Suzuki Marine DF40A Owner's Manual

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OWNER'S MANUAL

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Page 1 DF40A DF50A DF50AV DF60A DF60AV OWNER’S MANUAL ENGLISH...
Page 2 • Have all scheduled maintenance per- with the contents of this owner’s man- formed. Consult your authorized ual. Be aware of all outboard motor fea- Suzuki marine dealer as required. tures and all safety and maintenance requirements.
Page 3 FOREWORD • Do not modify or remove any outboard motor standard equipment. To do so may make the motor unsafe to use. The proper care and maintenance that your • Learn and obey all applicable naviga- outboard motor requires is outlined in this man- ual.
Page 4 1- 800-336-BOAT (2628). Your state’s department of boating and your Suzuki Marine dealer can supply you with addi- tional information on boating safety and regula- tions, or you can call the U.S. Coast Guard Boating Safety Hotline toll-free at 1-800-368- 5647.
Page 5: Table Of Contents
TABLE OF CONTENTS OPERATION ......... 30 BEFORE ATTEMPTING TO START THE ENGINE........FUEL AND OIL........6 STARTING THE ENGINE ....GASOLINE ..........EMERGENCY STARTING ....FILLING THE FUEL TANK ....SHIFTING AND SPEED CONTROL ... ENGINE OIL .......... STOPPING THE ENGINE ....GEAR OIL ..........
Page 6: Fuel And Oil
• Be sure that any oxygenated fuel blend you injection system components. use has octane ratings of at least 87 pump Your Authorized Suzuki Marine Dealer can pro- octane ((R+M)/2 method). vide you advice about water-separating fuel fil- • If you are not satisfied with the driveability or ter systems and installation.
Page 7: Filling The Fuel Tank
3. Turn the air-vent screw 1 on top of the fuel NOTICE tank cap 2 fully counterclockwise to open the vent. Gasoline kept in the fuel tank for long NOTE: periods of time will produce varnish and VENT SCREW should be CLOSED for trans- gum, which can damage the engine.
Page 8: 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.
Page 9: 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
Anode Flush plug Gear oil level plug Anti-cavitation plate Water intake hole Trim tab (Anode) Gear oil drain plug DF40A/50A/60A Priming bulb MONITOR-TACHOMETER FUEL HOSE SIDE MOUNT TYPE TOP MOUNT TYPE Power trim and tilt (P.T.T.) switch Power trim and tilt (P.T.T.) switch...
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 DF50AV/60AV...
Page 12: Motor Installation
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.
Page 13: Battery Installation
To hook up the battery, first connect the red terminals. lead from the motor to the positive battery ter- If a terminal cap is required, contact your autho- minal, then connect the black lead to the nega- rized Suzuki marine dealer. tive battery terminal.  WARNING Hexagon- Hexagon-...
Page 14: Use Of Electrical Accessories
(min –1 If the engine speed is not within this range, con- sult your authorized Suzuki Marine Dealer to determine which propeller size is best for you. If you change propellers, be sure to perform the above check again, to confirm that the engine speed under full throttle is within the specified range.
Page 15: Propeller Installation
PROPELLER INSTALLATION ADJUSTMENTS  WARNING TRIM ANGLE ADJUSTMENT To help maintain steering stability and good performance, always maintain the proper trim Failure to take proper precautions when angle as shown in the illustration. The appropri- installing or removing the propeller can ate trim angle varies depending on the combi- result in severe personal injury.
Page 16 NOTICE If you operate the boat with the motor trimmed beyond the maximum trim posi- tion, the water intake holes may be above the water line, causing severe engine damage due to overheating. Tilt range Never operate the boat with the motor trimmed beyond the maximum trim posi- Trim range tion.
Page 17: Trim Tab 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. 3. Tighten the bolt that holds the trim tab in place.
Page 18: Setting Of Tilt Upper Limit Position
SETTING OF TILT UPPER LIMIT POSITION 5. Press the “UP” side of the PTT switch for <DF50AV/60A/60AV> three seconds and the buzzer will sound If the outboard motor contacts the motor well of twice briefly indicating the setting has been the boat during full tilt up operation, the upper canceled.

Page 19: Motor Cover Fastening Adjustment
CAUTION SYSTEM  WARNING The caution systems are designed to alert you to certain situations which may cause damage Setting of the tilt upper limit position will to your outboard motor. not prevent the outboard motor from tilt- ing fully up and contacting the motor well NOTICE if the motor’s lower unit hits an object at high speed.
Page 20: Indicator Check
Revolution Caution System. dition that can cause damage to your out- board motor. Consult your authorized Suzuki marine dealer if the Over-Revolution Caution If any of the four lamps does not come on System activates for no apparent reason.
Page 21: Oil Pressure Caution System
3 minutes after beginning of the To check the oil level, stop the engine and above CAUTION system activation. 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.
Page 22 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- sulted as soon as possible. NOTE: If pilot hole water discharge is sufficient, buzzer and TEMP lamp may still operate until engine temperature decreases.
Page 23: Battery Voltage Caution System
• If this caution system activates continuously, Consult your authorized Suzuki marine even after you have stopped using engine or dealer for repair of the control system. boat accessories, contact your authorized...
Page 24: Oil Change Reminder System
OIL CHANGE REMINDER NOTE: • Canceling of the system activation is possible SYSTEM regardless of whether or not the engine oil has been replaced. Once the system has This system informs the operator of the time for operated, however, Suzuki strongly recom- replacing engine oil on the basis of the mainte- mends that the engine oil be replaced before nance schedule.
Page 25: Engine Stalling Caution System
ENGINE STALLING OPERATION OF TILTING CAUTION SYSTEM SYSTEMS This system informs the operator when the POWER TRIM AND TILT motor stalls while it is operating. The “Power Trim and Tilt” is operated by press- When the engine stalls for any reason, the cau- ing the switch.
Page 26: Manual Tilting
2. Pull down the tilt lever as shown in the illus- tration. DF50AV/60A/60AV  CAUTION DF40A/50A 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...
Page 27: Inspection Before Boating
INSPECTION BEFORE  CAUTION BOATING The remote Power Trim and Tilt switch  WARNING will work when the ignition switch is off. If someone activates the switch while you are moving the tilt lever, your hand could Failure to inspect your boat and motor be injured.
Page 28 1. Place the motor in a vertical position, then The oil on the dipstick should be between the remove the motor cover 1 by unlocking the upper and lower limits shown on the dipstick. If lever 2. the oil level indication is near the lower limit, add enough oil to raise the level to the upper limit.
Page 29: Break-In
BREAK-IN • Check the battery solution level. The level should be kept between the MAX and the MIN level lines at all times. If the Proper operation during this break-in period will level drops below the MIN level line, refer help ensure maximum life and performance to MAINTENANCE section.
Page 30: Operation
OPERATION 2. For the next 1 hour: Safe boating conditions permitting, operate the engine in gear at 4000 r/min. or at three- BEFORE ATTEMPTING TO START THE quarter throttle. Avoid running the engine at ENGINE full throttle. 1. Lower the motor into the water. 3.
Page 31 3. Make sure that the motor fuel hose and the 5. Make sure the lock plate is in place and the hose from the boat’s fuel tank are securely emergency stop switch cord is fastened attached and clamped. securely to your wrist or appropriate clothing area such as your belt.
Page 32: Starting The Engine
1. Squeeze the fuel line priming bulb several  WARNING times until you feel resistance. Failure to properly attach the emergency stop switch cord or to take proper pre- cautions to help ensure that the emer- gency stop switch works as intended may result in serious injury or death to the operator or passengers.
Page 33 “START” position to start the engine, the engine as soon as possible and consult your starter system can be damaged. authorized Suzuki Marine Dealer. Turn the ignition key to the “START” posi- tion once and release it to start the engine.
Page 34: Emergency Starting
EMERGENCY STARTING  WARNING If you must get the engine running, but are unable to do so because of starter system fail- ure or battery discharge, you can use the emer- Operating the boat when the emergency gency starting procedure to start the engine. stop switch is not operating properly can be hazardous.
Page 35 3. With the ignition key turned off, loosen the 9. Turn the ignition key to the “ON” position. screws securing the ring gear cover and 10. After following steps for normal starting pro- remove the ring gear cover. cedure, pull the emergency starter rope sharply to start the engine.
Page 36: Shifting And Speed Control
SHIFTING AND SPEED CONTROL NEUTRAL NOTICE 32˚ 32˚ REVERSE Severe engine damage may occur if (a) FORWARD 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.
Page 37: Stopping The Engine
STOPPING THE ENGINE  WARNING NOTE: When it is necessary to stop the engine in an Unauthorized use of your boat could lead emergency, pull the emergency stop switch lock plate out of the emergency stop switch by pull- to an accident or damage to your boat. ing the emergency stop switch cord.
Page 38: Mooring
Trolling speed can be controlled to install the optional Troll Mode switch. Please contact your authorized Suzuki Marine Do not allow your motor to rub against Dealer for more information. quay walls, piers or other boats when the boat is tied up.
Page 39: Operation In Salt Water
How to use the Troll Mode Cancelling the troll mode: Setting the troll mode: The troll mode can be cancelled by shifting the 1. Shift into forward or reverse gear and make remote control lever to the neutral position, or sure that the throttle is fully closed (in-gear by increasing the engine speed to 3000 rpm or idle speed).
Page 40: Motor Removal And Transporting
(1) Fully steer the motor to the starboard from your boat, we recommend that you ask side. your authorized Suzuki Marine Dealer to do the (2) Pull the drain hose end 1 out. work for you. (3) Loosen the vapor separator drain screw 2 and drain the gasoline into a suitable container.
Page 41 3. Rest the motor on a case protector with the NOTICE starboard side downwards as shown. 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.
Page 42: 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 43: Inspection And Maintenance
INSPECTION AND MAINTENANCE NOTICE At each interval, be sure to perform the indi- cated service. Maintenance intervals should be judged by number of hours or number of MAINTENANCE, REPLACEMENT months, whichever comes first. REPAIR EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PER- ...
Page 44 Suzuki recommends that only your indicated in the chart. Failure to perform authorized Suzuki marine dealer or a maintenance more frequently could qualified service mechanic perform main- result in damage.
Page 45: Spark Plug
If the plug tends to run cold (usually evidenced by black- ening of the insulator or a wet electrode), per- formance may suffer. Ask your authorized Suzuki Marine dealer to evaluate either of these problems to determine the cause. Insulator Center...
Page 46 To maintain a strong spark, you should clean NOTICE and adjust the plug at the interval shown in the maintenance schedule. Remove carbon deposits from the spark plug Use of improper spark plugs or improp- using a small wire brush or spark plug cleaner, erly tightening spark plugs can cause and adjust the gap as follows: severe engine damage.
Page 47: Breather And Fuel Line
Consult your authorized Never perform any ENGINE OIL proce- Suzuki Marine Dealer if it is necessary to dure with the motor running, as serious replace them. injury can occur.
Page 48 3. Place a drain pan under the engine oil drain 7. Check the engine oil level. screw.  CAUTION The engine oil temperature may be high enough to burn your fingers when the drain plug is loosened. UPPER LIMIT Wait until the drain plug is cool enough to touch with bare hands before removing it.
Page 49: Gear Oil
If the gear oil has a milky color, it is con- gear oil level hole 1. taminated with water. Immediately con- DF40A/50A/60A MODEL tact your authorized Suzuki marine dealer Approximately 610 ml (20.6/21.5 US/lmp oz.) for advice. Do not operate your outboard will be required.
Page 50: Lubrication
Before applying grease through the steering bracket grease nipple, lock the motor in the fully tilted up position. Your authorized Suzuki Marine Dealer may also have additional recommendations due to regional climate or operating conditions. Please consult him for advice.
Page 51: Bonding Wires
Avoid contact with eyes, skin, clothing, NOTE: and painted surfaces. If battery acid Consult your authorized Suzuki Marine Dealer comes in contact with any of these, flush for inspection and replacement of internal immediately with large amounts of water.
Page 52: Engine Oil Filter
ENGINE OIL FILTER  WARNING The engine oil filter must be changed by an authorized Suzuki Marine Dealer periodically. Replace engine oil filter with a new one at initial If you are not careful when checking or 20 hours (1 month).
Page 53: Flushing The Water Passages
FLUSHING THE WATER NOTICE PASSAGES Severe engine damage can occur in as lit- After operation in muddy, brackish, or salt tle as 15 seconds if the engine is started water, you should flush the water passages and without supplying water to the cooling motor surface with clean, fresh water.
Page 54 4. Place the remote control lever in the “NEU- 2. Install garden hose directly or by using a TRAL” position with the propeller removed hose connector matched to flushing point thread B. and start the motor. As soon as the engine Thread B: 0.75 –...
Page 55: Submerged Motor
1. Get the motor out of the water as soon as possible. 2. Remove the motor cover and immediately 7. Have your authorized Suzuki Marine Dealer wash the engine thoroughly with fresh water inspect the engine as soon as possible.
Page 56: Storage Procedure
(for example, at the end of the boating sea- son), it is recommended that you take your severe personal injury. motor to your authorized Suzuki Marine Dealer. However, if you choose to prepare the motor for When the engine is running, keep your storage yourself, follow the procedure outlined hands, hair, clothing, etc., away from the...
Page 57: Battery Storage
BATTERY STORAGE AFTER STORAGE 1. When the outboard motor will not be used for a month or longer, remove the battery When taking your motor out of storage, follow and store it in a cool, dark place. Do not set the procedure below to return it to operating battery on concrete or earth, as this will condition:...
Page 58: Identification Number Location
Ignition key number stamped position 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. Spare key • Fuse is blown out.
Page 59 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.
Page 60: Specifications
If a new fuse blows in a short time after PTT switch fuse: 15A installation, you may have a major electri- Ignition coil/Injector/ECM/IAC fuse: 30A cal system problem. Fuel pump fuse: 15A Spare fuse: 30A Consult your SUZUKI marine dealer. SPECIFICATIONS Item DF40A DF50A/50AV DF60A/60AV Engine Type...
Page 61: Chart Of Total Operating Hours Indication
CHART OF TOTAL OPERATING HOURS INDICATION MONITOR-TACHOMETER Total Needle 1 operating REV-LIMIT lamp 2 flashing * hours indication 0h-(49h) 50h- 500rpm 60h- 600rpm 540h- 5400rpm 550h- 500rpm 1 time 560h- 600rpm 1 time 1040h- 5400rpm 1 time 1050h- 500rpm 2 times 1540h- 5400rpm 2 times...
Page 62 WIRING DIAGRAM...

This manual is also suitable for:

Df50a Df50av Df60a Df60av