Suzuki DF350A Service Manual
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Suzuki DF350A Service Manual

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Summary of Contents for Suzuki DF350A

  • Page 1 9 9 5 0 0 - 9 8 L 0 0 - 0 1 E...
  • Page 2 CAUTION ciples. WARNING This service manual is intended for authorized Suzuki outboard motor dealers and qualified service technicians only. Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result...
  • Page 3 FOREWORD This manual contains an introductory description of the SUZUKI DF350A Outboard motors and procedures for inspection, service and overhaul of their main components. General knowledge information is not included. Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning this motor.
  • Page 4 TABLE OF CONTENTS Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Tune-Up........0B-1 Power Head..............1-i Precautions .............. 1-1 Engine Control ............1A-1 Engine Electrical Devices........1C-1 Power Unit Mechanical ..........1D-1 Power Unit Lubrication ........... 1E-1 Power Unit Cooling System ........
  • Page 5 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Precautions............00-1 General Precautions ........... 00-1...
  • Page 6 00-1 Precautions: Precautions Precautions Precautions General Precautions CENHN1110000001 The WARNING, CAUTION and NOTICE messages below describe some general precautions that you should observe when servicing the outboard motor. These general precautions apply to many of the service procedures, but they will not necessarily be repeated for every procedure to which they apply.
  • Page 7 • To protect the Earth’s natural resources, properly dispose of used motor parts. Replacement Parts NOTICE Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems and damage. Use only genuine SUZUKI replacement parts or their equivalent. Genuine SUZUKI parts are high quality parts which are designed and built specially for SUZUKI outboard motors.
  • Page 8 00-3 Precautions:...

  • Page 9: Table Of Contents

    Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Scheduled Maintenance ........0B-2 Periodic Maintenance Schedule Chart....0B-2 General Description ..........0A-1 Lubrication Point ..........0B-3 Symbols .............. 0A-1 Service Instructions ..........0B-4 Abbreviations ............0A-2 Engine Oil Level Check........0B-4 Wire Color Symbols ..........

  • Page 10: General Information

    Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI Outboard Motor Gear Oil. Apply SUZUKI Super Grease A. Apply SUZUKI Moly Paste.

  • Page 11: Abbreviations

    DBW: Drive By Wire PORT: Port DC: Direct Current PTT: Power Trim and Tilt DOHC: Double Over Head Camshaft SPC System: Suzuki Precision Control System ECM: Engine Control Module SPS: Shift Position Sensor ETV: Electronic Throttle Valve STBD: Starboard ESA: Electronic Shift Actuator SIGP: Start-In-Gear Protection EX (Ex.): Exhaust...

  • Page 12: Wire Color Symbols

    0A-3 General Information: Wire Color Symbols CENHN1110101003 There are two kinds of colored wire used in this product. One is single colored wire and the other is dual colored (striped) wire. The single colored wire uses only one color symbol. example: B (Black). The dual colored wire uses two color symbols.

  • Page 13: Outboard Motor Identification Number Location

    Engine Serial Number Location oil. A second engine serial number plate is pressed into a Suzuki recommends the use of SAE 10W-40 or 10W-30 boss on the cylinder block. SUZUKI MARINE 4-CYCLE ENGINE OIL (ECSTAR). If SUZUKI MARINE 4-CYCLE ENGINE OIL is not...

  • Page 14: Break-In Procedures

    0A-5 General Information: Break-In Procedures Throttle Recommendation CENHN1110101007 NOTICE NOTE Failure to follow the break-in procedures Avoid maintaining a constant engine speed described below can result in severe engine for an extended period at any time during the damage. engine break-in period by varying the throttle position occasionally.

  • Page 15: Propeller Selection Guide

    Suzuki recommends a 12 V cranking type lead acid power within a specified engine speed range. The battery for the DF350A. maximum rated power delivered by the DF350A model is Minimum battery requirement for starting the engine is shown below.

  • Page 16: Specifications

    0A-7 General Information: Specifications Specifications CENHN1110107001 NOTE These specifications are subject to change without notice. Model Pre-Fix Data Item Unit DF350AT PRE-FIX 35001F Dimensions and Weight Data Item Unit DF350AT Overall length (front to back) mm (in.) 974 (38.3) Overall width (side to side) mm (in.) 562 (22.1) mm (in.)
  • Page 17 NMMA FC-W 10W-40 or 10W-30 8.0 (8.5/7.0): Oil change only Engine oil amounts L (US/Imp. qt) 8.5 (9.0/7.5): Oil filter change SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear Gear oil oil, API classification GL-5. Gearcase oil capacity L (US/Imp. qt) Approx.

  • Page 18: Service Data

    0A-9 General Information: Service Data CENHN1110107002 NOTE These service data are subject to change without notice. Powerhead Data Item Unit DF350AT Recommended operating range r/min 5 700 – 6 300 Idle speed r/min 550 – 650 (in-gear: 550 – 650) **Cylinder compression pressure 700 –...
  • Page 19 General Information: 0A-10 Valve / Valve Guide Data Item Unit DF350AT mm (in.) 37.9 (1.49) Valve diameter mm (in.) 31.4 (1.2) Tappet clearance (Valve lash) std. mm (in.) 0.23 – 0.27 (0.009 – 0.011) (Cold engine condition) std. mm (in.) 0.33 –...
  • Page 20 0A-11 General Information: Cylinder / Piston / Piston Ring Data Item Unit DF350AT Cylinder distortion Limit mm (in.) 0.05 (0.002) std. mm (in.) 0.045 – 0.065 (0.0018 – 0.0026) Piston to cylinder clearance Limit mm (in.) 0.10 (0.0039) Cylinder bore std.
  • Page 21 General Information: 0A-12 Crankshaft / Conrod Data Item Unit DF350AT Conrod small end inside diameter std. mm (in.) 22.010 – 22.018 (0.8665 – 0.8669) std. mm (in.) 0.045 – 0.063 (0.0018 – 0.0025) Conrod big end oil clearance Limit mm (in.) 0.080 (0.0031) Conrod big end inside diameter std.
  • Page 22 0A-13 General Information: Starter Motor Data Item Unit DF350AT Max. continuous time of use Sec. Motor output std. mm (in.) 12.3 (0.48) Brush length Limit mm (in.) 7.0 (0.28) std. mm (in.) 0.5 (0.02) Commutator undercut Limit mm (in.) 0.2 (0.01) std.

  • Page 23: Tightening Torque Specifications

    General Information: 0A-14 Tightening Torque Specifications CENHN1110107003 NOTICE Failure to use the correct fasteners or to properly use fasteners can cause parts or system damage. • When fasteners are removed, always reinstall them at the locations from which they were removed. •...

  • Page 24: Special Tools And Equipment

    (“7” marked bolt) Special Tools and Equipment Recommended Service Material CENHN1110108001 93691–80030 99000–22B22 99000–25350 99000–31140 99000–32020 SUZUKI Silicone Seal SUZUKI Outboard SUZUKI Water SUZUKI Bond 1207B SUZUKI Thread Lock (100 g) Motor Gear Oil Resistant Grease EP2 (100 g) Super 1333B (50 g) (250 g) 99000–32160...

  • Page 25: Special Tool

    General Information: 0A-16 Special Tool CENHN1110108002 09900–20101 09900–20202 09900–20203 09900–20204 09900–20205 Vernier calipers (150 Micrometer (25 – 50 Micrometer (50 – 75 Micrometer (75 – 100 Micrometer (0 – 25 09900–20605 09900–20606 09900–20607 09900–20701 09900–20803 Dial calipers (10 – 34 Dial gauge Dial gauge Magnetic stand...
  • Page 26 0A-17 General Information: 09915–78211 09916–10911 09916–14521 09916–19030 09916–34542 Oil pressure gauge Valve lapper Valve lifter attachment Valve lifter Valve guide reamer adapter handle 09916–34550 09916–37320 09916–44310 09916–56011 09916–57330 Valve guide reamer (ø Valve guide reamer (ø Valve guide remover Valve guide installer Valve guide installer 5.5 mm) 10.5 mm)
  • Page 27 General Information: 0A-18 09930–39210 09930–39411 09930–40113 09930–40120 09930–89240 Flywheel remover bolt Flywheel remover Flywheel holder Rotor holder 4-pin connector test attachment cord 09930–89290 09930–89340 09930–89850 09944–09610 09944–09820 18 pin & 34 pin test 26-pin & 34-pin test 26-pin (B) test cord PTT trim cap tool PTT cylinder cap tool cord...

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