “REVERSE” wear on the gear and clutch engagement sur-
or from “REVERSE” to “FORWARD”, or faces.
(b) care is not taken when operating the
boat in reverse.
NEUTRAL

Always allow the engine speed to return 32˚ 32˚

to idle before shifting. Exercise caution REVERSE
and use minimal speed when operating FORWARD
the boat in reverse. Be sure the handle/
shift lever is in the desired position
before accelerating.

NOTICE

If you shift gears when the engine is not NOTE:

running, the shifting mechanism can be Top mount type
damaged. Not equipped with a lock-out lever. Exercise
care when selecting neutral position.
Avoid shifting gears when the engine is
not running. Top mount
type NEUTRAL

35˚ 35˚

REVERSE
FORWARD

31
Speed control STOPPING THE ENGINE
To increase speed after you have shifted into
gear, continue moving the control handle for- NOTE:
ward or rearward. 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 pull-
 WARNING ing the emergency stop switch cord.

To stop the engine:

Since the same handle is used for shift- 1. Shift into “NEUTRAL”.
ing and speed control it is possible to 2. After operating at full throttle, cool off the
move the handle past the detent and engine a few minutes by allowing it to idle or
engage the throttle. This can cause the troll at low speed.
boat to move suddenly resulting in per-
sonal injury or property damage. Side mount Top mount
type type
You must be careful not to move the con-
trol handle too far forward or rearward
when shifting.

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

Always leave the ignition key in the “OFF”
position when the motor is not running, or
the battery can discharge.

32
 MOORING
NOTICE 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 pro-
If the ignition key is left ON when the
tect it from damage by underwater obstacles at
engine is not running, the battery will dis- low tide or corrosion from salt water.
charge.
Refer to the TILT LEVER section for details on
Always turn the ignition key OFF when how to tilt up the motor.
the engine is not running.
NOTICE
 WARNING
Improperly securing your boat may cause
Unauthorized use of your boat could lead damage to your boat or motor, or other
to an accident or damage to your boat. property damage.

To prevent unauthorized use of your boat, Do not allow your motor to rub against
be sure to remove the key and emergency quay walls, piers or other boats when the
stop switch lock plate when the boat is boat is tied up.
unattended.

4. After stopping the engine, disconnect the

fuel line from the outboard motor if there is a
fuel connector.

 WARNING

If you leave the motor stopped for a long

period of time with the fuel line con-
nected , 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.

33
OPERATION IN SHALLOW WATER OPERATION IN SALT WATER
When operating your boat in shallow water, it After operating the motor in salt water, you
may be necessary to tilt the motor higher than should flush the water passages with clean,
the normal trim angle. When you tilt the motor fresh water as outlined in the FLUSHING THE
beyond the normal trim angle, however, you WATER PASSAGES section. If you do not flush
should only operate the boat at slow speeds. the water passages, salt can corrode the motor
After returning to deep water, be sure to lower and shorten its life.
the motor to the normal trim angle.

To tilt the motor higher than the normal trim OPERATION IN FREEZING WEATHER
angle, use the Power Trim and Tilt switch. When operating your outboard motor in freez-
ing temperatures, you should keep the lower
 WARNING 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
When the motor is beyond the maximum drains completely.
trim position, the swivel bracket will not
have side support from the clamp bracket NOTICE
and the tilt system will be unable to cush-
ion the engine if the lower unit strikes an
obstruction. This could lead to occupant If you leave your outboard motor out of
injury. In addition, beyond the maximum the water in freezing temperatures with
trim position, the water intake holes may water still in the cooling system, the
be above the water line, which can result water can freeze and expand, causing
in severe engine damage from overheat- severe damage to the motor.
ing.
When your outboard is in the water in
Do not operate the engine above 1500 freezing temperatures, keep the lower
r/min or operate the boat in a planning unit submerged in the water at all times.
attitude with the engine beyond the maxi- When the motor is stored out of the water
mum trim position. in freezing temperatures stand it up in the
vertical position so that the cooling sys-
tem drains completely.
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.

34
MOTOR REMOVAL AND Horizontal transport:
1. Drain the engine oil. Refer to the ENGINE
TRANSPORTING OIL section.
2. Drain the gasoline from the vapor separator
MOTOR REMOVAL as follows:
If it is necessary to remove the outboard motor (1) Remove the motor cover.
from your boat, we recommend that you ask (2) Remove the side cover rubber 1 from the
your authorized Suzuki Marine Dealer to do the side cover. Remove the side cover bolts and
work for you. side cover.

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

Vertical transport:
Attach the clamp bracket to a stand by securing
two transom bolts.

(3) Pull the drain hose end 2 out. Loosen the

vapor separator drain screw 3, and drain
the gasoline into a suitable container.

 WARNING

Gasoline is extremely flammable and

toxic. It can cause a fire and can be haz-
ardous 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.

35
(4) After draining, retighten the screws 3. TRAILERING
(5) Install the side cover and side cover rubber.
(6) Install the motor cover. When trailering your boat with the motor
3. Rest the motor on a case protector with the attached, keep the motor in the normal operat-
port side downwards as shown. ing position unless there is not enough ground
clearance. If you need more ground clearance,
trailer the motor in a tilted position using a tran-
som saver bar or similar device to support the
weight of the motor.

NOTICE

If you are not careful when resting the

outboard on its side and do not take NOTICE
proper precautions such as first draining
the engine oil and cooling water com-
pletely, damage can occur. Engine oil If you use the tilt up lock arm to hold the
may enter the cylinder from the sump, motor in the fully tilted up position when
water may enter the cylinder through the trailering the boat, towing motion or poor
exhaust port, or the outer casings may be road surfaces may cause unexpected tilt
damaged. lock release, resulting in damage to the
motor and the tilt lock mechanism.
Always drain the engine oil and cooling
water completely before laying the motor Never use the tilt up lock arm to hold the
on its side, and be careful laying the motor in the fully tilted up position when
motor down. trailering the boat. Use a transom saver
bar or similar device to support the
weight of the motor.
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.

36
INSPECTION AND MAINTENANCE
NOTICE cated service. Maintenance intervals should be
judged by number of hours or number of
months, whichever comes first.
MAINTENANCE, REPLACEMENT OR
REPAIR OF EMISSION CONTROL
DEVICES AND SYSTEMS MAY BE PER-  WARNING
FORMED BY ANY MARINE SI ENGINE
REPAIR ESTABLISHMENT OR INDIVIDUAL
USING ANY PART WHICH HAS BEEN Exhaust gas contains carbon monoxide,
CERTIFIED UNDER THE PROVISIONS IN a dangerous gas that is difficult to detect
THE CLEAN AIR ACT Sec. 207 (a) (2). because it is colorless and odorless.
Breathing carbon monoxide can cause
death or severe injury.
MAINTENANCE SCHEDULE
It is important to inspect and maintain your out- Never start the engine or let it run indoors
board motor regularly. Follow the chart below. or where there is little or no ventilation.
At each interval, be sure to perform the indi-

Interval
Initial 20 hrs. Every 50 hrs. Every 100 hrs. Every 200 hrs.
or 1 month or 3 months or 6 months or 12 months
Item to be serviced
Spark plug – – I R
Breather & Fuel line I I I I
Engine oil R – R R
Gear oil R – R R
Lubrication – I I I
Anodes & Bonding wires – I I I
Battery – I I I
Low pressure fuel filter – I I I
Replace every 400 hours or 2 years.
* Engine oil filter R – – R
* High pressure fuel filter Replace every 1000 hours.
* Ignition timing – – – I
* Idle speed I – – I
* Valve clearance – – – I
* Water pump – – – I
* Water pump impeller – – – R
* Propeller nut & pin I – I I
* Bolts & Nuts T – T T

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 man-
ufacturer).

37
  WARNING NOTICE

Improper maintenance or failure to per- The maintenance intervals in the chart

form recommended maintenance can be were established for normal usage of
hazardous. Poor maintenance or lack of your outboard motor. If your outboard
maintenance increases the chance of an motor is used under severe conditions
accident or equipment damage. such as frequent full throttle operation or
frequent operation in muddy, silty, sandy,
Be sure to have maintenance performed acidic, or shallow water, you may need to
according to the schedule in the above perform maintenance more often than
chart. Suzuki recommends that only your indicated in the chart. Failure to perform
authorized Suzuki marine dealer or a maintenance more frequently could
qualified service mechanic perform main- result in damage.
tenance on those items in the chart above
which are marked with an asterisk (*). You Consult your authorized Suzuki marine
may perform maintenance on the dealer regarding appropriate mainte-
unmarked items by referring to the nance intervals for your usage condi-
instructions in this section if you have tions. When replacing parts on your
mechanical experience. If you are not outboard motor, Suzuki strongly recom-
sure whether you can successfully com- mends that you use genuine Suzuki parts
plete any of the unmarked maintenance or their equivalent.
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.

38
SPARK PLUG formance may suffer. Ask your authorized
Remove the spark plugs as follows: Suzuki Marine dealer to evaluate either of these
problems to determine the cause.
1. Remove the bolt securing the ignition coil.
2. Pull out the ignition coil.
3. Loosen and remove the spark plug using the
box wrench in the tool bag.
Insulator

Center
electrode

Gap
Ground electrode

NOTICE

Use of improper spark plugs or improp-

Your outboard motor comes equipped with the erly tightening spark plugs can cause
following “standard” spark plug for normal severe engine damage.
usage.
• Do not experiment with other spark
Standard spark plug NGK DCPR6E plug brands unless you can determine
that they are directly equivalent to the
specified brand, or you may experience
NOTICE engine damage which will not be cov-
ered under warranty. Note that after-
market cross-reference charts may not
Non-resistor types of spark plugs will be accurate.
interfere with the function of the elec- • To install a spark plug; seat it as far as
tronic ignition, causing misfiring, or possible by hand, then use a wrench to
causing problems with other electronic tighten it to either the recommended
boat equipment and accessories. torque setting or the specified rotation
angle.
Use ONLY resistor type spark plugs in
your outboard motor. Tightening torque
1.6 – 1.9 kg-m (11.6 – 13.7 lb-ft)
Your authorized Suzuki Marine Dealer can Rotation angle
determine if the standard spark plug is suitable
for your type of motor usage by inspecting the New plug 1/2 – 3/4 of a turn
color of the plug’s porcelain center electrode Re-use plug 1/12 – 1/8 of a turn
insulator after operation.
• Do not overtighten or cross-thread a
If the plug tends to run hot (usually evidenced spark plug, as this will damage the alu-
by whitening of the insulator or a burnt elec- minum threads of the cylinder head.
trode), stop using your motor immediately as
severe engine damage may result. If the plug
tends to run cold (usually evidenced by black-
ening of the insulator or a wet electrode), per-

39
To maintain a strong spark, you should clean BREATHER AND FUEL LINE
and adjust the plug at the interval shown in the Inspect the breather and fuel line for leaks,
maintenance schedule. cracks, swelling, or other damage. If the
Remove carbon deposits from the spark plug breather and fuel line are damaged in any way,
using a small wire brush or spark plug cleaner, they must be replaced. Consult your authorized
and adjust the gap as follows; Suzuki Marine dealer if it is necessary to
replace them.
0.7 – 0.8 mm
Spark plug gap
(0.028 – 0.031 in.)
Breather line

Fuel line

Breather line

Fuel line

 WARNING
If the electrode or insulator is damaged, or if
either shows excessive wear, then the spark Fuel leakage can contribute to an explo-
plug should be replaced. sion 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.

40
ENGINE OIL 3. Place a drain pan under the engine oil drain
screw.
 WARNING
 CAUTION
Never perform any ENGINE OIL proce-
dure with the motor running, as serious The engine oil temperature may be high
injury can occur. enough to burn your fingers when the
drain plug is loosened.
The motor must be shut off before any
ENGINE OIL procedures are performed. Wait until the drain plug is cool enough to
touch with bare hands before removing it.
NOTICE
4. Remove the engine oil drain screw 1 and
gasket 2, then let the engine oil drain.
Extended trolling can reduce oil life. Your
engine may be damaged if you do not
change engine oil more frequently under
this type of use.

Change your engine oil more frequently if

your engine is used for extended trolling.

Engine oil change

The oil should be changed when engine is
warm so that the oil will drain thoroughly from
the engine.

To change the engine oil: 5. After draining, secure the engine oil drain
1. Place the motor in a vertical position and screw with a new gasket.
remove the motor cover.
2. Remove the oil filler cap.
NOTICE

A previously-used gasket may leak,

resulting in engine damage.

Do not re-use gaskets. Be sure to always

use new gaskets.

NOTE:
There are spare gaskets in the tool bag.

6. Fill with recommended engine oil to the

upper level.
Oil capacity: 4.0 L (4.2/3.5 US/Imp. qt.)
Engine oil: SAE (or NMMA FC-W) 10W-40
API (or NMMA FC-W) Classifica-
tion SG, SH, SJ, SL, SM

41
7. Check the engine oil level. 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.
UPPER LIMIT

LOWER LIMIT

NOTE:
To avoid incorrect measurement of engine oil
level, check oil level only when the engine has
cooled.

8. Reinstall the oil filler cap.

 WARNING Periodic gear oil replacement is essential for

long life of your outboard motor.
Engine oil can cause injury to people or
pets. Repeated, prolonged contact with To change the gear oil:
1. Make sure the motor is in an upright posi-
used engine oil may cause skin cancer.
tion. Place a drain pan under the lower cas-
Even brief contact with used oil may irri- ing.
tate skin. 2. Remove the gear oil drain plug 2, then
remove the gear oil level plug 1.
• Keep new and used oil away from chil-
dren and pets.
• Wear a long-sleeve shirt and water-
proof gloves when handling oil.
• Wash with soap if oil contacts your
skin.
• Launder any clothing or rags that are
wet with oil.

NOTE:
Recycle or properly dispose of used engine oil.
Do not throw it in the trash, or pour it on the
ground, down a drain, or into the water.

3. After the oil has drained completely, inject

the specified gear oil into the gear oil drain
hole 2 until it just starts to come out of the
gear oil level hole 1. Approximately 850 ml
(28.7/30.0 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.

42
NOTE: LUBRICATION
To avoid insufficient injection of gear oil, check Proper lubrication is important for the safe,
the gear oil level 10 minutes after doing the pro- smooth operation and long life of each working
cedure in the step 4. If the oil level is low, slowly part of your outboard motor. The following chart
inject the gear oil into the gear oil level hole 1 shows the lubrication points of your motor and
up to the correct level. the recommended lubricant:

 WARNING LOCATION LUBRICANT

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 irri-
tate skin.
Throttle/Shift linkage Marine-grade
• Keep new and used oil away from chil- water resistant
dren and pets. grease
• Wear a long-sleeve shirt and water-
proof gloves when handling oil.
• Wash with soap if oil contacts your
skin.
• Launder any clothing or rags that are
wet with oil.
Propeller shaft
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

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 con-

taminated with water. Immediately con-
tact 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.

43
 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 protect-
ing. 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-corro-
sion measures may be helpful under those con-
ditions. Consult your authorized Suzuki Marine
Dealer for details.

Marine-grade
Swivel bracket
water resistant
grease
(Grease Gun)

Clutch lever

NOTE:
When the anode in the gear case is inspected
or replaced, it is necessary to remove the water
filter 1.

Steering bracket

Your authorized Suzuki Marine Dealer may also

have additional recommendations due to
regional climate or operating conditions.
Please consult him for advice.

44
 BATTERY
NOTICE If you are using a maintenance-free battery,
inspect the window area according to the
instructions on the battery to make sure the bat-
If anodes are not properly maintained,
tery is in good condition.
underwater aluminum surfaces (such as
the lower unit) will suffer galvanic corro- If you are not using a maintenance-free battery,
sion damage. the battery fluid level should be checked every
50 hours of operation or 3 months. The battery
• Periodically inspect anodes to make solution level must be kept between the MAX
sure they have not become detached. and the MIN level lines at all times. If the level
• Do not paint anodes, as this will render drops below the MIN level line, add DISTILLED
them ineffective. WATER ONLY until the battery solution level
• Periodically clean anodes with a wire reaches the MAX level line.
brush to remove any coating which
might decrease their protective ability.  WARNING

Battery acid is poisonous and corrosive,

BONDING WIRES and can cause severe injury.
Bonding wires are used to electrically connect
the engine components so they exist in a com-
mon ground circuit. This allows them to be pro-
Avoid contact with eyes, skin, clothing,
tected against electrolysis by the anodes. and painted surfaces. If battery acid
These wires and their terminals should be comes in contact with any of these, flush
checked periodically to be sure they have not immediately with large amounts of water.
been damaged. 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

Battery posts, terminals, and related

accessories contain lead and lead com-
pounds that may be hazardous.

Wash hands after handling.

45
 NOTICE FLUSHING THE WATER
PASSAGES
If you add diluted sulphuric acid to the After operation in muddy, brackish, or salt
battery after it has been initially serviced, water, you should flush the water passages and
you will damage the battery. motor surface with clean, fresh water.
If you do not flush the water passages, salt can
NEVER add diluted sulphuric acid to the corrode the motor and shorten its life. Flush the
battery after it has been initially serviced. water passages as follows.
Follow the battery manufacturer’s
instructions for specific maintenance
procedures. ENGINE RUNNING – Vertical position –
Suzuki recommends that you flush the water
passage by using this method.

ENGINE OIL FILTER To flush the water passages, you must obtain a
The engine oil filter must be changed by autho- commercially available engine flush device.
rized Suzuki Marine Dealer periodically.
Replace engine oil filter with a new one at initial
20 hours (1 month).
 WARNING
Replace engine oil filter with a new one at every
200 hours (12 months). Exhaust gas contains carbon monoxide,
a dangerous gas that is difficult to detect
because it is colorless and odorless.
FUEL FILTER Breathing carbon monoxide can cause
The fuel filter must be inspected by authorized
Suzuki Marine Dealer periodically.
death or severe injury.

Low pressure fuel filter Never start the engine or let it run indoors
Inspect low pressure fuel filter at every 50 hours or where there is little or no ventilation.
(3 months).
Replace low pressure fuel filter with a new one  WARNING
at every 400 hours (2 years).

High pressure fuel filter Failure to take proper precautions when

Replace high pressure fuel filter with a new one flushing the water passages can be haz-
at every 1000 hours. ardous.

When flushing the water passages,

always take the following precautions:
• Make sure that the engine remains in
NEUTRAL. If shifted into gear, the pro-
peller 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.

46
 3. Place the remote control lever in the “NEU-
NOTICE TRAL” position with the propeller removed
and start the motor. As soon as the engine
Severe engine damage can occur in as lit- starts, water should spray out of the pilot
tle as 15 seconds if the engine is started water hole 2, indicating proper water pump
operation. If no water spray is evident, stop
without supplying water to the cooling the motor immediately and consult your
system. dealer.

Never start the motor without supplying

water to the cooling system.

1. Install the flushing attachment 1 so that the

water intake holes are covered by the rubber
cups on the attachment.
2. 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. 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.
5. Allow the water to continue circulating for a
few minutes.
6. Stop the motor, then turn off the water.
7. Remove the flushing attachment from the
water intake hole.
8. Clean the motor surface and apply a coat of
automotive wax on the external finish of the
motor.

47
ENGINE NOT RUNNING – Vertical position – 2. Install garden hose directly or by using a
1. Remove one of the plug A or C from the hose connector matched to flushing point
two flushing ports. thread B.
Thread B: 0.75 – 11.5 NHR (American stan-
dard hose coupling threads for garden hose
applications.)

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

– Full tilt up position –
1. Raise the engine to the full tilt up position.
2. Follow the “ENGINE NOT RUNNING – Verti-
cal 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.

48
SUBMERGED MOTOR NOTICE
If your motor has been accidentally submerged
in water, it must receive a special repair service Severe engine damage may occur if you
as soon as possible to prevent corrosion. If pos- continue cranking the engine when you
sible, have a qualified marine dealer service the encounter friction or resistance.
engine. If immediate servicing is not available,
take the following steps to help protect your
motor. In the event that your motor is acciden- If you encounter friction or resistance
tally submerged, take the following steps: while cranking the engine, stop at once
and do not attempt to start the engine
1. Get the motor out of the water as soon as until you find and correct the problem.
possible.
2. Remove the engine cover and immediately 7. Have your authorized Suzuki marine dealer
wash the engine thoroughly with fresh water inspect the engine as soon as possible.
to completely remove all salt, mud, and sea-
weed. NOTICE
3. Remove the spark plugs. Drain the water
from the cylinders through the spark plug
holes by manually turning the flywheel sev- If the fuel supply is contaminated with
eral times. water, engine damage may occur.
4. Check if any water is evident in the engine
oil. If water is seen, remove the oil drain plug If the boat’s fuel tank filler and vent were
and drain the oil. After draining, tighten the
submerged, inspect the fuel supply to
oil drain plug.
5. Drain the fuel line and all filters.
make sure it is not contaminated with
water.
 WARNING

Gasoline is extremely flammable and

toxic. It can cause a fire and can be haz-
ardous to people and pets.

Keep flames and sparks away from gaso-

line. 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 fly-
wheel several times. Don’t use the electric
starter, as this may bend the connecting
rods.

49
STORAGE PROCEDURE NOTICE
MOTOR STORAGE
Severe engine damage can occur in as lit-
When storing your motor for a long period of tle as 15 seconds if the engine is started
time (for example, at the end of the boating sea- without supplying water to the cooling
son), it is recommended that you take your system.
motor to your authorized Suzuki Marine Dealer.
However, if you choose to prepare the motor for
Never start the motor without supplying
storage yourself, follow the procedure outlined
below: water to the cooling system.

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 sta-
bilizer can.
4. Flush the water passages in the motor thor-
oughly. Refer to the FLUSHING THE
WATER PASSAGES (Engine running) sec-
tion.
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 exter-
nal finish of the motor. If paint damage is evi-
dent, 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.

50
BATTERY STORAGE AFTER STORAGE
1. When the outboard motor will not be used When taking your motor out of storage, follow
for a month or longer, remove the battery the procedure below to return it to operating
and store it in a cool, dark place. Do not set condition:
battery on concrete or earth, as this will
accelerate loss of charge. 1. Thoroughly clean the spark plugs. Replace
2. Wash the casing and terminals using fresh them if necessary.
water only, then dry with clean cloth. 2. Check the gear-case oil level and if neces-
3. Fully charge the battery. If the battery will be sary, add gear oil according to the procedure
stored for a long period of time, check the outlined in the GEAR OIL section.
specific gravity of the fluid at least once a 3. Lubricate all moving parts according to the
month and recharge the battery when the LUBRICATION section.
charge is low. 4. Check the engine oil level.
5. Clean the motor and wax the painted sur-
 WARNING faces.
6. Recharge the battery before installing it.

Failure to take proper precautions when

charging the battery can be hazardous.
Batteries produce explosive vapors that GENERAL INFORMATION
can ignite. Battery acid is poisonous and
corrosive, and can cause severe injury. WARRANTIES (For U.S.A)
• Do not smoke and keep battery away The warranties covering your outboard motor
from open flames and sparks. are explained in a separate Limited Warranty
• To avoid creating a spark when charg- booklet given to you at the time of sale. Please
ing the battery, connect the battery read this booklet carefully so you can under-
stand your rights and responsibilities.
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.)

51
IDENTIFICATION NUMBER LOCATION EMISSION CONTROL
The model and identification numbers of your INFORMATION
outboard motor are stamped on a plate
attached to the clamp bracket. Record these NOTICE
numbers below for future reference. It is impor-
tant to know these numbers when you place a • THIS ENGINE IS CERTIFIED TO OPER-
parts order or if your motor is stolen. ATE ON UNLEADED GASOLINE OF 87
OCTANE ((R+M)/2 METHOD) OR
Model Number: GREATER.
• EXHAUST EMISSION CONTROL
SYSTEM:
Identification Number: ECM, MFI

TROUBLESHOOTING
This troubleshooting guide is provided to help
you find the cause of common complaints.

NOTICE

Failure to troubleshoot a problem cor-

rectly can damage your outboard motor.
Improper repairs or adjustments may
Ignition Key Number: damage the outboard motor instead or
fixing it. Such damage may not be cov-
ered 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.
Ignition key number
• Fuse is blown out.
stamped position
• Emergency stop switch lock plate is not in
Spare key 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.

52
Engine speed will not increase (Engine NOTE:
power is low): Use the fuse puller at the back of fuse box
• Engine is overloaded. cover, when the fuse is pulled off and installed.
• Caution/Diagnosis system is activated.
• Propeller is damaged. 4. Inspect the fuse and replace with new fuse if
• Propeller is not properly matched to loads. needed.

Engine vibrates excessively:

• Engine mounting bolts or clamp screws are
loose. Main fuse (40A)
• 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. Normal fuse Blown fuse

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

53
  WARNING

If you replace a blown fuse with a fuse

having a different amperage rating or STARTER MAIN

10A
SPARE
with a substitute such as aluminum foil or RELAY RELAY

a wire, extensive electrical system dam-

SPARE

SPARE
40A

30A
10A
30A
MAIN
age and a fire may result.

Always replace a blown fuse with a fuse

of the same type and rating.

NOTICE 1 Main fuse: 40A

2 Spare fuse: 30A
3 Spare fuse: 10A
If a new fuse blows in a short time after 4 Starter motor relay fuse: 30A
installation, you may have a major electri- 5 PTT switch fuse: 10A
cal system problem. 6 Ignition coil/Injector/ECM/Fuel pump fuse: 30A
7 IAC fuse: 10A
Consult your SUZUKI marine dealer. 8 Spare fuse: 40A

SPECIFICATIONS
Item DF70AT DF80AT DF90AT
Engine Type 4 Stroke
Number of Cylinders 4
Bore and Stroke 75.0 × 85.0 mm
(2.95 × 3.35 in.)
Piston Displacement 1502 cm3
(91.6 cu. in.)
Maximum output 51.5 kW (70 PS) 58.8 kW (80 PS) 66.2 kW (90 PS)
Full Throttle Operating Range 5000 – 6000 5500 – 6300
r/min. (min–1) r/min. (min–1)
Idle speed (in Neutral) 700 ± 50 r/min. (min–1)
Ignition System Full-transistor
Engine Lubrication Trochoid pump pressure lubrication
Engine Oil Capacity 4.0 L (4.2/3.5 US/Imp. qt.)
Power rated in accordance with NMMA procedure.

54
CHART OF TOTAL OPERATING HOURS INDICATION
Total MONITOR-TACHOMETER
operating Needle 1 REV-LIMIT
hours indication lamp 2 flashing *
0h-(49h) No No
50h- 500rpm No
60h- 600rpm No
: : :
: : :
540h- 5400rpm No
550h- 500rpm 1 time
560h- 600rpm 1 time
: : :
: : :
1040h- 5400rpm 1 time
1050h- 500rpm 2 times
: : :
: : :
1540h- 5400rpm 2 times
1550h- 500rpm 3 times
: : :
: : :
2030h- 5300rpm 3 times
2040h or over 5400rpm 3 times
*: One flashing is corresponded to 500 hours.

FLOWCHART OF OIL CHANGE REMINDER SYSTEM

*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.

55
56
WIRE COLOR
B : Black Lg/B : Light green with Black
Bl : Blue Lg/R : Light green with Red
Br : Brown Lg/W : Light green with White
G : Green O/B : Orange with Black
Gr : Gray O/W : Orange with White
Lbl : Light blue O/Y : Orange with Yellow
Lg : Light green P/Bl : Pink with Blue
O : Orange P/W : Pink with White
P : Pink R/B : Red with Black
R : Red R/G : Red with Green
W : White R/W : Red with White
Y : Yellow R/Y : Red with Yellow
B/Br : Black with Brown V/W : Violet with White
B/G : Black with Green W/B : White with Black
B/O : Black with Orange W/Bl : White with Blue
MAP W
B/R : Black with Red W/G : White with Green R CMP
SENSOR B/W CYLINDER TEMP
B/W : Black with White W/R : White with Red SENSOR #1
B/Y : Black with Yellow W/Y : White with Yellow SENSOR
B/W Lg/W B
Bl/B : Blue with Black Y/Bl : Yellow with Blue IAC Y/Bl B/W B
B/Bl
Bl/R : Blue with Red Y/G : Yellow with Green
Bl/W : Blue with White
Br/Y : Brown with Yellow W/B
R/Y MAGNETO IGNITION COIL #1
Gr/R
G/R : Green with Red Gr/R
R/G CKP SENSOR FUEL INJECTOR
G/W : Green with White W/Bl
Gr
Gr/R : Gray with Red O O/B
B O #1
Gr/Y : Gray with Yellow THROTTLE Br/Y
R
SENSOR B/W
FUEL PUMP
STARTER
IAT SENSOR MOTOR
WIRING DIAGRAM

B/W
Lg/B M
OIL PRESSURE SWITCH

B/G
R
R
R

R/B
1.0 ± 0.3 kgf/cm2 B/R B/R
Gr Gr
ON
SHIFT TRIM IGNITION COIL #2
Bl

B/W
SENSOR SENSOR FUEL INJECTOR
Gr

R/B
Bl B/Br
B Gr #2
STARTER
MAIN MOTOR FUSE BOX EX-MANI TEMP
LIGHTING R/G
NEUTRAL
RELAY RELAY SENSOR

Bl
B SWITCH

Bl
SWITCH Gr V/W B

Y
B
B/W B

Y
B
B N ON FUSE
R/G F.R OFF
B ENGINE CONTROL MODULE 10A 30A 30A 10A 40A

B
R/G
Gr Gr
RECTIFIER &

Bl
Bl
B B METER

R/G
Y
Y

B
B
REGULATOR

W
W

Gr
R
R

R/B
W
W

G
Gr
W/R

Y/G
R
Gr/R
R/G

W
Gr
W
B Y
Y
Y

R/G
R IGNITION COIL #3

B
R
B FUEL INJECTOR

R/G
Gr Gr TRIM W/Y W/Y

W
Gr

Lbl
Bl

B
Bl

Y
R/B

B/G
P/W
B/W

W/Y
B/Bl
B B

Bl/W
R/W

W/B
R/G
Y/B

P/Bl
B/W
W/Y
B B

B/W
W/Y
O/W
Lg/R
B/R

Y/G
Y/Bl
METER

R/W

Bl/B
G/W
Gr Gr #3

P
B
G

Br
Gr/Y

B
O

Br
Lg
V/W

P/Bl
R/W
Bl/R
Bl/B

Br/Y
Lg/B

R/Y
R/B
G/Y
O/Y
Y/G

O/B
B

Lg/W
Lg/W

P/W
B/Br
Gr/Y

W/Bl
Bl/W
R/G R/G
B B

Gr Gr

Y/G
B B TACHOMETER Bl/B Bl/B SPEED
G/Y G/Y
Y Y P P SENSOR WATER PRESSURE

B/Bl
WITH LED G/W G/W
SENSOR
R

10A Bl/B
R
B/W

B/W
Bl/W

PTT SWITCH NEUTRAL SWITCH R R

REMOTE CONTROL BOX DN UP N ON
F.R OFF IGNITION COIL #4
W-TUBE FUEL INJECTOR
Gr
Lg/R Lg
Lbl B Gr #4
PUSH FREE ST IG OFF Lg
R
GND B
IGNITION SWITCH
STOP G

BATT W

SUZUKI
IG Gr
Br Br W/Y W/Y
START Br Br Br B
BZ Bl/B Bl/B
G/Y G/Y
RESET O Lbl Lbl P P/W
W/R W/R G/W G/W
PUSH TURN P P Lbl Lbl
O P P
O
B

W O O/W
W W W
Gr Gr Br Br Br Br
BZ Bl Bl W/R Y Y/B
G G G Bl/R
G G CAUTION BUZZER Gr Gr Gr B/G
B/W

B B Bl Bl/W Bl/W Bl/W

B B B B
W
EMERGENCY

W
STOP SWITCH
Gr

W
B/G
LOCK PLATE IN RUN Lbl Lbl

B
W/R W/R

W
B/Bl
LOCK PLATE OFF STOP P P
Y

P/W
O/Y

P/W
B

SDS
P/W
B/G
W/R

Bl/B
G/W

CONNECTOR
JOINT
G/W
Bl/B
P
Lbl

CONNECTOR #1
Lg/W

B/W W Gr/R R B/G B P Lbl B/Bl R.R/W GAUGE CAP

CONNECTOR
P

JOINT JOINT DIGITAL GAUGE

P
Lbl
W/R

GAUGE

W
P/W
P/W

CONNECTOR #3 CONNECTOR #2 DIAGRAM

O/Y

Lbl
B

Bl Bl CONNECTOR

R
B
Bl/B
G/W
B/G

G G (OPTION) DN UP
G/W
Bl/B

CAP SDS
PTT SWITCH

B
CONNECTOR
BATTERY PTT
12V 100AH PTT MOTOR RELAY
IMPORTANT • Inspect the boat and motor before each
 WARNING/  CAUTION/ NOTICE/ NOTE trip. See the INSPECTION BEFORE
Please read this manual and follow its instruc- BOATING section for important items.
tions carefully. To emphasize special informa- • Become thoroughly familiar with all
tion, the symbol  and the words WARNING, operating and handling characteristics
CAUTION, NOTICE and NOTE have special of your boat and motor. Practice at low
meanings. Pay special attention to the mes- and moderate speeds until you are
sages highlighted by these signal words. competent at handling the boat and
motor. Do no attempt to operate at maxi-
 WARNING
mum performance until you are com-
Indicates a potential hazard that could pletely familiar with all of these
result in death or serious injury. characteristics.
• Carry boating safety and emergency
 CAUTION equipment. This important equipment
includes; flotation aids for each person
Indicates a potential hazard that could (plus one throwable buoyant cushion in
result in minor or moderate injury. any boat 16 feet or longer), fire extin-
guisher, sound signaling device, visual
NOTICE distress signals, anchor, bilge pump,
bucket, compass, emergency starter Prepared by
Indicates a potential hazard that could rope, extra fuel and oil, first aid kit,
result in damage to the motor or boat. flashlight, food and water, mirror, pad-
dles, tool kit, and transistor radio. Be
NOTE:
sure you are carrying the equipment
Indicates special instructions to make mainte-
nance easier or instructions clearer.
appropriate for your trip before launch- Outboard Motor Engineering Department
ing.
• Never start the engine or let it run
BREAK-IN INFORMATION indoors or where there is little or no
FOR YOUR OUTBOARD MOTOR May, 2010
ventilation. Exhaust gas contains car-
The first 10 hours are the most important in the bon monoxide, a gas that is colorless Part No. 99011-87L02-03A
life of your engine. Proper operation during this and odorless and can cause death or Printed in Japan
break-in period is essential to help ensure max-
severe injury.
imum life and performance.
Refer to the BREAK-IN section of this manual
• Instruct your passengers on how to
operate the boat, how to deal with © COPYRIGHT SUZUKI MOTOR CORPORATION 2010
for specific break-in recommendations.
emergencies, and how to operate
IMPORTANT NOTICE TO OWNERS safety and emergency equipment.
• Do not hold onto the motor cover or
 WARNING any other parts of your outboard motor
while getting on or off your boat.
• Ensure that everyone wears a life jacket
Failure to take the proper precautions on board.
may increase the risk of death or severe • Never operate the boat while under the
injury to you and your passengers. influence of alcohol or other drugs.
• Distribute all weight load evenly in the
• Prior to first-time use of your outboard boat.
motor, familiarize yourself thoroughly • Have all scheduled maintenance per-
with the contents of this owner’s man- formed. Consult your authorized
ual. Be aware of all outboard motor fea- Suzuki marine dealer as required.
tures and all safety and maintenance
requirements.