Related Manuals for Suzuki DF40A
Summary of Contents for Suzuki DF40A
- Page 1 DF40A DF50A DF50AV DF60A DF60AV OWNER’S MANUAL ENGLISH...
- Page 2 • Do not hold onto the motor cover or any This symbol appears in various locations on other parts of your outboard motor while your Suzuki product to refer you to important getting on or off your boat. information in the owner’s manual.
- Page 3 FOREWORD • Never remove the flywheel cover (except for when emergency starting). Thank you for choosing a Suzuki outboard motor. Please read this manual carefully and NOTE: review it from time to time. It contains important Mounting radio transceiver or navigational...
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Page 4: Table Of Contents
TABLE OF CONTENTS IDENTIFICATION NUMBER LOCATION..........5 FUEL AND OIL........5 LOCATION OF SAFETY LABELS ..8 LOCATION OF PARTS....... 10 MOTOR MOUNTING......13 BATTERY INSTALLATION ....13 USE OF ELECTRICAL ACCESSORIES ........15 PROPELLER SELECTION AND INSTALLATION........15 ADJUSTMENT........16 INDICATOR .......... -
Page 5: Identification Number Location
IDENTIFICATION Suzuki recommends that you install a water- separating fuel filter assembly between your NUMBER LOCATION boat’s fuel tank(s) and outboard motor(s). Fuel filtration systems of this type will help prevent The model and identification numbers of your water that may be present in your boat’s fuel outboard motor are stamped on a plate tank(s) from contaminating your motor’s elec-... - Page 6 NOTE: NOTICE If you are not satisfied with the operation or fuel economy of your outboard motor when you are Gasoline kept in the fuel tank for long periods using gasoline/alcohol blends, you should of time will produce varnish and gum, which switch back to unleaded gasoline containing no can damage the engine.
- Page 7 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...
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Page 8: Location Of Safety Labels
LOCATION OF SAFETY LABELS Read and follow all of the labels on your out- Keep the labels on your outboard motor or fuel board motor or fuel tank. Make sure you under- tank. Do not remove them for any reason. stand all of the labels. -
Page 10: Location Of Parts
LOCATION OF PARTS REMOTE CONTROL MODEL Motor cover Power trim and tilt (P.T.T.) switch (Reverse side) MONITOR-TACHOMETER Engine oil drain plug Pilot water hole Clamp bracket Flush plug Anode Flush plug Gear oil level plug Anti-cavitation plate Water intake hole Trim tab (Anode) Gear oil drain plug... - Page 11 Motor cover Power trim and tilt (P.T.T.) switch (Reverse side) Engine oil drain plug Pilot water hole Clamp bracket Flush plug Anode Anode (Reverse side) Anode Gear oil level plug Anti-cavitation plate Water intake hole Trim tab Gear oil drain plug DF50AVT/60AVT...
- Page 12 TILLER HANDLE MODEL Power trim and tilt (P.T.T.) switch (Reverse side) (DF40ATH/50ATH/60ATH) Ignition key Tachometer/Indicator Motor cover Shift lever Power trim and tilt (P.T.T.) switch (DF40ATH/50ATH/ 60ATH) Throttle control grip Troll mode switch Emergency stop switch Pilot water Engine oil drain plug hole Clamp bracket Flush plug...
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Page 13: Motor Mounting
“Certification Plate”. Contact your the engine. authorized Suzuki marine dealer if you are • Additional electrical loads from the boat will unable to locate the hull “Certificate Plate”. require larger capacity batteries. Consult... - Page 14 Suzuki recommends that you install the termi- • Be sure to attach battery leads correctly. nal cap on the positive battery terminal to pre- •...
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Page 15: Use Of Electrical Accessories
It is essential to use a propeller on your out- ing condition of the motor. For detailed informa- board motor that is properly matched to your tion, please ask your authorized Suzuki Marine boat’s operating characteristics. The speed of Dealer. -
Page 16: Adjustment
• Trim angle too large (Boat tends to “porpoise”) 1. Coat the propeller shaft splines 1 liberally with Suzuki water resistant grease to help prevent corrosion. 2. Place the stopper 2 on the shaft. • Proper trim angle 3. - Page 17 DF40A (T), DF50A (T), DF50AV (T), DF60A heating. (T), DF60AV (T) MODEL Make a test run in the boat to determine if the Never operate the boat with the motor trim angle needs to be adjusted.
- Page 18 To adjust the trim tab: 1. Loosen the bolt A that holds the trim tab in place. DF40A (TH/QH), DF50A (TH), DF60A (QH) MODEL 2. If the boat tends to veer to port, move the For adjustment, use the steering tension lever A.
- Page 19 3. Shift the motor into “NEUTRAL”. “NEUTRAL” “NEUTRAL” IDLE SPEED ADJUSTMENT The idle speed has been factory adjusted between 750 – 850 r/min in neutral. NOTE: If idle speed cannot be set within the specified range, contact your authorized Suzuki Marine Dealer.
- Page 20 4. Remote control model: SETTING THE TILT UPPER POSITION LIMIT Using the throttle only function of the remote control box, move the warm-up lever upward 7. Press the “UP” side of the PTT switch so until the caution buzzer sounds one time. that the optimum full tilt up position for the boat can be obtained.
- Page 21 MOTOR COVER FASTENING ADJUST- 3. Confirm the tiller handle angle after returning down the tiller handle if it is convenient to the MENT operator. If you feel the motor cover fastening is loose or too tight when locking the lever, adjust as fol- NOTE: lows: •...
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Page 22: Indicator
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 REMOTE CONTROL MODEL Each time the ignition key is turned to the “ON”... - Page 23 “ON” position, the lamp or System. buzzer may be broken or a failure may exist in the system circuit. Consult your authorized Consult your authorized Suzuki marine dealer Suzuki marine dealer. if the Over-Revolution Caution System acti- vates for no apparent reason.
- Page 24 Check the oil level and add oil if necessary. If due to the CAUTION system, the engine can be the oil level is correct, consult your authorized started again. Suzuki Marine Dealer. However the CAUTION system will repeatedly activate until eliminating the cause. NOTICE...
- Page 25 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 con- This system will be canceled automatically sulted as soon as possible.
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Page 26: Diagnostic System
If the diagnostic system activates while you are operating your outboard motor, there is an abnormal condition in one of the sensor sig- nals of the control system. Consult your authorized Suzuki marine dealer for repair of the control system. NOTE: Remote control model: 4. -
Page 27: Engine Stalling Caution System
Once the system has This system informs the operator when the operated, however, Suzuki strongly recom- motor stalls while it is operating. mends that the engine oil be replaced before When the engine stalls for any reason, the cau- canceling the system activation. -
Page 28: Operation Of Tilting Systems
“RELEASE” Position (UP) Use this position only when you tilt the motor SYSTEMS TILT LOCK LEVER DF40A (QH), DF60A (QH) MODEL The tilt lock lever A has two positions. “LOCK” Position (DOWN) Use this position always when you operate the motor. - Page 29 4. Move the tilt lock lever 1 to the “lock” posi- To hold the motor in the fully raised position: tion, then pull down the tilt bracket 2 as 1. Shift into “NEUTRAL”. 2. Move the tilt lock lever 1 to the “release” shown.
- Page 30 POWER TRIM AND TILT MANUAL TILTING DF40A (T/TH), DF50A (T/TH), DF50AV DF40A (T/TH), DF50A (T/TH), DF50AV (T/TH), DF60A (T/TH), DF60AV (T/TH) (T/TH), DF60A (T/TH), DF60AV (T/TH) MODEL MODEL The “Power Trim and Tilt” is operated by press- If you are unable to tilt the motor using the ing the switch.
- Page 31 TILT BRACKET NOTICE DF40A (T/TH), DF50A (T/TH), DF50AV (T/TH), DF60A (T/TH), DF60AV (T/TH) Damage can occur if you use the tilt bracket MODEL The Tilt Bracket is provided so you can support other than when the boat is moored or is oth- the motor in a tilted position for non-moving erwise stationary.
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Page 32: Inspection Before Boating
INSPECTION BEFORE 2. Pull out the oil dipstick 3 and wipe oil off with a clean cloth. BOATING WARNING Failure to inspect your boat and motor before beginning a trip can be hazardous. Before boating, always perform the inspec- tions described in this section. -
Page 33: Break-In
BREAK-IN To fill the engine oil: 1. Remove the oil filler cap. 2. Fill the recommended engine oil to the upper Proper operation during this break-in period will level. help ensure maximum life and performance from your engine. The following guidelines will explain proper break-in procedures. -
Page 34: Operation
OPERATION NOTE: You may throttle up beyond the recommended operating range to plane your boat, then imme- BEFORE ATTEMPTING TO START THE diately reduce the throttle to the recommended ENGINE operating range. 1. The motor has been lowered into the water. 2. - Page 35 5. Make sure the lock plate is in place and NOTE: attach the emergency stop switch cord to a A spare plastic lock plate is provided for tempo- part of your body. rary use only. Remove it from the cord and place it in a safe place on board your boat.
- Page 36 1. Squeeze the fuel line priming bulb several NOTICE times until you feel resistance. If you hold the ignition key at the “START” position to start the engine, the starter system can be damaged. Turn the ignition key to the “START” position once and release it to start the engine.
- Page 37 WARNING engine as soon as possible and consult your authorized Suzuki Marine Dealer. If you touch electrical components when rope- starting the engine, you can get a severe elec- trical shock.
- Page 38 WARNING 2. Remove the motor cover. 3. Remove the flywheel cover. If you attempt to reinstall the ring gear cover or motor cover after starting the engine you can be injured. Do not attempt to reinstall the ring gear cover or motor cover after starting the engine.
- Page 39 TILLER HANDLE MODEL REMOTE CONTROL MODEL Shifting Shifting To shift the motor into “FORWARD”, set the To shift into “FORWARD”, squeeze the lock-out throttle control grip to the idle position and pull lever on the control handle and move the con- trol handle forward to approximately position A, the shift lever towards you firmly.
- Page 40 STOPPING THE ENGINE WARNING NOTE: When it is necessary to stop the engine in an Unauthorized use of your boat could lead to emergency, pull the emergency stop switch lock an accident or damage to your boat. plate out of the emergency stop switch by pull- ing the emergency stop switch cord.
- Page 41 To monitor engine speed correctly during the troll mode operation, Suzuki recommends the NOTE: use of the Suzuki 2-scale Monitor Tachometer. The troll mode system will not operate if the (Remote control model) switch is depressed when the handle/shift lever is in the neutral position.
- Page 42 OPERATION IN SHALLOW WATER DF40A (T/TH), DF50A (T/TH), DF50AV When operating your boat in shallow water, it (T/TH), DF60A (T/TH), DF60AV (T/TH) may be necessary to tilt the motor higher than MODEL the normal trim angle. When you tilt the motor...
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Page 43: Motor Removal And Transporting
If it is necessary to remove the outboard motor drains completely. from your boat, we recommend that you ask your authorized Suzuki Marine Dealer to do the work for you. NOTICE If you leave your outboard motor out of the... - Page 44 WARNING NOTICE Gasoline is extremely flammable and toxic. It If you are not careful when resting the out- can cause a fire and can be hazardous to peo- board on its side and do not take proper pre- ple and pets. cautions such as first draining the engine oil and cooling water completely, damage can Use a proper, safe container to store any gas-...
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Page 45: Trailering
TRAILERING When trailering your boat with the motor attached, keep the motor in the normal operat- ing position unless there is not enough ground clearance. If you need more ground clearance, trailer the motor in a tilted position using a tran- som saver bar or similar device to support the weight of the motor. -
Page 46: Inspection And Maintenance
INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE WARNING It is important to inspect and maintain your out- board motor regularly. Follow the chart below. At each interval, be sure to perform the indi- Exhaust gas contains carbon monoxide, a cated service. Maintenance intervals should be dangerous gas that is difficult to detect judged by number of hours or number of because it is colorless and odorless. - Page 47 • Prolonged continuous operation at the Suzuki recommends that only your authorized maximum speed Suzuki marine dealer or a qualified service • Prolonged continuous operation at idling mechanic perform maintenance on those speed or trolling speed items in the chart above which are marked •...
- Page 48 If the standard plug is not suit- 1. Remove the bolts securing the fuel hose able for your operating, consult your authorized guard A. Suzuki Marine Dealer. 2. Remove the bolt securing the ignition coil. NOTICE 3. Pull out the ignition coil.
- Page 49 Consult your authorized brush or spark plug cleaner, and adjust the gap Suzuki Marine Dealer if it is necessary to according to the following chart: replace them. 0.8 – 0.9 mm...
- Page 50 ENGINE OIL 3. Place a drain pan under the engine oil drain screw. WARNING CAUTION Never perform any ENGINE OIL procedure with the motor running, as serious injury can The engine oil temperature may be high occur. enough to burn your fingers when the drain plug is loosened.
- Page 51 DF40A/50A/60A MODEL: Approximately 610 ml (20.6/21.5 US/lmp oz.) will be required. DF50AV/60AV MODEL: Approximately 1050 ml (35.5/37.0 US/lmp...
- Page 52 Swivel bracket If the gear oil has a milky color, it is contami- nated with water. Immediately contact your authorized Suzuki marine dealer for advice. Do not operate your outboard until the oil is Marine-grade changed and the cause of the contamination water resistant is corrected.
- Page 53 • Periodically clean anodes with a wire brush to remove any coating which might decrease their protective ability. NOTE: DF40A/50A/50AV/60AV, DF60A (QH) Consult your authorized Suzuki Marine Dealer for inspection and replacement of internal anodes attached to the cylinder block/cylinder head. Bonding wires...
- Page 54 The engine oil filter must be changed by an the MAX and the MIN level lines at all times. If authorized Suzuki Marine Dealer periodically. the level drops below the MIN level line, add Replace engine oil filter with a new one at initial DISTILLED WATER ONLY until the battery 20 hours (1 month).
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Page 55: Flushing The Water Passages
Flush the water passages as follows. ENGINE RUNNING – Vertical position – Suzuki recommends that you flush the water passages by using this method. WARNING 3. Install the flushing attachment 2 so that the... - Page 56 ENGINE NOT RUNNING ENGINE NOT RUNNING – Vertical position – – Full tilt up position – 1. Make sure that the motor is stopped. 1. Raise the engine to the full tilt up position. 2. Remove the plug A from the flushing port 2.
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Page 57: Submerged Motor
SUBMERGED MOTOR 7. Take the motor to your authorized Suzuki Marine Dealer as soon as possible to be overhauled. A motor that has been accidentally submerged in water must be overhauled as soon as possi- NOTICE ble to prevent corrosion. In the event that your... -
Page 58: Storage Procedure
Suzuki Marine Dealer. tery solution at least once a month and However, if you choose to prepare the motor for recharge the battery when low. -
Page 59: After Storage
5. Clean the motor and wax the painted sur- If you are not sure about the proper action to faces. correct a problem, consult your Suzuki marine 6. Recharge the battery before installing it. dealer. Starter motor will not operate: •... - Page 60 4. Inspect the fuse and replace with the new If a new fuse blows in a short time after instal- fuse if needed. lation, you may have a major electrical system problem. Main fuse (30A) Consult your SUZUKI marine dealer. Normal fuse Blown fuse...
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Page 61: Specifications
Ignition System Full-transistor Engine Lubrication Trochoid pump pressure lubrication Engine Oil Capacity 2.7 L (2.9/2.4 US/lmp qt) Gear Oil Capacity DF40A/50A/60A model: 610 cm (ml) (20.6/21.5 US/Imp oz) DF50AV/60AV model: 1050 cm (ml) (35.5/37.0 US/Imp oz) Spark Plug NGK DCPR6E Spark Plug Gap 0.8 –... -
Page 62: Information Regarding Ec - Directive
INFORMATION REGARDING EC – DIRECTIVE (For European countries) Sound Pressure Level Regulation Sound pressure level limit 72 dB (A): DF40A/50A 2013 / 53 / EU 75 dB (A): DF60A Sound pressure level is measured according to ISO 14509-1:2008. Vibration on tiller handle grip Tiller handle grip vibration total value of this motor measured under related EC Directive does not exceed 2.5m/s... - Page 63 (TILLER HANDLE MODEL) Tachometer 1 indication 2nd indication 1st indication (The hours subtracted Total (Indication of number the hours indicated in operating of time in which the the first step indication hours operating hours attain from the total operat- to 500 hours in the 3rd ing hours.
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Page 64: Flowchart Of Oil Change Reminder System
NOTE: “0” of the first step indication signifies 0 time, “100” means 1 time (500 hours), “200” means 2 times (1000 hours = 500 × 2), and “300” means 3 times (1500 hours = 500 × 3). The total operating hours are the sum of hours indicated in the first step indication, and the indi- cated hours of second step indication (indicated in units of 10 hours). - Page 65 DF40AT/40AST/50AT/50AVT/60AT/60AVT...
- Page 66 DF40ATH/50ATH/50AVTH/60ATH/60AVTH SUZUKI...
- Page 67 DF40AQH/60AQH SUZUKI...
- Page 68 Prepared by August, 2017 Part No. 99011-88L70-054 Printed in Japan © COPYRIGHT SUZUKI MOTOR CORPORATION 2017...