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Related Manuals for Suzuki DF150
Summary of Contents for Suzuki DF150
- Page 1 DF150 DF175 OWNER’S MANUAL ENGLISH...
- Page 2 Consult your authorized with the contents of this owner’s man- Suzuki marine dealer as required. ual. Be aware of all outboard motor fea- • Do not modify or remove any outboard tures and all safety and maintenance motor standard equipment. To do so requirements.
- Page 3 Please read this • Use extreme caution when purchasing manual carefully before operating your replacement parts or accessories. new Suzuki and review the manual from Suzuki strongly recommends that you time to time. It contains important infor- use only genuine Suzuki replacement mation on safety, operation, and mainte- parts/accessories or their equivalent.
- 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.
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Page 5: Table Of Contents
TABLE OF CONTENTS BREAK-IN ..........25 OPERATION ......... 26 BEFORE ATTEMPTING TO START FUEL AND OIL........4 THE ENGINE........GASOLINE ..........STARTING THE ENGINE ....ENGINE OIL .......... SHIFTING AND SPEED CONTROL ... GEAR OIL ..........STOPPING THE ENGINE ....LOCATION OF SAFETY LABELS .. -
Page 6: Fuel And Oil
Use of improper or poor quality problems resulting from the use of such fuels fuel can affect performance and may are not the responsibility of Suzuki and may not damage your motor and fuel system. be covered under the New Outboard Motor Lim- ited Warranty. -
Page 7: Engine Oil
• Never permit anyone other than an good quality engine oil. adult to refill the fuel tank. Suzuki recommends the use of SAE 10W-40 • If you use a portable fuel tank, always SUZUKI MARINE 4-CYCLE ENGINE OIL. If stop the motor and remove the fuel SUZUKI MARINE 4-CYCLE ENGINE OIL is not tank from the boat to refill it. -
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 Motor cover Power trim and tilt (P.T.T.) switch Flush plug (No. 2) Pilot water hole (Reverse side) Flush plug Clamp bracket Engine oil drain plug Anti-cavitation plate Air vent hole plug Anode Trim tab Gear oil level plug Water intake hole Gear oil drain plug SIDE MOUNT TYPE... -
Page 11: Motor Installation
Consult power listed on the boat’s “Certification your Suzuki dealer for proper battery installa- Plate”. Contact your authorized Suzuki tion information. marine dealer if you are unable to locate •... -
Page 12: Battery Installation
BATTERY INSTALLATION To remove the battery, first disconnect the black lead from the negative terminal, then discon- Secure the battery in a dry area of the boat, nect the red lead from the positive terminal. away from vibration. Connecting and disconnecting the battery as NOTE: described above will help minimize the chance •... -
Page 13: Sub Battery Cable
For getting a detailed informa- lowing range: tion, please inquire of your authorized Suzuki Marine Dealer. 5000 – 6000 DF150 r/min. (min –1... -
Page 14: Propeller Installation
• Trim angle too small (Boat tends to “plow”) • 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. -
Page 15: Trim Tab Adjustment
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 16: Throttle Tension Adjustment
NOTE: board side. 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. -
Page 17: Caution System
If the Caution System activates while you cuit. Consult your authorized Suzuki are operating your outboard motor, stop marine dealer. the motor as soon as possible and cor-... -
Page 18: Over-Revolution Caution System
Revolution Caution System. to do so. WARNING Consult your authorized Suzuki marine dealer if the Over-Revolution Caution System activates for no apparent reason. If you attempt to remove or reinstall the motor cover while the engine is running, you may be injured. -
Page 19: Cooling Water Caution System
COOLING WATER CAUTION SYSTEM NOTICE This system is activated when the cylinder wall temperature is too high due to insufficient water cooling. Your engine may become severely dam- aged If you rely on the Oil Pressure Cau- NOTE: tion System to indicate the need to add The cooling water caution system will not detect engine oil. -
Page 20: Battery Voltage Caution System
If If this system activates, the red CHECK either of the above situations arises, your ENGINE lamp will light and buzzer will begin a authorized Suzuki Marine Dealer must be con- series of beep. sulted as soon as possible. NOTE:... -
Page 21: Diagnostic System
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. -
Page 22: Cancellation
• 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 recom- mends that the engine oil be replaced before canceling the system activation. -
Page 23: Operation Of Tilting Systems
TILT LIMITER CAM OPERATION OF TILTING If the outboard motor contacts the motor well of SYSTEMS the boat while tilting, adjust the tilt limiter cam to limit maximum tilt position. POWER TRIM AND TILT 1. Place the motor in the normal running posi- The “Power Trim and Tilt”... -
Page 24: Manual Tilting
MANUAL TILTING TILT LEVER If you are unable to tilt the motor using the The Tilt Lever is provided so you can support “Power Trim and Tilt” because of an electrical the motor in a tilted position for non-moving problem or some other problem, you can move engine support. -
Page 25: Inspection Before Boating
INSPECTION BEFORE To release the Tilt Lever, tilt the motor all the way up using the Power Trim and Tilt “UP” BOATING switch, and pull up the Tilt Lever. CAUTION WARNING The remote Power Trim and Tilt switch Failure to inspect your boat and motor will work when the ignition switch is off. - Page 26 1. Place the motor in a vertical position, 3. Insert the dipstick all the way into the then remove the motor cover 1 by engine, then remove it again. unlocking the lever 2 and 3. UPPER LIMIT LOWER LIMIT The oil on the dipstick should be between 2.
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Page 27: 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 28: 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 29: Starting The Engine
4. Make sure the lock plate is in place and the WARNING emergency stop switch cord is fastened securely to your wrist or appropriate clothing area such as your belt. Failure to properly attach the emergency stop switch cord or to take proper pre- Side mount Top mount cautions to help ensure that the emer-... - Page 30 If you notice that water does not spray out of the pilot water hole, stop the engine as soon as possible and consult your authorized Suzuki Marine Dealer. 3. Turn the ignition key to the “ON” position, then observe the monitor-tachometer indica- tion.
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Page 31: Shifting And Speed Control
B, as shown in the illustration. A detent or notch is present on all Suzuki con- trol boxes to provide a “feel” for positions A, B, and neutral. Always shift quickly and firmly from... -
Page 32: Stopping The Engine
STOPPING THE ENGINE NOTE: NEUTRAL When it is necessary to stop the engine in an emergency, pull the emergency stop switch lock 32˚ 32˚ plate out of the emergency stop switch by pull- REVERSE ing the emergency stop switch cord. FORWARD To stop the engine: 1. -
Page 33: Mooring
MOORING NOTICE 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 pro- If the ignition key is left ON when the tect it from damage by underwater obstacles at engine is not running, the battery will dis- low tide or corrosion from salt water. -
Page 34: Operation In Shallow Water
OPERATION IN SHALLOW WATER OPERATION IN SALT WATER When operating your boat in shallow water, it After operating the motor in salt water, you may be necessary to tilt the motor higher than should flush the water passages with clean, the normal trim angle. -
Page 35: Motor Removal And Transporting
(1) Remove the motor cover 1. from your boat, we recommend that you ask (2) Remove the eight (8) bolts using a 8 mm box your authorized Suzuki Marine Dealer to do the wrench, then remove the side cover 2. work for you. - Page 36 (3) Pull the drain hose end 3 out. 3. Rest the motor on a case protector with the (4) Loosen the vapor separator drain screw 4 port side downwards as shown. and drain the gasoline into a suitable con- tainer. NOTICE ...
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Page 37: 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 38: Inspection And Maintenance
INSPECTION AND MAINTENANCE NOTICE At each interval, be sure to perform the indi- cated service. Maintenance intervals should be MAINTENANCE, REPLACEMENT judged by number of hours or number of REPAIR EMISSION CONTROL months, whichever comes first. DEVICES AND SYSTEMS MAY BE PER- FORMED BY ANY MARINE SI ENGINE ... - Page 39 When replacing parts on your mechanical experience. If you are not outboard motor, Suzuki strongly recom- sure whether you can successfully com- mends that you use genuine Suzuki parts plete any of the unmarked maintenance or their equivalent. jobs, ask your authorized Suzuki marine dealer to do the maintenance for you.
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Page 40: 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. -
Page 41: Breather And Fuel Line
Remove carbon deposits from the spark plug they must be replaced. Consult your authorized using a small wire brush or spark plug cleaner, Suzuki Marine dealer if it is necessary to and adjust the gap as follows: replace them. 0.7 – 0.8 mm Spark plug gap (0.028 –... -
Page 42: Engine Oil
ENGINE OIL 3. Place a drain pan under the engine oil drain screw. WARNING CAUTION Never perform any ENGINE OIL proce- dure with the motor running, as serious The engine oil temperature may be high injury can occur. enough to burn your fingers when the drain plug is loosened. -
Page 43: Gear Oil
GEAR OIL 7. Check the engine oil level. To check the gear oil level, adjust the engine to an upright position, 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. - Page 44 10 minutes after doing the pro- cedure in the step 4. If the oil level is low, slowly tact your authorized Suzuki marine dealer inject the gear oil into the gear oil level hole 1 for advice. Do not operate your outboard up to the correct level.
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Page 45: Lubrication
LUBRICATION Your authorized Suzuki Marine Dealer may also Proper lubrication is important for the safe, have additional recommendations due to smooth operation and long life of each working regional climate or operating conditions. part of your outboard motor. The following chart Please consult him for advice. -
Page 46: Bonding Wires
BATTERY BONDING WIRES Bonding wires are used to electrically connect If you are using a maintenance-free battery, the engine components so they exist in a com- inspect the window area according to the mon ground circuit. This allows them to be pro- instructions on the battery to make sure the bat- tected against electrolysis by the anodes. -
Page 47: Engine Oil Filter
ENGINE RUNNING – Vertical position – procedures. Suzuki recommends that you flush the water passage by using this method. ENGINE OIL FILTER To flush the water passages, you must obtain a The engine oil filter must be changed by autho- commercially available engine flush device. - Page 48 NOTICE Severe engine damage can occur in as lit- tle 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. Install the flushing attachment 1 so that the water intake holes are covered by the rubber 4.
- Page 49 ENGINE NOT RUNNING – Vertical position – 2. Install garden hose directly or by using a 1. Remove one of the plug A or C from the hose connector matched to flushing point two flushing ports. thread B. Thread B: 0.75 – 11.5 NHR (American stan- dard hose coupling threads for garden hose applications.) 3.
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Page 50: Submerged Motor
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. to completely remove all salt, mud, and sea- weed. -
Page 51: Storage Procedure
If paint damage son), it is recommended that you take your is evident, apply touch up paint before wax- motor to your authorized Suzuki Marine Dealer. ing. However, if you choose to prepare the motor for 9. -
Page 52: 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 53: Emission Control Information
Such damage may not be cov- Spare key ered under warranty. If you are not sure about the proper action to correct a problem, consult your Suzuki marine dealer. EMISSION CONTROL INFORMATION Starter motor will not operate: • Shift lever is not in NEUTRAL. - Page 54 Engine overheats: 4. Remove the Sub battery cable fuse. • 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. 3.
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Page 55: Specifications
IAC, CMP, VSV, VVT fuse: 10A cal system problem. Main fuse: 60A Isolator select fuse: 30A Spare fuse: 60A Consult your SUZUKI marine dealer. Spare fuse: 30A Spare fuse: 10A Spare fuse: 15A Sub battery cable fuse: 15A SPECIFICATIONS... -
Page 56: 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 57: Wiring Diagram
WIRING DIAGRAM DF150... - Page 58 DF175...
- Page 59 Prepared by Outboard Motor Engineering Department April, 2010 Part No. 99011-96J05-03A Printed in Japan © COPYRIGHT SUZUKI MOTOR CORPORATION 2010...