DF150 EN DF175

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ENGLISH

DF150DF175

OWNER’S MANUAL

EN

https://www.boat-manuals.com/

Prepared by

Outboard Motor Engineering Department

April, 2010

Part No. 99011-96J05-03A

Printed in Japan

© COPYRIGHT SUZUKI MOTOR CORPORATION 2010

IMPORTANT WARNING/ CAUTION/ NOTICE/ NOTEPlease read this manual and follow its instruc-tions carefully. To emphasize special informa-tion, the symbol and the words WARNING,CAUTION, NOTICE and NOTE have specialmeanings. Pay special attention to the mes-sages highlighted by these signal words.

NOTE:Indicates special instructions to make mainte-nance easier or instructions clearer.

BREAK-IN INFORMATIONFOR YOUR OUTBOARD MOTORThe first 10 hours are the most important in thelife of your engine. Proper operation during thisbreak-in period is essential to help ensure max-imum life and performance.Refer to the BREAK-IN section of this manualfor specific break-in recommendations.

IMPORTANT NOTICE TO OWNERS

WARNING

Indicates a potential hazard that couldresult in death or serious injury.

CAUTION

Indicates a potential hazard that couldresult in minor or moderate injury.

NOTICE

Indicates a potential hazard that couldresult in damage to the motor or boat.

WARNING

Failure to take the proper precautionsmay increase the risk of death or severeinjury to you and your passengers.

• Prior to first-time use of your outboardmotor, familiarize yourself thoroughlywith the contents of this owner’s man-ual. Be aware of all outboard motor fea-tures and all safety and maintenancerequirements.

• Inspect the boat and motor before each

trip. See the INSPECTION BEFOREBOATING section for important items.

• Become thoroughly familiar with alloperating and handling characteristicsof your boat and motor. Practice at lowand moderate speeds until you arecompetent at handling the boat andmotor. Do no attempt to operate at maxi-mum performance until you are com-pletely familiar with all of thesecharacteristics.

• Carry boating safety and emergencyequipment. This important equipmentincludes; flotation aids for each person(plus one throwable buoyant cushion inany boat 16 feet or longer), fire extin-guisher, sound signaling device, visualdistress signals, anchor, bilge pump,bucket, compass, emergency starterrope, extra fuel and oil, first aid kit,flashlight, food and water, mirror, pad-dles, tool kit, and transistor radio. Besure you are carrying the equipmentappropriate for your trip before launch-ing.

• Never start the engine or let it runindoors or where there is little or noventilation. Exhaust gas contains car-bon monoxide, a gas that is colorlessand odorless and can cause death orsevere injury.

• Instruct your passengers on how tooperate the boat, how to deal withemergencies, and how to operatesafety and emergency equipment.

• Do not hold onto the motor cover orany other parts of your outboard motorwhile getting on or off your boat.

• Ensure that everyone wears a life jacketon board.

• Never operate the boat while under theinfluence of alcohol or other drugs.

• Distribute all weight load evenly in theboat.

• Have all scheduled maintenance per-formed. Consult your authorizedSuzuki marine dealer as required.

• Do not modify or remove any outboardmotor standard equipment. To do somay make the motor unsafe to use.


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NOTE:Mounting radio transceiver or navigationalequipment antennae too close to the enginecowling can cause electrical noise interference.Suzuki recommends that antennae be mountedat least one meter (40 inches) away from theengine cowling.

• Learn and obey all applicable naviga-tion rules.

• Pay attention to all weather forecasts.Do not set out if weather is unsettled.

• Use extreme caution when purchasingreplacement parts or accessories.Suzuki strongly recommends that youuse only genuine Suzuki replacementparts/accessories or their equivalent.Inappropriate or poor quality replace-ment parts or accessories can createunsafe operating conditions. FOREWORD

The proper care and maintenance that youroutboard motor requires is outlined in this man-ual. By following these instructions explicitly youwill ensure a long trouble-free operating life foryour outboard motor. This outboard motor alsoconforms to the U.S Environmental ProtectionAgency emission regulations which apply tonew outboard motors. The proper adjustment ofengine components is necessary for this out-board motor to comply with the EPA regula-tions. Therefore, please follow the maintenanceinstructions closely to ensure emission compli-ance. Your Suzuki dealer has experienced tech-nicians that are trained to provide your outboardmotor with the best possible service with theright tools and equipment.

All information in this manual is based on thelatest product information available at the timeof publication. Due to improvements or otherchanges, there may be discrepancies betweenthis manual and your outboard motor. Suzukireserves the right to make production changesat any time, without notice and without incurringany obligation to make the same or similarchanges to outboard motor previously built orsold.

This manual should be considered a per-manent part of the outboard motor andshould remain with the outboard motorwhen resold or otherwise transferred to anew owner or operator. Please read thismanual carefully before operating yournew Suzuki and review the manual fromtime to time. It contains important infor-mation on safety, operation, and mainte-nance.


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PLEASE PRESERVE NATUREProtect and preserve your boating waters andtheir land access. Never pollute the water orland with oil, gas, or other harmful products. Forexample, make sure you dispose of used gearoil properly following a gear oil change. Alsoremember not to litter. With a little bit of effort,our boating waters can be enjoyed for manyyears to come.

Suzuki Motor Corporation believes in conserva-tion and protection of Earth’s natural resources.

To that end, we encourage every outboardmotor owner to recycle, trade in, or properly dis-pose of, as appropriate, used oil and batteries.

TAKE A BOATING SAFETY CLASSAn educated boater will enjoy boating more andwill be a safer boater. We recommend that youtake a boating safety class.Classes explaining required and recommendedequipment for small boats and offering trainingin good seamanship are conducted by the U.S.Coast Guard Auxiliary, the U.S. Power Squad-ron, and many Red Cross chapters. For infor-mation on classes in your area, call toll-free 1-800-336-BOAT (2628).Your state’s department of boating and yourSuzuki Marine dealer can supply you with addi-tional information on boating safety and regula-tions, or you can call the U.S. Coast GuardBoating Safety Hotline toll-free at 1-800-368-5647.

California Proposition 65 Warning

WARNING

Engine exhaust, some of its constituents,and certain product components containor emit chemicals known to the State ofCalifornia to cause cancer and birthdefects or other reproductive harm.


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TABLE OF CONTENTS

FUEL AND OIL....................................... 4GASOLINE............................................ 4ENGINE OIL .......................................... 5GEAR OIL ............................................. 5

LOCATION OF SAFETY LABELS ..... 6LOCATION OF PARTS......................... 8MOTOR INSTALLATION .................... 9BATTERY INSTALLATION ................ 9

BATTERY REQUIREMENT .................. 9BATTERY INSTALLATION ................ 10SUB BATTERY CABLE...................... 11DUAL BATTERY CHARGING SYSTEM.............................................. 11USE OF ELECTRICAL ACCESSORIES................................... 11

PROPELLER SELECTION AND INSTALLATION................................... 11

PROPELLER SELECTION ................. 11PROPELLER INSTALLATION ........... 12

ADJUSTMENTS.................................... 12TRIM ANGLE ADJUSTMENT............. 12TRIM TAB ADJUSTMENT.................. 13THROTTLE TENSION ADJUSTMENT .................................... 14IDLE SPEED ADJUSTMENT.............. 14MOTOR COVER FASTENING ADJUSTMENT .................................... 14

CAUTION SYSTEM............................. 15INDICATOR CHECK........................... 15OVER-REVOLUTION CAUTION SYSTEM.............................................. 16OIL PRESSURE CAUTION SYSTEM.............................................. 16COOLING WATER CAUTION SYSTEM.............................................. 17BATTERY VOLTAGE CAUTION SYSTEM.............................................. 18

DIAGNOSTIC SYSTEM ...................... 19OIL CHANGE REMINDER SYSTEM................................................. 19

SYSTEM ACTIVATION....................... 19CANCELLATION ................................ 20

ENGINE STALLING CAUTION SYSTEM................................................. 20OPERATION OF TILTING SYSTEMS............................................... 21

POWER TRIM AND TILT .................... 21TILT LIMITER CAM............................. 21MANUAL TILTING .............................. 22TILT LEVER ........................................ 22

INSPECTION BEFORE BOATING ... 23

BREAK-IN ............................................. 25OPERATION ......................................... 26

BEFORE ATTEMPTING TO START THE ENGINE....................................... 26STARTING THE ENGINE ................... 27SHIFTING AND SPEED CONTROL ... 29STOPPING THE ENGINE ................... 30MOORING ........................................... 31OPERATION IN SHALLOW WATER................................................ 32OPERATION IN SALT WATER .......... 32OPERATION IN FREEZING WEATHER........................................... 32

MOTOR REMOVAL AND TRANSPORTING ................................. 33

MOTOR REMOVAL ............................ 33MOTOR TRANSPORTING.................. 33

TRAILERING ....................................... 35INSPECTION AND MAINTENANCE................................... 36

MAINTENANCE SCHEDULE ............. 36SPARK PLUG ..................................... 38BREATHER AND FUEL LINE ............ 39ENGINE OIL ........................................ 40GEAR OIL ........................................... 41LUBRICATION.................................... 43CORROSION PREVENTION .............. 43

ANODES............................................ 43BONDING WIRES .............................. 44

BATTERY............................................ 44ENGINE OIL FILTER .......................... 45FUEL FILTER...................................... 45BALANCER CHAIN ............................ 45

FLUSHING THE WATER PASSAGES............................................. 45SUBMERGED MOTOR....................... 48STORAGE PROCEDURE ................... 49

MOTOR STORAGE............................. 49BATTERY STORAGE......................... 50

AFTER STORAGE ............................... 50GENERAL INFORMATION............... 50

WARRANTIES .................................... 50IDENTIFICATION NUMBER LOCATION.......................................... 50

EMISSION CONTROLINFORMATION.................................... 51TROUBLESHOOTING........................ 51SPECIFICATIONS ............................... 53CHART OF TOTAL OPERATING HOURS INDICATION ......................... 54FLOWCHART OF OIL CHANGE REMINDER SYSTEM.......................... 54WIRING DIAGRAM ............................ 55


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FUEL AND OIL

GASOLINESuzuki highly recommends that you use alco-hol-free unleaded gasoline whenever possible,with a minimum pump octane rating of 87((R+M)/2 method). In some areas, the onlyfuels that are available are oxygenated fuels.Oxygenated fuels which meet the minimumoctane requirement and the requirementsdescribed below may be used in your outboardmotor without jeopardizing the New OutboardMotor Limited Warranty.

NOTE:Oxygenated fuels are fuels which contain oxy-gen-carrying additives such as MTBE or alco-hol.

Suzuki recommends that you install a water-separating fuel filter assembly between yourboat’s fuel tank(s) and outboard motor(s). Fuelfiltration systems of this type will help preventwater that may be present in your boat’s fueltank(s) from contaminating your motor’s elec-tronic fuel injection system. Water contamina-tion can cause poor engine performance andcan also cause damage to the electronic fuelinjection system components.Your Authorized Suzuki Marine Dealer can pro-vide you advice about water-separating fuel fil-ter systems and installation.

NOTICE

Use of leaded gasoline can cause enginedamage. Use of improper or poor qualityfuel can affect performance and maydamage your motor and fuel system.

Use only unleaded gasoline. Do not usefuel having lower than the recommendedoctane, or fuel that may be stale or con-taminated by dirt/water etc.

Gasoline Containing MTBEUnleaded gasoline containing MTBE (MethylTertiary Butyl Ether) may be used in your out-board motor if the MTBE content is not greaterthan 15%. This oxygenated fuel does not con-tain alcohol.

Gasoline/Ethanol BlendsBlends of unleaded gasoline and ethanol (grainalcohol), also known as gasohol, may be usedin your outboard motor if the ethanol content isnot greater than 10%.

Gasoline/Methanol BlendsAvoid using blends of unleaded gasoline andmethanol (wood alcohol) whenever possible.DO NOT USE fuels containing more than 5%methanol under any circumstances. Fuel sys-tem damage or outboard motor performanceproblems resulting from the use of such fuelsare not the responsibility of Suzuki and may notbe covered under the New Outboard Motor Lim-ited Warranty.

Fuel containing 5% or less methanol may besuitable for use in your outboard motor if theycontain cosolvents and corrosion inhibitors.

Fuel Pump LabelingIn some states, pumps that dispense oxygen-ated fuels are required to be labeled for the typeand percentage of oxygenate, and whetherimportant additives are present. Such labelsmay provide enough information for you todetermine if a particular blend of fuel meets therequirements listed above. In other states,pumps may not be clearly labeled as to the con-tent or type of oxygenate and additives. If youare not sure that the fuel you intend to usemeets these requirements, check with the ser-vice station operator or the fuel suppliers.

NOTE:• Be sure that any oxygenated fuel blend you

use has octane ratings of at least 87 pumpoctane ((R+M)/2 method).

• If you are not satisfied with the driveability orfuel economy of your outboard motor whenyou are using a gasoline/alcohol blend, youshould switch back to unleaded gasoline con-taining no alcohol.


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• If engine pinging is experienced, substituteanother brand, as there are differencesbetween brands.

• Unleaded gasoline will extend spark plug life.

WARNING

Gasoline is extremely flammable andtoxic. It can cause a fire and can be haz-ardous to people and pets.

Always take the following precautionswhen refueling:• Never permit anyone other than an

adult to refill the fuel tank.• If you use a portable fuel tank, always

stop the motor and remove the fueltank from the boat to refill it.

• Do not fill the fuel tank all the way tothe top or fuel may overflow when itexpands due to heating by the sun.

• Be careful not to spill fuel. If you do,wipe it up immediately.

• Do not smoke, and keep away fromopen flames and sparks.

NOTICE

Gasoline kept in the fuel tank for longperiods of time will produce varnish andgum, which can damage the engine.

Always use fresh gasoline.

NOTICE

Fuels containing alcohol can cause paintdamage, which is not covered under theNew Outboard Motor Limited Warranty.

Be careful not to spill fuel containingalcohol while refueling. If fuel is spilled,wipe it up immediately.

ENGINE OIL

Oil quality is a major contributor to yourengine’s performance and life. Always selectgood quality engine oil.Suzuki recommends the use of SAE 10W-40SUZUKI MARINE 4-CYCLE ENGINE OIL. IfSUZUKI MARINE 4-CYCLE ENGINE OIL is notavailable, select a NMMA certified FC-W oil orgood quality 4-cycle motor oil from the followingchart according to the average temperatures inyour area.

NOTE:In very cold weather (below 5°C (41°F), useSAE (or NMMA FC-W) 5W-30 for easier start-ing and smooth operation.

GEAR OILSuzuki recommends the use of SUZUKIHYPOID GEAR OIL. If it is not available, useSAE 90 hypoid gear oil which is rated GL-5under the API classification system.

NOTICE

Use of poor quality engine oil canadversely affect engine performance andlife.

Suzuki recommends that you use SuzukiMarine 4-Cycle Engine Oil or its equiva-lent.

–20 –10 0 10 20 30

–4 14 32 50 68 86

40

104TEMP.

API Classification SAE Viscosity Grade

10W–40

10W–30

˚F

˚C

SGSHSJSLSM


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LOCATION OF SAFETY LABELS

Read and follow all of the labels on your out-board motor or fuel tank. Make sure you under-stand all of the labels.

Keep the labels on your outboard motor or fueltank. Do not remove them for any reason.


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LOCATION OF PARTS

MONITOR-TACHOMETER PRIMING BULB

Power trim and tilt (P.T.T.) switch

Remote control handle

Warm-up leverLock-out lever Ignition key

Emergency stop switch

Throttle tension adjuster

SIDE MOUNT TYPE

TOP MOUNT TYPE

REMOTE CONTROL BOX (Option)

Engine oil drain plug

Flush plugClamp bracket

Anode

Water intake hole

Power trim and tilt(P.T.T.) switch

Pilot water hole (Reverse side)

Anti-cavitation plate

Trim tab

Motor cover

Gear oil level plug

Air vent hole plug

Gear oil drain plug

Flush plug (No. 2)

Power trim and tilt(P.T.T.) switch

Remote control handle

Free accelerator button

Ignition key

Emergencystop switch


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MOTOR INSTALLATION

NOTE:It is against federal regulations for any marinedealer to service a motor that exceeds the rec-ommended maximum horsepower for yourboat.

Suzuki strongly recommends that you haveyour outboard motor, controls and gaugesinstalled by your authorized Suzuki MarineDealer. He has the tools, the facilities and theknow-how.

WARNING

Overpowering your boat can be hazard-ous. Excessive horsepower will have anadverse effect on hull safety and maycause operating/handling difficulties. Theboat may also sustain stress and hulldamage.

Never install an outboard motor withhorsepower exceeding the manufac-turer’s recommended maximum horse-power listed on the boat’s “CertificationPlate”. Contact your authorized Suzukimarine dealer if you are unable to locatethe hull “Certificate Plate”.

WARNING

Failure to have your outboard motor andassociated controls and gauges properlyinstalled can result in personal injury ordamage.

Suzuki strongly recommends that youhave your outboard motor, controls andgauges installed by your authorizedSuzuki marine dealer. He has the tools,the facilities, and the know-how to do thejob correctly.

BATTERY INSTALLATION

BATTERY REQUIREMENTChoose a 12 Volt cranking-type lead acid bat-tery that meets the specifications shown below.

850 Marine Cranking Amps (MCA)/ABYC,or 670 Cold Cranking Amps (CCA)/SAEor 180 Reserve Capacity (RC) Minutes/SAE

NOTE:• The specifications listed above are the mini-

mum battery rating requirements for startingthe engine.

• If your boat application requires additionalbattery loads, it is recommended that an aux-iliary battery or batteries be installed. Consultyour Suzuki dealer for proper battery installa-tion information.

• Dual-purpose (Cranking/Deep-cycle) batter-ies can be used if they meet the minimumspecifications listed above (MCA, CCA, orRC).

• Do not use a Deep Cycle battery for the maincranking battery.

• The use of Maintenance-Free, sealed, or Gel-Cell batteries is not recommended becausethey may not be compatible with Suzuki’scharging system.

• When connecting batteries in parallel, theymust be of the same type, capacity, manufac-turer, and of similar age. When replacementis necessary, they should be replaced as aset. Consult your Suzuki dealer for properbattery installation information.


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BATTERY INSTALLATIONSecure the battery in a dry area of the boat,away from vibration.

NOTE:• It is recommended that the battery be

installed in an enclosed battery case.• When connecting batteries, hexagon-nuts

must be used to secure battery leads to bat-tery posts.

To hook up the battery, first connect the redlead from the motor to the positive battery ter-minal, then connect the black lead to the nega-tive battery terminal.

Red lead

Sub battery cable

Black lead

Hexagon-nut

To remove the battery, first disconnect the blacklead from the negative terminal, then discon-nect the red lead from the positive terminal.

Connecting and disconnecting the battery asdescribed above will help minimize the chanceof creating an accidental short circuit andsparks.

WARNING

Batteries produce flammable hydrogengas and may explode if they are nearflames or sparks.

• Never smoke or cause sparks whenworking near the battery. Keep the bat-tery away from open flames. To avoidcreating a spark when charging the bat-tery, connect the battery charger cablesto the proper terminals before turningthe charger on.

• Do not place the battery near the fueltank.

WARNING

Battery acid is poisonous and corrosive.It can cause severe injury and can dam-age painted surfaces.

Avoid contact with eyes, skin, clothing,and painted surfaces. If battery acidcomes in contact with any of these, flushimmediately with large amounts of water.If acid contacts the eyes or skin, getimmediate medical attention.

NOTICE

The electrical system or its componentsmay be damaged if proper battery pre-cautions are not followed.

• Be sure to attach battery leads cor-rectly.

• Do not disconnect battery leads fromthe battery while the engine is running.


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SUB BATTERY CABLEThe sub battery cable 1 is used to supply volt-age to the engine control system. In the midstof the cable, a 15A fuse 2 is provided to pro-tect the control circuit.If the sub battery cable is not correctly con-nected to the battery, engine cannot be started.

DUAL BATTERY CHARGING SYSTEMIf installing the battery isolator lead assembly,available as optional parts, and changing theposition of 30A fuse from standard to option,dual battery charging system will be effective.Be sure to check if the 30A fuse in OPT positionis blown, when the second battery for accesso-ries will not be charged. Please ask your authorized Suzuki MarineDealer for installation of the isolator leadassembly.

USE OF ELECTRICAL ACCESSORIESThe amount of power (12V DC) available foraccessories depends on the operating condi-tion of the motor. For getting a detailed informa-tion, please inquire of your authorized SuzukiMarine Dealer.

NOTE:Use of too much power for electrical accesso-ries under certain operating conditions cancause the battery to discharge.

PROPELLER SELECTION AND INSTALLATION

PROPELLER SELECTIONIt is essential to use a propeller on your out-board motor that is properly matched to yourboat’s operating characteristics. The speed ofthe engine when you operate your boat at fullthrottle depends on the propeller you use.Excessive engine speed can seriously damagethe motor, while low engine speed at full throttlewill adversely affect the performance. Youroperating load will also affect propeller selec-tion. Smaller loads generally require larger-pitch propellers; larger loads generally requiresmaller-pitch propellers. Your authorized SuzukiMarine Dealer will assist you in selecting a suit-able propeller for your boat.

You can determine if your propeller is appropri-ate for use with your boat by using a tachome-ter to measure engine speed when operatingyour boat at full throttle, under minimum loadconditions. If you are using an appropriate pro-peller, the engine speed will be within the fol-lowing range:

If the engine speed is not within this range, con-sult your authorized Suzuki Marine Dealer todetermine which propeller size is best for you.

If you change propellers, be sure to perform theabove check again, to confirm that the enginespeed under full throttle is within the specifiedrange.

NOTICE

Installing a propeller with either too muchor too little pitch will cause incorrectmaximum engine speed, which mayresult in severe damage to the motor.

Ask your authorized Suzuki marinedealer to assist you in selecting a suit-able propeller for your boat.

DF1505000 – 6000r/min. (min–1)

DF1705500 – 6100r/min. (min–1)


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PROPELLER INSTALLATION

To install a propeller on your outboard motor,use the following procedure:

1. Coat the propeller shaft splines 1 liberallywith Suzuki water resistant grease to helpprevent corrosion.

2. Place the stopper 2 on the shaft.3. Align the propeller 3 with the propeller shaft

splines and slide the propeller onto the shaft.4. Place the spacer 4 and washer 5 on the

shaft.5. Install the propeller nut 6 and tighten it with

a torque wrench to 50 – 60 N·m (5.0 – 6.0kg-m/36.0 – 43.5 lb-ft).

6. Align the grooves in the propeller nut withthe hole in the shaft, then insert the cotterpin 7 and bend the pin ends over to lock it inplace.

To remove the propeller, reverse the above pro-cedure.

WARNING

Failure to take proper precautions wheninstalling or removing the propeller canresult in severe personal injury.

When installing or removing the propeller:• Always shift into “Neutral” and remove

the emergency stop switch lock plateso that the motor cannot be startedaccidentally.

• Wear gloves to protect hands, and“lock” the propeller by placing a blockof wood between the blades and theanti-cavitation plate.

ADJUSTMENTS

TRIM ANGLE ADJUSTMENTTo help maintain steering stability and goodperformance, always maintain the proper trimangle as shown in the illustration. The appropri-ate trim angle varies depending on the combi-nation of the boat, engine, and propeller, as wellas operating conditions.

Make a test run in the boat to determine if thetrim angle needs to be adjusted. Adjust the trimangle using the Power Trim and Tilt system.Refer to the POWER TRIM AND TILT section.

If you still cannot achieve good performance,there may be a problem with engine mountingheight. Consult your dealer for assistance.

• Trim angle too small (Boat tends to “plow”)

• Trim angle too large (Boat tends to “porpoise”)

• Proper trim angle


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WARNING

Trim angle greatly affects steering stabil-ity. If the trim angle is too small, the boatmay “plow” or “bow steer”. If the trimangle is too large, the boat may “chinewalk” from side to side or “porpoise” upand down. These conditions, which resultin loss of steering control, can causeoccupants to be thrown overboard.

Always maintain proper trim angle basedon the combination of your boat, engine,and propeller, as well as operating condi-tions.

WARNING

When the motor is tilted beyond the maxi-mum trim position, the swivel bracket willnot have side support from the clampbracket and the tilt system will be unableto cushion the engine if the lower unitstrikes an obstruction. This could lead tooccupant injury.

Do not operate the engine above 1500 r/minor operate the boat in a planing attitudewith the motor tilted beyond the maxi-mum trim position.

Trim range

Tilt range

TRIM TAB ADJUSTMENTThis adjustment is used to compensate for thepossible tendency of your boat to veer slightlyto port or starboard. This tendency could bedue to such things as propeller torque, motormounting position, etc.

To adjust the trim tab:1. Loosen the bolt A that holds the trim tab in

place.

NOTICE

If you operate the boat with the motortrimmed beyond the maximum trim posi-tion, the water intake holes may be abovethe water line, causing severe enginedamage due to overheating.

Never operate the boat with the motortrimmed beyond the maximum trim posi-tion.


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2. If the boat tends to veer to port, move therear end of the trim tab toward the port side.If the boat tends to veer to starboard, movethe rear end of the trim tab toward the star-board side.

3. Tighten the bolt that holds the trim tab inplace.

After adjusting the trim tab, check to see if theboat still tends to veer to one side. If necessary,readjust the trim tab.

THROTTLE TENSION ADJUSTMENTThe tension of the remote control handle can beadjusted according to your preference. Toincrease the tension, turn the adjuster A clock-wise. To decrease the tension, turn the adjustercounterclockwise.

NOTE:Top mount typeWhen adjusting the tension of the remote con-trol handle, consult your authorized SuzukiMarine Dealer.

Side mounttype

IDLE SPEED ADJUSTMENTThe idle speed has been factory adjustedbetween 600 – 700 r/min. in neutral.

NOTE:If idle speed cannot be set within the specifiedrange, contact your authorized Suzuki MarineDealer.

MOTOR COVER FASTENING ADJUSTMENTIf you feel motor cover fastening is loose or tootight when locking the levers, adjust as follows:

1. Loosen the bolts 1, 2 and 3.2. Adjust the position of brackets 4, 5 and 6.

To increase the fastening, move the bracketsto the direction A. To decrease the fasten-ing, move the brackets to the direction B.

3. Tighten the bolts.

Motor cover


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CAUTION SYSTEMThe caution systems are designed to alert youto certain situations which may cause damageto your outboard motor.

INDICATOR CHECKEach time the ignition key is turned to the “ON”position, four lamps – the REV LIMIT 1, theOIL 2, the TEMP 3 and the CHECK ENGINE4 in the monitor-tachometer will light brieflyand the buzzer will also sound for the first twoseconds, regardless of the motor conditions.

For the next three seconds, the monitor-tachometer will indicate the total motor operat-ing hours by means of the lamp flashing andneedle indicating.After this brief check period, the monitor-tachometer will return to their stand-by modeand will only respond to motor conditionsrequiring a caution alert.

NOTICE

Your outboard motor may become dam-aged if you rely on the Caution System toalert you to any malfunction that mayoccur or to give you an indication of theneed for maintenance.

To avoid damage to your outboard motor,regularly inspect and maintain it.

NOTICE

Continuing to operate your outboardmotor with the Caution System activatedcan result in severe damage to your out-board motor.

If the Caution System activates while youare operating your outboard motor, stopthe motor as soon as possible and cor-rect the problem or consult your autho-rized Suzuki marine dealer forassistance.

NOTE:For checking the total motor operating hours,refer to the CHART OF TOTAL OPERATINGHOURS INDICATION on the last page.

NOTICE

If the Caution System is not workingproperly, you may not be alerted to a con-dition that can cause damage to your out-board motor.

If any of the four lamps does not come onor the buzzer does not sound when theignition key is turned to the “ON” posi-tion, the lamps or buzzer may be brokenor a failure may exist in the system cir-cuit. Consult your authorized Suzukimarine dealer.


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OVER-REVOLUTION CAUTION SYSTEMThis system is activated when engine speedexceeds maximum recommended speed formore than 10 seconds.

If this system activates, engine speed willautomatically be reduced to approximately3000 r/min. with red REV LIMIT lamp lit.

This system must be reset by moving the throt-tle to the idle position for about one second torestore full engine operation.

NOTICE

If the Over-Revolution Caution Systemactivates at recommended maximumthrottle and you are sure that the propel-ler pitch is sufficient and there are no fac-tors like “over-trimming” or “ventilation”,there may be a problem with the Over-Revolution Caution System.

Consult your authorized Suzuki marinedealer if the Over-Revolution CautionSystem activates for no apparent reason.

OIL PRESSURE CAUTION SYSTEMThis system operates when the engine lubricat-ing oil pressure drops below the correct level.

If this system activates, the red OIL lamp willlight and a buzzer will begin a series of beep. Inaddition, when this system is activated at 1000r/min. or higher, engine speed will automaticallybe reduced to approximately 1000 r/min. withREV LIMIT lamp lit.

If you continue to run, the engine will automati-cally stop 3 minutes after beginning of theabove CAUTION system activation.

NOTE:In case that the engine is automatically stoppeddue to the CAUTION system, the engine can bestarted again.However the CAUTION system will repeatedlyactivate until eliminating the cause.

If this system activates, stop the engine imme-diately, if wind and water conditions make it safeto do so.

Check the oil level and add oil if necessary. Ifthe oil level is correct, consult your authorizedSuzuki Marine Dealer.

WARNING

If you attempt to remove or reinstall themotor cover while the engine is running,you may be injured.

Before checking the oil level, stop theengine and remove the motor cover.


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NOTICE

Your engine may become severely dam-aged If you rely on the Oil Pressure Cau-tion System to indicate the need to addengine oil.

Check the engine oil level periodicallyand add oil as necessary.

NOTICE

Operating the engine with the Oil Pres-sure Caution System activated can resultin severe engine damage.

If the Oil Pressure Caution System acti-vates, stop the engine as soon as possi-ble and add engine oil, if necessary, orotherwise correct the problem.

COOLING WATER CAUTION SYSTEMThis system is activated when the cylinder walltemperature is too high due to insufficient watercooling.

NOTE:The cooling water caution system will not detecthigh combustion chamber temperature causedby, for example, an oil system malfunction, poorquality fuel, or spark plugs with an incorrectheat range.

If this system activates, the red TEMP lamp willlight and the buzzer will begin a series of beep.In addition, when this system is activated at3000 r/min. or higher, engine speed willautomatically be reduced to approximately3000 r/min. with REV LIMIT lamp lit.

If you continue to run, the engine will automati-cally stop 3 minutes after beginning of theabove CAUTION system activation.

NOTE:In case that the engine is automatically stoppeddue to the CAUTION system, the engine can bestarted again.However the CAUTION system will repeatedlyactivate until eliminating the cause.

If the cooling water caution system activateswhen operating, reduce engine speed immedi-ately and check if water is being dischargedfrom the pilot water hole. If no water is seen, fol-low the procedures outlined below.

Water and wind conditions permitting, stop theengine, tilt it out of the water and remove anydebris like seaweed, plastic bags or sand thatmay have blocked the water intakes.Lower the engine into the water, being sure thatwater intakes are immersed, and restart it.


18

Check (A) that water discharges from the pilothole and (B) that the red TEMP lamp is nolonger lit.Be aware that the red TEMP lamp may lightagain if engine temperature rises abnormally. Ifeither of the above situations arises, yourauthorized Suzuki Marine Dealer must be con-sulted as soon as possible.

NOTE:If pilot hole water discharge is sufficient, buzzerand TEMP lamp may still operate until enginetemperature decreases. Run engine in NEU-TRAL only until the caution systems are can-celled.

NOTE:Remember that the cooling water caution sys-tem cannot detect overheating caused by, forexample, an oil system malfunction, poor qual-ity fuel, or incorrect spark plugs.

NOTE:If the engine is operated beyond the maximumtrim position, the water intake holes may beabove the water line. In this situation, the cool-ing water caution system may activate.

NOTICE

Operating the engine with the CoolingWater Caution System activated canresult in severe engine damage.

If the Cooling Water Caution System acti-vates, stop the engine as soon as possi-ble, wind and water conditionspermitting, and inspect the engineaccording to the above instructions. Con-sult your authorized Suzuki marine dealerif you cannot correct the problem.

BATTERY VOLTAGE CAUTION SYSTEMThis system is activated when the battery volt-age deficiency which could impair your motor’sperformance occurs.

If this system activates, the red CHECKENGINE lamp will light and buzzer will begin aseries of beep.

This system will be canceled automaticallywhen the battery voltage restores to the propervoltage level. Refrain from using any electricalequipment such as P.T.T. system, hydraulic trimtabs, hydraulic jack plate, etc.

NOTE:• A marginal battery may have enough power

to start your engine, yet may still cause thiscaution system to activate whenever engineor boat accessory use places a high currentdemand on the battery.

• If this caution system activates continuously,even after you have stopped using engine orboat accessories, contact your authorizedSuzuki Marine Dealer.

WARNING

Failure to take proper precautions wheninspecting or servicing the battery can behazardous.

Do not attempt to inspect or service thebattery without first reading the warn-ings, cautions, and instructions in the“BATTERY INSTALLATION” section ofthis manual.


19

DIAGNOSTIC SYSTEM

If abnormal conditions exist in any sensor sig-nal being sent to the control unit, the self-diag-nostic system warns of the abnormal condition.

If this system activates, the red CHECKENGINE lamp will flash and a buzzer willsound.

Also incorporated is a fail-safe provision thatallows the operation at a restricted speed evenunder such a failure condition.

NOTE:• The CHECK ENGINE lamp will light briefly

when the ignition key is turned to the “ON”position.

• The failed system can be identified by themode of the red CHECK ENGINE lamp flash-ing and buzzer sounding.This diagnostic code is designed to appearwhile the ignition key is turned on.

• The buzzer sound with diagnostic systemactivating will be canceled by pushing theignition key in.

NOTICE

If the diagnostic system activates whileyou are operating your outboard motor,there is an abnormal condition in one ofthe sensor signals of the control system.

Consult your authorized Suzuki marinedealer for repair of the control system.

OIL CHANGE REMINDER SYSTEM

This system informs the operator of the time forreplacing engine oil on the basis of the mainte-nance schedule.The system is designed to register the totaloperating hours of the outboard motor andfunction its operation when the preprogrammedhours have reached.(Refer to the INSPECTION AND MAINTE-NANCE section and the last page.)

SYSTEM ACTIVATIONWhen the total operating hours have reachedthe preprogrammed hours, the OIL lamp willflash. If the engine is not running, the buzzerwill begin a series of double beeps additionally.This indication will repeat until you cancel thesystem activation.


20

CANCELLATION1. Turn the ignition key to the “ON” position.2. Pull out the emergency stop switch plate 1.3. Pull up the emergency stop switch knob 2

three times in 10 seconds. A short beep willbe heard if the cancellation is successfullyfinished.

4. Turn the ignition key to the “OFF” position.5. Set the plate 1 in the original position.

NOTE:• Canceling of the system activation is possible

regardless of whether or not the engine oilhas been replaced. Once the system hasoperated, however, Suzuki strongly recom-mends that the engine oil be replaced beforecanceling the system activation.

• Even if the engine oil has been replaced withthe system not operating, it is still necessaryto perform the cancellation.

ENGINE STALLING CAUTION SYSTEM

This system informs the operator when themotor stalls while it is operating.When the engine stalls for any reason, the cau-tion buzzer sounds twice briefly.


21

OPERATION OF TILTING SYSTEMS

POWER TRIM AND TILTThe “Power Trim and Tilt” is operated by press-ing the switch. To tilt the motor up, press theupper part of the switch. To tilt the motor down,press the lower part of the switch.

WARNING

The power trim and tilt (PTT) switch canbe accidentally activated when the igni-tion key is off, resulting in injury.

Keep all persons away from the outboardmotor to help prevent accidental activa-tion of the PTT system.

UP

UP

DOWN

DOWN

Side mounttype

Top mounttype

DOWN

UP

TILT LIMITER CAMIf the outboard motor contacts the motor well ofthe boat while tilting, adjust the tilt limiter cam tolimit maximum tilt position.1. Place the motor in the normal running posi-

tion.2. Rotate the tilt limiter cam:

To reduce the amount of tilt, move the tab Aof cam upward.To increase the amount of tilt, move the tabA of cam downward.

3. To check your adjustment, tilt the motor fullyup to check for motor contact.Adjust further if necessary.Return the motor to the normal running posi-tion for each adjustment, and repeat yourcheck after each adjustment.

WARNING

Adjusting the tilt limiter cam will not pre-vent the outboard motor from tilting fullyup and contacting the motor well if themotor’s lower unit hits an object at highspeed. Such tilting could damage yourmotor and boat and injure boat occu-pants.

Keep all occupants away from the motorwhen operating at high speed.


22

MANUAL TILTINGIf you are unable to tilt the motor using the“Power Trim and Tilt” because of an electricalproblem or some other problem, you can movethe motor manually. To tilt the motor up ordown, turn the manual release screw A twoturns counterclockwise, move the motor to thedesired position, then retighten the releasescrew.

CAUTION

The motor is very heavy. When you tilt itmanually, you could injure your back orslip and fall causing injury.

When you tilt the motor manually, ensurethat your grip and footing are secure andthat you are able to support the weight ofthe engine.

TILT LEVERThe Tilt Lever is provided so you can supportthe motor in a tilted position for non-movingengine support.

To set the Tilt Lever:1. Tilt the motor all the way up by pressing the

Power Trim and Tilt “UP” switch.2. Pull down the Tilt Lever as shown in the illus-

tration.3. Lower the motor by pressing the Power Trim

and Tilt “DOWN” switch, until the motor issupported by the Tilt Lever.

4. Continue to operate the Power Trim and Tilt“DOWN” switch until the trim rods are com-pletely retracted.

NOTICE

If you do not retract the trim rams com-pletely when mooring, they may becomedeteriorated or corroded.

Be sure to retract the trim rams com-pletely when mooring.


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To release the Tilt Lever, tilt the motor all theway up using the Power Trim and Tilt “UP”switch, and pull up the Tilt Lever.

CAUTION

The remote Power Trim and Tilt switchwill work when the ignition switch is off. Ifsomeone activates the switch while youare moving the tilt lever, your hand couldbe injured.

Keep all persons away from the remotePower Trim and Tilt switch while you aremoving the tilt lever.

NOTICE

Damage can occur if you use the tilt leverother than when the boat is moored or isotherwise stationary.

The tilt lever relieves pressure from thepower trim and tilt and should only beused when the boat is stationary. Do notuse the tilt lever when trailering your boatand motor. Refer to the TRAILERING sec-tion of this manual.

INSPECTION BEFORE BOATING

It is important to make sure that your boat andmotor are in good condition and that you areproperly prepared for an emergency.Always perform the following checks before youbegin boating:

• Check that you have enough fuel for theintended run.

• Check the level of engine oil in the sump.

To check the oil level:

NOTE:To avoid an incorrect assessment of engineoil level, check the level only when theengine has cooled.

WARNING

Failure to inspect your boat and motorbefore beginning a trip can be hazardous.

Before boating, always perform theinspections described in this section.

NOTICE

Running the engine with an insufficientamount of oil can cause serious enginedamage.

Always check the oil level before eachtrip and add oil if necessary.


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1. Place the motor in a vertical position,then remove the motor cover 1 byunlocking the lever 2 and 3.

2. Pull out the oil dipstick and wipe oil offwith a clean cloth.

NOTE:If the engine oil is contaminated or discol-ored, replace with fresh engine oil. Refer tothe ENGINE OIL section.

3. Insert the dipstick all the way into theengine, then remove it again.

The oil on the dipstick should be betweenthe upper and lower limits shown on the dip-stick. If the oil level indication is near thelower limit, add enough oil to raise the levelto the upper limit.

To fill the engine with oil:1. Remove the oil filler cap.2. Fill with recommended engine oil to the

upper level.

3. Tighten the oil filler cap securely.

NOTICE

Running the engine with an excessiveamount of oil can damage the engine.

Do not overfill the engine with oil.

UPPER LIMIT

LOWER LIMIT


25

• Check the battery solution level.The level should be kept between the MAXand the MIN level lines at all times. If thelevel drops below the MIN level line, referto MAINTENANCE section.

• Make sure that the battery leads aresecurely connected to the battery termi-nals.

• Visually check the propeller to make sureit is not damaged.

• Make sure the motor is securely mountedto the transom.

• Check for proper operation of the PowerTrim and Tilt.

• Check for proper trim angle.

• Make sure you have the boating safetyand emergency equipment on board.

BREAK-IN

Proper operation during this break-in period willhelp ensure maximum life and performancefrom your engine. The following guidelines willexplain proper break-in procedures.

Break-in period: 10 hours

Break-in procedure1. For the initial 2 hours:

Allow sufficient idling time (about 5 minutes)for the engine to warm up after cold enginestarting.

After warming up, run the engine at idling speedor the lowest in-gear speed for about 15 min-utes.During the remaining 1 hour and 45 minutes, ifsafe boating conditions permit, operate theengine in gear at less than 1/2 (half) throttle(3000 r/min.).

NOTE:You may throttle up beyond the recommendedoperating range to plane your boat, then imme-diately reduce the throttle to the recommendedoperating range.

NOTICE

Failure to follow the break-in proceduresdescribed below can result in severeengine damage.

Be sure to follow the engine break-in pro-cedures described below.

NOTICE

Running at high speed without sufficientwarm-up may cause severe engine dam-age such as piston seizure.

Always allow sufficient idling time (5 min-utes) for the engine to warm-up beforerunning at high speed.


26

2. For the next 1 hour:Safe boating conditions permitting, operatethe engine in gear at 4000 r/min. or at three-quarter throttle. Avoid running the engine atfull throttle.

3. Remaining 7 hours:Safe boating conditions permitting, operatethe engine in gear at desired engine speed.You may occasionally use full throttle; how-ever do not operate the engine continuouslyat full throttle for more than 5 minutes at anytime.

NOTICE

Running continuously at full throttle formore than 5 minutes at a time during thelast 7 hours of break-in operation maycause severe engine damage such as sei-zure.

During the last 7 hours of break-in opera-tion, do not operate at wide open throttlefor more than 5 minutes at a time.

OPERATION

BEFORE ATTEMPTING TO START THE ENGINE1. Lower the motor into the water.2. Make sure that the motor fuel hose and the

hose from the boat’s fuel tank are securelyattached and clamped.

3. Make sure the motor is in “NEUTRAL”.

Side mounttype

Top mounttype


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4. Make sure the lock plate is in place and theemergency stop switch cord is fastenedsecurely to your wrist or appropriate clothingarea such as your belt.

Side mounttype

Top mounttype

NOTE:There is a spare plastic lock plate for temporaryuse only. Remove it from the cord and place ina safe place on the boat. However, the originalcord and lock plate should be replaced as soonas possible.

STARTING THE ENGINE

NOTE:If the emergency stop switch lock plate is not inposition, the starter motor cannot operate.

WARNING

Failure to properly attach the emergencystop switch cord or to take proper pre-cautions to help ensure that the emer-gency stop switch works as intended mayresult in serious injury or death to theoperator or passengers.

Always take the following precautions:• Make sure that the emergency stop

switch cord is fastened securely to theoperator’s wrist or to an appropriateclothing area (belt etc.).

• Ensure that no obstructions impede orrestrict emergency stop switch opera-tion.

• Be careful not to pull the stop switchcord or knock out the lock plate duringnormal operation. The motor will stopabruptly, and the loss of forwardmotion may unexpectedly throw occu-pants forward.

WARNING

Exhaust gas contains carbon monoxide,a dangerous gas that is difficult to detectbecause it is colorless and odorless.Breathing carbon monoxide can causedeath or severe injury.

Never start the engine or let it run indoorsor where there is little or no ventilation.


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1. Squeeze the fuel line priming bulb severaltimes until you feel resistance.

2. Side mount type:Make sure the warm-up lever is in the fullyclosed position.

3. Turn the ignition key to the “ON” position,then observe the monitor-tachometer indica-tion. If nothing abnormal is indicated, thenturn the key to the “START” position to startthe engine.

NOTE:If the engine fails to start after 5 seconds, wait10 seconds and try again.

4. Warm up the engine for about 5 minutes.

Cooling water checkAs soon as the engine starts, water shouldspray out of the pilot water hole 1, indicatingthat the water pump and cooling system areworking properly. If you notice that water doesnot spray out of the pilot water hole, stop theengine as soon as possible and consult yourauthorized Suzuki Marine Dealer.

NOTICE

If you turn the ignition key to “START”position for more than 5 seconds, thestarter system could be damaged.

Never turn the ignition key to “START”position for more than 5 seconds.

NOTICE

If the OIL lamp remains lit while operatingthe outboard, the oil level may be lowenough to damage the engine.

Stop the engine and check the oil level.


29

NOTICE

Never operate your outboard motor whenthere is no water coming out of the pilotwater hole, or severe damage can result.

After starting the engine, check to makesure that there is water coming out of thepilot water hole.

WARNING

Operating the boat when the emergencystop switch is not operating properly canbe hazardous.

Before starting off, check to make surethat the emergency stop switch operatesproperly.

SHIFTING AND SPEED CONTROL

ShiftingTo shift into “FORWARD”, squeeze the lock-outlever on the control handle and move the con-trol handle forward to approximate position A,as shown in the illustration.

To shift into “REVERSE”, squeeze the lock-outlever on the control handle and move the con-trol handle rearward to approximate position 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 fromneutral to position A or B to prevent abnormalwear on the gear and clutch engagement sur-faces.

NOTICE

Severe engine damage may occur if (a)engine speed is not allowed to return toidle and boat speed is not reduced whenshifting from “FORWARD” to “REVERSE”or from “REVERSE” to “FORWARD”, or(b) care is not taken when operating theboat in reverse.

Always allow the engine speed to returnto idle before shifting. Exercise cautionand use minimal speed when operatingthe boat in reverse. Be sure the handle/shift lever is in the desired positionbefore accelerating.

NOTICE

If you shift gears when the engine is notrunning, the shifting mechanism can bedamaged.

Avoid shifting gears when the engine isnot running.


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NOTE:Top mount typeNot equipped with a lock-out lever. Exercisecare when selecting neutral position.

Speed controlTo increase speed after you have shifted intogear, continue moving the control handle for-ward or rearward.

WARNING

Since the same handle is used for shift-ing and speed control it is possible tomove the handle past the detent andengage the throttle. This can cause theboat to move suddenly resulting in per-sonal injury or property damage.

You must be careful not to move the con-trol handle too far forward or rearwardwhen shifting.

NEUTRAL

32˚ 32˚

FORWARDREVERSE

Top mounttype NEUTRAL

FORWARD

REVERSE

35˚ 35˚

STOPPING THE ENGINENOTE:When it is necessary to stop the engine in anemergency, pull the emergency stop switch lockplate out of the emergency stop switch by pull-ing the emergency stop switch cord.

To stop the engine:1. Shift into “NEUTRAL”.2. After operating at full throttle, cool off the

engine a few minutes by allowing it to idle ortroll at low speed.

3. Turn the ignition key to the “OFF” position.Always leave the ignition key in the “OFF”position when the motor is not running, orthe battery can discharge.

Side mounttype

Top mounttype


31

4. After stopping the engine, disconnect thefuel line from the outboard motor if there is afuel connector.

5. Twist the air-vent screw on the fuel tank capclockwise to shut the vent (if equipped )

NOTE:To make sure that the emergency stop switchoperates properly, stop the engine occasionallyby pulling out the lock plate, while operating theengine at idling speed.

NOTICE

If the ignition key is left ON when theengine is not running, the battery will dis-charge.

Always turn the ignition key OFF whenthe engine is not running.

WARNING

Unauthorized use of your boat could leadto an accident or damage to your boat.

To prevent unauthorized use of your boat,be sure to remove the key and emergencystop switch lock plate when the boat isunattended.

WARNING

If you leave the motor stopped for a longperiod of time with the fuel line con-nected , fuel can leak out.

Disconnect the fuel line from fuel tank, ifthere is a fuel connector, whenever youleave the motor stopped for a long periodof time.

MOORINGThe motor should be tilted up out of the waterwhen you moor the boat in shallow water or ifthe motor will not be used for some time, to pro-tect it from damage by underwater obstacles atlow tide or corrosion from salt water.

Refer to the TILT LEVER section for details onhow to tilt up the motor.

NOTICE

Improperly securing your boat may causedamage to your boat or motor, or otherproperty damage.

Do not allow your motor to rub againstquay walls, piers or other boats when theboat is tied up.


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OPERATION IN SHALLOW WATERWhen operating your boat in shallow water, itmay be necessary to tilt the motor higher thanthe normal trim angle. When you tilt the motorbeyond the normal trim angle, however, youshould only operate the boat at slow speeds.After returning to deep water, be sure to lowerthe motor to the normal trim angle.

To tilt the motor higher than the normal trimangle, use the Power Trim and Tilt switch.

WARNING

When the motor is beyond the maximumtrim position, the swivel bracket will nothave side support from the clamp bracketand the tilt system will be unable to cush-ion the engine if the lower unit strikes anobstruction. This could lead to occupantinjury. In addition, beyond the maximumtrim position, the water intake holes maybe above the water line, which can resultin severe engine damage from overheat-ing.

Do not operate the engine above 1500r/min or operate the boat in a planningattitude with the engine beyond the maxi-mum trim position.

NOTICE

If the motor hits bottom, serious damagecan occur.

Do not allow the motor to hit bottom. Ifthe motor does strike bottom, inspect itimmediately for damage.

OPERATION IN SALT WATERAfter operating the motor in salt water, youshould flush the water passages with clean,fresh water as outlined in the FLUSHING THEWATER PASSAGES section. If you do not flushthe water passages, salt can corrode the motorand shorten its life.

OPERATION IN FREEZING WEATHERWhen operating your outboard motor in freez-ing temperatures, you should keep the lowerunit submerged in the water at all times.When taking motor out of the water, stand it upin a vertical position until the cooling systemdrains completely.

NOTICE

If you leave your outboard motor out ofthe water in freezing temperatures withwater still in the cooling system, thewater can freeze and expand, causingsevere damage to the motor.

When your outboard is in the water infreezing temperatures, keep the lowerunit submerged in the water at all times.When the motor is stored out of the waterin freezing temperatures stand it up in thevertical position so that the cooling sys-tem drains completely.


33

MOTOR REMOVAL AND TRANSPORTING

MOTOR REMOVALIf it is necessary to remove the outboard motorfrom your boat, we recommend that you askyour authorized Suzuki Marine Dealer to do thework for you.

MOTOR TRANSPORTINGWhen transporting the motor, place the motoreither vertically or horizontally.

Vertical transport:Attach the clamp bracket to a stand by securingtwo transom bolts.

Horizontal transport:1. Drain the engine oil. Refer to the ENGINE

OIL section.2. Drain the gasoline from the vapor separator

as follows:(1)Remove the motor cover 1.(2)Remove the eight (8) bolts using a 8 mm box

wrench, then remove the side cover 2.

(Bolt in the motor cover)

(Bolt in the motor cover)


34

(3)Pull the drain hose end 3 out.(4)Loosen the vapor separator drain screw 4

and drain the gasoline into a suitable con-tainer.

(5)After draining, retighten the drain screw andreinstall the all items back in place.

WARNING


Use a proper, safe container to store anygasoline drained from the outboardmotor. Keep gasoline away from sparks,flames, people, and pets.

3. Rest the motor on a case protector with theport side downwards as shown.

NOTICE

If you are not careful when resting theoutboard on its side and do not takeproper precautions such as first drainingthe engine oil and cooling water com-pletely, damage can occur. Engine oilmay enter the cylinder from the sump,water may enter the cylinder through theexhaust port, or the outer casings may bedamaged.

Always drain the engine oil and coolingwater completely before laying the motoron its side, and be careful laying themotor down.

NOTICE

If you let the lower unit of your outboardsit higher than the power head duringtransporting or storing, water may trickleinto the power head, causing damage tothe engine.

Never let the lower unit sit higher than thepower head when transporting or storingyour outboard.


35

TRAILERING

When trailering your boat with the motorattached, keep the motor in the normal operat-ing position unless there is not enough groundclearance. If you need more ground clearance,trailer the motor in a tilted position using a tran-som saver bar or similar device to support theweight of the motor.

NOTICE

If you use the tilt up lock arm to hold themotor in the fully tilted up position whentrailering the boat, towing motion or poorroad surfaces may cause unexpected tiltlock release, resulting in damage to themotor and the tilt lock mechanism.

Never use the tilt up lock arm to hold themotor in the fully tilted up position whentrailering the boat. Use a transom saverbar or similar device to support theweight of the motor.


36

INSPECTION AND MAINTENANCE

NOTICE

MAINTENANCE SCHEDULEIt is important to inspect and maintain your out-board motor regularly. Follow the chart below.

At each interval, be sure to perform the indi-cated service. Maintenance intervals should bejudged by number of hours or number ofmonths, whichever comes first.

I: Inspect and clean, adjust, lubricate, or replace, if necessary T: Tighten R: Replace

NOTE:Water-separating fuel filterReplace the filter element every 12-months (or more frequently if recommended by the filter manu-facturer).

MAINTENANCE, REPLACEMENT ORREPAIR OF EMISSION CONTROLDEVICES AND SYSTEMS MAY BE PER-FORMED BY ANY MARINE SI ENGINEREPAIR ESTABLISHMENT OR INDIVIDUALUSING ANY PART WHICH HAS BEENCERTIFIED UNDER THE PROVISIONS INTHE CLEAN AIR ACT Sec. 207 (a) (2).

WARNING



Interval

Item to be serviced

Initial 20 hrs.or 1 month

Every 50 hrs.or 3 months



Spark plug – – I R

Breather & Fuel line I I I I

Engine oil R – R R

Gear oil R – R R

Lubrication – I I I

Anodes & Bonding wires – I I I

Battery – I I I

* Low pressure fuel filter– I I I

Replace every 400 hours or 2 years.

* Engine oil filter R – – R

* High pressure fuel filter Replace every 1000 hours.

* Ignition timing – – – I

* Idle speed I – – I

* Balancer chain Replace every 1600 hours.

* Valve clearance – – – I

* Water pump – – – I

* Water pump impeller – – – R

* Propeller nut & pin I – I I

* Bolts & Nuts T – T T


37

WARNING

Improper maintenance or failure to per-form recommended maintenance can behazardous. Poor maintenance or lack ofmaintenance increases the chance of anaccident or equipment damage.

Be sure to have maintenance performedaccording to the schedule in the abovechart. Suzuki recommends that only yourauthorized Suzuki marine dealer or aqualified service mechanic perform main-tenance on those items in the chart abovewhich are marked with an asterisk (*). Youmay perform maintenance on theunmarked items by referring to theinstructions in this section if you havemechanical experience. If you are notsure whether you can successfully com-plete any of the unmarked maintenancejobs, ask your authorized Suzuki marinedealer to do the maintenance for you.

WARNING

The safety of you and your passengersdepends on how well you maintain youroutboard motor.

Follow all inspection and maintenanceinstructions carefully. If you do not haveprior mechanical experience, do notattempt to perform maintenance on youroutboard motor. You could be injured ormay damage the motor.

NOTICE

The maintenance intervals in the chartwere established for normal usage ofyour outboard motor. If your outboardmotor is used under severe conditionssuch as frequent full throttle operation orfrequent operation in muddy, silty, sandy,acidic, or shallow water, you may need toperform maintenance more often thanindicated in the chart. Failure to performmaintenance more frequently couldresult in damage.

Consult your authorized Suzuki marinedealer regarding appropriate mainte-nance intervals for your usage condi-tions. When replacing parts on youroutboard motor, Suzuki strongly recom-mends that you use genuine Suzuki partsor their equivalent.


38

SPARK PLUGRemove the spark plugs as follows:1. Remove the bolt securing the ignition coil.2. Pull out the ignition coil.3. Loosen and remove the spark plug using the

box wrench in the tool bag.

Your outboard motor comes equipped with thefollowing “standard” spark plug for normalusage.

Your authorized Suzuki Marine Dealer candetermine if the standard spark plug is suitablefor your type of motor usage by inspecting thecolor of the plug’s porcelain center electrodeinsulator after operation.

If the plug tends to run hot (usually evidencedby whitening of the insulator or a burnt elec-trode), stop using your motor immediately assevere engine damage may result. If the plugtends to run cold (usually evidenced by black-ening of the insulator or a wet electrode), per-formance may suffer. Ask your authorizedSuzuki Marine dealer to evaluate either of theseproblems to determine the cause.

Standard spark plug NGK BKR6E

NOTICE

Non-resistor types of spark plugs willinterfere with the function of the elec-tronic ignition, causing misfiring, orcausing problems with other electronicboat equipment and accessories.

Use ONLY resistor type spark plugs inyour outboard motor.

NOTICE

Use of improper spark plugs or improp-erly tightening spark plugs can causesevere engine damage.

• Do not experiment with other sparkplug brands unless you can determinethat they are directly equivalent to thespecified brand, or you may experienceengine damage which will not be cov-ered under warranty. Note that after-market cross-reference charts may notbe accurate.

• To install a spark plug; seat it as far aspossible by hand, then use a wrench totighten it to either the recommendedtorque setting or the specified rotationangle.

Tightening torque

2.5 – 2.8 kg-m (18.1 – 20.0 lb-ft)

Rotation angle

New plug 1/2 – 3/4 of a turn

Re-use plug 1/12 – 1/8 of a turn

• Do not overtighten or cross-thread aspark plug, as this will damage the alu-minum threads of the cylinder head.

Centerelectrode

Insulator

Ground electrode

Gap


39

To maintain a strong spark, you should cleanand adjust the plug at the interval shown in themaintenance schedule.Remove carbon deposits from the spark plugusing a small wire brush or spark plug cleaner,and adjust the gap as follows:

If the electrode or insulator is damaged, or ifeither shows excessive wear, then the sparkplug should be replaced.

Spark plug gap0.7 – 0.8 mm

(0.028 – 0.031 in.)

BREATHER AND FUEL LINEInspect the breather and fuel line for leaks,cracks, swelling, or other damage. If thebreather and fuel line are damaged in any way,they must be replaced. Consult your authorizedSuzuki Marine dealer if it is necessary toreplace them.

WARNING

Fuel leakage can contribute to an explo-sion or fire, resulting in serious personalinjury.

Have your authorized Suzuki marinedealer replace the fuel line if there is anyevidence of leaking, cracking or swelling.

Breather line

Fuel line


40

ENGINE OIL

Engine oil changeThe oil should be changed when engine iswarm so that the oil will drain thoroughly fromthe engine.

To change the engine oil:1. Place the motor in a vertical position and

remove the motor cover.2. Remove the oil filler cap.

WARNING

Never perform any ENGINE OIL proce-dure with the motor running, as seriousinjury can occur.

The motor must be shut off before anyENGINE OIL procedures are performed.

NOTICE

Extended trolling can reduce oil life. Yourengine may be damaged if you do notchange engine oil more frequently underthis type of use.

Change your engine oil more frequently ifyour engine is used for extended trolling.

3. Place a drain pan under the engine oil drainscrew.

4. Remove the engine oil drain screw 1 andgasket 2, then let the engine oil drain.

5. After draining, secure the engine oil drainscrew with a new gasket.

NOTE:There are spare gaskets in the tool bag.

6. Fill with recommended engine oil to theupper level.

Oil capacity: 8.0 L (8.5/7.0 US/Imp. qt)

Engine oil: SAE (or NMMA FC-W) 10W-40 API (or NMMA FC-W) Classifica-tion SG, SH, SJ, SL, SM

CAUTION

The engine oil temperature may be highenough to burn your fingers when thedrain plug is loosened.

Wait until the drain plug is cool enough totouch with bare hands before removing it.

NOTICE

A previously-used gasket may leak,resulting in engine damage.

Do not re-use gaskets. Be sure to alwaysuse new gaskets.


41

7. Check the engine oil level.

NOTE:To avoid incorrect measurement of engine oillevel, check oil level only when the engine hascooled.

8. Reinstall the oil filler cap.

NOTE:Recycle or properly dispose of used engine oil.Do not throw it in the trash, pour it on theground, down a drain, or into the water.

WARNING

Engine oil can cause injury to people orpets. Repeated, prolonged contact withused engine oil may cause skin cancer.Even brief contact with used oil may irri-tate skin.

• Keep new and used oil away from chil-dren and pets.

• Wear a long-sleeve shirt and water-proof gloves when handling oil.

• Wash with soap if oil contacts yourskin.

• Launder any clothing or rags that arewet with oil.

UPPER LIMIT

LOWER LIMIT

GEAR OILTo check the gear oil level, adjust the engine toan upright position, remove the gear oil levelplug 1 and look into the hole. The oil levelshould be at the bottom edge of the hole. If theoil level is low, add the specified gear oil untilthe level reaches the bottom edge of the hole.Then, reinstall and tighten the plug.

Periodic gear oil replacement is essential forlong life of your outboard motor.

To change the gear oil:1. Make sure the motor is in an upright posi-

tion. Place a drain pan under the lower cas-ing.

2. Remove the gear oil drain plug 2, thenremove the air vent hole plug 3.


42

3. After the oil has drained completely, injectthe specified gear oil into the gear oil drainhole 2 until it just starts to come out of theair vent hole 3. Approximately 1100 ml(37.2/38.7 US/lmp. oz.) will be required.

4. Reinstall and tighten the air vent hole plug3, then quickly reinstall and tighten the gearoil drain plug 2.

NOTE:To avoid insufficient injection of gear oil, checkthe gear oil level 10 minutes after doing the pro-cedure in the step 4. If the oil level is low, slowlyinject the gear oil into the gear oil level hole 1up to the correct level.

NOTE:Recycle or properly dispose of used gear oil.Do not throw it in the trash, or pour it on theground, down a drain, or into the water.

WARNING

Gear oil can cause injury to people orpets. Repeated, prolonged contact withused gear oil may cause skin cancer.Even brief contact with used oil may irri-tate skin.

• Keep new and used oil away from chil-dren and pets.

• Wear a long-sleeve shirt and water-proof gloves when handling oil.

• Wash with soap if oil contacts yourskin.

• Launder any clothing or rags that arewet with oil.

NOTICE

If fishing line wraps around the rotatingpropeller shaft, the propeller shaft oil sealcan become damaged and can allowwater to enter the gear case causingsevere damage.

If the gear oil has a milky color, it is con-taminated with water. Immediately con-tact your authorized Suzuki marine dealerfor advice. Do not operate your outboarduntil the oil is changed and the cause ofthe contamination is corrected.


43

LUBRICATIONProper lubrication is important for the safe,smooth operation and long life of each workingpart of your outboard motor. The following chartshows the lubrication points of your motor andthe recommended lubricant:

LOCATION LUBRICANT

Throttle/Shift linkage

Marine-grade water resistant grease

Propeller shaft

Trim ram pad

Swivel bracketMarine-grade water resistant grease(Grease Gun)

Steering bracket

Your authorized Suzuki Marine Dealer may alsohave additional recommendations due toregional climate or operating conditions.Please consult him for advice.

CORROSION PREVENTIONANODESThe motor is protected from exterior corrosionby anodes. These anodes control electrolysisand help prevent corrosion. The anodes willcorrode in place of the parts they are protect-ing. You should periodically inspect each of theanodes and replace them when 2/3 of the metalhas corroded away.

In certain areas of the country, the water isunusually harsh on metal. Additional anti-corro-sion measures may be helpful under those con-ditions. Consult your authorized Suzuki MarineDealer for details.

NOTICE

If anodes are not properly maintained,underwater aluminum surfaces (such asthe lower unit) will suffer galvanic corro-sion damage.

• Periodically inspect anodes to makesure they have not become detached.

• Do not paint anodes, as this will renderthem ineffective.

• Periodically clean anodes with a wirebrush to remove any coating whichmight decrease their protective ability.


44

BONDING WIRESBonding wires are used to electrically connectthe engine components so they exist in a com-mon ground circuit. This allows them to be pro-tected against electrolysis by the anodes.These wires and their terminals should bechecked periodically to be sure they have notbeen damaged.

BATTERYIf you are using a maintenance-free battery,inspect the window area according to theinstructions on the battery to make sure the bat-tery is in good condition.

If you are not using a maintenance-free battery,the battery fluid level should be checked every50 hours of operation or 3 months. The batterysolution level must be kept between the MAXand the MIN level lines at all times. If the leveldrops below the MIN level line, add DISTILLEDWATER ONLY until the battery solution levelreaches the MAX level line.

WARNING

Battery acid is poisonous and corrosive,and can cause severe injury.

Avoid contact with eyes, skin, clothing,and painted surfaces. If battery acidcomes in contact with any of these, flushimmediately with large amounts of water.If acid contacts the eyes or skin, getimmediate medical attention.

WARNING

If you are not careful when checking orservicing the battery, you can cause ashort circuit, which could result in anexplosion, fire, or circuit damage.

Disconnect the negative (black) cablewhen checking or servicing the battery.Be careful not to allow a metal tool orother metal object to touch the battery’spositive terminal and the motor at thesame time.

WARNING

Battery posts, terminals, and relatedaccessories contain lead and lead com-pounds that may be hazardous.

Wash hands after handling.


45

ENGINE OIL FILTERThe engine oil filter must be changed by autho-rized Suzuki Marine Dealer periodically.Replace engine oil filter with a new one at initial20 hours (1 month).Replace engine oil filter with a new one at every200 hours (12 months).

FUEL FILTERThe fuel filter must be inspected by authorizedSuzuki Marine Dealer periodically.

Low pressure fuel filterInspect low pressure fuel filter at every 50 hours(3 months).Replace low pressure fuel filter with a new oneat every 400 hours (2 years).

High pressure fuel filterReplace high pressure fuel filter with a new oneat every 1000 hours.

BALANCER CHAINThe balancer chain must be changed by autho-rized Suzuki Marine Dealer periodically.Replace balancer chain with a new one at every1600 hours.

NOTICE

If you add diluted sulphuric acid to thebattery after it has been initially serviced,you will damage the battery.

NEVER add diluted sulphuric acid to thebattery after it has been initially serviced.Follow the battery manufacturer’sinstructions for specific maintenanceprocedures.

FLUSHING THE WATER PASSAGES

After operation in muddy, brackish, or saltwater, you should flush the water passages andmotor surface with clean, fresh water.If you do not flush the water passages, salt cancorrode the motor and shorten its life. Flush thewater passages as follows.

ENGINE RUNNING – Vertical position –Suzuki recommends that you flush the waterpassage by using this method.

To flush the water passages, you must obtain acommercially available engine flush device.

WARNING



WARNING

Failure to take proper precautions whenflushing the water passages can be haz-ardous.

When flushing the water passages,always take the following precautions:• Make sure that the engine remains in

NEUTRAL. If shifted into gear, the pro-peller shaft will turn and could causesevere personal injury.

• Make sure the motor is properlyclamped to a secure stand or boat, andremain in attendance until flushing iscompleted.

• Keep children and pets away from thearea, and stay clear of all moving parts.


46

1. Install the flushing attachment 1 so that thewater intake holes are covered by the rubbercups on the attachment.

2. Connect a garden hose to the flushingattachment and turn on the water to obtainenough flow so that plenty of excess water isflowing out from around the rubber cups onthe attachment.

3. Place the remote control handle in the“NEUTRAL” position with the propellerremoved and start the motor. As soon as theengine starts, water should spray out of thepilot water hole 2, indicating proper waterpump operation. If no water spray is evident,stop the motor immediately and consult yourdealer.

NOTICE

Severe engine damage can occur in as lit-tle as 15 seconds if the engine is startedwithout supplying water to the coolingsystem.

Never start the motor without supplyingwater to the cooling system.

4. Allow the engine to run only at idle speedwhile flushing. Readjust the water flow, ifnecessary, so that there is still plenty ofexcess water flowing out from around therubber cups.

5. Allow the water to continue circulating for afew minutes.

6. Stop the motor, then turn off the water.7. Remove the flushing attachment from the

water intake hole.8. Clean the motor surface and apply a coat of

automotive wax on the external finish of themotor.


47

ENGINE NOT RUNNING – Vertical position –1. Remove one of the plug A or C from the

two flushing ports.

2. Install garden hose directly or by using ahose connector matched to flushing pointthread B.Thread B: 0.75 – 11.5 NHR (American stan-dard hose coupling threads for garden hoseapplications.)

3. Turn on the water to obtain a good waterflow. Flush the engine for about five minutes.

4. Turn off the water.5. Remove the hose and connector (if used)

then reinstall the plug into the flushing port.6. Leave the motor in a vertical position until

the engine is drained completely.

ENGINE NOT RUNNING– Full tilt up position –1. Raise the engine to the full tilt up position.2. Follow the “ENGINE NOT RUNNING – Verti-

cal position” instructions.DO NOT RUN ENGINE IN THE FULL TILTUP POSITION.

3. Lower the motor to a vertical position untilthe engine is drained completely.


48

SUBMERGED MOTOR

If your motor has been accidentally submergedin water, it must receive a special repair serviceas soon as possible to prevent corrosion. If pos-sible, have a qualified marine dealer service theengine. If immediate servicing is not available,take the following steps to help protect yourmotor. In the event that your motor is acciden-tally submerged, take the following steps:

1. Get the motor out of the water as soon aspossible.

2. Remove the motor cover and immediatelywash the engine thoroughly with fresh waterto completely remove all salt, mud, and sea-weed.

3. Remove the spark plugs. Drain the waterfrom the cylinders through the spark plugholes by manually turning the flywheel sev-eral times.

4. Check if any water is evident in the engineoil. If water is seen, remove the oil drain plugand drain the oil. After draining, tighten theoil drain plug.

5. Drain the fuel line and all filters.

6. Pour one tablespoon of engine oil in througheach spark plug hole. Coat the engine innerparts with oil by manually turning the fly-wheel several times. Don’t use the electricstarter, as this may bend the connectingrods.

WARNING


Keep flames and sparks away from gaso-line. Dispose of unwanted fuel properly.

7. Have your authorized Suzuki marine dealerinspect the engine as soon as possible.

NOTICE

Severe engine damage may occur if youcontinue cranking the engine when youencounter friction or resistance.

If you encounter friction or resistancewhile cranking the engine, stop at onceand do not attempt to start the engineuntil you find and correct the problem.

NOTICE

If the fuel supply is contaminated withwater, engine damage may occur.

If the boat’s fuel tank filler and vent weresubmerged, inspect the fuel supply tomake sure it is not contaminated withwater.


49

STORAGE PROCEDURE

MOTOR STORAGEWhen storing your motor for a long period oftime (for example, at the end of the boating sea-son), it is recommended that you take yourmotor to your authorized Suzuki Marine Dealer.However, if you choose to prepare the motor forstorage yourself, follow the procedure outlinedbelow:

1. Change the gear oil as outlined in the GEAROIL section.

2. Change the engine oil as outlined in theENGINE OIL section.

3. Fill a high quality fuel stabilizer to the fueltank according to the instructions on the sta-bilizer can.

4. Flush the water passages in the motor thor-oughly. Refer to the FLUSHING THEWATER PASSAGES (Engine running) sec-tion.

5. Readjust the water flow, run the engine atabout 1500 r/min. in neutral for five minutesto distribute the stabilized fuel through theengine.

6. Stop the engine. Then turn off the water anddisconnect the flushing attachment.

7. Lubricate all other specified parts. Refer tothe LUBRICATION section. Spray entirepowerhead with a rust preventative (not apenetrating oil product).

8. Apply a coat of automotive wax on theexternal finish of the motor. If paint damageis evident, apply touch up paint before wax-ing.

9. Store the motor in an upright position in adry, well-ventilated area. Select an areawith constant temperature to avoid corro-sion caused by condensation. Do not storenext to furnaces, heaters, etc.

WARNING

When the engine is running, there aremany moving parts that could causesevere personal injury.

When the engine is running, keep yourhands, hair, clothing, etc., away from theengine.

NOTICE

Severe engine damage can occur in as lit-tle as 15 seconds if the engine is startedwithout supplying water to the coolingsystem.

Never start the motor without supplyingwater to the cooling system.


50

BATTERY STORAGE1. When the outboard motor will not be used

for a month or longer, remove the batteryand store it in a cool, dark place. Do not setbattery on concrete or earth, as this willaccelerate loss of charge.

2. Wash the casing and terminals using freshwater only, then dry with clean cloth.

3. Fully charge the battery. If the battery will bestored for a long period of time, check thespecific gravity of the fluid at least once amonth and recharge the battery when thecharge is low.

WARNING

Failure to take proper precautions whencharging the battery can be hazardous.Batteries produce explosive vapors thatcan ignite. Battery acid is poisonous andcorrosive, and can cause severe injury.

• Do not smoke and keep battery awayfrom open flames and sparks.

• To avoid creating a spark when charg-ing the battery, connect the batterycharger cables to the proper terminalsbefore turning the charger on.

• Handle the battery with extreme careand avoid skin contact with batteryacid.

• Wear proper protective clothing (Safetyglasses, gloves, etc.)

AFTER STORAGE

When taking your motor out of storage, followthe procedure below to return it to operatingcondition:

1. Thoroughly clean the spark plugs. Replacethem if necessary.

2. Check the gear-case oil level and if neces-sary, add gear oil according to the procedureoutlined in the GEAR OIL section.

3. Lubricate all moving parts according to theLUBRICATION section.

4. Check the engine oil level.5. Clean the motor and wax the painted sur-

faces.6. Recharge the battery before installing it.

GENERAL INFORMATION

WARRANTIES (For U.S.A)The warranties covering your outboard motorare explained in a separate Limited Warrantybooklet given to you at the time of sale. Pleaseread this booklet carefully so you can under-stand your rights and responsibilities.

IDENTIFICATION NUMBER LOCATIONThe model and identification numbers of youroutboard motor are stamped on a plateattached to the clamp bracket. Record thesenumbers below for future reference. It is impor-tant to know these numbers when you place aparts order or if your motor is stolen.

Model Number:

Identification Number:


51

EMISSION CONTROLINFORMATION

NOTICE

Ignition Key Number:

• THIS ENGINE IS CERTIFIED TO OPER-ATE ON UNLEADED GASOLINE OF 87OCTANE ((R+M)/2 METHOD) ORGREATER.

• EXHAUST EMISSION CONTROLSYSTEM:ECM, MFI

Ignition key numberstamped position

Spare key

TROUBLESHOOTING

This troubleshooting guide is provided to helpyou find the cause of common complaints.

Starter motor will not operate:• Shift lever is not in NEUTRAL.• Fuse is blown out.• Emergency stop switch lock plate is not in

position.

Engine will not start (hard to start):• Fuel tank is empty.• Fuel hose is not properly connected to

engine.• Fuel hose is kinked or pinched.• Spark plug is fouled.

Engine idles unstably or stalls:• Fuel hose is kinked or pinched.• Spark plug is fouled.

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.• Foreign object (seaweed etc.) is tangled on

propeller.• Propeller is damaged.

NOTICE

Failure to troubleshoot a problem cor-rectly can damage your outboard motor.Improper repairs or adjustments maydamage the outboard motor instead orfixing it. Such damage may not be cov-ered under warranty.

If you are not sure about the properaction to correct a problem, consult yourSuzuki marine dealer.


52

Engine overheats:• Cooling water intake(s) are blocked.• Engine is overloaded.• Propeller is not properly matched to loads.

FUSE1. Turn the ignition key to the “off” position.2. Remove the motor cover.3. Remove the fuse box cover and pull off the

fuse.

NOTE:Use the fuse puller at the back of fuse boxcover, when the fuse is pulled off and installed.

Fuse box cover

4. Remove the Sub battery cable fuse.

5. Inspect the fuse and replace with new fuse ifneeded.

Sub battery cable fuse case

Normal fuse

Main fuse (60A)/Isolator fuse (30A)

Blown fuse

Normal fuse

Blade type fuse

Blown fuse


53

WARNING

If you replace a blown fuse with a fusehaving a different amperage rating orwith a substitute such as aluminum foil ora wire, extensive electrical system dam-age and a fire may result.

Always replace a blown fuse with a fuseof the same type and rating.

NOTICE

If a new fuse blows in a short time afterinstallation, you may have a major electri-cal system problem.

Consult your SUZUKI marine dealer.

1 Starter motor relay fuse: 30A2 PTT switch fuse: 10A3 Ignition coil/Injector/Engine control module/

Fuel pump fuse: 30A4 IAC, CMP, VSV, VVT fuse: 10Aa Main fuse: 60Ab Isolator select fuse: 30Ac Spare fuse: 60Ad Spare fuse: 30Ae Spare fuse: 10Af Spare fuse: 15Ag Sub battery cable fuse: 15A

SPECIFICATIONS

Power rated in accordance with NMMA procedure.

Item DF150 DF175

Engine Type 4 Stroke

Number of Cylinders 4

Bore and Stroke 97.0 × 97.0 mm (3.81 × 3.81 in.)

Piston Displacement 2867 cm3 (174.9 cu. in.)

Maximum output 110.3 kW (150PS) 128.7 kW (175PS)

Full Throttle Operating Range 5000 – 6000r/min. (min–1)

5500 – 6100r/min. (min–1)

Idle speed (in Neutral) 600 – 700 r/min. (min–1)

Ignition System Full-transistor

Engine Lubrication Trochoid pump pressure lubrication

Engine Oil Capacity 8.0 L (8.5/7.0 US/Imp. qt.)


54

CHART OF TOTAL OPERATING HOURS INDICATION

*: One flashing is corresponded to 500 hours.

FLOWCHART OF OIL CHANGE REMINDER SYSTEM

*1: Lapse of initial 20 hour’s operation*2: Lapse of 80 hour’s operation*3: Lapse of 100 hour’s operation*4: When performing cancellation before system activation

NOTE:This system will activate up to 2100 hour’s operation.

Totaloperating

hours

MONITOR-TACHOMETERNeedle 1indication

REV-LIMITlamp 2 flashing *

0h-(49h) No No50h- 500rpm No60h- 600rpm No

::

::

::

540h- 5400rpm No550h- 500rpm 1 time560h- 600rpm 1 time

::

::

::

1040h- 5400rpm 1 time1050h- 500rpm 2 times

::

::

::

1540h- 5400rpm 2 times1550h- 500rpm 3 times

::

::

::

2030h- 5300rpm 3 times2040h or over 5400rpm 3 times


55

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Prepared by

Outboard Motor Engineering Department

April, 2010

Part No. 99011-96J05-03A

Printed in Japan

© COPYRIGHT SUZUKI MOTOR CORPORATION 2010

IMPORTANT WARNING/ CAUTION/ NOTICE/ NOTEPlease read this manual and follow its instruc-tions carefully. To emphasize special informa-tion, the symbol and the words WARNING,CAUTION, NOTICE and NOTE have specialmeanings. Pay special attention to the mes-sages highlighted by these signal words.

NOTE:Indicates special instructions to make mainte-nance easier or instructions clearer.

BREAK-IN INFORMATIONFOR YOUR OUTBOARD MOTORThe first 10 hours are the most important in thelife of your engine. Proper operation during thisbreak-in period is essential to help ensure max-imum life and performance.Refer to the BREAK-IN section of this manualfor specific break-in recommendations.

IMPORTANT NOTICE TO OWNERS

WARNING

Indicates a potential hazard that couldresult in death or serious injury.

CAUTION

Indicates a potential hazard that couldresult in minor or moderate injury.

NOTICE

Indicates a potential hazard that couldresult in damage to the motor or boat.

WARNING

Failure to take the proper precautionsmay increase the risk of death or severeinjury to you and your passengers.

• Prior to first-time use of your outboardmotor, familiarize yourself thoroughlywith the contents of this owner’s man-ual. Be aware of all outboard motor fea-tures and all safety and maintenancerequirements.

• Inspect the boat and motor before each

trip. See the INSPECTION BEFOREBOATING section for important items.

• Become thoroughly familiar with alloperating and handling characteristicsof your boat and motor. Practice at lowand moderate speeds until you arecompetent at handling the boat andmotor. Do no attempt to operate at maxi-mum performance until you are com-pletely familiar with all of thesecharacteristics.

• Carry boating safety and emergencyequipment. This important equipmentincludes; flotation aids for each person(plus one throwable buoyant cushion inany boat 16 feet or longer), fire extin-guisher, sound signaling device, visualdistress signals, anchor, bilge pump,bucket, compass, emergency starterrope, extra fuel and oil, first aid kit,flashlight, food and water, mirror, pad-dles, tool kit, and transistor radio. Besure you are carrying the equipmentappropriate for your trip before launch-ing.

• Never start the engine or let it runindoors or where there is little or noventilation. Exhaust gas contains car-bon monoxide, a gas that is colorlessand odorless and can cause death orsevere injury.

• Instruct your passengers on how tooperate the boat, how to deal withemergencies, and how to operatesafety and emergency equipment.

• Do not hold onto the motor cover orany other parts of your outboard motorwhile getting on or off your boat.

• Ensure that everyone wears a life jacketon board.

• Never operate the boat while under theinfluence of alcohol or other drugs.

• Distribute all weight load evenly in theboat.

• Have all scheduled maintenance per-formed. Consult your authorizedSuzuki marine dealer as required.

• Do not modify or remove any outboardmotor standard equipment. To do somay make the motor unsafe to use.


Documents

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