Suzuki DF70A Setup Manual
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Also See for DF70A:
- Service manual (342 pages) ,
- Owner's manual (132 pages) ,
- Owner's manual (77 pages)
Table of Contents
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Table of Contents
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Summary of Contents for Suzuki DF70A
- Page 1 DF70A/80A/90A For ’09 model 9 9 5 0 5 - 8 7 L 0 0 - 0 1 E...
- Page 2 FOREWORD This outboard motor has been designed and produced utilizing Suzuki’s most modern technology. The finest product, however, cannot perform properly unless it is correctly assembled and serviced. This set-up manual has been produced to aid you in properly assembling and servicing this outboard motor.
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Page 3: Table Of Contents
CONTENTS IMPORTANT ........................3 SYMBOL ..........................3 MATERIALS REQUIRED ....................3 HANG TAGS ........................4 OUTBOARD MOTOR INSTALLATION ................5 HORSEPOWER SELECTION ..................5 MOTOR DIMENSIONS ....................5 TRANSOM DIMENSIONS .................... 6 ESTABLISHING THE CENTER-LINE ................6 LIFTING THE MOTOR ....................8 MOUNTING TO THE TRANSOM ................. -
Page 4: Important
SYMBOL DEFINITION Torque control required. Data beside it indicates specified Apply THREAD LOCK “1342”. torque. Apply SUZUKI WATER RESISTANT Use special tool. GREASE. Apply SUZUKI SILICONE SEAL. MATERIALS REQUIRED WATER RESISTANT SUZUKI SILICONE GREASE SEAL... -
Page 5: Hang Tags
HANG TAGS It is mandatory that every new Suzuki outboard motor be assembled and serviced in accordance with the instructions in the set-up manual. A critical step in the set-up and pre-delivery process of every outboard motor is to attach the hang tags to the outboard motor. -
Page 6: Outboard Motor Installation
• The rig should not be underpowered, as this will not allow the performance balance you are trying to achieve. Determine the customer’s needs, application and use of the perspective rig to make the best overall horsepower recommendation. MOTOR DIMENSIONS DF70A/80A/90A X: 1075 (42.3) L : 956 (37.6) 510 (20.1) 122 (4.8) -
Page 7: Transom Dimensions
TRANSOM DIMENSIONS DF70A/80A/90A 360 (14.2) Unit: mm (in) 327 (12.9) Transom top surface φ 5 – 13.5 13.5 (0.53) 251 (10) 38 (1.5) ESTABLISHING THE CENTER-LINE To establish the center of the transom you may use the following procedure: (1) Measure across the transom from chine to chine and make a mark on the transom face at 1/2 of this measurement. - Page 8 For twin engine installation you may use the following procedure: (Minimum engine center-line distance is 660 mm/26 in.) (1) Following the horizontal line from chine to chine, mark the line at 330 mm (13 in.) on both sides of the previously established single engine vertical center-line.
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Page 9: Lifting The Motor
LIFTING THE MOTOR Use a hoist which has a minimum lift capacity of at least 450 kg (1 000 lbs.) when lifting the motor. Use lifting eye only. Do not lift the motor using a fly- wheel or crankshaft lifting attachment. Attach lift to lifting eye on cylinder block. -
Page 10: Mounting To The Transom
MOUNTING TO THE TRANSOM Contained parts Item Part name Part number Q’ty Bolt (M12) 09100-12091 Washer (OD 35 mm) 09160-12044 Washer (OD 22 mm) 09160-12110 Nut (M12) 09159-12014 41153-94500 (1) Center the motor on the transom. 360 (14.2) 327 (12.9) Make sure that anti-cavitation plate is located 0 –... - Page 11 NOTE: • To insure water-tightness, sealant (SUZUKI SILICONE SEAL or equivalent) should be applied to all bolt holes. Apply the sealant to the shanks of the bolts, but not the threads. • Do not use an impact tool to tighten or loosen the transom nuts.
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Page 12: Wire Harness Installation
WIRE HARNESS INSTALLATION Contained parts Item Part name Part number Q’ty Grommet 61124-87L00 Battery sub wire (3.7 m) 36625-93J00 Battery sub wire (6.5 m) 36625-93J10 Remote control harness 36620-93J00 • Depending on the model specification, the battery sub wire varies. •... - Page 13 Fuel hose Battery cable Speed meter pickup tube Grommet Battery sub wire Remote control harness NOTE: Route the tube 3, battery cable 2, battery sub wire B and remote control harness C under the remote control cable holder (hatched area). (5) Push the grommet A into the front panel.
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Page 14: Control Cables Installation
CONTROL CABLES INSTALLATION Contained parts Item Part name Part number Q’ty Remote control box 67200-93J00 (Side-mount type) Cable connector 67467-89J01 Washer 09160-06055 Lock pin 09385-06012 Band 09407-25402 Depending on the model specification, the remote control box is optional. Required parts Part name Part number Q’ty... - Page 15 (5) Install the cable stopper 1 using the washer and bolt 2 to secure the clutch control cable and throttle control cable. (6) Position the remote control handle into “NEUTRAL”. — Clutch control cable — (7) Make sure that the clutch control arm 6 is in the neutral position.
- Page 16 (16) Move the remote control handle to the fully opened posi- tion. Check that the throttle lever C is in fully opened posi- tion. (17) Return the remote control handle to the neutral position. Check that the throttle control arm 9 is in fully closed posi- tion.
- Page 17 Cable connectors and turnbackles must be threaded at least 12 mm (0.5 in) onto cable. NOTE: After assembly, make sure that the cables are not stretched or otherwise stressed when the outboard motor is turned all the way to the right and left.
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Page 18: Drag Link Installation
(1) Thread the steering cable seal F onto the port side end of the motor tilt tube 1. (2) Apply SUZUKI WATER RESISTANT GREASE to the steer- ing cable 2. (3) Insert the cable 2 into the tube 1 from the starboard side, then tighten the cable retaining nut 3 to the torque speci- fied by the cable manufacturer. - Page 19 (4) Connect the drag link A to the steering cable end 2 with washers E and safety nut D as shown. Tighten the nut D to the specified torque, then BACK THE NUT OFF 1/8 TURN. Safety nut D : 10 N·m (1.0 kgf-m, 7.0 lb-ft) (5) Move the steering cable until the hole of drag link A aligns with the thread hole on the steering bracket 4.
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Page 20: Fuel Hose
FUEL HOSE Gasoline is extremely flammable and toxic. Always observe following precautions when working around gasoline or servicing the fuel system. • Keep the working area well ventilated and away from open flame (such as gas heater) or sparks. •... -
Page 21: Battery
BATTERY BATTERY REQUIREMENT Suzuki recommends a 12-volt cranking-type lead acid battery for the DF70A/80A/90A. Minimum battery requirement for starting the engine is provided below. The battery must satisfy one of the specifications described below. 650 Marine Cranking Amps (MCA)/ABYC, or 512 Cold Cranking Amps (CCA)/SAE... -
Page 22: Connection Of Battery Cable
Store the battery free from splash of water, etc. and fix it Red tube Black tube securely to the hull with a battery band or the like to prevent it from falling down during boating. NOTE: It is recommended that the battery be installed in an enclosed case. -
Page 23: Setting Tilt Up Limit Position
SETTING TILT UP LIMIT POSITION If the outboard motor contacts the motor well of the boat during full tilt up operation, the upper limit setting should be reset. Perform this set-up after the current position setting has been canceled, as explained in the following procedure. CANCELING TILT UP POSITION LIMIT SETTING (1) Turn the ignition key to the “ON”... - Page 24 (11) Top mount type Using the throttle only function of the remote control box, move the control handle forward until the caution buzzer sounds one time. Side mount type Using the throttle only function of the remote control box, move the warm-up lever upward until the caution buzzer sounds one time.
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Page 25: Engine Oil
ENGINE OIL The choice of engine oil is a major factor affecting engine performance and life. Use the following engine oil. Recommended oil: • 4 stroke motor oil • API classification: SG, SH, SJ, SL, SM or NMMA FC-W Classification: SG, SH, SJ, SL, SM •... -
Page 26: Propeller
× × × Installation of propeller (1) Coat the propeller shaft 1 with the SUZUKI water-resistant grease. (2) Place the stopper 2 on the propeller shaft. (3) Slide the propeller 3 onto the propeller shaft. (4) Place the spacer 4 and washer 5 on the propeller shaft. -
Page 27: Wiring Diagram
WIRING DIAGRAM Side Mount Remoto Control... - Page 28 Top Mount or Flush Mount Remote Control (Single)
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Page 29: Digital Gauge System
DIGITAL GAUGE SYSTEM MODIFICATION OF HARNESS CONNECTION For operating the digital gauge, disconnect the gauge connector A from gauge connector B, and connect the gauge connector A to the SDS communication connector as shown in the illustration. Gauge connector Gauge connector Gauge connector Gauge connector SDS communication... - Page 30 DIGITAL GAUGE WIRING DIAGRAM 1. Voltage meter 2. Fuel gauge 3. Trim gauge 4. Speedometer 5. Tachometer Sub fuel Main fuel sensor sensor Active hub unit Battery Interface module Remote control wire (PORT) Label (P) Trim sender connector (PORT) Label (C) Remote control wire (Center) Harness adaptor (P/no 36646-87L00)
- Page 31 Prepared by Quality Administration Department June, 2008 Part No. 99505-87L00-01E Printed in Japan...