SERVICE AND WARRANTY MANUAL - Suzuki Marine Outboard Motors

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SERVICE ANDWARRANTY MANUAL4-STROKEB OAT I N G M A D E B E T T E R

BOATING MADE BETTER

CONGRATULATIONSon the purchase of your new Suzuki outboard!Suzuki Marine is truly unique and there is no other outboard brand like it inthe world. With better acceleration, better fuel efficiency and better value,Suzuki brings you boating made better.This manual has been presented to you by your Authorised Suzuki MarineDealer, who would have explained to you the operation of your new outboardand its safety features, plus the terms and conditions of its warranty.This manual must be kept in a safe, dry place, and is your reference point forthe service history of your outboard.Please ensure that this book is properly filled in when your outboard isserviced, as it will verify the outboard’s service history, thereby enhancing thevalue of your investment.Should you resell your outboard, please supply this booklet to the next owneras their record of service.Signature of Authorised Suzuki Marine Dealer/ / 20Delivery Date

GENUINE SUZUKI MARINE PARTSAND ACCESSORIESSuzuki Marine strongly recommends you keep it real by using Genuine SuzukiMarine Parts and Accessories, which are built to the highest standards ofquality and performance, and are designed to fit your outboard’s exactspecifications.While non-genuine parts may be available in the market place, the use ofthese parts and accessories may affect the outboard’s performance andshorten its useful life. Installation of non-genuine parts and accessories mayvoid any separate warranty which you may be able to claim fromSuzuki Motor Corporation, as well as void this warranty and any otherwarranty to which you may otherwise be entitled.Keep it realSUZUKI MARINE GENUINE SPARE PARTS

CONTENTSDealer pre-delivery inspection checklist . 7Suzuki Marine oils. 8Warranty policy. 9Recreational usage.9Commercial usage. 10Components covered by warranty. 11Warranty limitations and exclusions. 12General warranty conditions. 16Completion of warranty card . 17Obtaining warranty coverage. 18General tips and advice . 19Removing the outboard from the boat. 19Outboard security line attachment . 19What to do if your outboard is stolen . 19Servicing your outboard. 20Scheduled maintenance and service policy. 20Suzuki Marine 5 year warranty manual 1

CONTENTS (CONTINUED)Service record. 221 Month or 20-hour service inspection . 2212 Month or 100-hour service inspection . 232 Year or 200-hour service inspection . 243 Year or 300-hour service inspection . 254 Year or 400-hour service inspection . 265 Year or 500-hour service inspection . 27Suzuki outboard log. 28Update contact details. 29Change of ownership details. 31Transfer of registration inspection checklist. 31Change of ownership details. 33Transfer of registration inspection checklist. 332 Suzuki Marine 5 year warranty manual

OWNER/S & OUTBOARD DETAILS REGISTRATION FORM – OWNER’S COPYOwner’s name:Address:Suburb:State:Contact number:Postcode:Email:Selling dealer:Suzuki outboard model:Outboard serial number:Key number:Usage:commercialInvoice number:recreationalDelivery date:OWNER’S CONFIRMATION – Please tick to indicate ‘Yes’I have read and understood this Service & Warranty Policy.I have received the Owner’s Manual and understand the correct operating and maintenance procedurefor this model of outboard.I have received a practical demonstration from the selling Dealer with the correct operating procedureof my new Suzuki outboard.My new Suzuki outboard has been set up and fitted to my boat to my satisfaction.I hereby consent to being sent future marketing or promotional material from The Haines Group and/orits affiliated Companies/ Dealers/ Retailers.I agree that The Haines Assurance Program shall not be liable for any loss or damage (including butnot limited to, loss or damage as a result of Suzuki Motor Corporation’s negligence, death, personalinjury or harm of any kind) what-so-ever that is suffered (including, but not limited to, direct, indirect,or consequential loss) or sustained in connection with the use of the outboards. This clause does notaffect, and is not intended to affect, any rights that I might have, which are not able to be excludedunder applicable consumer protection laws.DEALER CONFIRMATION – Please tick to indicate ‘Yes’The pre-delivery of this model outboard has been completed by a trained technician who understandsthe inspections and procedures that must be done as detailed in the pre-delivery Inspection Sheet herein, and as outlined in the Suzuki Technical Service Manual.A full demonstration of this model outboard operation has been performed with the new owner oroperator of this outboard. All safety aspects of operating this outboard have been explained anddemonstrated in detail.The outboard has been correctly installed to the Owner’s boat.I have demonstrated the emergency kill lanyard operation and other features of the outboard.The Haines Assurance Program complies with the National Privacy Principles in the Privacy Act 1988.The Haines Assurance Program collects and uses your information for purposes related to your purchaseof a Suzuki outboard, such as warranty and safety purposes: for example, we may need to contact youin the unlikely event of a safety recall campaign. We also use this information to keep you up-to-datewith developments relating to our outboard products. We will not divulge your information to any otherorganisation. In the course of managing our business and for on-going customer service, we may shareinformation about you with our affiliated companies and related companies as well as our Dealers orRetailers. Our Retailers, affiliated companies and related companies may also share information with usabout you: for example, to help us learn more about your expectations of us and how we can meet them.For more information about our privacy practices or to see what information The Haines Assurance Programholds relating to you, please contact our Administrator. If you do not wish to receive future marketing orpromotional material, please indicate this in the box provided above.Owner’s signature:Date:Dealer’s signature:Date:Suzuki Marine 5 year warranty manual 3

OWNER/S & OUTBOARD DETAILS REGISTRATION FORM – OWNER’S COPYRECREATIONAL APPLICATION ONLY (4-STROKE DF2.5 to DF300A)The dealer’s copy (yellow) must be completed and submitted to The HainesAssurance Program electronically (by the dealer) immediately upon deliveryof the outboard to the owner.Failure to do so will void this warranty (see page 19).The obligation is on both the dealer and the owner to ensure that thisapplication has been submitted.4 Suzuki Marine 5 year warranty manual

OWNER/S & OUTBOARD DETAILS REGISTRATION FORM – DEALER’S COPYOwner’s name:Address:Suburb:State:Contact number:Postcode:Email:Selling dealer:Suzuki outboard model:Outboard serial number:Key number:Usage:commercialInvoice number:recreationalDelivery date:OWNER’S CONFIRMATION – Please tick to indicate ‘Yes’I have read and understood this Service & Warranty Policy.I have received the Owner’s Manual and understand the correct operating and maintenance procedurefor this model of outboard.I have received a practical demonstration from the selling Dealer with the correct operating procedureof my new Suzuki outboard.My new Suzuki outboard has been set up and fitted to my boat to my satisfaction.I hereby consent to being sent future marketing or promotional material from The Haines Group and/orits affiliated Companies/ Dealers/ Retailers.I agree that The Haines Assurance Program shall not be liable for any loss or damage (including butnot limited to, loss or damage as a result of Suzuki Motor Corporation’s negligence, death, personalinjury or harm of any kind) what-so-ever that is suffered (including, but not limited to, direct, indirect,or consequential loss) or sustained in connection with the use of the outboards. This clause does notaffect, and is not intended to affect, any rights that I might have, which are not able to be excludedunder applicable consumer protection laws.DEALER CONFIRMATION – Please tick to indicate ‘Yes’The pre-delivery of this model outboard has been completed by a trained technician who understandsthe inspections and procedures that must be done as detailed in the pre-delivery Inspection Sheet herein, and as outlined in the Suzuki Technical Service Manual.A full demonstration of this model outboard operation has been performed with the new owner oroperator of this outboard. All safety aspects of operating this outboard have been explained anddemonstrated in detail.The outboard has been correctly installed to the Owner’s boat.I have demonstrated the emergency kill lanyard operation and other features of the outboard.The Haines Assurance Program complies with the National Privacy Principles in the Privacy Act 1988.The Haines Assurance Program collects and uses your information for purposes related to your purchaseof a Suzuki outboard, such as warranty and safety purposes: for example, we may need to contact youin the unlikely event of a safety recall campaign. We also use this information to keep you up-to-datewith developments relating to our outboard products. We will not divulge your information to any otherorganisation. In the course of managing our business and for on-going customer service, we may shareinformation about you with our affiliated companies and related companies as well as our Dealers orRetailers. Our Retailers, affiliated companies and related companies may also share information with usabout you: for example, to help us learn more about your expectations of us and how we can meet them.For more information about our privacy practices or to see what information The Haines Assurance Programholds relating to you, please contact our Administrator. If you do not wish to receive future marketing orpromotional material, please indicate this in the box provided above.Owner’s signature:Date:Dealer’s signature:Date:Suzuki Marine 5 year warranty manual 5

OWNER/S & OUTBOARD DETAILS REGISTRATION FORM – DEALER’S COPYRECREATIONAL APPLICATION ONLY (4-STROKE DF2.5 to DF300A)The dealer’s copy (yellow) must be completed and submitted to The HainesAssurance Program electronically (by the dealer) immediately upon deliveryof the outboard to the owner.Failure to do so will void this warranty (see page 19).The obligation is on both the dealer and the owner to ensure that thisapplication has been submitted.6 Suzuki Marine 5 year warranty manual

DEALER PRE-DELIVERY INSPECTION CHECKLISTDEALER PRE-DELIVERY INSPECTIONCHECKLISTDealer/technician inspect the following items: tick indicates ‘DONE’Engine oil level (DF models)Transmission fluid levelPTT hydraulic fluid levelAll engine fixturesOperation of control box & cablesStart-in-gear functionCheck gear shift adjustmentAdjustment of tilt limit switchEngine’s fuel lines & connectionsSteering system for correct operationElectrical looms & connectionsPropeller installation & sizeBattery cable connectionsCharging systemInstrument operationEmergency stop switch or lanyardPlease ensure you refer to the Suzuki Technical Service Manual to completethis pre-delivery inspection and for further information relating to theoutboard. ** Inspections may vary between 2-stroke & 4-stroke models. **Date:DEALER STAMPDealer/technician initials:Suzuki Marine 5 year warranty manual 7

SUZUKI MARINE OILSMotul is a specialist oil company that concentrates exclusively onmanufacturing performance oils. Since 1853, Motul has been designing andblending special oils for everyday use that give high performance as standard,so you can use the same oil as race engines use, off-the-shelf.Why does Suzuki choose Motul?The world’s best 4-stroke deserves the world’s best oil and Motul offersthe right blend of lubricants to give the required protection to the Suzukioutboard range. Motul has had over 20 years technical partnership withSuzuki high performance engines combining the best engineering brains fortechnical development.The National Marine Manufacturers Association (NMMA) recommends FC-WTMoil for outboards and this has been verified and approved by Suzuki Marine,Japan.Why should you choose Motul?Choosing Suzuki Motul oil will mean less wear in your engine. The anticorrosion properties mean that the oil clings to the internal working parts ofyour engine which protects them. When you drop your oil each service, theoil will be in better condition and so will your engine. Protect your investmentwith Suzuki Motul.FC-WTM background Meets specifications for emission and fuel economy targeted by NMMA. Satisfies engine testing for dedicated marine outboard applications. Simulates real engine operation to check whether oils can sustain filmthickness. Reflects actual marine outboard engine operation in the specification ofFC-W. More focus on marine engine design, corrosion protection with saltywater. Sustainable capability of oil film thickness.8 Suzuki Marine 5 year warranty manual

WARRANTY POLICYRECREATIONAL USAGE1.DF 4-STROKE MODELS (DF2.5 TO DF300AP)Any new Suzuki DF2.5 to DF300AP 4-stroke model outboard sold andregistered by an Authorised Suzuki Marine Dealer from 1 September 2013, forrecreational usage in Australia and New Zealand, will be warranted againstdefects in the materials or workmanship for a period of five (5) years fromthe date of purchase from an Authorised Suzuki Marine Dealer in Australia orNew Zealand, subject to the matters & exclusions noted on pages 9–18 ofthis manual.Specific items are excluded from:a.The fourth and fifth years of the recreational usage warranty forDF2.5 to DF300AP.b.The second half of the one year commercial usage warranty(if applicable).Suzuki standard equipment supplied with the outboard such as gauges,remote control boxes, fuel tank and fuel line, propeller, outboard wiringlooms, outboard and side covers, paint, rubber components, i.e. coolinghoses, tubes and fittings (such as wire/clamps) will be warranted for oneyear only from the date of registration for both recreational and commercialusages.Additional benefits – hard stand storingUp to a maximum value of 250 (upon receipted proof of incurred costs),per claim per year will be reimbursed for any boat that requires removal fromthe water and re-launching in relation to warranty work carried out on theoutboard – providing that the outboard is still in its warranty period.NOTE: All such claims will only be initiated through the AuthorisedSuzuki Marine Dealer carrying out the work.Suzuki Marine 5 year warranty manual 9

WARRANTY POLICY (CONTINUED)COMMERCIAL USAGE2.DF 4-STROKE MODELSAny new Suzuki DF2.5 to DF300AP 4-stroke model outboard sold andregistered by an Authorised Suzuki Marine Dealer from 1 September 2013, forcommercial usage, such as for hire or any other income-generating activities,shall be covered by warranty against defective parts and/or workmanship fora period of one (1) year from the date of purchase from an Authorised SuzukiMarine Dealer in Australia or New Zealand. The second half of the one yearwarranty is subject to the matters and exclusions noted on pages 9–18 of thismanual.3.GOVERNMENT USAGEAny new Suzuki DF2.5 to DF300AP 4-stroke model outboard sold andregistered by an Authorised Suzuki Marine Dealer from 1 September 2013,for commercial usage by any Government funded department, rescueor lifesaving operations, shall be covered by warranty against defectiveparts and/or workmanship for a period of three (3) years, from the dateof purchase from an Authorised Suzuki Marine Dealer in Australia or NewZealand. The third year of the three year warranty is subject to the mattersand exclusions noted on pages 9–18 of this manual.Note: Commercial usage of an outboard registered for recreational use willvoid this warranty.10 Suzuki Marine 5 year warranty manual

WARRANTY POLICY (CONTINUED)COMPONENTS COVERED BY WARRANTY1.DF 4-STROKE MODELS (DF2.5 TO DF300AP)§§Recreational Warranty: 5 years from the date of purchase§§Commercial Warranty: 1 year from the date of purchase§§Government Warranty: 3 years from the date or purchaseThe fourth and fifth years of the recreational usage warranty, the third yearof the government usage warranty and the second half of the 12-monthcommercial warranty are limited to the following components:Power head componentsCrankshaftPiston & ringsCrankcase componentsEngine oil sealsC.D.I unitCylinder head componentsOil pump assemblyIgnition coilCamshaftValves & springsMagneto assemblyFuel pump assembly (diaphragm type only)Engine mid-sectionSwivel bracketClamp bracketSteering bracketPower trim & tilt assemblyLower TransmissionDrive shaft housingPinion gear setDrive shaftReplacement components used for warranty rectification will be warrantedfor the balance of the applicable warranty period on the outboard.Suzuki Marine 5 year warranty manual 11

WARRANTY POLICY (CONTINUED)WARRANTY LIMITATIONS AND EXCLUSIONSThis warranty does not apply or extend to:1.Any outboard motor which has been subjected to misuse, competition(including racing), negligence, alterations, accidents, fitting ofnon-authorised parts or accessories.2.Any routine service work over and above the repair and replacement ofdefective parts.3.An outboard that:a.Has not been operated in accordance with the instructions detailedin the Suzuki Owner’s Manual; orb.For which specified service checks are not carried out at theintervals listed on the Service Record pages of this manual or onlinelodgement by Authorised Suzuki Dealership.4.Normal service and regular maintenance procedures necessitated bynormal usage, such as outboard tuning, fuel system adjustment, partsor repairs made necessary by normal usage, i.e. normal wearing partslike spark plugs, fuses, carbon brushes, fuel and oil filters, rubber parts(except oil seals), bolts, nuts, pins and screws.5.Expense of returning the outboard motor to an Authorised Suzuki MarineDealer and the expense incurred in returning the outboard motor t

A full demonstration of this model outboard operation has been performed with the new owner or operator of this outboard. All safety aspects of operating this outboard have been explained and demonstrated in detail. The outboard has been correctly installed to the Owner’s boat.

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