Suzuki DF25A Owner's Manual
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Suzuki DF25A Owner's Manual

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DF25A
DF30A
OWNER'S MANUAL
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ENGLISH
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Summary of Contents for Suzuki DF25A

  • Page 1 DF25A DF30A 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...

  • Page 4: Table Of Contents

    DIAGNOSTIC SYSTEM ...... 26 OIL CHANGE REMINDER SYSTEM..........27 ENGINE STALLING CAUTION SYSTEM..........28 OPERATION OF TILTING SYSTEMS (DF25A/25AR/30A/30AR) . 29 OPERATION OF TILTING SYSTEMS (DF30AQ)......32 OPERATION OF TILTING SYSTEMS (DF25AT/25ATH/30AT/ 30ATH) ........... 33 INSPECTION BEFORE BOATING ... 35 BREAK-IN ..........

  • 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 Always select ple and pets. good quality engine oil. Suzuki recommends the use of SAE 10W-40 or Always take the following precautions when 10W-30 SUZUKI MARINE 4-CYCLE ENGINE refueling: OIL.
  • Page 7 GEAR OIL Suzuki recommends the use of SUZUKI OUT- BOARD MOTOR GEAR OIL. If it is not avail- able, use SAE 90 hypoid gear oil which is rated GL-5 under the API classification system.

  • 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 TILLER HANDLE MODEL (DF25A/30A) Motor cover Starter grip Shift lever Throttle control grip Throttle tension Clamp bracket adjuster Pilot water hole Clamp screw Flush plug Tilt pin Anode Engine oil Anode drain plug Anode Anode (Only transom L)
  • Page 11 TILLER HANDLE MODEL (DF30AQ) Motor cover Starter grip Shift lever Throttle control grip Throttle tension Clamp bracket adjuster Pilot water hole Clamp screw Flush plug Engine oil Anode drain plug Anode Anode Anode (Only transom L) Gear oil level plug Trim tab Water intake hole (Anode)
  • Page 12 TILLER HANDLE MODEL (DF25ATH/30ATH) Motor cover Starter grip Shift lever Throttle control grip Throttle tension Clamp bracket adjuster Pilot water hole Clamp screw Flush plug Engine oil drain plug Anode Anode Anode Anode (Only transom L) Gear oil level plug Trim tab Water intake hole (Anode)
  • Page 13 REMOTE CONTROL MODEL (DF25AR/30AR) Motor cover Starter grip Clamp bracket Pilot water hole Clamp screw Tilt pin Engine oil Anode Flush plug drain plug Anode Anode Anode (Only transom L) Gear oil level plug Trim tab Water intake hole (Anode) Water intake Gear oil drain plug hole...
  • Page 14 REMOTE CONTROL MODEL (DF25AT/30AT) Motor cover Starter grip Power trim and tilt (P.T.T.) switch Clamp bracket Clamp screw Pilot water hole Engine oil drain plug Anode Flush plug Anode Anode Anode (Only transom L) Gear oil level plug Trim tab Water intake hole (Anode) Water intake...
  • Page 15 Power trim and tilt (P.T.T.) switch (DF25AT/30AT) Lock-out Remote control handle lever Warm-up lever Ignition key Throttle tension adjuster Emergency stop switch REMOTE CONTROL BOX (DF25AR/25AT/30AR/30AT) Air-vent screw Fuel line Priming bulb FUEL TANK (All models)

  • Page 16: Motor Mounting

    “Certification Plate”. Contact your authorized Suzuki marine dealer if you are unable to locate the hull “Certificate Plate”. Install the bolts 2, washers 3, washers 4 and nuts 5, as illustrated and tighten the bolts TILLER HANDLE MODEL sequentially.

  • Page 17: Battery Installation

    Consult obstructed by any part of the boat. Also make your Suzuki dealer to determine the proper sure that the battery cable (if provided) doesn’t battery sizing for your boat and engine com- interfere with movement of the motor.
  • Page 18 The electrical system or its components may be damaged if proper battery precautions are Suzuki recommends that you install the termi- not followed. nal cap on the positive battery terminal to pre- vent an accidental short circuit of battery •...

  • Page 19: Use Of Electrical Accessories

    NOTE: Use of too much power for electrical accesso- Ask your authorized Suzuki marine dealer to ries under certain operating conditions can assist you in selecting a suitable propeller for cause the battery to discharge.

  • Page 20: 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. • Proper trim angle 2. Place the stopper 2 on the shaft.
  • Page 21 DF25A/25AR/30A/30AR 3. Lower the motor back down. Make a test run in the boat to determine if the To lower the bow, move the pin towards the trim angle needs to be adjusted. boat. To raise the bow, move the pin away from the boat.
  • Page 22 3. Tighten the bolt that holds the trim tab in NOTICE place. If you operate the boat with the motor trimmed After adjusting the trim tab, check to see if the beyond the maximum trim position, the water boat still tends to veer to one side. If necessary, intake holes may be above the water line, readjust the trim tab.

  • Page 23: Caution System

    If the Caution System activates while you are turn the adjuster counterclockwise. operating your outboard motor, stop the motor as soon as possible and correct the problem or consult your authorized Suzuki marine dealer for assistance. CAUTION LAMP CHECK TILLER HANDLE MODEL Each time the starter system is operated, the three caution lamps –...
  • Page 24 Consult your authorized oil if necessary. If the oil level is correct, con- Suzuki marine dealer. sult your authorized Suzuki marine dealer. REMOTE CONTROL MODEL Each time the ignition key is turned to the “ON” OVER-REVOLUTION CAUTION SYSTEM position, the three caution lamps –...
  • Page 25 If you continue to run, the engine will automati- cally stop 3 minutes after beginning of the Check the oil level and add oil if necessary. If above CAUTION system activation. the oil level is correct, consult your authorized Suzuki Marine Dealer.

  • Page 26: Diagnostic System

    If either of the above situations arises, your The failed system can be identified by the mode authorized Suzuki Marine Dealer must be con- of the CHECK ENGINE lamp flashing. sulted as soon as possible.

  • Page 27: Oil Change Reminder System

    The system is designed to register the total operating hours of the outboard motor and Consult your authorized Suzuki marine dealer function its operation when the preprogrammed for repair of the control system. hours have reached.

  • Page 28: Engine Stalling Caution System

    • 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 29: Operation Of Tilting Systems (Df25A/25Ar/30A/30Ar)

    OPERATION OF TILTING SYSTEMS (DF25A/25AR/30A/30AR) RELEASE LEVER The release lever A has two positions. “Lock” Position Use this position whenever you operate the motor in “REVERSE” gear and whenever you operate the motor in deep water where you do  WARNING not expect to encounter underwater objects.
  • Page 30 1. Shift into “NEUTRAL”. 2. Pull the motor slightly towards you and 2. Move the release lever 1 to the “release” slowly let the motor down. position.  WARNING 3. Grab the handle on the back of the motor cover and tilt the motor all the way up until it is automatically locked in the fully tilted up If you do not take proper precautions when position by the tilt up lock arm 2.
  • Page 31 SHALLOW WATER POSITION To lower the motor back down: To set the shallow water position: 1. Move the release lever 1 to the lock posi- 1. Shift into “NEUTRAL”. tion. 2. Move the release lever 1 to the release position. 2.

  • Page 32: Operation Of Tilting Systems (Df30Aq)

    OPERATION OF TILTING NOTICE SYSTEMS (DF30AQ) If you use the throttle grip handle to raise or TILT LOCK LEVER lower the motor, the handle may break. The tilt lock lever is provided so you can sup- port the motor in a tilted position for non-moving Never use the throttle grip handle to raise or engine support.

  • Page 33: Operation Of Tilting Systems (Df25At/25Ath/30At/30Ath)

    OPERATION OF TILTING To lower the motor: 1. Move the release lever 1 to the release SYSTEMS position. (DF25AT/25ATH/30AT/30ATH) 2. Pull the motor slightly towards you and pull up the tilt lock lever 2. POWER TRIM AND TILT The “Power Trim and Tilt” is operated by press- ing the switch.
  • Page 34 MANUAL TILTING If you are unable to tilt the motor using the “Power Trim and Tilt” because of an electrical problem or some other problem, you can move the motor manually. To tilt the motor up or down, turn the manual release screw A two turns counterclockwise, move the motor to the desired position, then retighten the release screw.

  • Page 35: Inspection Before Boating

    INSPECTION BEFORE NOTICE BOATING Damage can occur if you use the tilt lock lever  WARNING other than when the boat is moored or is oth- erwise stationary. Failure to inspect your boat and motor before The tilt lock lever relieves pressure from the beginning a trip can be hazardous.
  • Page 36 2. Pull out the oil dipstick 1 and wipe oil off NOTICE with a clean cloth. Running the engine with an excessive amount of oil can damage the engine. Do not overfill the engine with oil. 3. Tighten the oil filler cap securely. •...

  • Page 37: Break-In

    BREAK-IN NOTE: You may throttle up beyond the recommended operating range to plane your boat, then imme- Proper operation during this break-in period will diately reduce the throttle to the recommended help ensure maximum life and performance operating range. from your engine. The following guidelines will explain proper break-in procedures.

  • Page 38: Operation

    OPERATION 4. Set the release lever 2 to the “Lock” posi- tion. (DF25A/25AR/30A/30AR/30AQ) BEFORE ATTEMPTING TO START THE DF25A/25AR/30A DF25A/25AR/30A/30AR ENGINE 1. The motor has been lowered into the water. 2. The fuel hose is securely connected to the fuel tank and the motor.
  • Page 39  WARNING 6. The lock plate is in place and the end of the emergency stop switch cord is attached to a part of your body. Failure to properly attach the emergency stop switch cord or to take proper precautions to help ensure that the emergency stop switch works as intended may result in serious injury or death to the operator or passengers.
  • Page 40 STARTING THE ENGINE TILLER HANDLE MODEL 1. Squeeze the fuel line priming bulb several  WARNING times until you feel resistance. Exhaust gas contains carbon monoxide, a dangerous gas that is difficult to detect because it is colorless and odorless. Breath- ing carbon monoxide can cause death or severe injury.
  • Page 41 If the caution lamp does not come on briefly once the starter system is operated, the cau- tion lamp may be broken or a failure may exist in the system circuit. Consult your authorized Suzuki marine dealer.
  • Page 42 Consult your authorized Suzuki marine dealer. 5. Warm up the engine for about 5 minutes.
  • Page 43 Suzuki Marine Dealer. If you must get the engine running, but are unable to do so because of recoil starter sys- tem failure, you can use the emergency starting procedure to start the engine.
  • Page 44 2. Remove the motor cover by turning the lock 5. Remove the four bolts securing the recoil lever in the direction of the arrow and lifting starter assembly and timing belt cover in the cover off. place. 3. Remove the NSI cable 1 from the recoil 6.
  • Page 45 SHIFTING AND SPEED CONTROL 9. Tie a knot in one end of the emergency starter rope located in the tool kit. Tie the NOTICE other end around the screw-driver handle in the tool kit. 10. Hook the knotted end of the rope in the pul- Severe engine damage may occur if (a) engine ley notch and wind the rope around the pul- speed is not allowed to return to idle and boat...
  • Page 46 Speed Control Speed Control After shifting, control the engine speed by twist- To increase speed after you have shifted into ing the throttle control grip. gear, continue moving the control handle for- ward or rearward.  WARNING FASTER Since the same handle is used for shifting and speed control it is possible to move the han- dle past the detent and engage the throttle.
  • Page 47  WARNING 4. After stopping the engine, disconnect the fuel connector from outboard motor.  WARNING If you leave the motor stopped for a long period of time with the fuel line connected, fuel can leak out. If you leave the motor stopped for a long period of time with the fuel line connected, Disconnect the fuel line, whenever you leave fuel can leak out.
  • Page 48 Refer to the TILT UP LOCK ARM section should only operate the motor at slow speeds. (DF25A/25AR/30A/30AR) or TILT LOCK LEVER Refer to the SHALLOW WATER POSITION section (DF25AT/25ATH/30AT/30ATH/30AQ) for section.
  • Page 49 OPERATION IN SHALLOW WATER To lower motor back down: (DF30AQ) 1. Shift into “NEUTRAL”. 2. Move the release lever 1 to the release When operating your boat in shallow water, it may be necessary to tilt the motor higher than position.
  • Page 50 OPERATION IN SHALLOW WATER OPERATION IN FREEZING WEATHER (DF25AT/25ATH/30AT/30ATH) When operating your outboard motor in freez- ing temperatures, you should keep the lower When operating your boat in shallow water, it unit submerged in the water at all times. may be necessary to tilt the motor higher than When taking motor out of the water, stand it up the normal trim angle.

  • Page 51: Motor Removal And Transporting

    MOTOR REMOVAL AND  WARNING TRANSPORTING Gasoline is extremely flammable and toxic. It MOTOR REMOVAL can cause a fire and can be hazardous to peo- TILLER HANDLE MODEL ple and pets. 1. Make sure that the engine has stopped com- pletely.
  • Page 52 If it is necessary to remove the outboard motor from your boat, we recommend that you ask Spilled fuel or fuel vapor can cause a fire and your authorized Suzuki Marine Dealer to do the is hazardous to health. work for you.

  • Page 53: 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 54: 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 55 When replacing Be sure to have maintenance performed parts on your outboard motor, Suzuki strongly according to the schedule in the above chart. recommends that you use genuine Suzuki Suzuki recommends that only your authorized parts or their equivalent.
  • Page 56 Rotation angle able for your operating, consult your authorized New plug 1/2 – 3/4 of a turn Suzuki outboard motor dealer. Re-use plug 1/12 – 1/8 of a turn • Do not overtighten or cross-thread a spark plug, as this will damage the aluminum...
  • Page 57 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 Spark plug gap (0.031 –...
  • Page 58 ENGINE OIL 3. Place a drain pan under the engine oil drain plug.  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 59 7. Check the engine oil level. To change the gear oil: 1. Tilt up the motor fully. (Refer to OPERATION OF TILTING SYS- TEMS section.) Turn the starboard side of the motor down- UPPER LIMIT ward. So that the drain plug 1 is located at the bottom.
  • Page 60 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 Clamp screw changed and the cause of the contamination is corrected.
  • Page 61 • Periodically clean anodes with a wire brush Transom “L” only to remove any coating which might decrease their protective ability. NOTE: Consult your authorized Suzuki Marine Dealer for inspection and replacement of internal anodes attached to the cylinder block/cylinder head. Trim tab...
  • Page 62 BATTERY BONDING WIRE The battery solution level must be kept between DF25A/25AR/30A/30AR the MAX and the MIN level lines at all times. If Bonding wire is used to electrically connect the the level drops below the MIN level line, add...

  • Page 63: Flushing The Water Passages

    The fuel filter must be inspected by authorized Suzuki Marine Dealer periodically. ENGINE RUNNING – Vertical position – Suzuki recommends that you flush the water Low pressure fuel filter passages using this method. Inspect low pressure fuel filter at initial 20 hours (1 month).
  • Page 64 ENGINE NOT RUNNING NOTICE – Vertical position – 1. Make sure that the motor is stopped. Severe engine damage can occur in as little as 2. Remove the plug A from the flushing port. 15 seconds if the engine is started without supplying water to the cooling system.

  • Page 65: Submerged Motor

    ENGINE NOT RUNNING SUBMERGED MOTOR – Full tilt up position – 1. Raise the engine to the full tilt up position. A motor that has been accidentally submerged 2. Follow the “ENGINE NOT RUNNING – Verti- in water must be overhauled as soon as possi- cal position”...

  • Page 66: Storage Procedure

    STORAGE PROCEDURE 7. Take the motor to your authorized Suzuki Marine Dealer as soon as possible to be overhauled. MOTOR STORAGE When storing your motor for a long period of NOTICE time (for example, at the end of the boating sea- son), it is recommended that you take your motor to your authorized Suzuki Marine Dealer.

  • Page 67: After Storage

    If you are not sure about the proper action to ignite. Battery acid is poisonous and corro- correct a problem, consult your Suzuki marine sive, and can cause severe injury. dealer. • Do not smoke and keep battery away from Recoil starter/starter motor will not oper- open flames and sparks.
  • Page 68 If a new fuse blows in a short time after instal- lation, you may have a major electrical system problem. Consult your SUZUKI marine dealer. Main fuse: 30A (white fuse case): All electric starter model ECM fuse: 10A (yellow fuse case): DF25AT/25AR/...

  • Page 69: Specifications

    SPECIFICATIONS Item DF25A DF30A Engine Type 4 Stroke Number of Cylinders Bore and Stroke 60.4 × 57.0 mm (2.38 × 2.24 in) Piston Displacement 490 cm (29.9 cu. in) Maximum output 18.4 kW (25 PS) 22.1 kW (30 PS) Full Throttle Operating Range 5000 –...

  • Page 70: Flowchart Of Oil Change Reminder System

    FLOWCHART OF OIL CHANGE REMINDER SYSTEM Action Starting operation (*1) (*4) Indication Cancellation (*2) (*4) Indication Cancellation (*3) (*4) Indication Cancellation (*3) (*4) Indication Cancellation *1: Lapse of initial 20 hour’s operation *2: Lapse of 80 hour’s operation *3: Lapse of 100 hour’s operation Repeat *4: When performing cancellation before system activation...

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