DF225 - Outboard motor SUZUKI - Free user manual and instructions

USER MANUAL DF225 SUZUKI

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol ▲ and the words WARNING, CAUTION, NOTICE and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.

WARNING

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

CAUTION

Indicates a potential hazard that could result in minor or moderate injury.

NOTICE

Indicates a potential hazard that could result in damage to the motor or boat.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

This symbol appears in various locations on your Suzuki product to refer you to important information in the owner's manual.

IMPORTANT NOTICE TO OWNERS

WARNING

Failure to take the proper precautions may increase the risk of death or severe injury to you and your passengers.

• Prior to first-time use of your outboard motor, familiarize yourself thoroughly with the contents of this owner's manual. Be aware of all outboard motor features and all safety and maintenance requirements.

• Inspect the boat and motor before each trip. See the INSPECTION BEFORE BOATING section for important items.

• Become thoroughly familiar with all operating and handling characteristics of your boat and motor. Practice at low and moderate speeds until you are competent at handling the boat and motor. Do not attempt to operate at maximum performance until you are completely familiar with all of these characteristics.

• Carry boating safety and emergency equipment. This important equipment includes; flotation aids for each person (plus one throwable buoyant cushion in any boat 16 feet or longer), fire extinguisher, sound signaling device, visual distress signals, anchor, bilge pump, bucket, compass, emergency starter rope, extra fuel and oil, first aid kit, flashlight, food and water, mirror, paddles, tool kit, and transistor radio. Be sure you are carrying the equipment appropriate for your trip before launching.
• Never start the engine or let it run indoors or where there is little or no ventilation. Exhaust gas contains carbon monoxide, a gas that is colorless and odorless and can cause death or severe injury.
• Instruct your passengers on how to operate the boat, how to deal with emergencies, and how to operate safety and emergency equipment.
• Do not hold onto the motor cover or any other parts of your outboard motor while getting on or off your boat.
• Ensure that everyone wears a PFD (Personal Flotation Device) on board.
• Never operate the boat while under the influence of alcohol or other drugs.
• Distribute all weight load evenly in the boat.
• Have all scheduled maintenance performed. Consult your authorized Suzuki marine dealer as required.
• Do not modify or remove any outboard motor standard equipment. To do so may make the motor unsafe to use.
• Learn and obey all applicable navigation rules.
• Pay attention to all weather forecasts. Do not set out if weather is unsettled.
• Use extreme caution when purchasing replacement parts or accessories. Suzuki strongly recommends that you use only genuine Suzuki replacement parts/accessories or their equivalent. Inappropriate or poor quality replacement parts or accessories can create unsafe operating conditions.

- Never remove the flywheel cover (except for when emergency starting).

NOTE:

Mounting radio transceiver or navigational equipment antennae too close to the engine cowling can cause electrical noise interference. Suzuki recommends that antennae be mounted at least one meter (40 inches) away from the engine cowling.

This manual should be considered a permanent part of the outboard motor and should remain with the outboard motor when resold or otherwise transferred to a new owner or operator. Please read this manual carefully before operating your new Suzuki and review the manual from time to time. It contains important information on safety, operation, and maintenance.

FOREWORD

Thank you for choosing a Suzuki outboard motor. Please read this manual carefully and review it from time to time. It contains important information on safety, operation, and maintenance. A thorough understanding of the information presented in this manual will help you experience safe, enjoyable boating.

All information in this manual is based on the latest product information available at the time of publication. Due to improvements or other changes, there may be discrepancies between this manual and your outboard motor. Suzuki reserves the right to make changes at any time without notice.

TABLE OF CONTENTS

IDENTIFICATION NUMBER LOCATION.... 5

FUEL AND OIL.... 5

LOCATION OF SAFETY LABELS ..... 8

LOCATION OF PARTS...... 9

MOTOR MOUNTING...... 10

BATTERY INSTALLATION ...... 10

USE OF ELECTRICAL ACCESSORIES 12

PROPELLER SELECTION AND INSTALLATION.... 13

ADJUSTMENT.... 14

CAUTION SYSTEM 16

DIAGNOSTIC SYSTEM 19

OIL CHANGE REMINDER SYSTEM.... 20

ENGINE STALLING CAUTION SYSTEM.... 20

WATER IN FUEL ALERT SYSTEM.... 20

OPERATION OF TILTING SYSTEMS.... 21

INSPECTION BEFORE BOATING ... 23

BREAK-IN 25

OPERATION 26

MOTOR REMOVAL AND TRANSPORTING 31

TRAILERING.... 33

INSPECTION AND MAINTENANCE.... 34

FLUSHING THE WATER PASSAGES.... 45

SUBMERGED MOTOR 47

STORAGE PROCEDURE 48

AFTER STORAGE 49

TROUBLESHOOTING 49

SPECIFICATIONS 51

INFORMATION REGARDING EC - DIRECTIVE .... 51

CHART OF TOTAL OPERATING HOURS INDICATION .... 52

FLOWCHART OF OIL CHANGE REMINDER SYSTEM.... 52

IDENTIFICATION NUMBER LOCATION

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

Technical line drawing of a mechanical component with no visible text or symbols

FUEL AND OIL

GASOLINE

Suzuki highly recommends that you use alcohol-free unleaded gasoline whenever possible, with a minimum octane rating of 91 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane content may be used, provided the guidelines that follow are met.

NOTICE

Use of leaded gasoline can cause engine damage. Use of improper or poor quality fuel can affect performance and may damage your motor and fuel system.

Use only unleaded gasoline. Do not use fuel having lower than the recommended octane, or fuel that may be stale or contaminated by dirt/water etc.

NOTE:

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

Suzuki recommends that you install a water-separating fuel filter assembly between your boat's fuel tank(s) and outboard motor(s). Fuel filtration systems of this type will help prevent water that may be present in your boat's fuel tank(s) from contaminating your motor's electronic fuel injection system. Water contamination can cause poor engine performance and can also cause damage to the electronic fuel injection system components.

Your Authorized Suzuki Marine Dealer can provide you advice about water-separating fuel filter systems and installation.

Gasoline/Ethanol Blends

Blends of unleaded gasoline and ethanol (grain alcohol), also known as “GASOHOL”, are commercially available in some areas. Blends of this type may be used in your outboard motor if they are no more than 10% ethanol. Make sure this gasoline-ethanol blend has octane ratings no lower than those recommended for gasoline.

Use the recommended gasoline which conforms to the following labels.

E5 or E10

78RB0900

Pump Labeling for Gasoline/Alcohol Blends

In some states, pumps that dispense gasoline/ alcohol blends are required to be labeled for the type and percentage of alcohol content, and whether important additives are present. Such labels may provide enough information for you to determine if a particular blend of fuel meets the requirements listed above. In other states, pumps may not be clearly labeled as to the content or type of alcohol and additives. If you are not sure that the fuel you intend to use meets these requirements, check with the service station operator or the fuel suppliers.

NOTE:

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

Be sure that any gasoline/alcohol blend you use has octane ratings of at least 91 octane (Research method).

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

Unleaded gasoline will extend spark plug life.

WARNING

Gasoline is extremely flammable and toxic. It can cause a fire and can be hazardous to people and pets.

Always take the following precautions when refueling:

• Never permit anyone other than an adult to refill the fuel tank.
• If you use a portable fuel tank, always stop the motor and remove the fuel tank from the boat to refill it.
• Do not fill the fuel tank all the way to the top or fuel may overflow when it expands due to heating by the sun.
• Be careful not to spill fuel. If you do, wipe it up immediately.
• Do not smoke, and keep away from open flames and sparks.

NOTICE

Gasoline kept in the fuel tank for long periods of time will produce varnish and gum, which can damage the engine.

Always use fresh gasoline.

NOTICE

Fuels containing alcohol can cause paint damage, which is not covered under the New Outboard Motor Limited Warranty.

Be careful not to spill fuel containing alcohol while refueling. If fuel is spilled, wipe it up immediately.

ENGINE OIL

NOTICE

Use of poor quality engine oil can adversely affect engine performance and life.

Suzuki recommends that you use Suzuki Marine 4-Cycle Engine Oil or its equivalent.

Oil quality is a major contributor to your engine's performance and life. Always select good quality engine oil.

Suzuki recommends the use of SAE 10W-40 or 10W-30 SUZUKI MARINE 4-CYCLE ENGINE OIL. If SUZUKI MARINE 4-CYCLE ENGINE OIL is not available, select a NMMA certified FC-W oil or good quality 4-cycle motor oil from the following chart according to the average temperatures in your area.

NOTE:

In very cold weather (below 5^ C ( 41^ F)), use SAE (or NMMA FC-W) 5W-30 for easier starting and smooth operation.

GEAR OIL

S. SUSTIN SUSTIN NUTRICAL GEAR CO. 17-20-2018 19-20-2018 19-20-2018 19-20-2018 19-20-2018 19-20-2018 19-20-2018 19-20-2018 19-20-2018 19-20-2018 19- 20- 21- 22- 23- 24- 25- 26- 27- 28- 29- 30- 31- 32- 33- 34- 35- 36- 37- 38- 39- 40- 41- 42- 43- 44- 45- 46- 47- 48- 49- 50- 51- 52- 53- 54- 55- 56- 57- 58- 59- 60- 61- 62- 63- 64- 65- 66- 67- 68- 69- 70- 71- 72- 73- 74- 75- 76- 77- 78- 79- 80- 81- 82- 83- 84- 85- 86- 87- 88- 89- 90- 91- 92- 93- 94- 95- 96- 97- 98- 99- 100-101-102-103-104-105-106-107-108-109-110-111-112-113-114-115-116-117-118-119-120-121-122-123-124-125-126-127-128-129-130-131-132-133-134-135-136-137-138-139-140-141-142-143-144-145-146-147-148-149-150-151-152-153-154-155-156-157-158-159-160-161-162-163-164-165-166-167-168-169-170-171-172-173-174-175-176-177-178-179-180-181-182-183-184-185-186-187-188-189-190-191-192-193-194-195-196-197-198-199-200 SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. NUTRICAL GEAR CO. NUTRICAL GEAR CO. NUTRICAL GEAR CO. NUTRICAL GEAR CO. NUTRICAL GEAR CO. NUTRICAL GEAR CO. NUTRICAL GEAR CO. NUTRICAL GEAR CO. NUTRICAL GEAR CO. NUTRICAL GEAR CO. NUTRICAL GEAR CO. NUTRICAL GEAR CO. NUTRICALGEAR CO. NUTRICALGEAR CO. NUTRICALGEAR CO. NUTRICALGEAR CO. NUTRICALGEAR CO. NUTRICALGEAR CO. NUTRICALGEAR CO. NUTRICALGEAR CO. NUTRICALGEAR CO. NUTRICALGEAR CO. NUTRICALGEAR CO. NUTRICALGEAR CO. NUTRICALGEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL GEAR CO. SUSTIN NUTRICAL G ear SUSTIN NUTRICAL G ear SUSTIN NUTRICAL G ear SUSTIN NUTRICAL G ear SUSTIN NUTRICAL G ear SUSTIN NUTRICAL G ear SUSTIN NUTRICAL G ear SUSTIN NUTRICAL G ear SUSTIN NUTRICAL G ear SUSTIN NUTRICAL G ear SUSTIN NUTRICAL G ear

Suzuki recommends the use of SUZUKI OUTBOARD MOTOR GEAR OIL. If it is not available, use SAE 90 hypoid gear oil which is rated GL-5 under the API classification system.

Read and follow all of the labels on your outboard motor or fuel tank. Make sure you understand all of the labels.

Keep the labels on your outboard motor or fuel tank. Do not remove them for any reason.

WARNING AVERTISSEMENT

• Fuel can leak creating a fire hazard if you lay motor on its side. Drain fuel completely from vapor separator or carburetor before laying motor on its side.
  • See owner's manual for details.

Label symbol meanings These symbols mean as follows;

general warning symbol (caution or Warning)

ead owner's manual carefully

remote control lever/gear shift ever operation-two direction; forward/Neutral/Reverse

ngine start

azard caused by fire

hazard caused by laying the motor on its side

LOCATION OF PARTS

MONITOR-TACHOMETER Power trim and tilt (P.T.T.) switch Pilot water hole (Reverse side) Clamp bracket Anode Air vent hole plug Gear oil level plug Gear oil drain plug Motor cover Flush plug Engine oil drain plug Anti-cavitation plate Trim tab Water intake hole

Power trim and tilt (P.T.T.) switch Remote control handle Warm-up lever Ignition key Emergency stop switch Lock-out lever Throttle tension adjuster

REMOTE CONTROL BOX

Priming bulb

FUEL LINE

MOTOR MOUNTING

WARNING

Overpowering your boat can be hazardous. Excessive horsepower will have an adverse effect on hull safety and may cause operating/handling difficulties. The boat may also sustain stress and hull damage.

Never install an outboard motor with horsepower exceeding the manufacturer's recommended maximum horsepower listed on the boat's "Certification Plate". Contact your authorized Suzuki marine dealer if you are unable to locate the hull "Certificate Plate".

Suzuki strongly recommends that you have your outboard motor, controls and gauges installed by an authorized Suzuki Marine Dealer. He has the tools, the facilities and the know-how.

WARNING

Failure to have your outboard motor and associated controls and gauges properly installed can result in personal injury or damage.

Suzuki strongly recommends that you have your outboard motor, controls and gauges installed by your authorized Suzuki marine dealer. He has the tools, the facilities, and the know-how to do the job correctly.

BATTERY INSTALLATION

BATTERY REQUIREMENT

850 Marine Cranking Amps (MCA)/ABYC, or 670 Cold Cranking Amps (CCA)/SAE or 180 Reserve Capacity (RC) Minutes/SAE or 12 Volt 100 AH

NOTE:

• The specifications listed above are the minimum battery rating requirements for starting the engine.
• Additional electrical loads from the boat will require larger capacity batteries. Consult your Suzuki dealer to determine the proper battery sizing for your boat and engine combination.
• Dual-purpose (Cranking/Deep-cycle) batteries can be used if they meet the minimum specifications listed above (MCA, CCA, or RC).
• Do not use a Deep Cycle battery for the main cranking battery.
• When connecting batteries in parallel, they must be of the same type, capacity, manufacturer, and of similar age. When replacement is necessary, they should be replaced as a set. Consult your Suzuki dealer for proper battery installation information.

BATTERY INSTALLATION

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

NOTE:

• It is recommended that the battery be installed in an enclosed battery case.
• When connecting batteries, hexagon-nuts must be used to secure battery leads to battery posts.

To hook up the battery, first connect the red lead from the motor to the positive battery terminal, then connect the black lead to the negative battery terminal.

Red lead Sub battery cable Black lead

Hexagon-nut

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

Suzuki recommends that you install the terminal cap on the positive battery terminal to prevent an accidental short circuit of battery terminals.

If a terminal cap is required, contact your authorized Suzuki marine dealer.

WARNING

If you place the battery near the fuel tank, a spark from the battery may ignite the gasoline, causing a fire and/or an explosion.

Do not place the fuel tank in the same compartment/area as the battery.

WARNING

Batteries produce flammable hydrogen gas and may explode if they are near flames or sparks.

Never smoke or cause sparks when working near the battery. Keep the battery away from open flames. To avoid creating a spark when charging the battery, connect the battery charger cables to the proper terminals before turning the charger on.

WARNING

Battery acid is poisonous and corrosive. It can cause severe injury and can damage painted surfaces.

Avoid contact with eyes, skin, clothing, and painted surfaces. If battery acid comes in contact with any of these, flush immediately with large amounts of water. If acid contacts the eyes or skin, get immediate medical attention.

NOTICE

The electrical system or its components may be damaged if proper battery precautions are not followed.

• Be sure to attach battery leads correctly.
• Do not disconnect battery leads from the battery while the engine is running.

SUB BATTERY CABLE

The sub battery cable ① is used to supply voltage to the engine control system. In the midst of the cable, a 15A fuse ② is provided to protect the control circuit.

If the sub battery cable is not correctly connected to the battery, engine cannot be started.

Diagram of a battery pack with labeled components and wiring, showing terminal connections and grounding points.

USE OF ELECTRICAL ACCESSORIES

The amount of power (DC12V) available for accessories, however, depends on the operating condition of the motor. For getting a detailed information, please inquire of your authorized Suzuki Marine Dealer.

NOTE:

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

PROPELLER SELECTION AND INSTALLATION

PROPELLER SELECTION

It is essential to use a propeller on your outboard motor that is properly matched to your boat's operating characteristics. The speed of the engine when you operate your boat at full throttle depends on the propeller you use.

Excessive engine speed can seriously damage the motor, while low engine speed at full throttle will adversely affect the performance. Your operating load will also affect propeller selection. Smaller loads generally require larger-pitch propellers; larger loads generally require smaller-pitch propellers. Your authorized Suzuki Marine Dealer will assist you in selecting a suitable propeller for your boat.

NOTICE

Installing a propeller with either too much or too little pitch will cause incorrect maximum engine speed, which may result in severe damage to the motor.

Ask your authorized Suzuki marine dealer to assist you in selecting a suitable propeller for your boat.

You can determine if your propeller is appropriate for use with your boat by using a tachometer to measure engine speed when operating your boat at full throttle, under minimum load conditions. If you are using an appropriate propeller, the engine speed will be within the following range:

Full throttle operating range	DF200	5000 – 6000 r/min. (min ^-1 )
	DF225	5000 – 6000 r/min. (min ^-1 )
	DF250	5500 – 6100 r/min. (min ^-1 )

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

PROPELLER INSTALLATION

WARNING

Failure to take proper precautions when installing or removing the propeller can result in severe personal injury.

When installing or removing the propeller:

• Always shift into "Neutral" and remove the emergency stop switch lock plate so that the motor cannot be started accidentally.
• Wear gloves to protect hands, and "lock" the propeller by placing a block of wood between the blades and the anti-cavitation plate.

To install a propeller on your outboard motor, use the following procedure:

Technical diagram of a motor or gearbox with numbered parts labeled 1 through 7

1. Coat the propeller shaft splines ① liberally with Suzuki water resistant grease to help prevent corrosion.
2. Place the stopper ② on the shaft.
3. Align the propeller ③ with the propeller shaft splines and slide the propeller onto the shaft.
4. Place the spacer ④ and washer ⑤ on the shaft.
5. Install the propeller nut ⑥ and tighten it with a torque wrench to 50 - 60 N·m (5.0 - 6.0 kg·m/36.0 - 43.5 lb·ft).
6. Insert the cotter pin ⑦ and bend it so that it can't come off.

To remove the propeller, reverse the above procedure.

ADJUSTMENT

TRIM ANGLE ADJUSTMENT

To help maintain steering stability and good performance, always maintain the proper trim angle as shown in the illustration. The appropriate trim angle varies depending on the combination of the boat, engine, and propeller, as well as operating conditions.

Trim range Tilt range

WARNING

Trim angle greatly affects steering stability. If the trim angle is too small, the boat may "plow" or "bow steer". If the trim angle is too large, the boat may "chine walk" from side to side or "porpoise" up and down. These conditions, which result in loss of steering control, can cause occupants to be thrown overboard.

Always maintain proper trim angle based on the combination of your boat, engine, and propeller, as well as operating conditions.

WARNING

When the motor is tilted beyond the maximum trim position, the swivel bracket will not have side support from the clamp bracket and the tilt system will be unable to cushion the engine if the lower unit strikes an obstruction. This could lead to occupant injury.

Do not operate the engine above 1500 r/min or operate the boat in a planing attitude with the motor tilted beyond the maximum trim position.

NOTICE

If you operate the boat with the motor trimmed beyond the maximum trim position, the water intake holes may be above the water line, causing severe engine damage due to overheating.

Never operate the boat with the motor trimmed beyond the maximum trim position.

Make a test run in the boat to determine if the trim angle needs to be adjusted. Adjust the trim angle using the Power Trim and Tilt system. If necessary, you can change the limit of downward travel that can be achieved using the Power Trim and Tilt by moving the tilt pin to another position.

While operating your boat with the motor adjusted to the proper trim angle, observe the position of the needle on the TRIM GAUGE provided as optional part. When making future trim angle adjustment, use the TRIM GAUGE as a guide.

SUSUKI (Optional part)

TRIM TAB ADJUSTMENT

This adjustment is used to compensate for the possible tendency of your boat to veer slightly to port or starboard. This tendency could be due to such things as propeller torque, motor mounting position, etc.

To adjust the trim tab:

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

Technical diagram of a car interior showing labeled components and a circular component marked A

1. If the boat tends to veer to port, move the rear end of the trim tab toward the port side. If the boat tends to veer to starboard, move the starboard side.

Two identical line drawings of a propeller with internal blades, shown side by side (no text or symbols)

1. Tighten the bolt that holds the trim tab in place.

After adjusting the trim tab, check to see if the boat still tends to veer to one side. If necessary, readjust the trim tab.

THROTTLE TENSION ADJUSTMENT

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

Diagram of a hand using a tool to adjust or install a mechanical component, with no visible text or symbols.

IDLE SPEED ADJUSTMENT

The idle speed has been factory adjusted between 600 – 700 r/min in neutral.

NOTE:

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

MOTOR COVER FASTENING ADJUSTMENT

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

1. Loosen the bolts ①, ② and ③.
2. Adjust the position of brackets ④, ⑤ and ⑥. To increase the fastening, move the brackets to the direction Ⓐ. To decrease the fastening, move the brackets to the direction Ⓑ.
3. Tighten the bolts.

Motor cover ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ A A A B B

CAUTION SYSTEM

The caution systems are designed to alert you to certain situations which may cause damage to your outboard motor.

NOTICE

Your outboard motor may become damaged if you rely on the Caution System to alert you to any malfunction that may occur or to give you an indication of the need for maintenance.

To avoid damage to your outboard motor, regularly inspect and maintain it.

NOTICE

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

If the Caution System activates while you are operating your outboard motor, stop the motor as soon as possible and correct the problem or consult your authorized Suzuki marine dealer for assistance.

INDICATOR CHECK

Each time the ignition key is turned to the "ON" position, four lamps – the REV LIMIT ①, the OIL ②, the TEMP ③ and the CHECK ENGINE ④ in the monitor-tachometer will light briefly and the buzzer will also sound for the first two seconds, regardless of the motor conditions.

For the next three seconds, the monitor-tachometer will indicate the total motor operating 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.

x1000 ohms ④ ③ ② ①

NOTICE

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

If any of the four lamps does not come on or the buzzer does not sound when the ignition key is turned to the "ON" position, the lamp or buzzer may be broken or a failure may exist in the system circuit. Consult your authorized Suzuki marine dealer.

NOTE:

For checking the total motor operating hours, refer to the CHART OF TOTAL OPERATING HOURS INDICATION on the last page.

OVER-REVOLUTION CAUTION SYSTEM

This system is activated when engine speed exceeds maximum recommended speed for more than 10 seconds.

If this system activates, engine speed will automatically be reduced to approximately 3000 r/min. with red REV LIMIT lamp lit.

1000 m/min CHECK INLINE TEMP OFF LMT

17000 ohms CHECK INJNC HAMP OFF KEY LMT

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

NOTICE

If the Over-Revolution Caution System activates at recommended maximum throttle and you are sure that the propeller pitch is sufficient and there are no factors like “over-trimming” or “ventilation”, there may be a problem with the Over-Revolution Caution System.

Consult your authorized Suzuki marine dealer if the Over-Revolution Caution System activates for no apparent reason.

OIL PRESSURE CAUTION SYSTEM

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

If this system activates, the red OIL lamp will light and a buzzer will begin a series of beep. In addition, when this system is activated at 1000 r/min. or higher, engine speed will automatically be reduced to approximately 1000 r/min. with REV LIMIT lamp lit.

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

NOTE:

In case that the engine is automatically stopped due to the CAUTION system, the engine can be started again.

However the CAUTION system will repeatedly activate until eliminating the cause.

x1000 c/min CHEK ENGINE TEMP AS KEY LMT

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

WARNING

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

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

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

NOTICE

Your engine may become severely damaged If you rely on the Oil Pressure Caution System to indicate the need to add engine oil.

Check the engine oil level periodically and add oil as necessary.

NOTICE

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

If the Oil Pressure Caution System activates, stop the engine as soon as possible and add engine oil, if necessary, or otherwise correct the problem.

OVERHEAT CAUTION SYSTEM

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

If this system activates, the red TEMP lamp will light and a buzzer will begin a series of beep. In addition, when this system is activated at 3000 r/min. or higher, engine speed will automatically be reduced to approximately 3000 r/min. with REV LIMIT lamp lit.

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

NOTE:

In case that the engine is automatically stopped due to the CAUTION system, the engine can be started again.

However the CAUTION system will repeatedly activate until eliminating the cause.

x1000 ohms + - TEMP -5Ω -5Ω -5Ω LMT

If the overheat caution system activates when operating, reduce engine speed immediately and check if water is being discharged from the pilot water hole. If no water is seen, follow the procedures outlined below.

Water and wind conditions permitting, stop the engine, tilt it out of the water and remove any debris like seaweed, plastic bags or sand that may have blocked the water intakes.

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

Check (A) that water discharges from the pilot hole and (B) that the red TEMP lamp is no longer lit.

Be aware that the red TEMP lamp may light again if engine temperature rises abnormally. If either of the above situations arises, your authorized Suzuki Marine Dealer must be consulted as soon as possible.

NOTICE

Operating the engine with the overheat caution system activated can result in severe engine damage.

If the overheat caution system activates, stop the engine as soon as possible, wind and water conditions permitting, and inspect the engine according to the above instructions. Consult your authorized Suzuki marine dealer if you cannot correct the problem.

BATTERY VOLTAGE CAUTION SYSTEM

This system is activated when the battery voltage deficiency which could impair your motor's performance occurs.

If this system activates, the red CHECK ENGINE lamp will light and buzzer will begin a series of beep.

x1000 min CHECK ENGINE TEMP OFF REV LIMIT

This system will be canceled automatically when the battery voltage restores to the proper voltage level. Refrain from using any electrical equipment such as P.T.T. system, hydraulic trim tabs, hydraulic jack plate, etc.

WARNING

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

Do not attempt to inspect or service the battery without first reading the warnings, cautions, and instructions in the "BATTERY INSTALLATION" section of this manual.

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.

DIAGNOSTIC SYSTEM

If abnormal conditions exist in any sensor signal being input to the control unit, the self-diagnostic system warns of the abnormal condition.

If this system activates, the red CHECK ENGINE lamp will flash and a buzzer will sound.

x1000 ohms +325 ELEK INJNG TURP 6V ACV LMT

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

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

The diagnostic code is designed to appear when the ignition key is turned on.

NOTICE

If the diagnostic system activates while you are operating your outboard motor, there is an abnormal condition in one of the sensor signals of the control system.

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

NOTE:

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

OIL CHANGE REMINDER SYSTEM

This system informs the operator of the time for replacing engine oil on the basis of the maintenance schedule.

The system is designed to register the total operating hours of the outboard motor and function its operation when the preprogrammed hours have reached.

(Refer to the INSPECTION AND MAINTENANCE 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.

CANCELLATION

1. Turn the ignition key to the "ON" position.
2. Pull out the emergency stop switch plate ①.
3. Pull up the emergency stop switch knob ② three times in 10 seconds. A short beep will be heard if the cancellation is successfully finished.

Technical diagram showing two-step assembly steps of a mechanical component, labeled with number ① and ②.

1. Turn the ignition key to the "OFF" position.
2. Set the plate ① in the original position.

NOTE:

• Canceling of the system activation is possible regardless of whether or not the engine oil has been replaced. Once the system has operated, however, Suzuki strongly recommends that the engine oil be replaced before canceling the system activation.
• Even if the engine oil has been replaced with the system not operating, it is still necessary to perform the cancellation.

ENGINE STALLING CAUTION SYSTEM

This system informs the operator when the motor stalls while it is operating.

When the engine stalls for any reason, the caution buzzer sounds three times.

WATER IN FUEL ALERT SYSTEM

This engine is equipped with an integral fuel filter/water separator and associated alert system.

The alert system will activate if water separated from the fuel exceeds a specific volume.

If this system activates, the red REV-LIMIT lamp will flash and a buzzer will begin a series of double beeps when the engine is in neutral only.

x1000 min CHECK ENGINE TEMP O2 LMT

If this system activates, stop the engine immediately, if wind and water conditions are safe to do so, and check the fuel filter/water separator for water. Or consult your authorized Suzuki marine dealer.

For inspection and cleaning of the fuel filter, refer to the LOW PRESSURE FUEL FILTER in the INSPECTION AND MAINTENANCE section.

The "Power Trim and Tilt" is operated by pressing the switch. To tilt the motor up, press the upper part of the switch. To tilt the motor down, press the lower part of the switch.

UP DOWN

UP DOWN

WARNING

The power trim and tilt (PTT) switch can be accidentally activated when the ignition key is off, resulting in injury.

Keep all persons away from the outboard motor to help prevent accidental activation of the PTT system.

TILT LIMITER CAM

If the outboard motor contacts the motor well of the boat while tilting, adjust the tilt limiter cam to limit maximum tilt position.

1. Place the motor in the normal running position.
2. Rotate the tilt limiter cam:

To reduce the amount of tilt, move the tab Ⓐ of cam upward.

To increase the amount of tilt, move the tab Ⓐ of cam downward.

Technical diagram showing mechanical assembly with labeled component A and directional arrows indicating motion or movement.

1. To check your adjustment, tilt the motor fully up to check for motor contact.

Adjust further if necessary.

Return the motor to the normal running position for each adjustment, and repeat your check after each adjustment.

WARNING

Adjusting the tilt limiter cam will not prevent the outboard motor from tilting fully up and contacting the motor well if the motor's lower unit hits an object at high speed. Such tilting could damage your motor and boat and injure boat occupants.

Keep all occupants away from the motor when operating at high speed.

MANUAL TILTING

If you are unable to tilt the motor using the "Power Trim and Tilt" because of an electrical problem or some other problem, you can move the motor manually. To tilt the motor up or down, turn the manual release valve Ⓐ two turns counterclockwise, move the motor to the desired position, then retighten the release screw.

A 0.05x CLOSE C

CAUTION

The motor is very heavy. When you tilt it manually, you could injure your back or slip and fall causing injury.

When you tilt the motor manually, ensure that your grip and footing are secure and that you are able to support the weight of the engine.

TILT BRACKET

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

To set the Tilt Bracket:

1. Tilt the motor all the way up by pressing the Power Trim and Tilt "UP" switch.
2. Pull down the Tilt Bracket as shown in the illustration.

Technical line drawing of a mechanical component with a tool inserted, showing no text or symbols

1. Lower the motor by pressing the Power Trim and Tilt "DOWN" switch, until the motor is supported by the Tilt Bracket.
2. Continue to operate the Power Trim and Tilt "DOWN" switch until the trim rods are completely retracted.

Mechanical assembly diagram showing a valve mechanism with two directional arrows indicating movement (no text or labels)

NOTICE

If you do not retract the trim rams completely when mooring, they may become deteriorated or corroded.

Be sure to retract the trim rams completely when mooring.

To release the Tilt Lever, tilt the motor all the way up using the Power Trim and Tilt "UP" switch, and pull up the Tilt Lever.

CAUTION

The remote Power Trim and Tilt switch will work when the ignition switch is off. If someone activates the switch while you are moving the tilt bracket, your hand could be injured.

Keep all persons away from the remote Power Trim and Tilt switch while you are moving the tilt bracket.

NOTICE

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

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

INSPECTION BEFORE BOATING

WARNING

Failure to inspect your boat and motor before beginning a trip can be hazardous.

Before boating, always perform the inspections described in this section.

It is important to make sure that your boat and motor are in good condition and that you are properly prepared for an emergency.

Always perform the following checks before you begin boating:

• Make sure that you have enough fuel for the intended run.
- Check the level of engine oil in the sump.

NOTICE

Running the engine with an insufficient amount of oil can cause serious engine damage.

Always check the oil level before each trip and add oil if necessary.

To check the oil level:

NOTE:

To avoid an incorrect assessment of engine oil level, check the level only when the engine has cooled.

1. Place the motor in a vertical position, then remove the motor cover ① by unlocking the lever ② and ③.

Diagram showing three-step car wheel assembly with labeled parts and directional arrows indicating motion or movement.

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

Technical line drawing of a mechanical assembly with a highlighted component (no text or symbols)

NOTE:

If the engine oil is contaminated or discolored, replace with fresh engine oil (Refer to the INSPECTION AND MAINTENANCE/ENGINE OIL section).

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

UPPER LIMIT LOWER LIMIT

The oil on the dipstick should be between the upper and lower limits shown on the dipstick. If the oil level indication is near the lower limit, add enough oil to raise the level to the upper limit.

To fill the engine oil:

1. Remove the oil filler cap.

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

Diagram of a car engine intake manifold with a valve inserted, showing fluid flow direction (no text or labels)

NOTICE

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

Do not overfill the engine with oil.

1. Tighten the oil filler cap securely.

2. Check the battery solution level.
   The level should be kept between the MAX and the MIN level lines at all times. If the level drops below the MIN level line, refer to the INSPECTION AND MAINTENANCE section.
   • Make sure that the battery leads are securely connected to the battery terminals.

3. Visually check the propeller to make sure it is not damaged.
   • Make sure that the motor is securely mounted to the transom.
4. Check for proper operation of the Power Trim and Tilt.
5. Make sure that the tilt pin is securely installed in the proper position.
   • Make sure you have the boating safety and emergency equipment on board.
   • Make sure that the emergency stop switch operates properly.
6. Make sure the obstacle is not attached to water intake hole.

BREAK-IN

Proper operation during this break-in period will help ensure maximum life and performance from your engine. The following guidelines will explain proper break-in procedures.

NOTICE

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

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

Break-in period: 10 hours

Break-in procedure

1. For the initial 2 hours:

Allow sufficient idling time (about 5 minutes) for the engine to warm up after cold engine starting.

NOTICE

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

Always allow sufficient idling time (5 minutes) for the engine to warm-up before running at high speed.

After warming up, run the engine at idling speed or the lowest in-gear speed for about 15 minutes.

During the remaining 1 hour and 45 minutes, if safe boating conditions permit, operate the engine in gear at less than 1/2 (half) throttle (3000 r/min.).

NOTE:

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

1. For the next 1 hour:

Safe boating conditions permitting, operate the engine in gear at 4000 r/min. or at three-quarter throttle. Avoid running the engine at full throttle.

1. Remaining 7 hours:

Safe boating conditions permitting, operate the engine in gear at desired engine speed. You may occasionally use full throttle; however do not operate the engine continuously at full throttle for more than 5 minutes at any time.

NOTICE

Running continuously at full throttle for more than 5 minutes at a time during the last 7 hours of break-in operation may cause severe engine damage such as seizure.

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

OPERATION

BEFORE ATTEMPTING TO START THE ENGINE

1. The motor has been lowered into the water.
2. Make sure that the motor fuel hose and the hose from the boat's fuel tank are securely attached and clamped.

Diagram of a cable being inserted into a car's hose, showing rope routing and a directional arrow (no text or symbols)

1. Ensure that the boat fuel tank is correctly vented and that any in-line filters are free of dirt etc. If fuel tank filler cap has a manual vent, be sure that it is fully open.

Line drawing of a mechanical component with a central knob and a black arrow indicating direction (no text or symbols)

1. Make sure that the motor is in "NEUTRAL".

Technical diagram of a mechanical device with directional arrows indicating motion or force (no text or symbols)

1. Make sure the lock plate is in place and attach the emergency stop switch cord to a part of your body.

Technical line drawing of a mechanical device with a bolt and threaded connector (no text or symbols)

Line drawing of a worker in uniform holding a chain with a coiled spring (no text or symbols)

WARNING

Failure to properly attach the emergency stop switch cord or to take proper precautions to help ensure that the emergency stop switch works as intended may result in serious injury or death to the operator or passengers.

Always take the following precautions:

• Make sure that the emergency stop switch cord is fastened securely to the operator's wrist or to an appropriate clothing area (belt etc.).
• Ensure that no obstructions impede or restrict emergency stop switch operation.
• Be careful not to pull the stop switch cord or knock out the lock plate during normal operation. The motor will stop abruptly, and the loss of forward motion may unexpectedly throw occupants forward.

NOTE:

A spare plastic lock plate is provided for temporary use only. Remove it from the cord and place it in a safe place on board your boat. If you lose or break the emergency stop switch cord/lock plate assembly, replace it as soon as possible so that you can resume normal use of the emergency stop switch.

STARTING THE ENGINE

WARNING

Exhaust gas contains carbon monoxide, a dangerous gas that is difficult to detect because it is colorless and odorless. Breathing carbon monoxide can cause death or severe injury.

Never start the engine or let it run indoors or where there is little or no ventilation.

NOTE:

If the emergency stop switch lock plate is not in position, the starter motor cannot operate.

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

Illustration of a hand holding a cable with a textured grip (no text or symbols)

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

Technical line drawing of a mechanical device with a curved arrow indicating motion or change (no text or symbols)

1. Turn the ignition key to the "ON" position.
2. Turn the ignition key to the "START" position.

graph TD
    A["OFF"] --> B["ON"]
    B --> C["START"]

NOTICE

If you turn the ignition key to the "START" position for more than 5 seconds, the starter system could be damaged.

Never turn the ignition key to the "START" position for more than 5 seconds.

NOTE:

The continuous operating time of the starter motor is set at five seconds.

When this time is exceeded, the starter motor will automatically stop.

If the motor stops, wait about ten seconds for the motor to cool down and try again.

NOTICE

If the OIL lamp remains lit while operating the outboard, the oil level may be low enough to damage the engine.

Stop the engine and check the oil level.

1. Warm up the engine for about 5 minutes.

NOTICE

Operating the engine at high RPM or “wide open throttle” immediately after starting the engine without allowing the engine to warm up may cause engine failure.

Always allow the engine to warm up sufficiently before operating it at high speeds.

Cooling water check

As soon as the engine starts, water should spray out of the pilot water hole ①, indicating that the water pump and cooling system are working properly. If you notice that water does not spray out of the pilot water hole, stop the engine as soon as possible and consult your Suzuki Marine Dealer.

Technical diagram showing a car's side panel with labeled component 1 and directional arrows indicating movement or assembly.

NOTICE

Never operate your outboard motor when there is no water coming out of the pilot water hole, or severe damage can result.

After starting the engine, check to make sure that there is water coming out of the pilot water hole.

WARNING

Operating the boat when the emergency stop switch is not operating properly can be hazardous.

Before starting off, check to make sure that the emergency stop switch operates properly.

SHIFTING AND SPEED CONTROL

NOTICE

Severe engine damage may occur if (a) engine speed is not allowed to return to idle and boat speed is not reduced when shifting from "FORWARD" to "REVERSE" or from "REVERSE" to "FORWARD", or (b) care is not taken when operating the boat in reverse.

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

NOTICE

If you shift gears when the engine is not running, the shifting mechanism can be damaged.

Avoid shifting gears when the engine is not running.

Shifting

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

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

A NEUTRAL 32° 32° B FORWARD REVERSE

Speed Control

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

WARNING

Since the same handle is used for shifting and speed control it is possible to move the handle past the detent and engage the throttle. This can cause the boat to move suddenly resulting in personal injury or property damage.

You must be careful not to move the control handle too far forward or rearward when shifting.

STOPPING THE ENGINE

NOTE:

When it is necessary to stop the engine in an emergency, pull the emergency stop switch lock plate out of the emergency stop switch by pulling the emergency stop switch cord.

To stop the engine:

1. Shift into "NEUTRAL".
2. After operating at full throttle, cool off the engine a few minutes by allowing it to idle or troll at low speed.

Technical diagram of a mechanical device with directional arrows indicating motion or force (no text or symbols)

1. 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.

OFF ON START

NOTICE

If the ignition key is left ON when the engine is not running, the battery will discharge.

Always turn the ignition key OFF when the engine is not running.

WARNING

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

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

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

WARNING

If you leave the motor stopped for a long period of time with the fuel line connected, fuel can leak out.

Disconnect the fuel line from fuel tank, if there is a fuel connector, whenever you leave the motor stopped for a long period of time.

1. Twist the air-vent screw on the fuel tank cap clockwise to shut the vent (if equipped).

NOTE:

To make sure that the emergency stop switch operates properly, stop the engine occasionally by pulling out the lock plate, while operating the engine at idling speed.

MOORING

The motor should be tilted up out of the water when you moor the boat in shallow water or if the motor will not be used for some time, to protect it from damage by underwater obstacles at low tide or corrosion from salt water.

Refer to the TILT BRACKET section for details on how to tilt up the motor.

NOTICE

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

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

OPERATION IN SHALLOW WATER

When operating your boat in shallow water, it may be necessary to tilt the motor higher than the normal trim angle. When you tilt the motor beyond the normal trim angle, however, you should only operate the boat at slow speeds. After returning to deep water, be sure to lower the motor to the normal trim angle.

WARNING

When the motor is beyond the maximum trim position, the swivel bracket will not have side support from the clamp bracket and the tilt system will be unable to cushion the engine if the lower unit strikes an obstruction. This could lead to occupant injury. In addition, beyond the maximum trim position, the water intake holes may be above the water line, which can result in severe engine damage from overheating.

Do not operate the engine above 1500 r/min or operate the boat in a planning attitude with the engine beyond the maximum trim position.

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.

OPERATION IN SALT WATER

After operating the motor in salt water, you should flush the water passages with clean, fresh water as outlined in the FLUSHING THE WATER PASSAGES section. If you do not flush the water passages, salt can corrode the motor and shorten its life.

When operating your outboard motor in freezing temperatures, you should keep the lower unit submerged in the water at all times.

When taking motor out of the water, stand it up in a vertical position until the cooling system drains completely.

NOTICE

If you leave your outboard motor out of the water in freezing temperatures with water still in the cooling system, the water can freeze and expand, causing severe damage to the motor.

When your outboard is in the water in freezing temperatures, keep the lower unit submerged in the water at all times. When the motor is stored out of the water in freezing temperatures stand it up in the vertical position so that the cooling system drains completely.

MOTOR REMOVAL AND TRANSPORTING

MOTOR REMOVAL

If it is necessary to remove the outboard motor from your boat, we recommend that you ask your authorized Suzuki Marine Dealer to do the work for you.

MOTOR TRANSPORTING

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

Vertical transport:

Attach the motor to the carrier by securing clamp bracket with two sets of transom bolt and nut.

Never use display stand for transportation of the motor.

Technical line drawing of a boat or motor with wheels and guide rails (no text or symbols)

Horizontal transport:

1. Drain the engine oil. Refer to the ENGINE OIL section.
2. Drain the gasoline from the vapor separator ① as follows:

(1)Remove the motor cover.
(2) Pull the drain hose end ② out.

Technical line drawing of a mechanical assembly with no visible text or symbols

(3)Loosen the vapor separator drain screw ③ and drain the gasoline into a suitable container.

Technical diagram showing mechanical assembly steps with numbered annotations

WARNING

Gasoline is extremely flammable and toxic. It can cause a fire and can be hazardous to people and pets.

Use a proper, safe container to store any gasoline drained from the outboard motor. Keep gasoline away from sparks, flames, people, and pets.

(4)After draining, retighten the vapor separator drain screw ③, and then put the drain hose back.
3. Rest the motor on a case protector with the port side downwards as shown.

Technical line drawing of a propeller or turbine assembly with internal components (no text or symbols)

WARNING

Spilled fuel or fuel vapor can cause a fire and is hazardous to health.

Always take the following precautions:

• Drain the fuel from the fuel line and fuel vapor separator before transporting the boat/outboard motor and before removing the motor from the boat.
• DO NOT lay motor on its side without draining fuel.
• Keep the motor away from open flames or sparks.
• Wipe up spilled fuel immediately.

NOTICE

If spilled gasoline is just left on painted surface, it may cause a stain or discoloration of the surface coating.

Wipe off any spilled gasoline immediately with a soft cloth etc.

NOTICE

If you are not careful when resting the outboard on its side and do not take proper precautions such as first draining the engine oil and cooling water completely, damage can occur. Engine oil may enter the cylinder from the sump, water may enter the cylinder through the exhaust port, or the outer casings may be damaged.

Always drain the engine oil and cooling water completely before laying the motor on its side, and be careful laying the motor down.

NOTICE

If you let the lower unit of your outboard sit higher than the power head during transporting or storing, water may trickle into the power head, causing damage to the engine.

Never let the lower unit sit higher than the power head when transporting or storing your outboard.

TRAILERING

When trailering your boat with the motor attached, keep the motor in the normal operating position unless there is not enough ground clearance. If you need more ground clearance, trailer the motor in a tilted position using a trans-som saver bar or similar device to support the weight of the motor.

Technical line drawing of a mechanical component with motion lines and an arrow indicating direction (no text or symbols)

NOTICE

If you use the tilt bracket to hold the motor in the fully tilted up position when trailering the boat, towing motion or poor road surfaces may cause unexpected tilt lock release, resulting in damage to the motor and the tilt lock mechanism.

Never use the tilt bracket to hold the motor in the fully tilted up position when trailering the boat. Use a transom saver bar or similar device to support the weight of the motor.

INSPECTION AND MAINTENANCE

MAINTENANCE SCHEDULE

It is important to inspect and maintain your outboard motor regularly. Follow the chart below. At each interval, be sure to perform the indicated service. Maintenance intervals should be judged by number of hours or number of months, whichever comes first.

WARNING

Exhaust gas contains carbon monoxide, a dangerous gas that is difficult to detect because it is colorless and odorless. Breathing carbon monoxide can cause death or severe injury.

Never start the engine or let it run indoors or where there is little or no ventilation.

Item to be serviced\Interval	Initial 20 hrs. or 1 month	Every 100 hrs. or every 12 months	Every 200 hrs. or every 12 months	Every 300 hrs. or every 36 months
Spark plug I
Breather & Fuel line II
Engine oil R R
Gear oil R R
Lubrication II
Anodes (external) II
* Anodes (internal cylinder block/cylinder head)		I
Bonding wire II
Battery II
* Engine oil filter R R
Low pressure fuel filter	I	I
	Replace every 400 hours or every 2 years.
* Low pressure fuel pump filter	Replace every 1000 hours.
* High pressure fuel filter	Replace every 1000 hours.
* Idle speed I		I
* Valve clearance (lash)				I
* Water pump			I
* Water pump impeller			I	R
* Propeller nut & pin	II
* Bolts & Nuts	T	T
* Thermostat		I

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

NOTE:

Water-separating fuel filter

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

WARNING

Improper maintenance or failure to perform recommended maintenance can be hazardous. Poor maintenance or lack of maintenance increases the chance of an accident or equipment damage.

Be sure to have maintenance performed according to the schedule in the above chart. Suzuki recommends that only your authorized Suzuki marine dealer or a qualified service mechanic perform maintenance on those items in the chart above which are marked with an asterisk (*). You may perform maintenance on the unmarked items by referring to the instructions in this section if you have mechanical experience. If you are not sure whether you can successfully complete any of the unmarked maintenance jobs, ask your authorized Suzuki marine dealer to do the maintenance for you.

WARNING

The safety of you and your passengers depends on how well you maintain your outboard motor.

Follow all inspection and maintenance instructions carefully. If you do not have prior mechanical experience, do not attempt to perform maintenance on your outboard motor. You could be injured or may damage the motor.

NOTICE

The maintenance intervals in the chart are designed for normal usage of your outboard motor. If your outboard motor is used under severe conditions as outlined below, you may need to perform maintenance more often than indicated in the chart.

• Frequent full throttle operation
• Prolonged continuous operation at the maximum speed
• Prolonged continuous operation at idling speed or trolling speed

• Frequent operation in muddy, silty, sandy, acidic or shallow water
  • Operation without appropriate warmup

• Frequent abrupt acceleration and deceleration

• Frequent shift operation
  Failure to perform maintenance more frequently could result in damage.

Consult your authorized Suzuki marine dealer regarding appropriate maintenance intervals for your usage conditions. When replacing parts on your outboard motor, Suzuki strongly recommends that you use genuine Suzuki parts or their equivalent.

TOOL KIT

A tool kit is provided with your outboard motor. Keep the kit on board your boat and make sure that all of the items provided remain in the kit.

The tool kit contains the following items:

① Tool bag
② 8 mm Box wrench
③ 8 × 10 mm Box wrench
④ 16 mm Box wrench
⑤ Combination screw driver
⑥ Screwdriver handle
⑦ Pliers
⑧ Hexagon wrench 8 mm
⑨ Engine oil drain plug gasket (spare)

① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨

SPARK PLUG

Remove the spark plugs as follows:

1. Remove the bolt securing the ignition coil.
2. Pull out the ignition coil.
3. Loosen and remove the spark plug using the box wrench in the tool bag.

Mechanical assembly diagrams showing two views of a vehicle's suspension system with no visible text or symbols

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

NGK BKR6E Standard

NOTICE

Non-resistor types of spark plugs will interfere with the function of the electronic ignition, causing misfiring, or causing problems with other electronic boat equipment and accessories.

Use ONLY resistor type spark plugs in your outboard motor.

A normally operating spark plug is very light-brown in color. If the standard plug is not suitable for your operating, consult your authorized Suzuki Marine Dealer.

Technical line drawing of a spark plug (no text or symbols)

Technical illustration of a mechanical component with threaded top and hexagonal base (no text or symbols)

NOTICE

Use of improper spark plugs or improperly tightening spark plugs can cause severe engine damage.

• Do not experiment with other spark plug brands unless you can determine that they are directly equivalent to the specified brand, or you may experience engine damage which will not be covered under warranty. Note that aftermarket cross-reference charts may not be accurate.
• To install a spark plug; seat it as far as possible by hand, then use a wrench to tighten it to either the recommended torque setting or the specified rotation angle.

Tightening torque
25 – 29 N·m(2.5 – 2.9 kg·m, 18.0 – 21.0 lb·ft)
Rotation angle
New plug 1/2 –	3/4 of a turn
Re-use plug 1/1	12 – 1/8 of a turn

- Do not overtighten or cross-thread a spark plug, as this will damage the aluminum threads of the cylinder head.

To maintain a strong spark, you should clean and adjust the plugs at the intervals shown in the maintenance chart. Remove carbon deposits from the spark plugs using a small wire brush or spark plug cleaner, and adjust the gap according to the following chart:

Spark plug gap

0.7 – 0.8 mm(0.028 – 0.031 in.)

Technical illustration showing a hand using a tool to adjust a mechanical component, with no visible text or symbols.

1. Excessive wear
2. Breakage
3. Melting
4. Erosion
5. Yellow deposits
6. Oxidation

NOTE:

If the spark plug condition is found as shown in the illustration above, ensure it is replaced with new one. Otherwise, it will cause difficulty in starting the engine, increase fuel consumption, and result in engine troubles.

BREATHER AND FUEL LINE

Inspect the breather and fuel line for leaks, cracks, swelling, or other damage. If the breather and fuel line is damaged in any way, it must be replaced. Consult your authorized Suzuki Marine Dealer if it is necessary to replace them.

Breather line

Breather line

Fuel line

WARNING

Fuel leakage can contribute to an explosion or fire, resulting in serious personal injury.

Have your authorized Suzuki Marine Dealer replace the fuel line if there is any evidence of leaking, cracking or swelling.

ENGINE OIL

WARNING

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

The motor must be shut off before any ENGINE OIL procedures are performed.

NOTICE

Extended trolling can reduce oil life. Your engine may be damaged if you do not change engine oil more frequently under this type of use.

Change your engine oil more frequently if your engine is used for extended trolling.

Engine oil change

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

To change the engine oil:

1. Place the motor in a vertical position and remove the motor cover.
2. Remove the oil filler cap.

Technical line drawing of a vehicle engine compartment with a directional arrow indicating motion (no text or symbols)

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

CAUTION

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

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

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

Diagram showing car seatbelt mechanism with labeled parts and directional arrow indicating movement

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

NOTICE

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

Do not re-use gaskets. Be sure to always use new gaskets.

NOTE:

There are spare gaskets in the tool bag.

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

Oil capacity: 8.0 L

1. Check the engine oil level.

UPPER LIMIT LOWER LIMIT

NOTE:

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

1. Reinstall the oil filler cap.

WARNING

Engine oil can cause injury to people or pets. Repeated, prolonged contact with used engine oil may cause skin cancer. Even brief contact with used oil may irritate skin.

• Keep new and used oil away from children and pets.
• Wear a long-sleeve shirt and waterproof gloves when handling oil.
• Wash with soap if oil contacts your skin.
• Launder any clothing or rags that are wet with oil.

NOTE:

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

GEAR OIL

To check the gear oil level, remove the gear oil level plug ① and look into the hole. The oil level should be at the bottom edge of the hole. If the oil level is low, add the specified gear oil until the level reaches the bottom edge of the hole. Then, reinstall and tighten the plug.

Technical diagram of a submarine with labeled parts and numbered annotation

To change the gear oil:

1. Make sure the motor is in an upright position. Place a drain pan under the lower casing.
2. Remove the gear oil drain plug ②, then remove the air vent hole plug ③.

Technical diagram of a mechanical component with numbered parts labeled ② and ③

1. After the oil has drained completely, inject the specified gear oil into the gear oil drain hole ② until it just starts to come out of the air vent hole ③. Approximately 1.1 L (1.2/1.0 US/lmp. qt.) of oil will be required.

NOTE:

The oil level plug and the air vent hole plug are different from the oil drain plug.

The magnet is installed in the drain plug.

Clean the magnet if there is a metal powder on it.

Do not make a mistake in their positions when install them.

1. Reinstall and tighten the air vent hole plug ③, then quickly reinstall and tighten the gear oil drain plug ②.

NOTE:

To avoid insufficient injection of gear oil, check the gear oil level 10 minutes after doing the procedure in the step 4. If the oil level is low, slowly inject the gear oil into the gear oil level hole ① up to the correct level.

WARNING

Gear oil can cause injury to people or pets. Repeated, prolonged contact with used gear oil may cause skin cancer. Even brief contact with used oil may irritate skin.

• Keep new and used oil away from children and pets.
• Wear a long-sleeve shirt and waterproof gloves when handling oil.
• Wash with soap if oil contacts your skin.
• Launder any clothing or rags that are wet with oil.

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 contaminated with water. Immediately contact your authorized Suzuki marine dealer for advice. Do not operate your outboard until the oil is changed and the cause of the contamination is corrected.

LOW PRESSURE FUEL FILTER

The low pressure fuel filter must be replaced by an authorized Suzuki Marine Dealer periodically.

Replace low pressure fuel filter at every 400 hours (2 years).

WARNING

Gasoline is extremely flammable and toxic. It can cause a fire and can be hazardous to people and pets.

Always take the following precautions when servicing the fuel filter:

• Stop the motor before cleaning the fuel filter.
• Be careful not to spill fuel. If you do, wipe it up immediately.
• Do not smoke, and keep away from open flames and sparks.

WARNING

Cleaning solvent is toxic and an irritant, and can cause injury to people and pets.

Keep solvent away from children and pets. Dispose of solvent properly when you are finished.

Inspect and clean the fuel filter as follows:

1. Turn the engine off and allow it to cool.
2. Make sure that the ignition key is in the OFF position.
3. Remove the bolts ① securing the fuel filter cap ② in place.

Technical diagram of a mechanical assembly with numbered components, likely for maintenance or assembly instructions.

NOTICE

Improperly loosening the filter cup can cause sensor lead wire damage.

• Be careful not to twist the sensor lead wire when removing the filter cup.

• Disconnect the lead wire connector before removing the filter cup.

• Push the connector lock tab "a", then disconnect the water sensor lead wire connector ③.

"a" ③

1. Place a rag under the filter before removal to catch any spilled fuel.
2. Separate the filter cup ④ from the cap ② by turning the filter cup counterclockwise.

Line drawing of a hand holding a tool, with no visible text or symbols

1. Drain the fuel and water in the filter cup into a suitable container.

NOTICE

If spilled gasoline is just left on painted surface, it may cause a stain or discoloration of the surface coating.

Wipe off any spilled gasoline immediately with a soft cloth etc.

1. Pull out the filter element ⑤. Inspect the filter element ⑤, O-ring ⑥ and seal ring ⑦ for damage. If they are damaged, replace them.

Technical diagram showing labeled components of a mechanical or electrical component with numbered parts 4, 5, 6, and 7.

1. Wash the filter element with clean solvent and dry it.
2. Reinstall the seal ring and filter element in their original positions.
3. Verify that the O-ring is in place in the top of the filter cup and screw the filter cup back into place.
4. Connect the water sensor lead wire connector ③.
5. Reinstall the fuel filter with the attaching bolts.
6. Restart the engine and check that there are no leaks around the fuel filter.

NOTE:

If any water exists in the fuel filter cup, remove the cup and drain the water. Always dispose of excess fuel safely. For questions, consult your authorized Suzuki Marine Dealer.

LUBRICATION

Proper lubrication is important for the safe, smooth operation and long life of each working part of your outboard motor. The following chart shows the lubrication points of your motor and the recommended lubricant:

LOCATION LUBRICANT
Throttle/Shift linkage	Marine-grade water resistant grease
Propeller shaft
Trim ram pad

Mechanical assembly diagram showing a vehicle chassis with springs and levers (no text or labels)

Technical line drawing of a mechanical component with no visible text or symbols

Mechanical component diagram showing a lever mechanism with a black arrow indicating direction (no text or symbols present)

Illustration of a hand holding a pliers with motion lines indicating force or movement (no text or symbols)

Technical diagram showing a mechanical component with labeled section A and directional arrow indicating motion or force.

NOTE:

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

Use a hand operated grease gun and follow the steps below when servicing the grease nipple Ⓐ on the mount oil seal cover.

1. Turn the engine off and allow it to cool.
2. Inject approximately 10 grams of grease at initial 20 hours.

Inject approximately 5 grams of grease at every 100 hours (12 months).

Upper mount seal A

NOTICE

Using a hydraulic or air powered grease gun to service the grease nipple Ⓐ on the mount oil seal cover may cause damage to the oil seal.

Do not use powered grease guns when servicing grease nipple Ⓐ on the mount oil seal cover.

NOTE:

If grease will not inject into the fitting, consult your Authorized Suzuki Marine Dealer.

ANODES AND BONDING WIRES Anodes

The motor is protected from exterior corrosion by anodes. These pieces of anodes control electrolysis and prevent corrosion. The anodes will corrode in place of the parts they are protecting. You should periodically inspect each of the anodes and replace them when 2/3 of the metal has corroded away.

Technical line drawing of a car interior showing seat, dashboard, and control panel (no text or symbols)

Technical line drawing of a mechanical assembly with no visible text or symbols

NOTICE

If anodes are not properly maintained, underwater aluminum surfaces (such as the lower unit) will suffer galvanic corrosion damage.

• Periodically inspect anodes to make sure they have not become detached.
- Do not paint anodes, as this will render them ineffective.
- Periodically clean anodes with a wire brush to remove any coating which might decrease their protective ability.

NOTE:

Consult your authorized Suzuki Marine Dealer for inspection and replacement of internal anodes attached to the cylinder block/cylinder head.

Bonding wires

Bonding wires are used to electrically connect the engine components so they exist in a common ground circuit. This allows them to be protected against electrolysis by the anodes. These wires and their terminals should be checked periodically to be sure they have not been damaged.

Technical line drawing of a mechanical assembly with no visible text or symbols

Mechanical assembly diagram showing linkage components and motion arrows (no text or labels)

BATTERY

The battery solution level must be kept between the MAX and the MIN level lines at all times. If the level drops below the MIN level line, add DISTILLED WATER ONLY until the battery solution level reaches the MAX level line.

WARNING

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

Avoid contact with eyes, skin, clothing, and painted surfaces. If battery acid comes in contact with any of these, flush immediately with large amounts of water. If acid contacts the eyes or skin, get immediate medical attention.

WARNING

If you are not careful when checking or servicing the battery, you can cause a short circuit, which could result in an explosion, fire, or circuit damage.

Disconnect the negative (black) cable when checking or servicing the battery. Be careful not to allow a metal tool or other metal object to touch the battery's positive terminal and the motor at the same time.

WARNING

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

Wash hands after handling.

NOTICE

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

NEVER add diluted sulphuric acid to the battery after it has been initially serviced. Follow the battery manufacturer's instructions for specific maintenance procedures.

ENGINE OIL FILTER

The engine oil filter must be changed by authorized Suzuki Marine Dealer periodically. Replace engine oil filter with a new one at initial 20 hours (1 month).

Replace engine oil filter with a new one at every 200 hours (12 months).

FLUSHING THE WATER PASSAGES

After operation in muddy, brackish, or salt water, you should flush the water passages and motor surface with clean, fresh water.

If you do not flush the water passages, salt can corrode the motor and shorten its life. Flush the water passages as follows.

ENGINE RUNNING – Vertical position –

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

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

WARNING

Exhaust gas contains carbon monoxide, a dangerous gas that is difficult to detect because it is colorless and odorless. Breathing carbon monoxide can cause death or severe injury.

Never start the engine or let it run indoors or where there is little or no ventilation.

WARNING

Failure to take proper precautions when flushing the water passages can be hazardous.

When flushing the water passages, always take the following precautions:

• Make sure that the engine remains in NEU-TRAL. If shifted into gear, the propeller shaft will turn and could cause severe personal injury.
• Make sure the motor is properly clamped to a secure stand or boat, and remain in attendance until flushing is completed.
• Keep children and pets away from the area, and stay clear of all moving parts.

NOTICE

Severe engine damage can occur in as little as 15 seconds if the engine is started without supplying water to the cooling system.

Never start the motor without supplying water to the cooling system.

1. Make sure that the motor is stopped.
2. Install the flushing attachment ① so that the water intake holes are covered by the rubber cups on the attachment.
3. Connect a garden hose to the flushing attachment and turn on the water to obtain enough flow so that plenty of excess water is flowing out from around the rubber cups on the attachment.

Technical line drawing of a mechanical assembly with no visible text or symbols

1. Place the remote control handle in the "NEUTRAL" position with the propeller removed, start the motor and allow it to run at idle.
2. Readjust the water flow, if necessary, so that there is still plenty of excess water flowing out from around the rubber cups.
3. Allow the water to continue circulating for a few minutes.
4. Stop the motor, then turn off the water.
5. Remove the flushing attachment from the water intake hole.
6. Clean the motor surface and apply a coat of automotive wax on the external finish of the motor.

ENGINE NOT RUNNING

- Vertical position -

1. Make sure that the motor is stopped.
2. Remove one of the plug Ⓐ or Ⓒ from the two flushing port.

Diagram of a medical procedure with labeled point A and measurement lines

Technical diagram showing a car's side panel with a circular button labeled 'C' and a switch symbol.

1. Install garden hose by using a hose connector matched to flushing port thread Ⓑ.

Thread Ⓑ: 0.75 – 11.5 NHR (American standard hose coupling threads for garden hose applications.)

NOTE:

The hose connector (flushing attachment) matched to the flushing point thread Ⓑ is included in the crate parts.

Technical diagram showing a hand holding a screwdriver with labeled component B, likely illustrating a mechanical or electrical process.

1. Turn on the water to obtain a good water flow. Flush the engine for about five minutes.
2. Turn off the water.
3. Remove the hose and connector (if used) then reinstall the plug into the flushing port.
4. Leave the motor in a vertical position until the engine is drained completely.

ENGINE NOT RUNNING

- Full tilt up position -

1. Raise the engine to the full tilt up position.
2. Follow the "ENGINE NOT RUNNING – Vertical position" instructions.

DO NOT RUN ENGINE IN THE FULL TILT UP POSITION.

1. Lower the motor to a vertical position until the engine is drained completely.

SUBMERGED MOTOR

A motor that has been accidentally submerged in water must be overhauled as soon as possible to prevent corrosion. In the event that your motor is accidentally submerged, take the following steps:

1. Get the motor out of the water as soon as possible.
2. Wash it thoroughly with fresh water to completely remove all salt, mud, and seaweed.
3. Remove the spark plugs. Drain the water from the cylinders through the spark plug holes by manually turning the flywheel several times.
4. Check if any water is evident in the engine oil. If water is seen, remove the oil drain plug and drain the oil. After draining, tighten the oil drain plug.
5. Drain the fuel line.

WARNING

Gasoline is extremely flammable and toxic. It can cause a fire and can be hazardous to people and pets.

Keep flames and sparks away from gasoline. Dispose of unwanted fuel properly.

1. Pour engine oil into the engine through the spark plug holes. Coat the engine inner parts with oil by manually turning the fly-wheel several times.

NOTICE

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

If you encounter friction or resistance while cranking the engine, stop at once and do not attempt to start the engine until you find and correct the problem.

1. Take the motor to your authorized Suzuki Marine Dealer as soon as possible to be overhauled.

NOTICE

If the fuel supply is contaminated with water, engine damage may occur.

If the boat's fuel tank filler and vent were submerged, inspect the fuel supply to make sure it is not contaminated with water.

STORAGE PROCEDURE

MOTOR STORAGE

When storing your motor for a long period of time (for example, at the end of the boating season), it is recommended that you take your motor to your authorized Suzuki Marine Dealer. However, if you choose to prepare the motor for storage yourself, follow the procedure outlined below:

1. Change the gear oil as outlined in the GEAR OIL section.
2. Change the engine oil as outlined in the ENGINE OIL section.
3. Fill a fuel stabilizer to the fuel tank according to the instructions on the stabilizer can.
4. Flush the water passages in the motor thoroughly. Refer to the FLUSHING THE WATER PASSAGES (Engine running) section.
5. Readjust the water flow, run the engine at about 1500 r/min in neutral for five minutes to distribute the stabilized fuel through the engine.
6. Stop the engine. Then turn off the water and disconnect the flushing attachment.
7. Lubricate all other specified parts. Refer to the LUBRICATION section.
8. Apply a coat of automotive wax on the external finish of the motor. If paint damage is evident, apply touch up paint before waxing.
9. Store the motor in an upright position in a dry, well-ventilated area.

WARNING

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

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

NOTICE

Severe engine damage can occur in as little as 15 seconds if the engine is started without supplying water to the cooling system.

Never start the motor without supplying water to the cooling system.

BATTERY STORAGE

1. When the outboard motor will not be used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reusing it.
2. If the battery will be stored for a long period of time, check the specific gravity of the battery solution at least once a month and recharge the battery when low.

WARNING

Failure to take proper precautions when charging the battery can be hazardous. Batteries produce explosive vapors that can ignite. Battery acid is poisonous and corrosive, and can cause severe injury.

• Do not smoke and keep battery away from open flames and sparks.
• To avoid creating a spark when charging the battery, connect the battery charger cables to the proper terminals before turning the charger on.
• Handle the battery with extreme care and avoid skin contact with battery acid.
• Wear proper protective clothing (Safety glasses, gloves, etc.)

AFTER STORAGE

When taking your motor out of storage, follow the procedure below to return it to operating condition:

1. Thoroughly clean the spark plugs. Replace them if necessary.
2. Check the gear-case oil level and if necessary, add gear oil according to the procedure outlined in the GEAR OIL section.
3. Lubricate all moving parts according to the LUBRICATION section.
4. Check the engine oil level.
5. Clean the motor and wax the painted surfaces.
6. Recharge the battery before installing it.

TROUBLESHOOTING

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

NOTICE

Failure to troubleshoot a problem correctly can damage your outboard motor. Improper repairs or adjustments may damage the outboard motor instead or fixing it. Such damage may not be covered under warranty.

If you are not sure about the proper action to correct a problem, consult your Suzuki marine dealer.

Starter motor will not operate:

• Shift lever is not in NEUTRAL.
• Fuse is blown out.
• Emergency stop switch lock plate is not in position.

Engine will not start (hard to start):

• Fuel tank is empty.
• Fuel hose is not properly connected to engine.
• Fuel hose is kinked or pinched.
• Spark plug is fouled.

Engine idles unstably or stalls:

• Fuel hose is kinked or pinched.
• Spark plug is fouled.

Engine speed will not increase (Engine power is low):

• Engine is overloaded.
- Caution/Diagnosis system is activated.
- Propeller is damaged.
- Propeller is not properly matched to loads.

Engine vibrates excessively:

• Engine mounting bolts or clamp screws are loose.
• Foreign object (seaweed etc.) is tangled on propeller.
• Propeller is damaged.

Engine overheats:

• Cooling water intake(s) are blocked.
  • Engine is overloaded.
• Propeller is not properly matched to loads.

FUSE

1. Turn the ignition key to the "off" position.
2. Remove the motor cover and electric parts holder cover.

Electric parts holder cover

1. Remove the fuse cover and pull off the fuse.

Main fuse Spare fuse Sub fuse/ Fuse case

1. Remove the sub battery cable fuse.

Sub battery cable fuse case Spare fuse 15 15 Sub battery cable fuse

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

Main fuse (60A) Normal fuse Blown fuse

Sub fuse (30A) Normal fuse Blown fuse

NOTE:

If a fuse is blown, try to determine the root cause and correct it.

If the cause is not corrected, the fuse may be blown again.

WARNING

If you replace a blown fuse with a fuse having a different amperage rating or with a substitute such as aluminum foil or a wire, extensive electrical system damage and a fire may result.

Always replace a blown fuse with a fuse of the same type and rating.

NOTICE

If a new fuse blows in a short time after installation, you may have a major electrical system problem.

Consult your SUZUKI marine dealer.

SPECIFICATIONS

Item DF200 DF225 DF250
Engine Type 4 Stroke
Number of Cylinders 6
Bore and Stroke 95.0 × 85.0 mm	(3.74 × 3.35 in.)
Piston Displacement 3 614 cm	3(220.5 cu. in.)
Maximum output 147.1 kW (200PS)	165.5 kW (225PS)	183.9 kW (250PS)
Full Throttle Operating Range 5 000 – 6 000r/min. (min-1)			5 500 – 6 100r/min. (min-1)
Ignition System Full-transistor
Engine Lubrication Trochoid pump pressure lubrication
Engine Oil Capacity 8.0 L (8.5/7.0 US/Imp. qt.)
Gear Oil Capacity 1.1 L (1.2/1.0 US/Imp. qt.)
Spark Plug NGK BKR6E
Spark Plug Gap	0.7 – 0.8 mm (0.028 – 0.031 in.)
Valve Clearance (Lash)	IN.: 0.23 – 0.27 mm (0.009 – 0.011 in.)EX.: 0.33 – 0.37 mm (0.013 – 0.015 in.)
Fuel Type Alcohol-free unleaded gasoline
Minimum Fuel Octane Rating	91 (Research method)

INFORMATION REGARDING EC - DIRECTIVE

(For European countries)

Sound Pressure Level

Regulation	Sound pressure level limit
2013 / 53 / EU	75 dB(A)

Sound pressure level is measured according to ISO 14509-1:2008.

CHART OF TOTAL OPERATING HOURS INDICATION

*: One flashing is corresponded to 500 hours.

x1000 r/min CHECK ENGINE TEMP ON REY LIMIT ① ②

FLOWCHART OF OIL CHANGE REMINDER SYSTEM

graph TD
    A["Starting operation"] --> B{(*1)}
    B --> C["Indication"]
    C --> D{Cancellation}
    D --> E{(*2)}
    E --> F{Indication]
    F --> G{Cancellation}
    G --> H{(*3)}
    H --> I{Indication]
    I --> J{Cancellation}
    J --> K{(*3)}
    K --> L["Indication"]
    L --> M{Cancellation}
    M --> N["Repeat"]

*1: Lapse of initial 20 hour's operation
*2: Lapse of 80 hour's operation
*3: Lapse of 100 hour's operation
*4: When performing cancellation before system activation

WIRING DIAGRAM

DF200T/Z

graph TD
    A["CONNECTOR"] --> B["CYLINDER TEMP SENSOR"]
    B --> C["EXH MAIN TEMPSensor #2"]
    C --> D["THROTTLE POSITION SENSOR"]
    D --> E["MAP SENSOR"]
    E --> F["FUEL INJECTOR #2"]
    F --> G["FUEL INJECTOR #4"]
    G --> H["FUEL INJECTOR #5"]
    H --> I["IGNITION COIL #2"]
    I --> J["IGNITION COIL #4"]
    J --> K["IGNITION COIL #5"]
    K --> L["CONNECTOR"]
    L --> M["JOINT CONNECTOR"]
    M --> N["JOINT CONNECTOR"]
    N --> O["UNITED CONNECTOR"]
    O --> P["UNITED CONNECTOR"]
    P --> Q["UNITED CONNECTOR"]
    Q --> R["UNITED CONNECTOR"]
    R --> S["UNITED CONNECTOR"]
    S --> T["UNITED CONNECTOR"]
    T --> U["UNITED CONNECTOR"]
    U --> V["UNITED CONNECTOR"]
    V --> W["UNITED CONNECTOR"]
    W --> X["UNITED CONNECTOR"]
    X --> Y["UNITED CONNECTOR"]
    Y --> Z["UNITED CONNECTOR"]
    Z --> AA["UNITED CONNECTOR"]
    AA --> AB["UNITED CONNECTOR"]
    AB --> AC["UNITED CONNECTOR"]
    AC --> AD["UNITED CONNECTOR"]
    AD --> AE["UNITED CONNECTOR"]
    AE --> AF["UNITED CONNECTOR"]
    AF --> AG["UNITED CONNECTOR"]
    AG --> AH["UNITED CONNECTOR"]
    AH --> AI["UNITED CONNECTOR"]
    AI --> AJ["UNITED CONNECTOR"]
    AJ --> AK["UNITED CONNECTOR"]
    AK --> AL["UNITED CONNECTOR"]
    AL --> AM["UNITED CONNECTOR"]
    AM --> AN["UNITED CONNECTOR"]
    AN --> AO["UNITED CONNECTOR"]
    AO --> AP["UNITED CONNECTOR"]
    AP --> AQ["UNITED CONNECTOR"]
    AQ --> AR["UNITED CONNECTOR"]
    AR --> AS["UNITED CONNECTOR"]
    AS --> AT["UNITED CONNECTOR"]
    AT --> AU["UNITED CONNECTOR"]
    AU --> AV["UNITED CONNECTOR"]
    AV --> AW["UNITED CONNECTOR"]
    AW --> AX["UNITED CONNECTOR"]
    AX --> AY["UNITED CONNECTOR"]
    AY --> AZ["UNITED CONNECTOR"]
    AZ --> BA["UNITED CONNECTOR"]
    BA --> BB["UNITED CONNECTOR"]
    BB --> BC["UNITED CONNECTOR"]
    BC --> BD["UNITED CONNECTOR"]
    BD --> BE["UNITED CONNECTOR"]
    BE --> BF["UNITED CONNECTOR"]
    BF --> BG["UNITED CONNECTOR"]
    BG --> BH["UNITED CONNECTOR"]
    BH --> BI["UNITED CONNECTOR"]
    BI --> BJ["UNITED CONNECTOR"]
    BJ --> BK["UNITED CONNECTOR"]
    BK --> BL["UNITED CONNECTOR"]
    BL --> BM["UNITED CONNECTOR"]
    BM --> BN["UNITED CONNECTOR"]
    BN --> BO["UNITED CONNECTOR"]
    BO --> BP["UNITED CONNECTOR"]
    BP --> BQ["UNITED CONNECTOR"]
    BQ --> BR["UNITED CONNECTOR"]
    BR --> BS["UNITED CONNECTOR"]

graph TD
    A["AT SENSOR"] --> B["CYLINDER TEMP SENSOR"]
    B --> C["EXH MAIN TEMP SENSOR #2"]
    C --> D["THROTTLE POSITION SENSOR"]
    D --> E["MAP SENSOR"]
    E --> F["VACUUN SWITCHING VALVE"]
    F --> G["FUEL INJECTOR #2"]
    G --> H["FUEL INJECTOR #4"]
    H --> I["FUEL INJECTOR #6"]
    I --> J["IGNITION COIL #2"]
    J --> K["IGNITION COIL #4"]
    K --> L["IGNITION COIL #5"]
    L --> M["CONNECTOR"]
    M --> N["CONNECTOR"]
    N --> O["JOINT CONNECTOR"]
    O --> P["ENGINE CONTROL MODULE"]
    P --> Q["COPIER & REGULATOR"]
    Q --> R["FUSE 60A"]
    R --> S["STARTER MOTOR"]
    S --> T["FUSE 30A"]
    T --> U["ILEMPRESSURE SWITCH"]
    U --> V["OIL PRESSURE SWITCH"]
    V --> W["ENERGENCY LOCK PLATE IN RUN LOCK PLATE OFF STOP"]

    X["PIT SWITCH"] --> Y["LOW PRESSURE FUEL PUMP"]
    Y --> Z["HIGH PRESSURE FUEL PUMP"]
    Z --> AA["CAP"]
    AA --> AB["FUSE 15A"]
    AB --> AC["STARTER MOTOR RELAY"]
    AC --> AD["CAUTION SWITCH"]
    AD --> AE["FUSE 10A"]
    AE --> AF["CAUTION BUZZER"]

    AG["DIGITAL GAUGE DIAGRAM (OPTION)"] --> AH["MODIFICATION OF WIRING *1, *2."]
    AH --> AI["CAUDE CONNECTOR 2 CAP CONNECTION"]
    AI --> AJ["CAUDE CONNECTOR 1 CAP CONNECTION"]

    AK["WIRE COLOR"] --> AL["B: Black, Br: Brown, Dg: Dark Green, O: Green, Gr: Grey, Lvl: Light blue, Lg: Light green/White, O: Orange/Black, Gr: Grey, Lvl: Light blue, Lg: Light green, O: Orange/Blue, P/B: Pink/Black, PBI: Pink/Blue, P/R: Pink/White, R: Red/Black, RVB: Red/Green, RVY: Yellow, RVW: Red/White, RVZ: Blue/Black, RVB: Black/Brown, RVG: Black/Green, RVB: Black/Rad, RVW: White/Blue, RVZ: Black/White, RVV: Black/White, RVW: White/Red, RVZ: Blue/Black, RVR: Blue/Rad, RVY: Blue/White, RVZ: Blue/White, RVW: White/Blue, RVN: Green/Green, RVN: Green/Rad, RVQ: Green/White, RVY: Green/Yellow"]

    AL --> AM["GRIY : Gray / Yellow"]
    AL --> AN["LgR : Light green / Black"]
    AL --> AO["LgW : Light green / Red"]
    AL --> AP["OG : Orange / Black"]
    AL --> AQ["Gr : Grey"]
    AL --> AR["Lvl : Light blue"]
    AL --> AS["Lg : Light green / White"]
    AL --> AT["OG : Orange/Blue"]
    AL --> AU["Gr : Grey"]
    AL --> AV["Lvl : Light blue"]
    AL --> AW["OG : Light green / White"]
    AL --> AX["OG : Orange/Blue"]
    AL --> AY["P/B : Pink/Black"]
    AL --> AZ["PBI : Pink/Blue"]
    AL --> BA["R : Pink/White"]
    AL --> BB["R : Red/Black"]

    AN --> BC["GRIY : Gray / Yellow"]
    AN --> BD["LgR : Light green / Black"]
    AN --> BE["LgW : Light green / Red"]
    AN --> BF["OG : Orange/Black"]
    AN --> BG["Gr : Grey"]
    AN --> BH["Lvl : Light blue"]
    AN --> BI["Lg : Light green / White"]
    AN --> BJ["OG : Orange/Blue"]

    AO --> BK["GRIY : Gray / Yellow"]
    AO --> BL["LgR : Light green / Red"]
    AO --> BM["OG : Orange/Black"]
    AO --> BN["GRIY : Pink/Black"]
    AO --> BO["Lvl : Light green / White"]
    AO --> BP["OG : Orange/Blue"]

    AP --> BQ["GRIY : Gray / Yellow"]
    AP --> BR["LgR : Light green / Red"]
    AP --> BS["OG : Orange/Black"]

    AQ --> CA["GRIY : Pink/Black"]
    AQ --> CB["Lvl : Light green / White"]
    AQ --> CC["OG : Orange/Blue"]

    AR --> DA["GRIY : Pink/Blue"]
    AR --> DB["Lvl : Light green / White"]

    AS["WIRE COLOR"] --> AT["B: Black, Br: Brown, Dg: Dark Green, O: Green, Gr: Grey, Lvl: Light blue, Lg: Light green/White, O: Orange/Blue, P/B: Pink/Black, PBI: Pink/Blue, P/R: Pink/White, R: Red/Black, RVB: Red/Green, RVY: Yellow, RVW: Red/White, RVZ: Blue/Black, RVB: Black/Brown, RVG: Black/Green, RVB: Black/Rad, RVW: White/Blue, RVW: White/Green, RVZ: Black/White, RVW: White/Red, RVZ: Blue/Black, RVR: Blue/Rad, RVY: Blue/White, RVZ: Blue/Blue, RVW: White/Blue, RVN: Green/Green, RVN: Green/Rad"]

graph TD
    subgraph Power Supply
        A["AT SENSOR"] --> B["CYLINDER TEMP SENSOR"]
        B --> C["EXH MANI TEMP SENSOR #2"]
        C --> D["CMP SENSOR #1"]
        D --> E["CMP SENSOR #2"]
        E --> F["THROTTLE POSITION SENSOR"]
        F --> G["MAP SENSOR"]
        G --> H["VACUUM SWITCHING VALVE"]
        H --> I["FUEL INJECTOR #2"]
        I --> J["FUEL INJECTOR #4"]
        J --> K["FUEL INJECTOR #6"]
        K --> L["IGNITION COIL #2"]
        L --> M["IGNITION COIL #4"]
        M --> N["IGNITION COIL #5"]
        N --> O["OCV SOLENOID #2"]
        P["JOINT CONNECTOR"] --> Q["JOINT CONNECTOR"]
        R["JOINT CONNECTOR"] --> S["JOINT CONNECTOR"]
        T["ALTERNATOR"] --> U["CKP SENSOR"]
        V["RECTIFIER & REGULATOR"] --> W["RECEPTIFIER & REGULATOR"]
        X["STARTER MOTOR"] --> Y["MOBICATOR"]
        Z["ENGINE CONTROL MODULE"] --> AA["OIL PRESSURE SWITCH"]
        AB["UNIT CONNECTOR"] --> AC["SHIFT POSITION SENSOR"]
        AD["NEUTRAL SWITCH N→ON F.R→OFF"] --> AE["BATTERY"]
        AF["TILT LIMIT SWITCH"] --> AG["PPT MOTOR"]
        AH["TRIM SENDER"] --> AI["FUSE 15A"]
        AJ["PIESE REFLECTOR"] --> AK["FUSE 30A"]
        AL["MINIMUM SWITCH"] --> AM["FUSE 15A"]
        AN["CAUTION BUZZER"] --> AO["FUSE 15A"]
    end

    subgraph Power Supply
        AP["PIESE REFLECTOR"] --> AQ["FUSE 15A"]
        AR["MINIMUM SWITCH"] --> AS["FUSE 15A"]
        AT["CAUTION BUZZER"] --> AU["FUSE 15A"]
    end

    subgraph Digital Gauge Diagram
        AV["MODIFICATION OF WIRING #1, CAP"] --> AW["STARTER MOTOR RELAY"]
        AX["COOPERATION CONNECTOR 1"] --> AY["COOPERATION CONNECTOR 2"]
        AZ["METER ILLUMINATION SWITCH"] --> BA["METER ILLUMINATION SWITCH"]
    end

    style Power Supply fill:#f9f,stroke:#333
    style Digital Gauge Diagram fill:#ccf,stroke:#333
    style Power Supply fill:#cfc,stroke:#333
    style Digital Gauge Diagram fill:#fcc,stroke:#333
    style Power Supply fill:#ffc,stroke:#333
    style Digital Gauge Diagram fill:#fcc,stroke:#333
    style Power Supply fill:#ffc,stroke:#333
    style Digital Gauge Diagram fill:#fcc,stroke:#333
    style Power Supply fill:#ffc,stroke:#333
    style Power Supply fill:#ffc,stroke:#333
    style Power Supply fill:#ffc,stroke:#333
    style Power Supply fill:#ffc,stroke:#333
    style Power Supply fill:#ffc,stroke:#333
    style Power Supply fill:#ffc,stroke:#333
    style Power Supply fill:#ffc,stroke:#333
    style Power Supply fill:#ffc, stroke:#333
    style Power Supply fill:#ffc, stroke:#333
    style Power Supply fill:#ffc, stroke:#333
    style Power Supply fill:#ffc, stroke:#333
    style Power Supply fill:#ffc, stroke:#333
    style Power Supply fill:#ffc, stroke:#333
    style Power Supply fill:#ffc, stroke:#333
    style Power Supply fill:#ffc, stroke:#�33
    style Power Supply fill:#ffc, stroke:#333
    style Power Supply fill:#ffc, stroke:#333
    style Power Supply fill:#ffc, stroke:#333
    style Power Supply fill:#ffc, stroke:#333
    style Power Supply fill:#ffc, stroke:#333
    style Power Supply fill:#ffc, stroke:#333
    style Power Supply fill:#ffc, stroke:#334

Prepared by

SUZUKI MOTOR CORPORATION

August, 2018

Part No. 99011-93JG0-054

Printed in Japan

© COPYRIGHT SUZUKI MOTOR CORPORATION 2018