DF40A/DF50A/DF60A - Dan's Southside Marine

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DF40A/DF50A/DF60ADF40A/DF50A/DF60AOWNER’S MANUALKeep with boat at all times.This owner’s manual contains importantinformation on safety, operation andmaintenance.MANUEL DU PROPRIÉTAIRE300 TAKATSUKA, MINAMI, HAMAMATSU, JAPANPrinted in Japan99011-88L20-03B* 9 9 0 1 1 - 8 8 L 2 0 - 0 3 B *Conserver ce manuel en permanence dansle bateau. Ce manuel du proprietairecontient d’importantes informations sur lasecurite, le fonctionnement et l’entretien.Part No. 99011-88L20-03BSeptember, 2012 Eng. Fre. TK



IMPORTANT WARNING/ CAUTION/ NOTICE/ NOTEPlease read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING,CAUTION, NOTICE and NOTE have specialmeanings. Pay special attention to the messages highlighted by these signal words. WARNINGIndicates a potential hazard that couldresult in death or serious injury. CAUTIONIndicates a potential hazard that couldresult in minor or moderate injury.NOTICEIndicates a potential hazard that couldresult in damage to the motor or boat.NOTE:Indicates special instructions to make maintenance 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 maximum life and performance.Refer to the BREAK-IN section of this manualfor specific break-in recommendations.IMPORTANT NOTICE TO OWNERS WARNINGFailure 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 manual. Be aware of all outboard motor features and all safety and maintenancerequirements.2 Inspect the boat and motor before eachtrip. 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 not attempt to operate at maximum performance until you are completely 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 extinguisher, sound signaling device, visualdistress signals, anchor, bilge pump,bucket, compass, emergency starterrope, extra fuel and oil, first aid kit,flashlight, food and water, mirror, paddles, tool kit, and transistor radio. Besure you are carrying the equipmentappropriate for your trip before launching. Never start the engine or let it runindoors or where there is little or noventilation. Exhaust gas contains carbon 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 performed. 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. Learn and obey all applicable navigation 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 replacement parts or accessories can createunsafe operating conditions.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.This manual should be considered a permanent 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 information on safety, operation, and maintenance.FOREWORDThe proper care and maintenance that youroutboard motor requires is outlined in this manual. 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 outboard motor to comply with the EPA regulations. Therefore, please follow the maintenanceinstructions closely to ensure emission compliance. Your Suzuki dealer has experienced technicians 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 motors previously built orsold.3

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 conservation and protection of Earth’s natural resources.To that end, we encourage every outboardmotor owner to recycle, trade in, or properly dispose 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 Squadron, and many Red Cross chapters. For information on classes in your area, call toll-free 1800-336-BOAT (2628).Your state’s department of boating and yourSuzuki Marine dealer can supply you with additional information on boating safety and regulations, or you can call the U.S. Coast GuardBoating Safety Hotline toll-free at 1-800-3685647.California Proposition 65 Warning WARNINGEngine 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.4


FUEL AND OILGASOLINESuzuki highly recommends that you use alcohol-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.NOTICEUse 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 contaminated by dirt/water etc.Gasoline Containing MTBEUnleaded gasoline containing MTBE (MethylTertiary Butyl Ether) may be used in your outboard motor if the MTBE content is not greaterthan 15%. This oxygenated fuel does not contain 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 system 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 Limited Warranty.Fuel containing 5% or less methanol may besuitable for use in your outboard motor if theycontain cosolvents and corrosion inhibitors.Fuel Pump LabelingNOTE:Oxygenated fuels are fuels which contain oxygen-carrying additives such as MTBE or alcohol.Suzuki recommends that you install a waterseparating 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 electronic fuel injection system. Water contamination can cause poor engine performance andcan also cause damage to the electronic fuelinjection system components.Your Authorized Suzuki Marine Dealer can provide you advice about water-separating fuel filter systems and installation.6In some states, pumps that dispense oxygenated 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 content or type of oxygenate and additives. If youare not sure that the fuel you intend to usemeets these requirements, check with the service station operator or the fuel suppliers.NOTE: Be sure that any oxygenated fuel blend youuse 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 containing no alcohol. If engine pinging is experienced, substituteanother brand, as there are differencesbetween brands. Unleaded gasoline will extend spark plug life.

NOTICEGasoline kept in the fuel tank for longperiods of time will produce varnish andgum, which can damage the engine.Always use fresh gasoline.FILLING THE FUEL TANK3. Turn the air-vent screw 1 on top of the fueltank cap 2 fully counterclockwise to openthe vent.NOTE:VENT SCREW should be CLOSED for transportation and OPEN for OPERATlON and CAPREMOVAL.4. Locate the pressure relief tab 3 under thefuel tank cap and turn the cap counterclockwise until the tab engages the first lock.To fill the fuel tank:1. Always stop the engine before refilling thetank.2. Remove the portable fuel tank from the boatto refill it. WARNINGGasoline is extremely flammable andtoxic. It can cause a fire and can be hazardous to people and pets.Always take the following precautionswhen refueling: Never permit anyone other than anadult to refill the fuel tank. If you use a portable fuel tank, alwaysstop 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.NOTICEFuels 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.7

5. Press down on the tab, and release the lock,then rotate the fuel tank cap 1/4 turn. Thetab will engage the second lock.6. Press the tab down again and turn toremove the fuel tank cap.ENGINE OILNOTICEUse of poor quality engine oil canadversely affect engine performance andlife.Suzuki recommends that you use SuzukiMarine 4-Cycle Engine Oil or its equivalent.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.7. Carefully refill the fuel tank with gasoline.Do not over fill.8. Tighten the fuel tank cap until an audible“click” is heard.9. Tighten the air-vent screw on top of the fueltank cap.API ClassificationSAE Viscosity GradeSGSHSJSLSMTEMP.10W–4010W–30 C–20–10010203040 F–41432506886104NOTE:In very cold weather (below 5 C (41 F), useSAE (or NMMA FC-W) 5W-30 for easier starting 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.8

LOCATION OF SAFETY LABELSRead and follow all of the labels on your outboard motor or fuel tank. Make sure you understand all of the labels.Keep the labels on your outboard motor or fueltank. Do not remove them for any reason.8 WARNINGAVERTISSEMENT Fuel can leak creating a fire hazard ifyou lay motor on its side. Drain fuelcompletely from vapor separator orcarburetor before laying motor on its side. See owner’s manual for details. Le carburant risque de fuir et deprésenter un danger d’incendie si lemoteur est placé sur le côté.Vidanger entièrement le carburant duséparateur de vapeurs ou ducarburateur avant de procéder. Pour plus de détail, voir le manueldu propriétaire.9

LOCATION OF PARTSMotor coverPower trim and tilt(P.T.T.) switch(Reverse side)Engine oil drain plugPilot water holeClamp bracketFlush plugAnodeFlush plugGear oil level plugAnti-cavitation plateWater intake holeTrim tab(Anode)Gear oil drain plugPriming bulbMONITOR-TACHOMETERSIDE MOUNT TYPEPower trim andtilt (P.T.T.) switchFUEL HOSETOP MOUNT TYPEPower trim and tilt(P.T.T.) switchRemote control handleLock-outleverWarm-up leverIgnition keyIgnition keyRemote controlhandleEmergencystop switchEmergencystop switchFree accelerator buttonThrottle tension adjuster10REMOTE CONTROL BOX (Option)

MOTOR INSTALLATION WARNINGOverpowering your boat can be hazardous. 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 manufacturer’s recommended maximum horsepower listed on the boat’s “CertificationPlate”. Contact your authorized Suzukimarine dealer if you are unable to locatethe hull “Certificate Plate”.NOTE:It is against federal regulations for any marinedealer to service a motor that exceeds the recommended 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. WARNINGBATTERY INSTALLATIONBATTERY REQUIREMENTChoose a 12 Volt cranking-type lead acid battery that meets the specifications shown below.650 Marine Cranking Amps (MCA)/ABYC,or 512 Cold Cranking Amps (CCA)/SAEor 160 Reserve Capacity (RC) Minutes/SAENOTE: The specifications listed above are the minimum battery rating requirements for startingthe engine. Additional electrical loads from the boat willrequire larger capacity batteries. Consultyour Suzuki dealer to determine the properbattery sizing for your boat and engine combination. Dual-purpose (Cranking/Deep-cycle) batteries 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 GelCell 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, manufacturer, and of similar age. When replacementis necessary, they should be replaced as aset. Consult your Suzuki dealer for properbattery installation information.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.11

BATTERY INSTALLATIONSecure the battery in a dry area of the boat,away from vibration.NOTE: It is recommended that the battery beinstalled in an enclosed battery case. When connecting batteries, hexagon-nutsmust be used to secure battery leads to battery posts.To hook up the battery, first connect the redlead from the motor to the positive battery terminal, then connect the black lead to the negative battery terminal.HexagonnutHexagonnutRed leadBlackleadTo remove the battery, first disconnect the blacklead from the negative terminal, then disconnect 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. WARNINGBatteries produce flammable hydrogengas and may explode if they are nearflames or sparks.Never smoke or cause sparks when working near the battery. Keep the batteryaway from open flames. To avoid creatinga spark when charging the battery, connect the battery charger cables to theproper terminals before turning thecharger on. WARNINGBattery acid is poisonous and corrosive.It can cause severe injury and can damage painted surfaces.Hexagon-nut WARNINGIf you place the battery near the fuel tank,a spark from the battery may ignite thegasoline, causing a fire and/or an explosion.Do not place the fuel tank in the samecompartment/area as the battery.12Avoid 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.

NOTICEThe electrical system or its componentsmay be damaged if proper battery precautions are not followed. Be sure to attach battery leads correctly. Do not disconnect battery leads fromthe battery while the engine is running.USE OF ELECTRICAL ACCESSORIESThe amount of power (12V DC) available foraccessories depends on the operating condition of the motor. For getting a detailed information, please inquire of your authorized SuzukiMarine Dealer.NOTE:Use of too much power for electrical accessories under certain operating conditions cancause the battery to discharge.PROPELLER SELECTIONAND INSTALLATIONPROPELLER SELECTIONIt is essential to use a propeller on your outboard 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 selection. Smaller loads generally require largerpitch propellers; larger loads generally requiresmaller-pitch propellers. Your authorized SuzukiMarine Dealer will assist you in selecting a suitable propeller for your boat.NOTICEInstalling 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 suitable propeller for your boat.You can determine if your propeller is appropriate for use with your boat by using a tachometer to measure engine speed when operatingyour boat at full throttle, under minimum loadconditions. If you are using an appropriate propeller, the engine speed will be within the following range:DF40A5000 – 6000r/min. (min–1)DF50ADF60A5300 – 6300r/min. (min–1)If the engine speed is not within this range, consult 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.13

PROPELLER INSTALLATION WARNINGFailure 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 removethe 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.ADJUSTMENTSTRIM ANGLE ADJUSTMENTTo help maintain steering stability and goodperformance, always maintain the proper trimangle as shown in the illustration. The appropriate trim angle varies depending on the combination 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 sectionIf you still cannot achieve good performance,there may be a problem with engine mountingheight. Consult your dealer for assistance.To install a propeller on your outboard motor,use the following procedure: Trim angle too small (Boat tends to “plow”) Trim angle too large (Boat tends to “porpoise”)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 shaftsplines and slide the propeller onto the shaft.4. Place the spacer 4 and washer 5 on theshaft.5. Install the propeller nut 6 and tighten it witha 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 procedure.14 Proper trim angle

NOTICETilt rangeTrim rangeIf you operate the boat with the motortrimmed beyond the maximum trim position, 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 position. WARNINGTrim angle greatly affects steering stability. 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 conditions. WARNINGWhen the motor is tilted beyond the maximum 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 1500r/min or operate the boat in a planing attitude with the motor tilted beyond themaximum trim position.15

TRIM TAB ADJUSTMENTTHROTTLE TENSION 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.The tension of the remote control handle can beadjusted according to your preference. Toincrease the tension, turn the adjuster A clockwise. To decrease the tension, turn the adjustercounterclockwise.To adjust the trim tab:1. Loosen the bolt A that holds the trim tab inplace.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 starboard side.Side mounttypeNOTE:Top mount typeWhen adjusting the tension of the remote control handle, consult your authorized SuzukiMarine Dealer.IDLE SPEED ADJUSTMENTThe idle speed has been factory adjustedbetween 750 – 850 r/min. in neutral.NOTE:If idle speed cannot be set within the specifiedrange, contact your authorized Suzuki MarineDealer.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.16

SETTING OF TILT UPPER LIMIT POSITION DF60AT If the outboard motor contacts the motor well ofthe boat during full tilt up operation, the upperlimit setting should be reset.Perform this set-up after the current positionsetting has been canceled, as explained in thefollowing procedure.CANCELING THE TILT UPPER POSITIONLIMIT SETTING5. Press the “UP” side of the PTT switch forthree seconds and the buzzer will soundtwice briefly indicating the setting has beencanceled.UP1. Turn the ignition key to the “ON” position.2. Pull out the emergency stop switch lockplate.PTT switch6. Return the throttle to the fully closed position.SETTING THE TILT UPPER POSITIONLIMIT3. Make sure that remote control handle is in“NEUTRAL”.4. Using the throttle only function of the remotecontrol box, move the warm-up lever upwarduntil the caution buzzer sounds one time.“NEUTRAL”7. Press the “UP” side of the PTT switch sothat the optimum full tilt up position for

outboard motor requires is outlined in this man-ual. By following these instructions explicitly you will ensure a long trouble-free operating life for your outboard motor. This outboard motor also conforms to the U.S Environmental Protection Agency emission regulations which apply to new outboard motors. The proper adjustment of engine .

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