DF 350a Suzuki
DF 350a Suzuki
DF 350a Suzuki
99505-98L00-01E
TK
FOREWORD
This outboard motor has been designed and produced utilizing Suzuki’s
most modern technology. The finest product, however, cannot perform prop-
erly unless it is correctly assembled and serviced. This set-up manual has
been produced to aid you in properly assembling and servicing this outboard
motor.
NOTE:
This set-up manual has been prepared exclusively for the following models.
Applicable model and effective serial number:
35001F (DF350A)-810001 and later
* This manual has been prepared on the basis of the latest specifica-
tions at the time of publication. If modifications have been made
since then, differences may exist between the content of this manual
and the actual outboard motor.
* Illustrations in this manual are used to show the basic principles of
operation and work procedures and may not represent the actual
outboard motor exactly in detail.
* This manual is intended for those who have enough knowledge and
skills to service SUZUKI outboard motors. Without such knowledge
and skills, you should not attempt servicing by relying on this manual
only. Instead, please contact your nearby authorized SUZUKI out-
board motor dealer.
Apprentice mechanics or do-it-yourself mechanics that don’t
have the proper tools and equipment may not be able to properly
perform the services described in this manual. Improper assem-
bly and/or servicing may result in injury to the mechanic and may
render the engine unsafe for the boat operator and passengers.
Improper electronic calibration of the system will make this prod-
uct and/or the system inoperable or unsafe for use.
1
CONTENTS
2
IMPORTANT
WARNING/CAUTION/NOTICE/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION, NOTICE and NOTE have special meanings. Pay special attention
to the messages highlighted by these signal words.
Indicates a potential hazard that could result in death or serious injury.
NOTICE
Indicates a potential hazard that could result in damage to the motor or boat.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the
WARNINGS, CAUTIONS and NOTICE stated, you must use good judgement and basic mechanical safety
principles.
3
SYMBOL
Listed in the table below are symbols indicating special instructions and other important information neces-
sary for proper servicing. Please note the definition for each symbol. You will find these symbols used
throughout this manual. Refer back to this table if you are not sure of any symbol(s) meanings.
MATERIALS REQUIRED
WATER RESISTANT SUZUKI SILICONE
GREASE EP2 SEAL
99000-25350 93691-80030
(250 g/8.8 oz) (100 g/3.5 oz)
4
GENERAL INFORMATION
HANG TAGS
It is mandatory that every new Suzuki outboard motor be
assembled and serviced in accordance with the instructions in
the set-up manual.
A critical step in the set-up and pre-delivery process of every
outboard motor is to attach the hang tags to the outboard motor.
Hang tags are required to remain on the motor until it is deliv-
ered to the customer.
Be sure the hang tags are attached to the outboard motor as
shown.
5
EMISSION-RELATED INSTALLATION INSTRUCTIONS
Fuel lines and fuel tanks used for a vessel must meet the requirements of federal law (40 CFR 1045.112
and 40 CFR 1060).
If you install the engine in a way that makes the engine’s emission control information label hard to read dur-
ing normal engine maintenance, you must place a duplicate label on the vessel, as described in 40 CFR
1068.105
Failing to follow these instructions when installing a certified engine in a vessel violates federal
law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.
6
OUTBOARD MOTOR INSTALLATION
HORSEPOWER SELECTION
Overpowering your boat may cause operating/handling difficulties which could result in a crash.
The boat may also sustain hull damage or other damage due to stress.
MOTOR DIMENSIONS
710 (28.0) X: 1165 (45.9), XX: 1282 (50.4)
180 (7.1) 794 (31.3)
1206 (47.5)
890 (35)
X: 1956 (77.0), XX: 2083 (82.0)
FORWARD
6.0)
X: 634 (25)
XX: 278 (10.9)
X: 227 (8.9)
81 12˚
(3.2)
˚
71
4˚ 15˚
XX: 36 (1.4)
32˚ 32˚
X: 36 (1.4)
Unit : mm (in.)
7
TRANSOM DIMENSIONS
Unit: mm (in)
158 (6.2) 147 (5.8)
51 (2.0)
(4-places)
19 (0.75)
254 (10.0)
5 – φ 14.7
5 – φ 14.7
(4-places)
19 (0.75)
251 (9.9)
327 (12.9)
8
For twin engine installation you may use the following procedure: (Minimum engine center-line distance is
686 mm/27 in.)
(1) Following the horizontal line from chine to chine, mark the line at 343 mm (13.5 in.) on both sides of the
previously established single engine vertical center-line.
(2) Following the horizontal line from strake to strake, mark this line also at 343 mm (13.5 in.) on both sides
of the vertical center-line.
(3) Align a straightedge with these two sets of marks and draw the vertical center-line for a twin engine
installation.
(4) Drill mounting holes as in a twin engine installation.
Chine
Strake
343 mm
(13.5 in.)
NOTE:
Do not drill engine top mounting bolt holes higher than 25.4 mm (1 in.) below top edge of actual boat tran-
som.
9
LIFTING THE MOTOR
Lifting the outboard motor using a hoist with insuffi-
cient capacity can result in serious injury and/or dam-
age to the outboard motor.
Failure to use the proper attachment point for lifting
the outboard motor can result in severe injury and/or
damage to the outboard motor.
Use the lifting eye only. Do not lift the motor using a
flywheel lifting attachment.
Attach the sling straps to two rear lifting eyes on the engine.
Then install lift to sling straps.
Sling the motor and align with the holes drilled in transom.
10
MOUNTING TO THE TRANSOM
Contained parts
Mounting bolt
Choose mounting bolts matched to the boat transom.
11
NOTE:
• Drill the mounting holes vertically to the transom board.
• Drill the upper holes at least 25 mm (1.0 in) down from the transom top surface.
• To insure water-tightness, sealant (SUZUKI SILICONE SEAL or equivalent) should be applied to all bolt
holes. Apply the sealant to the shanks of the bolts, but not the threads.
• Do not use an impact tool to tighten or loosen the transom nuts.
• If the specified tightening torque can not be reached due to weak transom material, it may be necessary to
install a reinforcement plate to the transom board. If a reinforcement plate is required, contact the boat
manufacturer for recommendations. The transom reinforcement plate should be installed between the
transom surface and the washer B and /or D.
NOTICE
Use of hand tools: turning a lock nut E at high speed
with impact tool may damage the friction ring (nylon).
NOTICE
Never reuse the lock nut E after it has been threaded
into position and torqued.
NOTE:
If there is a clearance between the clamp bracket and the tran-
som top surface, place a proper spacer on the transom top sur-
face so that the motor weight can be supported by the transom
through the spacer. Spacer
NOTE:
Make sure that there is no clearance on matting surfaces
between the transom board and motor clamp brackets.
Otherwise, the motor clamp brackets may be damaged.
NOTICE
If the motor is not properly secured to the transom, it
can come off.
12
PRECAUTIONS FOR OUTBOARD MOTOR MOUNTING
Notice
After completing break-in (10 hours), retighten the transom nuts to the specified torque.
Check nuts periodically for tightness.
Check the transom for dents or cracks.
12b
TOP MOUNT REMOTE CONTROL BOX
The DBW Model control box is exclusive and does not use the mechanical remote control cable for shift/
throttle control. The shift/throttle control is actuated electronically by an SPC system.
LOCATION OF PARTS
P
S
13
DIMENSIONS
(Single Type)
131.5 mm
(5 in)
150.5 mm
(5.9 in)
188 mm
(7.4 in)
(3.2 in)
82 mm
50 mm
(2 in)
92 mm 67.4 mm
(3.6 in) (2.7 in)
172.5 mm 105 mm
(6.8 in) (4 in)
(Dual Type)
185 mm
(7.3 in)
150.5 mm
(5.9 in)
188 mm
(7.4 in)
(3.2 in)
82 mm
50 mm
(2 in)
92 mm 96.6 mm
(3.6 in) (3.8 in)
175 mm 132 mm
(6.8 in) (5.2 in)
14
REMOTE CONTROL LEVER OPERATING RANGE
• Forward
To shift into forward, push the remote control lever forward and downward thru approx. 17° on (F) side A.
When motor is in gear, push the control lever further downward will open the throttle.
• Reverse
To shift into reverse, pull the remote control lever backward and downward thru approx. 17° on (R) side
B. When motor is in gear, push the control lever further downward will open the throttle.
Throttle
Throttle range
range
65˚
Fully opened
85˚
Fully opened
15
2. Turn the adjust screw 2 with a hexagon wrench.
Turning the adjust screw clockwise:
friction will increase
Turning the adjust screw counterclockwise:
friction will decrease
NOTICE
Over tightening the friction adjust screw can cause
damage to the mechanism.
NOTE:
Be careful when tightening the adjust screw so that the tighten-
ing torque does not exceed 2.5 N·m.
16
2. Remove the rubber grommet 2 from the remote control box
upper cover.
NOTE:
Direction of the rubber grommet 2 the tab should be pointed
downward.
NOTE:
The cover gasket must be removed.
17
NOTE:
The position of the detent adjust screw 5 is as shown in right
figure.
NOTE:
Adjustment of detent force for the dual control lever can be
made independently as shown in right figure.
18
REMOTE CONTROL BOX POSITION Minimum 50 mm
(2 in )
Open, short circuit or poor electrical con-
nections can result in loss of electronic
throttle and gear shift control.
19
CONTAINED PARTS
Item Part name Q’ty
A Bolt (M5-50 mm) 4
B Washer (10 mm OD) 4
C Washer (16 mm OD) 4
D Nut (M5) 4
Seal (Single type) 1
E
Seal (Dual type) 1
F Spanner 1
G Allen wrench 1
IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.
WARNING
Indicates a potential hazard that could result in death or injury.
CAUTION
Indicates a potential hazard that could result in engine damage.
NOTE:
Indicates special information to make maintenance easier or instruction clearer.
M000 154 50
Aug., 2007 Printed in Japan
20
INSTALLATION
(1) Select the proper position of the remote control box, and
stick the template on the selected position. TOP MOUNT CONTROL MOUNTING TEMPLATE
67200-98J02
(2) Cut and drill as instructed on the attached template. 67200-98J12
ALL CONTROLS
NOTE:
After drilling the holes, make sure opening is free of sharp
edges.
(3) Fit the bolts 3 and the washers 4 into the slots located on
the corner of main frame under as shown.
Frame
(4) Peel the release paper of the seal 2. Stick the seal 2 on the
back side of the Remote Control Box main frame as shown.
(5) Route the BCM harnesses through the opening and connect
with the wire harnesses of the Remote Control Box.
21
(6) Place the Remote Control Box into position. Install the
washers 4, 5 on the bolts 3 and tighten the nuts 6.
Panel
22
FLUSH MOUNT REMOTE CONTROL BOX
The DBW Model control box is exclusive and does not use the mechanical remote control cable for shift/
throttle control. The shift/throttle control is actuated electronically by an SPC system.
LOCATION OF PARTS
23
DIMENSIONS
24
REMOTE CONTROL LEVER OPERATING RANGE
• Forward
To shift into forward, push the remote control lever forward and downward thru approx. 17° on (F) side A.
When motor is in gear, push the control lever further downward will open the throttle.
• Reverse
To shift into reverse, pull the remote control lever backward and downward thru approx. 17° on (R) side
B. When motor is in gear, push the control lever further downward will open the throttle.
Throttle Throttle
range range
47.5˚
Fully opened
85˚
Fully opened
25
REMOTE CONTROL LEVER
FRICTION ADJUSTMENT
Adjust the lever friction using the following procedure.
NOTE:
Be careful when tightening the adjust screw so that the tighten-
ing torque does not exceed 2.5 N·m.
NOTICE
Over tightening the friction adjust screw can cause
damage to the mechanism.
26
REMOTE CONTROL POSITION
Set the Remote Control Box in a position in which it does not 50 mm
obstruct the operations of the control lever and switches. Make (1-63/64 in.)
sure there is no obstruction on the path of the remote control
wire harness.
Allow a space so that the back of the Remote Control Box does
not contact any other parts.
Provide a space so that the remote control wire harness can be
routed without bending sharply.
INSTALLATION
(1) Select the proper position for the remote control, and attach
the template on the selected position. Cut out the shaded
portion and drill 4 installation holes of 6.5 mm (17/64 in.)
diameter.
NOTE:
After drilling the holes, make sure the opening is free of sharp
edges.
(2) Remove the top cover of the remote control by using a flat
head screwdriver as leverage.
(3) Route the BCM harnesses through the installation hole and
connect with the wire harness of the remote control box.
27
(4) Rotate the remote control box 1 turning in 90 degrees as
shown in the figure and place it into the installation hole.
(5) After the base of the remote control 1 touches the mount-
ing panel, turn the remote control clockwise to its normal
position.
28
PRECAUTION WHEN INSTALLING ELEC-
TRONIC SYSTEM COMPONENTS
Open, short circuit or poor electrical connections can result in
loss of electronic throttle and gear shift control.
If you do not disconnect the battery before connecting the wiring
harness to electrical equipment, you could get an electrical
shock.
NOTICE
Installing and routing the harness of SPC (Suzuki Precision Con-
trol) system components in an inappropriate location can result
in system failure.
29
CONNECTION OF CONTROL HARNESS
CONNECTING COMPONENTS
Open, short circuit or poor electrical connections can result in loss of electronic throttle and
gear shift control.
30
(2) Connect the 2-pin connector of the sub-battery cable (1) to
(1)
the connector (2) on the engine side. (2)
(3) Remove the terminal resistor dummy plugs (3), connect the
terminal resistors (4) into position.
(4)
(3)
31
QUADRUPLE ENGINE INSTALLATION
SYSTEM STRUCTURE AND OUTLINE
1. Remote Control box
On the Quadruple Engine Installation of DBW (Drive by Wire) models, all engines can be controlled by a
twin lever remote control box.
• The port remote control lever controls both port engine and port center engine.
• The starboard remote control lever controls both starboard engine and starboard center engine.
About BCM
The BCM for quadruple engine installation (p/no.: 36770-98J21) which has communication function with
other BCM is strictly designed for that system.
The BCM (p/no.: 36770-98J13) is for single, dual and triple engine installations.
Use the BCM and its quantity appropriate to the system.
The system doesn’t work correctly when the incorrect BCM is used.
• When the BCM for quadruple engine installation (P/No.: 36770-98J21) is used on single, dual and triple
engine installations, system error is indicated due to no communication can be made with other BCM. The
system error indication is turning on the LED diagnostic lamp in the switch panel and beeping the buzzer.
In this condition, there are no functions of changing station and throttle only.
• In reverse, when the BCM (P/No.: 36770-98J13) for single, dual and triple engine installations is used on
quadruple engine installation, there is a possibility of mismatch to the functions of “changing station” and
“throttle only” due to no communication between two port side engine group and two starboard side
engine one.
Example of mismatches;
(1) When changing station to the 2nd one from the 1st one at the starboard and starboard center engine
group, they can be controlled by the 2nd station but can’t do to the port and port center engine group.
(2) When selecting the throttle only function at the starboard and starboard center engine group, they
can be controlled throttle only but can’t do to the port and port center engine group.
3. Sub-Battery Cable
A sub-battery cable is required for each engine groups that are two port-side engines and two starboard-
side ones.
• One sub-battery cable for the group of port and port center engines.
• Another sub-battery cable for the group of starboard and starboard center engines.
32
4. Battery
• One battery is required for each of the engines in the case of quadruple engine installation as the same
manner for the other multiple engine installation.
• Connect the negative battery terminals of all batteries together to maintain the BCM power source in the
case of multiple engine installation.
• Use a negative cable mentioned above with AWG 2 or larger thickness (lower gauge number) to connect
the negative terminals of each engine batteries.
NOTE:
In multiple-motor installation, to maintain the BCM power source, all of the negative battery terminals should
be connected together.
Failure to follow these instructions may cause the wire to overheat and a fire may result.
Use a cable with AWG (American Wire Gauge) number 2 or larger thickness (lower gauge num-
ber) to connect the negative battery terminal.
5. System Wiring
Refer to page 55, 57 for the wiring of the system.
33
INSTALLATION OF SWITCH PANEL
NOTICE
Installing the switch panel in an inappropriate location can result in switch failure or operating
difficulties.
• Do not install the switch in a location where it is likely to be sprayed with water.
Exposure to water can cause failure of the switch.
• Be sure to install the switch on the dashboard in a location that makes it convenient for the
operator to use the switch.
Avoid locating the switch where the operator’s view of the switch is obstructed.
Install the emergency stop switch panel and main switch panel at an appropriate position on the dashboard.
Installing dimensions are as shown in the figure below.
68 (2.68)
61.3 (2.4)
53 (2.09)
33 (1.3)
108 (4.25)
93 (3.66)
Unit: mm (in.)
52 mm (2.04 in.)
37 mm
(1.45 in.)
52 mm (2.04 in.)
34
EMERGENCY SWITCH PANEL ASSEMBLY
43.5 (1.71)
70 (2.76) 23.5
50 (1.97) (0.93)
70 (2.76)
50 (1.97)
Unit: mm (in.)
35 mm
(1.38 in.)
35
SINGLE SWITCH PANEL ASSEMBLY
1.5 10 – 15 34 (1.34)
34 (1.34) (0.06) (0.4 – 0.6)
20 9
(0.79) (0.4)
70 (2.76)
M25 × P1.5
Unit: mm (in.)
25 mm
(0.98 in.)
36
DUAL SWITCH PANEL ASSEMBLY
84 (3.31)
1.5 10 – 15 35 (1.34)
(0.06) (0.4 – 0.6) 20 12
(0.79) (0.5)
76 (2.99)
M52 × P2
Unit: mm (in.)
52 mm
(2.03 in.)
37
TRIPLE SWITCH PANEL ASSEMBLY
84 (3.31)
1.5 10 – 15 35 (1.34)
(0.06) (0.4 – 0.6)
20 12
(0.79) (0.5)
76 (2.99)
M52 × P2
Unit: mm (in.)
52 mm
(2.03 in.)
38
TROLL MODE SWITCH
INSTALLATION
(1) Using hole saw and drill bit, drill hole through the dash
4 × ø 3.5 mm
panel at the location (X) shown. (9/64 in)
50 mm ø 52.2 mm
(1.97 in) (2–1/16 in)
Required tool
• 52.2 mm (2-1/16 in.) Hole saw
• 3.5 mm (9/64 in.) Drill bit
• Electric drill 50 mm
(1.97 in)
(2) Connect the leads, matching their color, as shown in the
illustration. (Refer to next page.)
39
WIRE CONNECTION
CAP
BATT+
Gr
Gr
Gr
B B/G
B
GND
Y/B
B TO
MAIN SWITCH
36623-98J20
TO BCM 36623-98J30
TO HARNESS BCM
Harness
CAP
TO TO
BUZZER PANEL SWITCH
BATT+
Gr
Gr Gr
TO
B B/G EMERGENCY
B STOP SWITCH
GND
36624-98J02
TO BCM
36624-98J11
TO HARNESS
BCM
Harness
TO PTT SW, LPS
SPC model;
A “Cap” is connected to the ( ) marked connector in the “BCM Harness”.
When the “Troll Mode Switch” is installed, it is necessary to remove the “Cap”
from the ( ) marked connector.
The removed “Cap” should be used as the plug for the unused connector.
NOTE:
The unused connector is for the “Analog Trim Meter”.
Therefore, it is not used for the SPC model.
40
INSTALLATION OF BCM (Boat control module)
NOTICE
Installing and routing the harness of SPC system components in an inappropriate location can
result in system failure.
NOTE:
Engine will not start with improper combination of BCM and ECM.
In this case:
• Caution buzzer sounds
• Gauge screen indicates “Check Control Unit C”
• Engine cranking does not take place
For this model, BCM must be used with the following part number.
For single, twin and triple engine installation: P/N: 36770-98J13 and later
For quadruple engine installation: P/N: 36770-98J21 and later
41
BCM (Boat Control Module)
16
(0.63) 110 (4.33)
95 (3.74)
(0.5)
12.5
79 (3.11)
(1.42)
36
(0.79)
Unit: mm (in.) 20
98 (3.86)
36770 - 9 8J ✽ ✽
92 (3.62)
2- φ 5.5
(2- φ 0.2)
24 (0.94)
Unit: mm (in.) Unit: mm (in.)
42
WIRING
BCM
J/C J/C
SDS connector
Battery cable
Troll switch
SINGLE ENGINE – SINGLE STATION
Fuse
30A
Fuse
5A
BATT
43
[Single engine – Single station]
44
Troll switch
2nd Station
BCM
J/C Label
[letter: 2nd]
J/C J/C
SDS connector
Cap
BCM
1st Station
J/C
Label
Fuse 10A Label
[letter: 1st]
[letter: E/G]
J/C
J/C
SINGLE ENGINE – DUAL STATIONS
SDS connector
Analog tachometer Isolator line
Sub battery cable
Cap YB B signal output lead wire
Sub battery cable
Battery cable
Troll switch
Fuse
30A
Fuse
5A
BATT
Engine
operating Accessory battery
battery
45
[Single engine – Dual stations]
46
BCM
P S
J/C
Label
J/C J/C [letter: R/CON]
Label
[letter: STBD] STBD
Isolator line
P S
SDS connector
Sub battery cable
YB Y B
Cap Sub battery cable
Analog tachometer
signal output lead wire Battery cable
DUAL ENGINES – SINGLE STATION
Troll switch
Label
[letter: PORT]
PORT
Fuse
30A
Isolator line
Fuse
5A
BATT Sub battery cable
Engine
Engine operating
operating Accessory battery battery
battery
47
[Dual engines – Single station]
48
Troll switch
2nd Station
BCM Label
[letter: STBD]
P S Label STBD
J/C
[letter: 2nd]
J/C J/C
Isolator line
1st Station
BCM
J/C
Label Label
Label Fuse [letter: R/CON] [letter: PORT]
[letter: 1st] 10A Label
P S J/C [letter: E/G]
J/C
PORT
DUAL ENGINES – DUAL STATIONS
P S
SDS connector Sub battery cable
Analog tachometer
Cap YB Y B signal output lead wire Isolator line
J/C
Sub battery cable
Engine
operating
Troll switch
Fuse battery
30A
Fuse
5A
BATT
Engine
operating Accessory battery
battery
49
[Dual engines – Dual stations]
50
Label
[letter: STBD] STBD
BCM
J/C
Isolator line
P S
Battery cable
Label
J/C [letter: R/CON]
J/C Label
[letter: CENTER]
CENTER
P S
J/C Isolator line
SDS connector
operating
battery
Troll switch
Label
[letter: PORT] PORT
Fuse
30A
Fuse
Isolator line
5A
BATT
Sub battery cable
Engine
operating
Engine
battery
operating Accessory battery
battery
51
[Triple engines – Single station]
52
Label
Troll switch [letter: R/CON]
2nd Station J/C
Label
BCM
[letter: STBD]
STBD
P S J/C
Label Isolator line
J/C
[letter: 2nd]
J/C J/C Sub battery cable
Battery cable
SDS connector
Cap Label
[letter: CENTER]
CENTER
1st Station
BCM
P S
SDS connector Sub battery cable
Analog tachometer Label
Cap YB Y B signal output lead wire [letter: E/G]
Isolator line
Troll switch
Fuse Engine operating
30A battery
Fuse
5A
BATT
Engine
operating Accessory battery
battery
53
[Triple engines – Dual stations]
54
BCM BCM
Label: STBD
C D Label
Label: STBD
[Letter: S]
STBD
Label: PORT
Label: PORT
A B
Label: PORT Label: STBD
STBD
Center
Label
[Letter: P]
Label
QUADRUPLE ENGINES – SINGLE STATION
[Letter: S]
PORT
Center
55
No. Part Name Part No.
1 Dual engine harness 36621-98J00
Remote control wire (6.5 m ) 36620-98J30
2
Remote control wire (9.5 m) 36620-98J40
3 BCM Quadruple harness 36623-98J40
4 Sub-Battery cable (2 m) 36625-98J10
5 Terminal resistor 33926-98J00
6 Troll control switch 37860-87L00
7 BCM 36770-98J21
56
1st station BCM BCM
Label: STBD Label: STBD
C D Label
[Letter: S]
STBD
Label: PORT
Label: PORT
A B
Label: PORT Label: STBD
STBD
Center
Label
2nd station [Letter: P]
BCM BCM
Label: STBD
C D
Label:
STBD
Label
QUADRUPLE ENGINES – DUAL STATIONS
not in use
A: Connect this connector to the multi function C: SDS communication connector (for PORT engine group) PORT
gauge system. (for PORT engine group).
Refer to page 91. D: SDS communication connector (for STBD engine group)
Label
[Letter: P]
B: Connect this connector to the multi function “Label PORT”: Harness for PORT engine group.
gauge system. (for STBD engine group). “Label STBD”: Harness for STBD engine group.
Refer to page 91.
57
No. Part Name Part No.
1 Dual engine harness 36621-98J00
Remote control wire (6.5 m) 36620-98J30
2
Remote control wire (9.5 m) 36620-98J40
3 Dual station harness 36622-98J00
4 BCM Quadruple harness 36623-98J40
5 Sub-Battery cable (2 m) 36625-98J10
6 Terminal resistor 33926-98J00
7 Troll control switch 37860-87L00
8 BCM 36770-98J21
NOTE:
To set the quadruple engine – dual station system, single station
kit for quadruple engine and dual station kit for quadruple engine
are needed.
58
BATTERY
BATTERY REQUIREMENT
Red tube Black tube
Suzuki recommends a 12-volt cranking-type lead acid battery for
the DF350A.
Minimum battery requirement for starting the engine is provided
below.
The battery must satisfy one of the specifications described
below.
Sub battery cable
1000 Marine Cranking Amps (MCA)/ABYC,
or 800 Cold Cranking Amps (CCA)/SAE
or 180 Reserve Capacity (RC) Minutes/SAE Battery cable Battery cable
or 12 V 130 AH
NOTE:
• The specifications listed above are the minimum battery rating
requirements for starting the engine.
• If your boat application requires additional battery loads, it is
recommended that an auxiliary battery or batteries be
installed.
• Dual-purpose (Cranking/Deep Cycle) batteries can be used if
they meet the minimum specifications listed above (MCA,
CCA, or RC).
• Do not use a Deep Cycle battery for the main cranking battery.
• The use of Maintenance-Free, sealed, or Gel-Cell batteries is
not recommended because they may not be compatible with
Suzuki’s charging system.
• When connecting batteries in parallel, they must be of the
same type, capacity, manufacturer, and of similar age. When
replacement is necessary, they should be replaced as a set.
59
INSTALLATION OF BATTERY
Failure to take proper precautions when handling the
battery may cause severe injury.
Store the battery free from splash of water, etc. and fix it
securely to the hull with a battery band or the like to prevent it
from falling down during boating.
NOTE:
It is recommended that the battery be installed in an enclosed
battery case.
NOTE:
In the case of multiple engine installation, be sure to use a bat-
tery for an engine respectively.
NOTE:
When extending the battery cable, use a cable of diameter
larger than equivalence of AV30 (AWG2).
NOTE:
Suzuki recommends that the customer, dealer, or boat builder
should install the terminal cap on the positive battery terminal to Positive
Battery
prevent an accidental short circuit of battery terminals. Terminal terminal
cap
If a terminal cap is required, contact your authorized Suzuki
Marine Dealer.
60
CONNECTION OF BATTERY CABLE Red tube Black tube
• Connect the battery cable securely to the battery.
• Connect the battery cable and sub battery cable to the posi-
tive + and negative - terminals of the battery.
NOTE:
Connect the sub battery cable securely to the positive + and
Sub battery
negative - terminals of the battery. cable
If the sub battery cable is not correctly connected to the battery,
the engine cannot start (operate). Fuse case/fuse
Battery cable Battery cable
NOTE:
Locate the sub-battery cable fuse at visible place for easy main-
tenance to boat operator.
NOTICE
Failure at the battery connection will cause incorrect
operation of the engine control system.
NOTE:
In multiple-motor installation, to maintain the BCM power
source, all of the negative battery terminals should be connected
Outboard Outboard
together. motor motor
Failure to follow these instructions may cause the wire
to overheat and a fire may result.
61
ISOLATOR LINE
The battery charging system is equipped with an isolator func-
tion.
When a sub battery is used in addition to the main battery for
engine operation, this function allows both the batteries to be
charged at the same time.
To modify the charging circuit and distribute the power to the
individual batteries, relocate the 40 amp. fuse in [STD] position
to [OPT x] position in the fuse box.
Required parts
Failure to follow these instructions may cause the wire
to overheat and a fire may result.
If you replace a blown fuse with a fuse having a differ-
ent amperage rating or with a substitute such as alu-
minum foil or a wire, extensive electrical system
damage and a fire may result.
62
Installation
(1) Remove the connector cover (1) from the isolator lead wire (1)
connector on the engine side.
(2) Connect the isolator lead wire connector (2) to the connec-
tor on the engine side.
(2)
(3) Remove the cover of the fuse box. “OPT” position of isolator
40 amp. fuse
Change the isolator 40 amp. fuse in the fuse box from
Terminal cover
“STD” to “OPT” position.
63
Cable connecting
NOTE:
• Maximum alternator output generated by a DF350A outboard
motor through the accessory isolator lead is 25 A. In multiple
engine installations (twin & triples) if the accessory isolator
lead wires are connected from each motor to a common auxil-
iary battery, the total alternator charge rate could be 50 A or
75 A respectively.
• As such, it is important to select an appropriate auxiliary bat-
tery charge (current) rate that meets the electrical power con-
sumption of your boats electrical equipment.
NOTE:
• Excessive charge rate may shorten battery life.
• Insufficient charge rate may cause discharge of the battery.
1 Battery cable +
2 Battery cable -
3 Sub battery cable
Engine operating Accessory battery Engine operating Accessory battery Engine operating 4 Isolator lead wire
battery battery battery 5 Cable connecting -
12 V 130 AH 12 V 130 AH 12 V 130 AH 12 V 130 AH 12 V 130 AH terminals of battery
64
SPC SYSTEM ELECTRONIC CALIBRATION
Improper electronic calibration of the system will
make this product and/or the system inoperable or
unsafe for use.
Required tool
The necessary tools are as follows.
65
CONNECTING PC AND BCM
(1) Connect your PC to the BCM of the outboard motor by
using the special tools.
NOTE:
• Check that your PC and the main switch of the outboard motor
are off before connecting the diagnostic harness.
• If two stations are available, a master BCM and sub BCM are
installed. To calibrate the system, connect the diagnostic har-
ness to the master BCM (main switch side BCM).
(If only one station is available, only the master BCM is
installed.)
66
BCM MAIN MENU
(1) Start the SDS program.
(2) The SDS program window appears.
(3) Click the “Main Menu (F1)” button (“F1” key on the key-
board). The following Menu dialog box appears. The BCM
part number is displayed in the lower left of this dialog box.
**
67
SYSTEM CALIBRATION
Calibrate the SPC system and registers information of outboard
motor and remote control box in the BCM.
Perform this item when an outboard motor, remote control box,
and meters, are first installed on the boat. Also perform this item
when the BCM is replaced or the ECM or remote control box of
the outboard motor is replaced.
SETTING CHANGE
Sets, changes, or resets the remote control lever and tilt down.
Perform this item when the remote control box is disassembled
or when the tilt position is changed.
SYSTEM CHECK
Enables you to check the system configuration registered in the
master BCM.
BCM INITIALIZATION
Deletes the (master or sub) BCM information registered in the
BCM after system calibration and system configuration informa-
tion (*Number of engine, Number of station).
Exit
Exits the SDS program.
Close (Esc)
Closes the menu box.
NOTE:
• The ECM or BCM calibrated in one boat cannot be reused in
another boat.
To reuse the ECM or BCM, be sure to calibrate the system
after deleting the BCM information by using the BCM INITIAL-
IZATION menu.
• The BCM INITIALIZATION menu cannot be used to delete the
diagnostic information registered in the BCM.
• Use the BCM INITIALIZATION menu to delete information for
the connected BCM.
(To delete information for the master BCM, connect the diag-
nostic harness to the master BCM. To delete information for
the sub BCM, connect the diagnostic harness to the sub BCM.)
68
SYSTEM CALIBRATION
Calibrate the system and register information in the BCM.
NOTE:
To change the system configuration after system calibration, be
sure to initialize the system by using the BCM INITIALIZATION
menu.
• Example: The system is calibrated as a single engine and then
the single engine is changed to the dual engine.
NOTE:
On Quadruple engine:
The electronic calibration for quadruple engine installation is
equal in two times of that for dual engine installation.
• Calibrate the group of port and port center engines first then
the group of starboard and starboard center engines.
• Or calibrate the group of starboard and starboard center
engines first then the group of port and port center engines.
69
(2) The following window appears. Click the “OK” button and
proceed to the next step (“Enter” key on the keyboard).
NOTE:
If the BCM has already been calibrated, the Confir-
mation window appears.
(3) The following window appears. Click the “OK” button and
proceed to the next step (“Enter” key on the keyboard).
70
NOTE:
• The station to which SDS was connected is regis-
tered as the master BCM. If SDS is connected to
the BCM of the second station and the system is
calibrated, the BCM of the second station serves
as the master BCM.
• If the “Cancel” button is clicked or the “Esc” key is
pressed during system calibration, the window
shown at right appears. Click the “OK” button to
calibrate the system. To continue system calibra-
tion, click the “Cancel” button.
(4) The following window appears. This window is used to register the system configuration.
In this window, select the number of stations and the number of engines by clicking the button, click
the “OK” button, and proceed to the next step.
(Keyboard) Move to a desired item by using the “Tab” key. Select a desired item by using the “Up” or
“Down” arrow key and press the “Enter” key to have the selected item accepted.
Clicking the “Cancel” button cancels system calibration.
NOTE:
If you make a selection different from the actual
configuration, the error screen is displayed.
71
(5) The following window appears. Check that the calibration are correct, click the “OK” button, and pro-
ceed to the next step (“Enter” key on the keyboard).
Clicking the “Cancel” button brings you back to the previous window.
(6) The following window appears. This window is used to register the outboard motor position in the BCM.
Operate the PTT switch of the outboard motor to perform full tilt down.
Click the “OK” button to have the outboard motor position accepted and proceed to the next step.
(Figure is an example of registering the PORT outboard motor.)
Clicking the “Cancel” button cancels system calibration.
NOTE:
• For the dual engines, register the PORT and STBD positions. For triple engines, register the PORT, CEN-
TER, and STBD positions.
• After full tilt down, the high-pressure fuel pump of the outboard motor is actuated for 3 seconds. Listen for
the actuation sound.
72
(7) The following window appears. This window is used to register the position of the remote control lever
in the BCM.
Set the lever to each position (Forward, Neutral, Reverse) and click the “Set” button.
If the set lever positions are correctly registered, “✓” mark is displayed in the “Status” column in the
right side of the window.
Repeat the same operation to register all the lever positions.
Clicking the “Cancel” button cancels system calibration.
73
NOTE:
• If the lever is not set to a correct position, the error message is displayed.
• Click the “OK” button, set the lever to the correct position, and click the “Set” button.
• For a dual control box, you must simultaneously operate both the levers.
• After all the lever positions have been registered, the following confirmation message is displayed.
74
SETTING CHANGE
Change or reset the remote control lever characteristics and full
tilt down position.
NOTE:
Change system settings when disassembling or replacing the
remote control lever, its related parts, or tilt-related parts.
Lever Characteristics
(1) Clicking the “SETTING CHANGE” button from
the Main Menu dialog box displays the follow-
ing window of boat station configuration regis-
tered in the BCM during system calibration.
* Figure is the “SETTING CHANGE” initial win-
dow registered as the single station.
75
(2) Clicking “LEVER POSITION (XXXXXX)” button from the Setup Change dialog box displays the follow-
ing window:
Set the lever to each position (Forward, Neutral, Reverse) and click the “Set” button.
If the set lever positions are correctly registered, “✓” mark is displayed in the “Status” column in the
right side of the window.
Repeat the same operation to register all the lever positions.
Clicking the “Cancel” button cancels system setting change.
76
NOTE:
• If the lever is not set to a correct position, the error message is
displayed.
Click the “OK” button, set the lever to the correct position, and
click the “Set” button.
• For the dual control box, you must simultaneously operate
both the levers.
• To change the dual station settings, select “First Station”,
“Second Station”, and “Both First and Second Stations.”
• After all the lever positions have been registered, the following
confirmation message is displayed:
(4) Clicking the “OK” button after all the lever posi-
tions have been registered displays the follow-
ing window:
Click the “OK” button to terminate setting
change.
77
Full Tilt Down Position
(1) Clicking the “Full Tilt Down Position” button
from the SETTING CHANGE dialog box dis-
plays the window.
(2) Operate the PTT switch of the outboard motor
to perform full tilt down.
Clicking the “OK” button registers the full tilt
down position and redisplays the SETTING
CHANGE completed window.
Click the “OK” button to complete setup
change.
SYSTEM CHECK
Check system settings.
System configuration
(1) Clicking the “SYSTEM CHECK” button from the Main Menu dialog box displays the following menu win-
dow.
78
(2) Clicking the “SYSTEM FORMATION” button from the menu
window displays the window.
The upper part of this window illustrates the system config-
uration registered in the BCM.
The following figure shows a dual station of triple outboard
motor type.
The lower part of this window shows the master BCM ID,
sub BCM ID, PORT ECM ID, CENTER ECM ID, and STBD
ECM ID.
Click the “OK” button to terminate system check.
NOTE:
If the illustration and description of the displayed system config-
uration differ from the registered configuration and the configu-
ration of actual boat, it means that the system is not correctly
calibrate.
In this case, be sure to calibrate the system.
79
BCM INITIALIZATION
Initialize the information registered in the BCM.
80
(3) The following BCM INITIALIZATION-CAUTION window appears.
Read the messages and follow the instruction. Then click the “OK” button and proceed to the next step.
To cancel BCM information deletion, click the “Cancel” button or press the “Esc” key on the keyboard.
(Keyboard) To delete BCM information, move to the “OK” button by using the “Tab” key and press the
“Enter” key to have the deletion accepted. To cancel BCM information deletion, move to the “Cancel”
button by using the “Tab” key and press the “Enter” key to have the cancellation accepted.
NOTE:
• By clicking the “OK” button, the initialization of
BCM information is completed. Click the “OK” but-
ton, turn “OFF” the engine switch (main switch)
and turn it “ON” again.
• If the initialization of BCM information fails, an
error message is indicated.
• Click the “OK” button and start from the step 1
again.
81
MULTI FUNCTION GAUGE DIMENSIONS & MOUNTINGS
NOTICE
Installing the gauges in an inappropriate location can result in gauge failure or operating diffi-
culties.
• Do not install the gauge in a location where it is likely to be sprayed with water.
Exposure to water can cause failure of the gauge.
• Install the gauges on the dashboard so that they can be easily operated and viewed by the
operator.
HOLE SIZES
NOTE: 105 (4.13)
105 (4.13)
contacted when cutting holes.
φ 84.5 (3.32)
φ 96 (3.78)
16.5 54.9
(0.65) (2.16)
Unit: mm (in.)
FASTENING TO PANEL
(1) Install the gasket (1) to gauge.
(2) Insert the gauge (2) into panel hole.
(3) Thread the nut (3) onto threaded housing of gauge and
tighten to back of panel.
3
1
2
82
MULTI FUNCTION GAUGE SYSTEM CONNECTION
Select the connection method from the examples in the following
pages and arrange the required wiring.
NOTE:
For setting up the multi-function gauge, refer to “INSTALLATION
INSTRUCTION MANUAL” packed in the gauge.
T- Connector
T-Connectors must be connected to be in a straight line as
shown in the illustration.
NOTE:
• Secure the T-connectors to a solid surface or to an existing
wire harness, do not leave them free-floating.
• Do not overstress cables or connectors by using excessive
force when tightening or pulling.
83
84
7
8P
8
TO BCM HARNESS
2
Gr
B
9
3P
6P
B Bl B R
Fuel level B R
4
1
3 5 6
SINGLE ENGINE – SINGLE STATION
9
8P 9
11 8P
TO BCM HARNESS
3 3 12
Gr
B 10
3P 6P
B Bl B R 13 4P 2 4P
B R
Fuel level
6P 5 6 7 8
1
4
SINGLE ENGINE – DUAL STATIONS
No. Part name Part No. Qty No. Part name Part No. Qty
Wire comp, gauge power (2.5 m) 36663-98J00 8 Terminator (male) 36665-88L10 1
1 1
Wire comp, gauge power (6 m) 36663-98J10 9 Multi function gauge set 34011-96L11 2
2 Wire comp, extension 36682-92E00 1 10 Adapter, gauge power 36666-96L00 1
3 Wire comp, extension (2’) 36662-88L10 2 11 Adapter comp, gauge 36661-96L00 1
4 Harness assy, network power 36663-88L00 1 12 GPS receiver module 39950-88L02 1
5 Terminator (female) 36665-88L00 1 13 Adapter, gauge for dual station 36665-96L00 1
6 T-connector 36664-88L00 4
Wire comp, extension (25 feet) 36662-88L00
Wire comp, extension (2 feet) 36662-88L10
7 1
Wire comp, extension (6 feet) 36662-88L20
Wire comp, extension (15 feet) 36662-88L30
85
86
1
8P
7
TO BCM HARNESS
3
10
B Gr
3P
B Bl B R 6P
B R
Fuel level
2 4 6
DUAL ENGINES – SINGLE STATION
9
5
1
8 8P
STBD
1 Multi function gauge set 34011-96L11 2
Wire comp, gauge power (2.5 m) 36663-98J00
2 1
Wire comp, gauge power (6 m) 36663-98J10
3 Wire comp, extension (2’) 36662-88L10 2
4 Harness assy, network power 36663-88L00 1 8P
5 T-connector 36664-88L00 4
6 Terminator (female) 36665-88L00 1
7 Adapter comp, gauge 36661-96L00 1
CENTER
4
15
1
1
8P
11 8P
TO BCM HARNESS
8P 4
4
B Gr 12
10
3P
6P
B Bl B R 4P
B R 4P
13 3
Fuel level
6P 7 8
2 9
5
6
DUAL ENGINES – DUAL STATIONS
1
14
Label
4
8P
[letter: STBD]
Label
[letter: CENTER]
8P
No. Part name Part No. Qty No. Part name Part No. Qty
1 Multi function gauge set 34011-96L11 4 Wire comp, extension (25 feet) 36662-88L00
Wire comp, gauge power (2.5 m) 36663-98J00 Wire comp, extension (2 feet) 36662-88L10
2 1 9 1
Wire comp, gauge power (6 m) 36663-98J10 Wire comp, extension (6 feet) 36662-88L20
3 Wire comp, extension (6.5m) 36682-92E00 1 Wire comp, extension (15 feet) 36662-88L30
4 Wire comp, extension (2’) 36662-88L10 4 10 Adapter, gauge power 36666-96L00 1
5 Harness assy, network power 36663-88L00 1 11 Adapter comp, gauge 36661-96L00 1
6 T-connector 36664-88L00 6 12 GPS receiver module 39950-88L02 1
7 Terminator (female) 36665-88L00 1 13 Adapter, gauge for dual station 36665-96L00 1
8 Terminator (male) 36665-88L10 1 14 Adapter comp. for multi 36667-96L00 1
15 Adapter, for dual gauge 36667-96L11 1
87
88
7
8
TO BCM HARNESS
8P
B Gr
2
10
3P
6P
B Bl B R
Fuel level B R
4 6
3 5
TRIPLE ENGINES – SINGLE STATION
7 2
No. Part name Part No. Qty
Wire comp, gauge power (2.5 m) 36663-98J00
CENTER
1 1
Wire comp, gauge power (6 m) 36663-98J10 8P
9
2 Wire comp, extension (2’) 36662-88L10 3
3 Harness assy, network power 36663-88L00 1
2
4 Terminator (female) 36665-88L00 1
5 T-connector 36664-88L00 5 7
6 Terminator (male) 36665-88L10 1
7 Multi function gauge set 34011-96L11 3
STBD
2nd STATION
3
14
9 8P 9
11
TO BCM HARNESS 13
8P
Gr 8P 3
3P 4P 14
B 6P 3 9
10
B Bl B R
B R 15 4P 2 3
Fuel level
8P
1
6P
5 7 8
4
6
TRIPLE ENGINES – DUAL STATIONS
89
90
8
9 8P
TO BCM HARNESS
(PORT SIDE) 3
Gr 6P
B
8P 8
3P
“B”
11
3
B Bl B R
“A”
Fuel level Gr 10
4P
3P
1 2 6
4
5 7
3P 4P
QUADRUPLE ENGINES – SINGLE STATION
8
8P
TO BCM HARNESS
9 3
(STBD SIDE)
“A”
3 Wire comp, extension (2’) 36662-88L10 4
4 Harness assy, network power 36663-88L00 1
5 Terminator (female) 36665-88L00 1
6 T-connector 36664-88L00 6 “A”; Label [letter; STBD]
7 Terminator (male) 36665-88L10 1 “B”; Label [letter; CENTER]
“B”
“B”
3P 8P 14
4
11
“A”
B Bl B R
Gr
13 4P
Fuel level
4P
1 2 6 7 8
5 9
3P
3
4P
3P 4P
10
11 4
10
TO BCM HARNESS
12 8P 4
(STBD SIDE)
10
15 4
QUADRUPLE ENGINES – DUAL STATIONS
6P
10
8P 4
“A”
13 “A”; Label [letter; STBD]
“B”; Label [letter; CENTER]
“B”
8P
No. Part name Part No. Qty No. Part name Part No. Qty
Wire comp, gauge power (2.5 m) 36663-98J00 9 Terminator (male) 36665-88L10 1
1 1
Wire comp, gauge power (6 m) 36663-98J10 10 Multi function gauge set 34011-96L11 8
2 Adapter, gauge for multi 36665-87L00 1 11 Adapter, gauge power 36666-96L00 2
3 Wire comp, extension 36682-92E00 2 12 Adapter comp, gauge 36661-96L00 2
4 Wire comp, extension (2’) 36662-88L10 8 13 Adapter, gauge for multi 36667-96L00 2
5 Harness assy, network power 36663-88L00 1 14 GPS receiver module 39950-88L02 1
6 Terminator (female) 36665-88L00 1 15 Adapter, for dual gauge 36667-96L11 2
7 T-connector 36664-88L00 10
Wire comp, extension (25 feet) 36662-88L00
Wire comp, extension (2 feet) 36662-88L10
8 1
Wire comp, extension (6 feet) 36662-88L20
Wire comp, extension (15 feet) 36662-88L30
91
KEYLESS START SYSTEM
The keyless start system emits a low-power radio
wave from the system control unit.
• If you have a pacemaker or cardioverter defibrillator
(ICD) implant, do not let the pacemaker or ICD come
within 22 cm (9 in.) of the keyless system transmit-
ter. The radio wave may affect the function of the
pacemaker or cardioverter defibrillator (ICD).
• If you use any electro-medical apparatus other than
a pacemaker or cardioverter defibrillator (ICD),
please contact the electro-medical apparatus manu-
facturer regarding the influence of the keyless start
system radio wave on your electro-medical appara-
tus.
NOTICE
Installing and routing the harness of the keyless start
system components in an inappropriate location can
result in system failure.
Be sure to take the following precautions:
• Avoid installing the keyless control unit where it will
be exposed to direct sun.
• Install the keyless control unit in a dry location, as
far as possible from where it might get splashed with
water.
• Install the keyless control unit so that the connector
faces downward.
• To avoid malfunction of the Keyless start system
caused by radio waves, antennas, or coaxial cables
of the radio, install navigation and other equipment
more than 50 cm (20 in.) away from the keyless con-
trol unit.
NOTE:
The keyless start system communicates between the key-fob
and the keyless control unit by means of a radio wave to control
the system.
The keyless control unit must not be installed in a location that
hinders communication with the system.
For example, being placed behind a metal cover or enclosure.
92
BCM
50
(for keyless system)
20
L’ A’ N’ / / / /
K’ / / / B’
Keyless
ECM control unit
Power relay (P/no. 37171-96L02
(P/no. 38860-96L00) or 37171-96L12)
KEYLESS START SYSTEM COMPONENT/WIRE CONNECTION DIAGRAM
93
94
BCM
E’ / F’ / G’
50
STBD
20
STBD
L’ A’ N’ / / / /
K’ / / / B’
CAN extension Resistor (1)
harness
(P/no. 36664-96L00)
PORT
PORT
BCM
CAN extension
harness
(P/no. 36664-96L00)
E’ / F’ / G’
Keyless Wiring – triple engines
STBD
50
STBD
20
L’ A’ N’ / / / /
K’ / / / B’
CAN extension
harness
(P/no. 36664-96L00)
Resistor (1)
Center
The structure of the system components and wiring
are basically the same as for the single engine.
However, the following items are added for triple engines:
1) Disconnect the resistor (1) from keyless CAN harness.
2) Connect the CAN extension harness connector
to connector which the resistor was attached.
3) Connect the other end of CAN extension harness
to CAN harness connector of engine main harness
for center engine.
4) Connect the CAN extension harness to engine main
harness for PORT engine.
5) Connect the resistor (1) to CAN extension harness as shown.
PORT
95
BCM
96
J/C J/C Resistor (1)
CAN extension
harness
(P/no. 36664-
96L00)
STBD
E’ / F’ / G’
Keyless Wiring – quadruple engines
50
CAN
extension
STBD harness
20 (P/no. 36664-
L’ A’ N’ / / / /
96L00)
K’ / / / B’
STBD center
CAN extension
The structure of the system components and wiring harness
are basically the same as for the single engine. (P/no. 36664-96L00) Resistor (1)
However, the following items are added for quadruple engines.
1) Disconnect the resistor (1) from keyless CAN harness. PORT center
2) Connect the CAN extension harness connector
to connector which the resistor was attached.
3) Connect the other end of CAN extension harness
to CAN harness connector of engine main harness
for STBD center engine.
4) Connect the CAN extension harness to engine
main harness for PORT center and PORT engines
as shown.
5) Connect the resistor (1) to CAN extension harness as shown.
PORT
COMPONENT PARTS INSTALLATION OF KEYLESS START SYSTEM
After connecting the keyless start system component parts and
wiring harness, each component parts should be installed as fol-
lows.
Refer to “KEYLESS START SYSTEM COMPONENT/WIRE
CONNECTION DIAGRAM”.
(2) Install the buzzer (3) onto its mounting post in the keyless
parts holder as shown.
(3) Place the ECM power relay and cushion (4) at the place in
keyless parts holder as shown.
(4) Assemble the keyless control unit (5) and cushion (6), then
install them into the keyless parts holder.
(5) Press the Black lead wire (7) and Yellow lead wire (8) con-
nectors at the front until lock as shown.
97
FUNCTION OF COMPONENT PARTS
MAIN KNOB KEY AND EMERGENCY KEY
NOTE:
The main switch panel is shipped from the factory with a regular
key and an emergency key.
The regular key must be in the switch to complete the installa-
tion process.
The emergency key is used to start the engine(s) when the key
FOBs have been lost or misplaced.
Removal: To remove the main knob key, turn the key clockwise
about 15 degrees (between the “Neutral” and ON/
OFF positions), then lift the key out of the cylinder.
Main knob key
Installation: To install the main key knob, insert the key into the
cylinder with light pressure and turn the key about
15 degrees (between the “Neutral” and ON/OFF
positions).
Emergency Key
“N”
The emergency key is used to create a pass code and to enter
the pass code to start the engine(s) when all key-fobs have been
lost or misplaced. If the keyless system is installed on a vessel
with multiple engines, the emergency key is used to set the
engine instances.
98
KEY FOB
When receiving signals from the keyless control unit, key fob
transmits ID codes to keyless control unit.
By pressing the key fob button for a longer time, the communica-
tion mode can be switched between transmittable (Unlock) and Red LED
non-transmittable (Lock) modes. Lock button
NOTE:
To confirm whether the key fob function is locked or
unlocked, press the lock button on the key fob briefly
and check the blinking time of the red LED on the key
fob.
The LED blinks short when it is locked, and it blinks
longer when it is unlocked.
99
INSTANCE SETTING
When the keyless start system is used in multiple motor installa-
tions, the position of each engine, such as PORT, CENTER,
STBD, must be registered in each ECM.
Necessary tool
The necessary tools are as follows.
NOTE:
“INSTANCE SETTING” must be performed before the initial reg-
istration ID code to the keyless unit and ECM.
NOTE:
The “Instance Setting” is required for the multiple motor installa-
tion only.
It is not necessary to register for the single motor installation.
(1) Connect the diagnostic harness and the USB cable (with a
USB adapter) between the USB port of your PC and the
ECM communication connector (4-pin connector).
100
(2) Remove the main knob key by turning the key clockwise
“N”
about 15 degrees (between the “Neutral” and ON/OFF
positions), then lift the key out of the cylinder.
“N”: Neutral
Emergency key
Emergency key
“N”: Neutral
101
(4) Start the SDS program.
(5) The first menu window appears.
(6) Click “Main Menu(F1)” or press the “F1” key from the keyboard.
The following main menu dialog box appears.
(7) Click the “Instance Setting” button from the Main Menu dialog box.
102
(8) Then following window appears.
This window is used to register the engine configuration.
Select the number of engines and the position of engines by clicking the “ ” button, then click the “OK”
button and proceed to the next step.
(Keyboard operation) Move to a desired item by using the “Tab” key. Select a desired item by using the
“Up” or “Down” arrow key and pressing the “Enter” key.
Click the “Cancel” button to cancel the engine configuration.
(9) Click the “OK” button (or “Enter” key on the keyboard) if the registration is correct.
Clicking the “Cancel” button returns to the previous screen.
103
(10) Click the “OK” button to complete the registration of the engine location.
The system then returns to the main menu.
(12) Change the connection of the diagnostic harness to the next engine (ECM).
The position of each engine must be registered to the ECM using the same procedure.
NOTE:
Once an ECM has been connected and paired to a key-
less start control unit, the ECM/outboard cannot be
started with a normal key switch.
To unpair an ECM from an keyless control unit, see
page “UNPAIRING AN ECM FROM THE KEYLESS
START SYSTEM”.
104
REGISTERING THE FIRST AND SECOND KEY-FOB ID CODES
ID codes of individual key-fobs must be registered to enable the keyless start system.
To register the ID code of the first and second key-fob, do the following:
(1) Complete the system wiring.
(2) Connect the battery cable and sub battery cable to the battery.
NOTE:
Two key-fob ID codes must be registered.
The system cannot be operated until two ID codes are
registered.
(4) Turn the main switch knob from “Neutral” to “ON & OFF”,
“N” “ON & OFF”
then release the knob.
The red LED on the key fob lights up; within 10 seconds,
briefly press the key fob button.
“N”: Neutral
NOTE:
If the buzzer emits five (5) short sounds when the main switch
knob is turned from “Neutral” to “ON & OFF” position, the key
fob function may be locked. Red LED
Press the lock button on the key-fob for more than one second Lock button
NOTE:
• If the ID code registration is not successfully completed, the
buzzer emits five (5) short sounds.
• If the registration is not successful, wait for about one minute,
then perform step 4 again.
105
How to register the second key-fob ID code
(6) Make sure the second key-fob is placed less than 0.3 m
(12 in) from the keyless control unit.
The first key-fob must be separated more than 1 m (3.2
feet) from the keyless control unit, or lock the first key-fob
function by operating its lock button.
(7) Using the same procedure that was used for registering the
first key-fob, register the second key-fob ID code by operat-
ing the main switch knob and the second key-fob.
NOTE:
For multiple engine applications, the instance setting must be
completed before this first key-on action.
106
ADDING KEY FOBS
Every key fob has a unique identification code.
The keyless start system can only be controlled by a key fob that
has been registered in the keyless control unit.
NOTE:
The first and second key fob ID codes are registered in the key-
less control unit at the time of the initial registration for the unit
ID code.
Refer to “REGISTERING THE FIRST AND SECOND KEY-FOB
ID CODES” in this manual.
NOTE:
“N” “ON & OFF”
A maximum of six (6) key-fobs can be registered in a keyless
start control unit.
Each additional key-fob must be registered.
Register one key-fob at a time.
(1) Make sure the engine is stopped, the control lever is in neu- Main switch knob
tral, and the key fob and the keyless start control unit are
within proper range. “N”: Neutral
(2) Turn the main switch knob from “Neutral” to “ON & OFF”
position and release it.
Confirm that the “SELECT” switch green LED turns on.
107
(3) Make sure only the key fob for registration should be
unlocked. All other key fobs must be locked.
(4) Make sure the key fob for registration is placed less than
0.3 m (12 in) from the keyless control unit.
Make sure that the keyless start system is ON and green
LED of the “SELECT” switch of the control panel is ON.
(5) Connect the yellow lead wire and black lead wire located in
the keyless control harness.
Black
Yellow
B
Y Y
B B
Y: Yellow, B: Black
108
(6) The buzzer will emit four (4) long beeps, followed by two (2) Buzzer sounding pattern
short beeps emitted four times.
ON
OFF
When you hear the two (2) short beeps, immediately 4 times
remove the lock plate from the stop switch, then reinstall it.
4 times
4 times
NOTE:
The buzzer emits short beeps, which indicate which key fob ID
code has been registered in the keyless control unit.
This pattern is repeated every five seconds until the yellow lead
wire and black lead wire are disconnected.
(7) Briefly press the lock button of the key-fob being added to
the keyless start system within ten (10) seconds of attach-
ing the lock plate to the emergency stop switch.
Red LED
Lock button
109
(8) When the ID code registration has been successfully per-
formed:
• The buzzer sounds a short beep to indicate registration
is complete.
Five (5) seconds after the successful registration beep, the
keyless start system buzzer emits a series of beeps to
indicate the number of the key fob just registered to the
system.
– For example, four (4) beeps indicates the key fob just
registered is the fourth key fob registered to the key-
less control unit.
– Remember, a maximum of six (6) key fobs can be reg-
istered on a single keyless control unit.
NOTE:
Adding another key fob to the keyless system must be done
within ten (10) seconds of reinstalling the lock plate.
If this is not done, the buzzer continues to sound.
(9) Disconnect the black lead wire from the yellow lead wire
and reconnect the black lead wires on the back of the key-
less start system parts holder.
Y
Y: Yellow, B: Black
(10) Make sure the keyless start system can be controlled with
the key fob registered in its ID code.
110
UNPAIRING AN ECM FROM THE KEYLESS START SYSTEM
When the outboard motor is resold, removed and started in a
test tank, or if it is necessary to use the ECM on another engine,
the ECM must be unpaired with the keyless control unit by eras-
ing the ID code in the ECM.
Do the following to erase the ID code:
NOTE:
The key-fob ID code registered in the keyless control unit cannot
be erased from the keyless control unit.
(1) Make sure the key-fob and the keyless control unit are
within communication range.
(2) Turn the main switch knob from “Neutral” to “ON & OFF”
“N” “ON & OFF”
position, then release the knob.
Confirm that the keyless start system has been turned ON.
“N”: Neutral
(3) Connect the black lead wire and the yellow lead wire in the
keyless control harness.
Black
Yellow
B
Y Y
B B
Y: Yellow, B: Black
111
(4) The buzzer starts sounding in the following patterns: Buzzer sounding pattern
Four (4) long sounds, followed by:
ON
– Two (2) short sounds emitted four (4) times OFF
– Three (3) short sounds emitted four (4) times 4 times
– Four (4) short sounds emitted four (4) times
4 times
4 times
(5) Disconnect the black wire lead from the yellow wire lead,
and then reconnect the two (2) black wire leads.
(6) The buzzer sounds when unpairing is completed success-
fully.
The LED on the “SELECT” switch goes OFF.
(7) Remove the battery cable from the battery.
NOTE:
After unpairing an ECM from the keyless start system, do not
turn the main switch knob to the “ON & OFF” position.
If the switch is turned, the ID code cross-check will be performed
again between the keyless control unit and ECM.
112
STEERING SYSTEM
Suzuki highly recommends installing a hydraulic steering system
on the DF350A.
Selection of an improper steering system or improp-
erly installing a steering system on the outboard
motor can cause steering/handling difficulties, result-
ing in loss of control and a crash.
113
FUEL HOSE
Gasoline is extremely flammable and toxic.
Service operation of any type performed on the fuel
system involves a risk of fire and injury if proper pre-
cautions are not taken.
CONNECTION
Connect the fuel hose.
(1) Connect the fuel hose 1 to the fuel hose joint and tighten
the connecting point with a clip 2.
(2) Connect the fuel hose 3 to the fuel pipe from the boat fuel Fuel hose joint
tank and tighten the connecting point with a clip.
NOTICE
Installing the fuel hose clip with the tabs facing the
battery cables and remote control cable can damage
the cables.
Clip tab
Fuel hose
114
RIGGING HOSE ADAPTER KIT
Contained parts
2
Item Part name Part number Q’ty
— Rigging hose adapter kit 67300-98J10 1
1 • Rigging hose adapter • 67361-90J10 1
1
2 • Pin • 09208-06009 2
2
3 • E-ring • 09383-04002 2
INSTALLATION
1. Insert the remote control wire, battery cable into the rigging
hose adapter.
2 1
NOTE:
Before connecting the rigging hose (5) to the rigging hose 3 3
adapter (2), apply silicone seal to clearance of a rigging hose (5)
and the rigging port grommet (1), to prevent water entry.
4 4
115
ENGINE OIL
Suzuki recommends use of Suzuki Marine 4-cycle Engine oil
(ECSTAR), or its equivalent.
Use of non-specified oil may adversely affect engine perfor-
mance and life.
NOTE:
The outboard motor is shipped from the factory without engine
oil.
“a”
116
(3) Pour recommended engine oil into oil filler opening.
Engine oil amount: 8.0 L (8.5/7.0 US/Imp. qt)
Upper Limit
Lower Limit
(5) Reinstall the oil filler cap and oil level dipstick, then turn the
oil level dipstick knob “a” clockwise until position shown in “a”
illustration.
NOTICE
Before installing motor cover, confirm the oil level dip-
stick knob “a” position.
The knob must be located as shown in illustration.
Otherwise Oil level dipstick knob will contact the
motor cover, possibly causing damage.
117
PROPELLER INSTALLATION
NOTICE
Installing a propeller with either too much or too little
pitch will cause incorrect maximum engine speed,
which may result in severe damage to the motor.
Selection
Select propellers as shown below so that the specified engine
rpm is obtained with the throttle fully opened.
Recommended full
DF350A 5 700 – 6 300 r/min
throttle speed range
NOTICE
Using the improper combination of front and rear pro-
pellers can cause lower unit damage.
118
Propeller installation
Front propeller:
(1) Coat both the propeller shaft splines liberally with Suzuki
water resistant grease.
(2) Install front propeller stopper (1) onto propeller shaft, then 5
4
slide on the front propeller (2). 3
2
(a)
(3) Fit the propeller nut stopper (4) to front propeller nut spacer Circle mark “A”
3
(3), then install them to propeller shaft.
NOTE:
The circular tab “A” of propeller nut stopper must be placed in
the groove with a circle mark as shown in illustration.
4
119
(4) Install front propeller nut (5), using special tool to reach 3
specified torque. 4
5 (a)
NOTE:
Front propeller nut is LH (Left Hand) thread.
Front propeller nut (a): 130 N·m (13.0 kgf-m, 94.0 lbf-ft)
tool
(5) Bend the propeller nut stopper tabs toward nut to secure
nut.
NOTE:
Two tabs must be bent to secure.
Rear propeller: 11
7 10 (b)
(6) Install rear propeller stopper (6) onto propeller shaft, then 9
8
slide on the rear propeller (7).
(7) Fit spacer (8), washer (9) and nut (10), then tighten nut to 6
specified torque.
(8) Push cotter pin (11) through nut and shaft, then bend to
secure.
120
Prepared by
May, 2017
Part No. 99505-98L00-01E
Printed in Japan
DF350A
Applicable model and effective serial number:
35001F (DF350A)-810001 and later
99505-98L00-01E
TK