Suzuki DF25 2006 Rigging Manual
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Suzuki DF25 2006 Rigging Manual

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DF25 -- DF250
2006 RIGGING MANUAL
9 9 5 1 8 - 0 3 0 6 0 - 0 1 E
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Summary of Contents for Suzuki DF25 2006

  • Page 1 DF25 -- DF250 2006 RIGGING MANUAL 9 9 5 1 8 - 0 3 0 6 0 - 0 1 E...

  • Page 2: Remote Controls

    FOREWORD GROUP INDEX This rigging manual details the set-up and pre-deliv- ery procedures for all 2006 model Suzuki outboard motor and accessories. These instructions and recommendations have UNCRATING been drawn up to assist your technicians in all vital areas of installing and setting up SUZUKI outboard motors.

  • Page 3: How To Use This Manual

    Refer back to this table if you are not sure of any symbol(s) meanings. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Data beside it indicates specified Apply THREAD LOCK “1342”. torque. Apply SUZUKI WATER RESISTANT Use special tool. GREASE. Apply SUZUKI SILICONE SEAL.

  • Page 4: General Information

    18 – 28 1.8 – 2.8 13.0 – 20.0 (7 marked or marked bolt) 10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5 MATERIALS REQUIRED WATER RESISTANT SUZUKI SILICONE GREASE SEAL 99000-25160 99000-31120 (250 g/8.8 oz) (50 g/1.7 oz)
  • Page 5 UNCRATING 1-1 UNCRATING CONTENTS UNCRATING PROCEDURES ...............1- 2 DF200/225/250 ..................1- 2...

  • Page 6: Uncrating Procedures

    1. Check damage due to vibration or impact dur- the crate. ing transportation. If there are any abnormal condition found, take photograph in the pres- ence of the carrier and notify to the Suzuki distributor. 2. Cut the strap A with scissors.
  • Page 7 UNCRATING 1-3 5. Remove the bolts D that tighten the steel 8. Remove the engine cover G. frame shown with in the illustration at 8 places in total, right and left. 9. Loosen two bolts I, on the right and left each, and remove the binding strap H.
  • Page 8 1-4 UNCRATING 13. Loosen four bolts O marked with 11. Lift the outboard motor up close to upright in the position using a hoist or crane so that the end illustration and remove the outboard motor plate L of the base plate P may not be lifted from the base plate.
  • Page 9 UNCRATING 1-5 LIFTING ENGINE  DO NOT USE FRONT LIFT EYE WHEN UNCRATING THE ENGINE The front lift eye is not designed nor intended to be used for removing the engine from its horizontal posi- tion in the shipping crate. Attempting to lift the motor from its horizontal crated position using the front lift eye creates a chain or sling angle which can cause the motor to swing when it is lifted.

  • Page 10: Table Of Contents

    MOTOR DIMENSIONS 2-1 MOTOR DIMENSIONS CONTENTS MOTOR DIMENSIONS ..................2- 2 DF4/5/6 ....................2- 2 DF9.9/15 ....................2- 3 DF25-V2, DF25/30, DF40/50, DF60/70, DF90/115/140, DF150/175, DF200/225/250 ..............2- 4 MAJOR DIMENSIONS ..................2- 5 CODE DEFINITION ..................2- 6...

  • Page 11: Motor Dimensions

    2-2 MOTOR DIMENSIONS MOTOR DIMENSIONS DF4/5/6 Unit: mm Tilt 1st position: 0˚ Tilt 2nd position: 4˚ Tilt 3rd position: 8˚ Tilt 4th position: 12˚ Tilt 5th position: 16˚ Shallow 1st position: 32˚ Shallow 2nd position: 44˚ Maximum tilt: 74˚...

  • Page 12: Df9.9/15

    MOTOR DIMENSIONS 2-3 DF9.9/15 Unit: mm Shallow drive 1st position: 27˚ 2nd position: 42˚...

  • Page 13: Df25-V2, Df25/30, Df40/50, Df60/70, Df90/115/140, Df150/175, Df200/225/250

    2-4 MOTOR DIMENSIONS DF25-V2, DF25/30, DF40/50, DF60/70, DF90/115/140, DF150/175, DF200/225/250 Unit: mm...

  • Page 14: Major Dimensions

    MOTOR DIMENSIONS 2-5 MAJOR DIMENSIONS Unit: mm DF200 DF25 DF40 DF60 DF90 DF150 Code DF25-V2 DF140 DF225 DF30 DF50 DF70 DF115 DF175 DF250 S: 117.5 S: 1 215 S: 1 263 L: 1 302.4 L: 1 342 L: 1 390 L: 1 493 L: 1 558 L: 1 611...

  • Page 15: Code Definition

    2-6 MOTOR DIMENSIONS CODE DEFINITION Code Definition and Description Minimum angle from transom board and bracket clamp (transom angle) Note: ABYC recommends boat transom angle be 14° ± 2° Maximum tilt-up angle Maximum steering angle on STBD side from centerline of motor body Maximum steering angle on PORT side from centerline of motor body Distance from centerline to the outermost end of the outboard motor on STBD side Distance from centerline to the outermost end of the outboard motor on PORT side...

  • Page 16: Motor Installation

    MOTOR INSTALLATION 3-1 MOTOR INSTALLATION CONTENTS HORSEPOWER SELECTION .................3- 2 CLAMP BRACKET DIMENSIONS ..............3- 3 DF4/5/6 ....................3- 3 DF9.9/15 ....................3- 3 DF25-V2 ....................3- 4 DF25/30, DF40/50 ..................3- 4 DF60/70, DF90/115 ................3- 5 DF140 .....................3- 5 DF150/175 ....................3- 6 DF200/225/250 ..................3- 6 MINIMUM SPACE ....................3- 7 DF25/30 SINGLE MOTOR ..............3- 7 DF25/30 DUAL MOTOR .................3- 8...

  • Page 17: Horsepower Selection

    3-2 MOTOR INSTALLATION HORSEPOWER SELECTION • States the maximum horsepower of outboard motor that can be safely used on that boat. There is severe product liability potential connected with rigging and selling a boat with an outboard motor exceeding the horsepower capacity limitation. •...

  • Page 18: Clamp Bracket Dimensions

    MOTOR INSTALLATION 3-3 CLAMP BRACKET DIMENSIONS DF4/5/6 Unit: mm (HOLES) (2 PLACES) DF9.9/15 (HOLES) (2 PLACES)

  • Page 19: Df25-V2

    3-4 MOTOR INSTALLATION DF25-V2 Unit: mm (HOLES) (4 PLACES) DF25/30, DF40/50 (HOLES) (8 PLACES)

  • Page 20: Df60/70, Df90/115

    MOTOR INSTALLATION 3-5 DF60/70, DF90/115 Unit: mm HOLES (10 PLACES) HOLES (2 PLACES) HOLES (2 PLACES) DF140 HOLES (10 PLACES) HOLES (2 PLACES) HOLES (2 PLACES)

  • Page 21: Df150/175

    3-6 MOTOR INSTALLATION DF150/175 Unit: mm HOLES (20 PLACES) DF200/225/250 HOLES (20 PLACES)

  • Page 22: Minimum Space

    MOTOR INSTALLATION 3-7 MINIMUM SPACE DF25/30 SINGLE MOTOR 840 mm 230 mm A Minimum D Minimum 33 inch 9 inch 190 mm 230 mm B Maximum E Minimum 7.4 inch 9 inch 190 mm C Maximum 7.4 inch...

  • Page 23: Df25/30 Dual Motor

    3-8 MOTOR INSTALLATION DF25/30 DUAL MOTOR 1 401 mm 181 mm A Minimum E Minimum 55 inch 7.1 inch 561 mm 190 mm B Minimum Maximum 22 inch 7.4 inch 230 mm 190 mm C Minimum G Maximum 9 inch 7.4 inch 230 mm D Minimum...

  • Page 24: Df40/50 Single Motor

    MOTOR INSTALLATION 3-9 DF40/50 SINGLE MOTOR 838 mm 230 mm A Minimum D Minimum 33 inch 9 inch 189 mm 230 mm B Maximum E Minimum 7.4 inch 9 inch 189 mm C Maximum 7.4 inch...

  • Page 25: Df40/50 Dual Motor

    3-10 MOTOR INSTALLATION DF40/50 DUAL MOTOR 1 397 mm 181 mm A Minimum E Minimum 55 inch 7.1 inch 559 mm 189 mm B Minimum Maximum 22 inch 7.4 inch 230 mm 189 mm C Minimum G Maximum 9 inch 7.4 inch 230 mm D Minimum...

  • Page 26: Df60/70 Single Motor

    MOTOR INSTALLATION 3-11 DF60/70 SINGLE MOTOR 838 mm 200 mm A Minimum D Minimum 33 inch 7.9 inch 219 mm 200 mm B Maximum E Minimum 8.6 inch 7.9 inch 219 mm C Maximum 8.6 inch...

  • Page 27: Df60/70 Dual Motor

    3-12 MOTOR INSTALLATION DF60/70 DUAL MOTOR 1 397 mm 121 mm A Minimum E Minimum 55 inch 4.8 inch 559 mm 219 mm B Minimum Maximum 22 inch 8.6 inch 200 mm 219 mm C Minimum G Maximum 7.9 inch 8.6 inch 200 mm D Minimum...

  • Page 28: Df90/115/140 Single Motor

    MOTOR INSTALLATION 3-13 DF90/115/140 SINGLE MOTOR 838 mm 179 mm A Minimum E Minimum 33 inch 7 inch 240 mm B Maximum 9.4 inch 240 mm C Maximum 9.4 inch 179 mm D Minimum 7 inch...

  • Page 29: Df90/115/140 Dual Motor

    3-14 MOTOR INSTALLATION DF90/115/140 DUAL MOTOR 1 498 mm 180 mm A Minimum E Minimum 59 inch 7 inch 660 mm 240 mm B Minimum Maximum 26 inch 9.4 inch 179 mm 240 mm C Minimum G Maximum 7 inch 9.4 inch 179 mm D Minimum...

  • Page 30: Df200/225/250 Single Motor

    MOTOR INSTALLATION 3-15 DF200/225/250 SINGLE MOTOR 940 mm 184 mm A Minimum D Minimum 37 inch 7.2 inch 286 mm 184 mm B Maximum E Minimum 11.3 inch 7.2 inch 286 mm C Maximum 11.3 inch...

  • Page 31: Df200/225/250 Dual Motor

    3-16 MOTOR INSTALLATION DF200/225/250 DUAL MOTOR 1 626 mm 114 mm A Minimum E Minimum 64 inch 4.5 inch 686 mm 286 mm B Minimum Maximum 27 inch 11.3 inch 184 mm 286 mm C Minimum G Maximum 7.2 inch 11.3 inch 184 mm D Minimum...

  • Page 32: Transom Centerline

    MOTOR INSTALLATION 3-17 TRANSOM CENTERLINE SINGLE MOTOR 1. Prepare a tape measure, marking pen and long ruler. 2. On the transom surface, measure the horizontal distance from chine to chine. Measure the center (1/2) of the chine-to-chine distance and mark B that position on the transom surface. 3.
  • Page 33 3-18 MOTOR INSTALLATION SINGLE MOTOR Checking of vertical line A. Check that the right and left spaces divided by vertical line A are equal. 1. Check that the length of lines D and D” are equal. 2. Check that the length of lines E and E” are equal. E”...

  • Page 34: Dual Motor

    MOTOR INSTALLATION 3-19 DUAL MOTOR For the distance between the centers, refer to minimum space of the previous section. 1. On the horizontal chine-to-chine distance, mark B the point at 1/2 of the distance between the engine centers away from and on each side of the vertical line A that has been previously measured for single engine mounting.

  • Page 35: Transom Drilling Template Instructions

    3-20 MOTOR INSTALLATION TRANSOM DRILLING TEMPLATE INSTRUCTIONS Tool name Part number Applicable model Transom Drilling Template 09914-89510 DF25/30 – DF200/225/250 TRANSOM DRILLING TEMPLATE There are two sizes, A and B, of the drilled hole. Hole name Model Drill bit diameter DF25/30 12.5 mm DF40/50...

  • Page 36: Df25/30, Df40/50 Bolt Hole Position

    MOTOR INSTALLATION 3-21 DF25/30, DF40/50 BOLT HOLE POSITION Unit: mm DF25/30, DF40/50 Clamp bracket DF60/70, DF90/115, DF140 BOLT HOLE POSITION DF60/70, DF90/115, DF140 Clamp bracket...

  • Page 37: Df150/175 Bolt Hole Position

    3-22 MOTOR INSTALLATION DF150/175 BOLT HOLE POSITION Unit: mm DF150/175 Clamp bracket DF200/225/250 BOLT HOLE POSITION DF200/225/250 Clamp bracket...

  • Page 38: Use Of Transom Drilling Template

    MOTOR INSTALLATION 3-23 USE OF TRANSOM DRILLING TEMPLATE 1. Get ready for a tape measure, water-based marking pen and long ruler. 2. On the transom surface, measure the horizontal distance from chine to chine. Measure the center (1/2) of the chine-to-chine distance and mark that position on the tran- som surface.
  • Page 39 3-24 MOTOR INSTALLATION 6. Install the Transom Drilling Template to transom board so that its center two holes are fitted to the vertical centerline A. Centerline A Transom Drilling Template Hole Centerline A Transom Drilling Template Hole 7. Adjust the height and horizontal position of Transom Drilling Template with its wing bolts.
  • Page 40 MOTOR INSTALLATION 3-25 9. Recheck the transom height from the upper edge of the tran- som board where there is a cutout of Transom Drilling Tem- plate using a tape measure. • In other words, confirm the position of the anti-Cavitation Plate.

  • Page 41: Lifting Motor

    3-26 MOTOR INSTALLATION LIFTING MOTOR  DO NOT USE FRONT LIFT EYE WHEN UNCRATING THE MOTOR The front lift eye is not designed nor intended to be used for removing the motor from its horizontal posi- tion in the shipping crate. Attempting to lift the motor from its horizontal crated position using the front lift eye creates a chain or sling angle which can cause the motor to swing when it is lifted.

  • Page 42: Engine Mount

    • Install the large washer B on the transom board side. • To ensure a water-tight engine installation, sealant (SUZUKI SILICONE SEAL or equivalent) should be applied to all bolt holes. • If tightening torque cannot reach to the specified torque due to weak transom material, it is necessary to...

  • Page 43: Mounting To The Transom Df60/70, Df90/115, Df140

    Part number Q’ty Bolt (1/2-20 UNF) 09100-12086 Washers 09160-13017 (Large: OD45 mm) Washers 09160-13016 (Small: OD26 mm) 09159-12062 41153-94500 Washer (with 2 holes) 41153-93J00 SUZUKI highly recommend to use six mounting bolts for a rigid-hull inflatable boat or similar application.
  • Page 44 • Drill the upper holes center at least 25 mm (1.0 in) down from the transom top surface. • To ensure a water-tightness, sealant (SUZUKI SILICONE SEAL or equivalent) should be applied to all bolt holes. Apply the sealant to shanks of bolts, but not threads.

  • Page 45: Bolt Transom Table ('06 Model)

    3-30 MOTOR INSTALLATION BOLT TRANSOM TABLE (’06 MODEL)

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