EN

DF40A __
DF50A __
DF50AV __
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DF60A __
DF60AV __
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OWNER’S MANUAL __
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ENGLISH

1
IMPORTANT • Become thoroughly familiar with all operat-
ing and handling characteristics of your-
 WARNING/  CAUTION/ NOTICE/ NOTE boat and motor. Practice at low and
Please read this manual and follow its instruc- moderate speeds until you are competent at
tions carefully. To emphasize special informa- handling the boat and motor. Do not
tion, the symbol  and the words WARNING, attempt to operate at maximum perfor-
CAUTION, NOTICE and NOTE have special mance until you are completely familiar with
meanings. Pay special attention to the mes- all of these characteristics.
sages highlighted by these signal words. • Carry boating safety and emergency equip-
ment. This important equipment includes;
 WARNING flotation aids for each person (plus one
throwable buoyant cushion in any boat 16
Indicates a potential hazard that could result
feet or longer), fire extinguisher, sound sig-
in death or serious injury.
naling device, visual distress signals,
anchor, bilge pump, bucket, compass,
 CAUTION emergency starter rope, extra fuel and oil,
Indicates a potential hazard that could result first aid kit, flashlight, food and water, mir-
in minor or moderate injury. ror, paddles, tool kit, and transistor radio.
Be sure you are carrying the equipment
appropriate for your trip before launching.
NOTICE • Never start the engine or let it run indoors
Indicates a potential hazard that could result or where there is little or no ventilation.
in damage to the motor or boat. Exhaust gas contains carbon monoxide, a
gas that is colorless and odorless and can
NOTE: cause death or severe injury.
Indicates special information to make mainte- • Instruct your passengers on how to operate
nance easier or instructions clearer. the boat, how to deal with emergencies, and
how to operate safety and emergency
equipment.
This symbol appears in various locations on • Do not hold onto the motor cover or any
your Suzuki product to refer you to important other parts of your outboard motor while
information in the owner’s manual. getting on or off your boat.
• Ensure that everyone wears a PFD (Per-
sonal Flotation Device) on board.
• Never operate the boat while under the
influence of alcohol or other drugs.
IMPORTANT NOTICE TO • Distribute all weight load evenly in the boat.
OWNERS • Have all scheduled maintenance performed.
Consult your authorized Suzuki marine
dealer as required.
 WARNING • Do not modify or remove any outboard
motor standard equipment. To do so may
Failure to take the proper precautions may make the motor unsafe to use.
increase the risk of death or severe injury to • Learn and obey all applicable navigation
you and your passengers. rules.
• Pay attention to all weather forecasts. Do
• Prior to first-time use of your outboard not set out if weather is unsettled.
motor, familiarize yourself thoroughly with • Use extreme caution when purchasing
the contents of this owner’s manual. Be replacement parts or accessories. Suzuki
aware of all outboard motor features and all strongly recommends that you use only
safety and maintenance requirements. genuine Suzuki replacement parts/accesso-
• Inspect the boat and motor before each trip. ries or their equivalent. Inappropriate or
See the INSPECTION BEFORE BOATING poor quality replacement parts or accesso-
section for important items. ries can create unsafe operating conditions.

2
 • Never remove the flywheel cover (except for
FOREWORD
when emergency starting).
Thank you for choosing a Suzuki outboard
motor. Please read this manual carefully and
NOTE:
review it from time to time. It contains important
Mounting radio transceiver or navigational
information on safety, operation, and mainte-
equipment antennae too close to the engine
nance. A thorough understanding of the infor-
cowling can cause electrical noise interference.
mation presented in this manual will help you
Suzuki recommends that antennae be mounted
experience safe, enjoyable boating.
at least one meter (40 inches) away from the
engine cowling.
All information in this manual is based on the
latest product information available at the time
This manual should be considered a per- of publication. Due to improvements or other
manent part of the outboard motor and changes, there may be discrepancies between
should remain with the outboard motor this manual and your outboard motor. Suzuki
when resold or otherwise transferred to a reserves the right to make changes at any time
new owner or operator. Please read this without notice.
manual carefully before operating your
new Suzuki and review the manual from
time to time. It contains important infor-
mation on safety, operation, and mainte-
nance.

3
TABLE OF CONTENTS
IDENTIFICATION NUMBER
LOCATION.............................................. 5
FUEL AND OIL....................................... 5
LOCATION OF SAFETY LABELS ..... 8
LOCATION OF PARTS....................... 10
MOTOR MOUNTING.......................... 13
BATTERY INSTALLATION .............. 13
USE OF ELECTRICAL
ACCESSORIES ..................................... 15
PROPELLER SELECTION AND
INSTALLATION................................... 15
ADJUSTMENT...................................... 16
INDICATOR .......................................... 22
CAUTION SYSTEM ............................. 22
DIAGNOSTIC SYSTEM ...................... 26
OIL CHANGE REMINDER
SYSTEM................................................. 26
ENGINE STALLING CAUTION
SYSTEM................................................. 27
OPERATION OF TILTING
SYSTEMS............................................... 28
INSPECTION BEFORE BOATING ... 32
BREAK-IN ............................................. 33
OPERATION ......................................... 34
MOTOR REMOVAL AND
TRANSPORTING ................................. 43
TRAILERING........................................ 45
INSPECTION AND
MAINTENANCE................................... 46
FLUSHING THE WATER
PASSAGES............................................. 55
SUBMERGED MOTOR ....................... 57
STORAGE PROCEDURE ................... 58
AFTER STORAGE ............................... 59
TROUBLESHOOTING ........................ 59
SPECIFICATIONS ............................... 61
INFORMATION REGARDING
EC – DIRECTIVE ................................. 62
CHART OF TOTAL OPERATING
HOURS INDICATION ......................... 62
FLOWCHART OF OIL CHANGE
REMINDER SYSTEM.......................... 64

4
IDENTIFICATION Suzuki recommends that you install a water-
separating fuel filter assembly between your
NUMBER LOCATION boat’s fuel tank(s) and outboard motor(s). Fuel
filtration systems of this type will help prevent
The model and identification numbers of your water that may be present in your boat’s fuel
outboard motor are stamped on a plate tank(s) from contaminating your motor’s elec-
attached to the clamp bracket. It is important to tronic fuel injection system. Water contamina-
know these numbers when you place a parts tion can cause poor engine performance and
order or if your motor is stolen. can also cause damage to the electronic fuel
injection system components.

Your Authorized Suzuki Marine Dealer can pro-

vide you advice about water-separating fuel fil-
ter systems and installation.

Gasoline/Ethanol Blends
Blends of unleaded gasoline and ethanol (grain
alcohol), also known as “GASOHOL”, are com-
mercially available in some areas. Blends of this
type may be used in your outboard motor if they
are no more than 10% ethanol. Make sure this
gasoline-ethanol blend has octane ratings no
lower than those recommended for gasoline.

Use the recommended gasoline which

conforms to the following labels.
FUEL AND OIL
GASOLINE
Suzuki highly recommends that you use alco- or
hol-free unleaded gasoline whenever possible,
with a minimum octane rating of 91 (Research
method). However, blends of unleaded gasoline 78RB0900*
and alcohol with equivalent octane content may
be used, provided the guidelines that follow are Pump Labeling for Gasoline/Alcohol
met. Blends
In some states, pumps that dispense gasoline/
NOTICE alcohol blends are required to be labeled for the
type and percentage of alcohol content, and
whether important additives are present. Such
Use of leaded gasoline can cause engine dam- labels may provide enough information for you
age. Use of improper or poor quality fuel can to determine if a particular blend of fuel meets
affect performance and may damage your the requirements listed above. In other states,
motor and fuel system. pumps may not be clearly labeled as to the con-
tent or type of alcohol and additives. If you are
Use only unleaded gasoline. Do not use fuel not sure that the fuel you intend to use meets
having lower than the recommended octane, these requirements, check with the service sta-
or fuel that may be stale or contaminated by tion operator or the fuel suppliers.
dirt/water etc.

NOTE:
Oxygenated fuels are fuels which contain oxy-
gen-carrying additives such as alcohol.

5
NOTE: NOTICE
If you are not satisfied with the operation or fuel
economy of your outboard motor when you are
using gasoline/alcohol blends, you should Gasoline kept in the fuel tank for long periods
switch back to unleaded gasoline containing no of time will produce varnish and gum, which
alcohol. can damage the engine.
Be sure that any gasoline/alcohol blend you use
has octane ratings of at least 91 octane Always use fresh gasoline.
(Research method).
If engine pinging is experienced, substitute NOTICE
another brand as there are differences between
brands.
Unleaded gasoline will extend spark plug life. Fuels containing alcohol can cause paint
damage, which is not covered under the New
Outboard Motor Limited Warranty.
 WARNING
Be careful not to spill fuel containing alcohol
Gasoline is extremely flammable and toxic. It while refueling. If fuel is spilled, wipe it up
can cause a fire and can be hazardous to peo- immediately.
ple and pets.
NOTE:
Always take the following precautions when The fuel tank supplied with this motor is its ded-
refueling: icated fuel reservoir and should not be used as
• Never permit anyone other than an adult to a fuel storage container.
refill the fuel tank.
• If you use a portable fuel tank, always stop
the motor and remove the fuel tank from the
boat to refill it.
• Do not fill the fuel tank all the way to the top
or fuel may overflow when it expands 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 from open
flames and sparks.

6
ENGINE OIL
NOTICE

Use of poor quality engine oil can adversely

affect engine performance and life.

Suzuki recommends that you use Suzuki

Marine 4-Cycle Engine Oil or its equivalent.

Oil quality is a major contributor to your

engine’s performance and life. Always select
good quality engine oil.
Suzuki recommends the use of SAE 10W-40 or
10W-30 SUZUKI MARINE 4-CYCLE ENGINE
OIL. If SUZUKI MARINE 4-CYCLE ENGINE
OIL is not available, select a NMMA certified
FC-W oil or good quality 4-cycle motor oil from
the following chart according to the average
temperatures in your area.

API Classification SAE Viscosity Grade

SG
SH 10W–40
SJ
SL
SM 10W–30
SN
˚C –20 –10 0 10 20 30 40
TEMP.
˚F –4 14 32 50 68 86 104

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

GEAR OIL

Suzuki recommends the use of SUZUKI OUT-

BOARD MOTOR GEAR OIL. If it is not avail-
able, use SAE 90 hypoid gear oil which is rated
GL-5 under the API classification system.

7
LOCATION OF SAFETY LABELS
Read and follow all of the labels on your out- Keep the labels on your outboard motor or fuel
board motor or fuel tank. Make sure you under- tank. Do not remove them for any reason.
stand all of the labels.

8 WARNING AVERTISSEMENT

• Fuel can leak creating a fire hazard if

you lay motor on its side. Drain fuel
completely from vapor separator or
carburetor before laying motor on its side.
• See owner’s manual for details.

• Le carburent risque de fuir et de

présenter un danger d’incendie si le
moteur est placé sur le côté.
Vidanger entièrement le carburant du
séparateur de vapeurs ou du
carburateur avant de procéder.
• Pour plus de détail, voir le manuel
du propriétaire.

8 WARNING AVERTISSEMENT
• To avoid injury, when engine is running,
keep your hands, hair, clothing, etc., away
from engine.
• See owner’s manual for details.
• Pour éviter toute blessure, quand le moteur
est en marche, éloigner les mains, les
cheveux, les vêtements, etc. du moteur.
• Pour plus de détail, voir le manuel
du propriétaire.

Label symbol meanings

These symbols mean as follows;
: General warning symbol : Engine start
(Caution or Warning)
: Hazard caused by fire
: Read owner’s manual carefully
: Hazard caused by laying the
: Remote control lever/gear shift motor on its side
lever operation-two direction;
Forward/Neutral/Reverse : Hazard caused by rotating parts

8
9
LOCATION OF PARTS
REMOTE CONTROL MODEL
Motor cover

Power trim and tilt

(P.T.T.) switch
(Reverse side)

MONITOR-TACHOMETER

Engine oil drain plug

Pilot water hole
Clamp bracket

Flush plug
Anode

Flush plug
Gear oil level plug
Anti-cavitation plate

Water intake hole

Trim tab
(Anode)
Gear oil drain plug

Power trim and tilt

(P.T.T.) switch
DF40AT/50AT/60AT

Lock-out Remote control handle

lever Warm-up lever

Throttle tension adjuster Ignition key

Emergency stop switch

Air-vent screw
REMOTE CONTROL BOX

Fuel hose

Priming bulb

FUEL TANK

10
 Motor cover

Power trim and tilt

(P.T.T.) switch
(Reverse side)

Engine oil drain plug

Pilot water hole
Clamp bracket

Flush plug
Anode
Anode
(Reverse side)

Anode

Anti-cavitation plate Gear oil level plug

Water intake hole

Trim tab

Gear oil drain plug

DF50AVT/60AVT

11
TILLER HANDLE MODEL

Power trim and tilt

(P.T.T.) switch
(Reverse side)
(DF40ATH/50ATH/60ATH)
Ignition key
Tachometer/Indicator
Motor cover Shift lever
Power trim
and tilt (P.T.T.)
switch
(DF40ATH/50ATH/
Throttle 60ATH)
control grip
Troll mode switch

Emergency
Pilot water stop switch
Engine oil drain plug
hole
Clamp bracket
Flush plug
Anode

Flush plug Gear oil level plug

Anti-cavitation
plate
Water intake
Trim tab hole
(Anode)
Gear oil drain plug

Anode
DF40ATH/QH/50ATH/60ATH (Reverse side)

Anode

Anti-cavitation Gear oil

plate level plug
Trim tab Water intake
hole

Air-vent screw
Gear oil
drain plug
DF50AVTH

Fuel hose

Priming bulb

FUEL TANK

12
MOTOR MOUNTING BATTERY INSTALLATION
 WARNING BATTERY REQUIREMENT
650 Marine Cranking Amps (MCA)/ABYC,
Overpowering your boat can be hazardous. or 512 Cold Cranking Amps (CCA)/SAE
Excessive horsepower will have an adverse or 160 Reserve Capacity (RC) Minutes/SAE
effect on hull safety and may cause operating/ or 12 Volt, 80 AH
handling difficulties. The boat may also sus-
tain stress and hull damage. NOTE:
• The specifications listed above are the mini-
Never install an outboard motor with horse- mum battery rating requirements for starting
power exceeding the manufacturer’s recom-
the engine.
mended maximum horsepower listed on the
• Additional electrical loads from the boat will
boat’s “Certification Plate”. Contact your
authorized Suzuki marine dealer if you are require larger capacity batteries. Consult
unable to locate the hull “Certificate Plate”. your Suzuki dealer to determine the proper
battery sizing for your boat and engine com-
bination.
Suzuki strongly recommends that you have
• Dual-purpose (Cranking/Deep-cycle) batter-
your outboard motor, controls and gauges
installed by an authorized Suzuki Marine ies can be used if they meet the minimum
Dealer. He has the tools, the facilities and the specifications listed above (MCA, CCA, or
know-how. RC).
• Do not use a Deep Cycle battery for the main
 WARNING cranking battery.
• When connecting batteries in parallel, they
must be of the same type, capacity, manufac-
Failure to have your outboard motor and asso- turer, and of similar age. When replacement
ciated controls and gauges properly installed is necessary, they should be replaced as a
can result in personal injury or damage. set. Consult your Suzuki dealer for proper
battery installation information.
Suzuki strongly recommends that you have
your outboard motor, controls and gauges
installed by your authorized Suzuki marine
dealer. He has the tools, the facilities, and the
know-how to do the job correctly.

13
BATTERY INSTALLATION
 WARNING
Secure the battery in a dry area of the boat,
away from vibration.
If you place the battery near the fuel tank, a
NOTE: spark from the battery may ignite the gaso-
• It is recommended that the battery be line, causing a fire and/or an explosion.
installed in an enclosed battery case.
Do not place the fuel tank in the same com-
• When connecting batteries, hexagon-nuts
partment/area as the battery.
must be used to secure battery leads to bat-
tery posts.
 WARNING
To hook up the battery, first connect the red
lead from the motor to the positive battery ter- Batteries produce flammable hydrogen gas
minal, then connect the black lead to the nega- and may explode if they are near flames or
tive battery terminal. sparks.

Hexagon- Hexagon- Never smoke or cause sparks when working

nut nut near the battery. Keep the battery away from
Black
open flames. To avoid creating a spark when
Red lead
lead charging the battery, connect the battery
charger cables to the proper terminals before
turning the charger on.

 WARNING

Battery acid is poisonous and corrosive. It

can cause severe injury and can damage
painted surfaces.

Avoid contact with eyes, skin, clothing, and

painted surfaces. If battery acid comes in con-
tact with any of these, flush immediately with
large amounts of water. If acid contacts the
Hexagon-nut eyes or skin, get immediate medical attention.

NOTICE
To remove the battery, first disconnect the black
The electrical system or its components may
lead from the negative terminal, then discon-
be damaged if proper battery precautions are
nect the red lead from the positive terminal.
not followed.
Suzuki recommends that you install the termi-
• Be sure to attach battery leads correctly.
nal cap on the positive battery terminal to pre-
• Do not disconnect battery leads from the
vent an accidental short circuit of battery
battery while the engine is running.
terminals.
If a terminal cap is required, contact your autho-
rized Suzuki marine dealer.

14
USE OF ELECTRICAL PROPELLER SELECTION
ACCESSORIES AND INSTALLATION
The amount of power (DC12V) available for PROPELLER SELECTION
accessories, however, depends on the operat- It is essential to use a propeller on your out-
ing condition of the motor. For detailed informa- board motor that is properly matched to your
tion, please ask your authorized Suzuki Marine boat’s operating characteristics. The speed of
Dealer. the engine when you operate your boat at full
throttle depends on the propeller you use.
NOTE: Excessive engine speed can seriously damage
Use of too much power for electrical accesso- the motor, while low engine speed at full throttle
ries under certain operating conditions can will adversely affect performance. Your operat-
cause the battery to discharge. ing load will also affect propeller selection.
Smaller loads generally require larger-pitch pro-
pellers; larger loads generally require smaller-
pitch propellers. Your authorized Suzuki Marine
Dealer will assist you in selecting a suitable pro-
peller for your boat.

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.

Ask your authorized Suzuki marine dealer to

assist you in selecting a suitable propeller for
your boat.

You can determine if your propeller is appropri-

ate for use with your boat by using a tachome-
ter to measure engine speed when operating
your boat at full throttle, under minimum load
conditions. If you are using an appropriate pro-
peller, the engine speed will be within the fol-
lowing range:

5000 – 6000
DF40A
Full throttle r/min. (min–1)
operating DF40AS
range 5300 – 6300
DF50A/50AV
r/min. (min–1)
DF60A/60AV

If the engine speed is not within this range, con-

sult your authorized Suzuki Marine Dealer to
determine which propeller size is best for you.

15
PROPELLER INSTALLATION ADJUSTMENT
 WARNING TRIM ANGLE ADJUSTMENT
To help maintain steering stability and good
Failure to take proper precautions when performance, always maintain the proper trim
installing or removing the propeller can result angle as shown in the illustration. The appropri-
in severe personal injury. ate trim angle varies depending on the combi-
nation of the boat, engine, and propeller, as well
When installing or removing the propeller: as operating conditions.
• Always shift into “Neutral” and remove the
emergency stop switch lock plate so that
the motor cannot be started accidentally.
• Wear gloves to protect hands, and “lock”
the propeller by placing a block of wood
between the blades and the anti-cavitation
plate.

To install a propeller on your outboard motor, • Trim angle too small (Boat tends to “plow”)
use the following procedure:

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

1. Coat the propeller shaft splines 1 liberally

with Suzuki water resistant grease to help
prevent corrosion.
2. Place the stopper 2 on the shaft. • Proper trim angle
3. Align the propeller 3 with the propeller shaft
splines and slide the propeller onto the shaft.
4. Place the spacer 4 and washer 5 on the
shaft.
5. Install the propeller nut 6 and tighten it with
a torque wrench to 50 – 60 N·m (5.1 – 6.1
kgf-m/37 – 44 lbf-ft).
6. Insert the cotter pin 7 and bend it so that it
can’t come off. Tilt range

To remove the propeller, reverse the above pro-

cedure. Trim range

16
  WARNING DF40A (QH) MODEL
Make a test run in the boat to determine if the
trim down limit position needs to be adjusted.
Trim angle greatly affects steering stability. If To adjust the trim angle:
the trim angle is too small, the boat may 1. Hold the motor in the fully tilted up position.
“plow” or “bow steer”. If the trim angle is too (Refer to TILT BRACKET section.)
large, the boat may “chine walk” from side to 2. Reposition the tilt pins A in the desired
side or “porpoise” up and down. These condi- holes.
tions, which result in loss of steering control,
can cause occupants to be thrown overboard.

Always maintain proper trim angle based on

the combination of your boat, engine, and pro-
peller, as well as operating conditions.

 WARNING

When the motor is tilted beyond the maximum

trim position, the swivel bracket will not have
side support from the clamp bracket and the 3. Lower the motor back down.
tilt system will be unable to cushion the
engine if the lower unit strikes an obstruction. To lower the bow, move the pin towards the
This could lead to occupant injury. boat. To raise the bow, move the pin away from
the boat.
Do not operate the engine above 1500 r/min or
operate the boat in a planing attitude with the  WARNING
motor tilted beyond the maximum trim posi-
tion.
If you operate the motor with the tilt pin
removed, you may not be able to control steer-
NOTICE ing as expected.

If you operate the boat with the motor trimmed Do not operate the motor with the tilt pin
beyond the maximum trim position, the water removed.
intake holes may be above the water line,
causing severe engine damage due to over- DF40A (T), DF50A (T), DF50AV (T), DF60A
heating. (T), DF60AV (T) MODEL
Make a test run in the boat to determine if the
Never operate the boat with the motor trim angle needs to be adjusted. Adjust the trim
trimmed beyond the maximum trim position. angle using the Power Trim and Tilt system.

While operating your boat with the motor

adjusted to the proper trim angle, observe the
position of the needle on the TRIM GAUGE pro-
vided as optional part. When making future trim
angle adjustment, use the TRIM GAUGE as a
guide.

17
 3. Tighten the bolt that holds the trim tab in
place.

After adjusting the trim tab, check to see if the

boat still tends to veer to one side. If necessary,
readjust the trim tab.

STEERING TENSION ADJUSTMENT

(Optional part) The steering on your outboard motor should be
smooth and not tight. Adjust the steering ten-
sion so that there is only a slight resistance to
TRIM TAB ADJUSTMENT steering movement.
This adjustment is used to compensate for the
possible tendency of your boat to veer slightly DF50AV (TH), DF60A (TH) MODEL
to port or starboard. This tendency could be To increase the steering tension, turn the steer-
due to such things as propeller torque, motor ing tension bolt A clockwise. To decrease the
mounting position, etc. steering tension, turn the steering tension bolt
counterclockwise.
To adjust the trim tab:
1. Loosen the bolt A that holds the trim tab in
place.

DF40A (TH/QH), DF50A (TH) MODEL

For adjustment, use the steering tension lever
A. To increase the steering tension, move the
2. If the boat tends to veer to port, move the lever A to the left. To decrease the steering
rear end of the trim tab toward the port side. tension, move the lever to the right.
If the boat tends to veer to starboard, move
the starboard side.

18
THROTTLE TENSION ADJUSTMENT SETTING OF TILT UPPER LIMIT POSITION
TILLER HANDLE MODEL DF40A (ST), DF50AV (T/TH),
The tension of the throttle control grip can be DF60A (T/TH), DF60AV (T) MODEL
adjusted according to your preference. To If the outboard motor contacts the motor well of
increase the tension, turn the throttle tension the boat during full tilt up operation, the upper
adjuster A clockwise. To decrease the tension, limit setting should be reset.
turn the adjuster counterclockwise. Perform this set-up after the current position
setting has been canceled, as explained in the
following procedure.
Increase
CANCELING THE TILT UPPER POSITION
LIMIT SETTING
1. Turn the ignition key to the “ON” position.
2. Pull out the emergency stop switch lock
Decrease plate.

REMOTE CONTROL MODEL

The tension of the remote control handle can be
adjusted according to your preference. To
increase the tension, turn the throttle tension
adjuster A clockwise. To decrease the tension,
turn the adjuster counterclockwise.

3. Shift the motor into “NEUTRAL”.

“NEUTRAL” “NEUTRAL”

IDLE SPEED ADJUSTMENT

The idle speed has been factory adjusted
between 750 – 850 r/min in neutral.

NOTE:
If idle speed cannot be set within the specified
range, contact your authorized Suzuki Marine
Dealer.

19
4. Remote control model: SETTING THE TILT UPPER POSITION
Using the throttle only function of the remote LIMIT
control box, move the warm-up lever upward 7. Press the “UP” side of the PTT switch so
until the caution buzzer sounds one time. that the optimum full tilt up position for the
boat can be obtained.
Tiller handle model: 8. Remote control model:
Turn the throttle control grip until the buzzer Using the throttle only function of the
sounds one time. remote control box, move the warm-up lever
upward until the caution buzzer sounds one
time.

Tiller handle model:

Turn the throttle control grip until the buzzer
sounds one time.
9. Press the “UP” side of PTT switch three
times within three seconds. The buzzer will
sound one time briefly indicating the setting
has been accepted.
10. Return the throttle to the fully closed posi-
tion and install the lock plate on the emer-
5. Press the “UP” side of the PTT switch for gency switch. Operate the full tilt up and full
three seconds and the buzzer will sound down operations several times by pressing
twice briefly indicating the setting has been the PTT switch and check that the setting of
canceled. both the trim lower limit and tilt upper limit
are properly set.

 WARNING

Setting of the tilt upper limit position will not

prevent the outboard motor from tilting fully
up and contacting the motor well if the
motor’s lower unit hits an object at high
speed. Such tilting could damage your motor
and boat and injure the boat occupants.

6. Return the throttle to the fully closed posi- Keep all occupants away from the motor when
tion. operating at high speed.

20
MOTOR COVER FASTENING ADJUST- 3. Confirm the tiller handle angle after returning
MENT down the tiller handle if it is convenient to the
If you feel the motor cover fastening is loose or operator.
too tight when locking the lever, adjust as fol-
lows: NOTE:
• When the stopper is installed as thick side
1. Loosen the bolt 1. upper, the tiller handle will be set to the larg-
2. Adjust the position of bracket 2. To increase est angle from level.
the fastening, move the bracket to the direc- • When the stopper is installed as thin side
tion A. To decrease the fastening, move the upper, the tiller handle will be set to the mid-
bracket to the direction B. dle angle from level.
3. Tighten the bolt 1. • When the stopper is not used, the tiller han-
dle will be set to the smallest angle from
level.

Largest angle

Middle angle
TILLER HANDLE ANGLE ADJUSTMENT
TILLER HANDLE MODEL
To adjust the tiller handle angle from level, use
the stopper and bolt which are included in the
tiller handle package. Nonuse
The tiller handle angle can be adjusted in three Smallest angle
positions.

To adjust the tiller handle angle:

1. When the stopper is not used, the tiller han-
dle will be the smallest angle. If you want to
enlarge the angle, raise up the tiller handle
to install the stopper.
2. Select the direction of the stopper 1 to
install it on to the tiller handle bracket and
tighten the bolt 2 securely.

21
INDICATOR CAUTION SYSTEM
TACHOMETER The caution systems are designed to alert you
TILLER HANDLE MODEL to certain situations which may cause damage
The tiller handle is equipped with the digital to your outboard motor.
tachometer/caution indicator.
The engine speed is indicated by the digits on NOTICE
the tachometer.
Your outboard motor may become damaged if
NOTE: you rely on the Caution System to alert you to
The actual engine speed (r/min) is ten times of any malfunction that may occur or to give you
the meter display value. an indication of the need for maintenance.

To avoid damage to your outboard motor, reg-

ularly inspect and maintain it.

NOTICE

Continuing to operate your outboard motor

with the Caution System activated can result
in severe damage to your outboard motor.

If the Caution System activates while you are

operating your outboard motor, stop the
motor as soon as possible and correct the
problem or consult your authorized Suzuki
marine dealer for assistance.

INDICATOR CHECK
REMOTE CONTROL MODEL
Each time the ignition key is turned to the “ON”
position, four lamps – the REV LIMIT 1, the
OIL 2, the TEMP 3 and the CHECK ENGINE
4 in the monitor-tachometer will light briefly
and the buzzer will also sound for the first two
seconds, regardless of the motor conditions.

For the next three seconds, the monitor-

tachometer will indicate the total motor operat-
ing hours by means of the lamp flashing and
needle indicating.
After this brief check period, the monitor-
tachometer will return to their stand-by mode
and will only respond to motor conditions
requiring a caution alert.

22
TILLER HANDLE MODEL REMOTE CONTROL MODEL
Each time the ignition key is turned to the “ON” If this system activates, engine speed will auto-
position, three lamps – the OIL 2, the TEMP 3 matically be reduced to approximately 3000
and the CHECK ENGINE 4 in the tachometer/ r/min. with red REV LIMIT lamp lit.
indicator will light briefly and the buzzer will also
sound for the first two seconds, regardless of
the motor conditions.

Tiller handle model Remote control model

This system must be reset by moving the throt-

tle to the idle position for about one second to
restore full engine operation.

NOTICE NOTICE

If the Caution System is not working properly, If the Over-Revolution Caution System acti-
you may not be alerted to a condition that can vates at recommended maximum throttle and
cause damage to your outboard motor. you are sure that the propeller pitch is suffi-
cient and there are no factors like “over-trim-
If any of the lamps does not come on or the ming” or “ventilation”, there may be a
buzzer does not sound when the ignition key problem with the Over-Revolution Caution
is turned to the “ON” position, the lamp or System.
buzzer may be broken or a failure may exist in
the system circuit. Consult your authorized Consult your authorized Suzuki marine dealer
Suzuki marine dealer. if the Over-Revolution Caution System acti-
vates for no apparent reason.
NOTE:
For checking the total motor operating hours,
refer to the CHART OF TOTAL OPERATING
HOURS INDICATION on the last page.
OIL PRESSURE CAUTION SYSTEM
(Remote control model and tiller handle model) This system operates when the engine lubricat-
ing oil pressure drops below the correct level.

If this system activates, the red OIL lamp will

OVER-REVOLUTION CAUTION SYSTEM light and a buzzer will begin a series of beep. In
This system is activated when engine speed addition, when this system is activated at 1000
exceeds maximum recommended speed for r/min. or higher, engine speed will automatically
more than 10 seconds. be reduced to approximately 1000 r/min.
TILLER HANDLE MODEL If you continue to run, the engine will automati-
If this system activates, engine speed will auto- cally stop 3 minutes after beginning of the
matically be reduced to approximately 3000 above CAUTION system activation.
r/min.

23
NOTE: NOTICE
In case that the engine is automatically stopped
due to the CAUTION system, the engine can be
started again. Operating the engine with the Oil Pressure
However the CAUTION system will repeatedly Caution System activated can result in severe
activate until eliminating the cause. engine damage.

Tiller handle model Remote control model If the Oil Pressure Caution System activates,
stop the engine as soon as possible and add
engine oil, if necessary, or otherwise correct
the problem.

OVERHEAT CAUTION SYSTEM

This system is activated when the cylinder wall
temperature is too high due to insufficient water
cooling.

If this system activates, stop the engine imme- If this system activates, the red TEMP lamp will
diately, if wind and water conditions make it safe light and a buzzer will begin a series of beep. In
to do so. addition, when this system is activated at 3000
r/min. or higher, engine speed will automatically
 WARNING be reduced to approximately 3000 r/min.

If you attempt to remove or reinstall the motor If you continue to run, the engine will automati-
cover while the engine is running, you may be cally stop 3 minutes after beginning of the
injured. above CAUTION system activation.

To check the oil level, stop the engine and NOTE:

then remove the motor cover. In case that the engine is automatically stopped
due to the CAUTION system, the engine can be
started again.
Check the oil level and add oil if necessary. If However the CAUTION system will repeatedly
the oil level is correct, consult your authorized activate until eliminating the cause.
Suzuki Marine Dealer.
Tiller handle model Remote control model
NOTICE

Your engine may become severely damaged If

you rely on the Oil Pressure Caution System
to indicate the need to add engine oil.

Check the engine oil level periodically and add

oil as necessary.

24
If the overheat caution system activates when BATTERY VOLTAGE CAUTION SYSTEM
operating, reduce engine speed immediately This system is activated when the battery volt-
and check if water is being discharged from the age deficiency which could impair your motor’s
pilot water hole. If no water is seen, follow the performance occurs.
procedures outlined below.
If this system activates, the red CHECK
Water and wind conditions permitting, stop the ENGINE lamp will light and buzzer will begin a
engine, tilt it out of the water and remove any series of beep.
debris like seaweed, plastic bags or sand that
may have blocked the water intakes. Tiller handle model Remote control model
Lower the motor into the water, being sure that
water intakes are immersed, and restart it.

Check (A) that water discharges from the pilot

hole and (B) that the red TEMP lamp is no
longer lit.
Be aware that the red TEMP lamp may light
again if engine temperature rises abnormally. If
either of the above situations arises, your
authorized Suzuki Marine Dealer must be con-
sulted as soon as possible. This system will be canceled automatically
when the battery voltage restores to the proper
NOTICE voltage level. Refrain from using any electrical
equipment such as P.T.T. system, hydraulic trim
tabs, hydraulic jack plate, etc.
Operating the engine with the overheat cau-
tion system activated can result in severe  WARNING
engine damage.

If the overheat caution system activates, stop Failure to take proper precautions when
the engine as soon as possible, wind and inspecting or servicing the battery can be haz-
water conditions permitting, and inspect the ardous.
engine according to the above instructions.
Consult your authorized Suzuki marine dealer Do not attempt to inspect or service the bat-
if you cannot correct the problem. tery without first reading the warnings, cau-
tions, and instructions in the “BATTERY
INSTALLATION” section of this manual.

NOTE:
• A marginal battery may have enough power
to start your engine, yet may still cause this
caution system to activate whenever engine
or boat accessory use places a high current
demand on the battery.
• If this caution system activates continuously,
even after you have stopped using engine or
boat accessories, contact your authorized
Suzuki Marine Dealer.

25
DIAGNOSTIC SYSTEM OIL CHANGE REMINDER
If abnormal conditions exist in any sensor sig-
SYSTEM
nal being input to the control unit, the self-diag-
This system informs the operator of the time for
nostic system warns of the abnormal condition.
replacing engine oil on the basis of the mainte-
nance schedule.
If this system activates, the red CHECK
The system is designed to register the total
ENGINE lamp will flash and a buzzer will
operating hours of the outboard motor and
sound.
function its operation when the preprogrammed
hours have reached.
Tiller handle model Remote control model
(Refer to the INSPECTION AND MAINTE-
NANCE section and the last page.)

SYSTEM ACTIVATION
When the total operating hours have reached
the preprogrammed hours, the OIL lamp will
flash. If the engine is not running, the buzzer
will begin a series of double beeps additionally.
This indication will repeat until you cancel the
Also incorporated is a fail-safe provision that system activation.
allows the operation at a restricted speed even
under such a failure condition. CANCELLATION
1. Turn the ignition key to the “ON” position.
The failed system can be identified by the mode 2. Pull out the emergency stop switch plate 1.
of the lamp flashing and buzzer sounding. 3. Pull up the emergency stop switch knob 2
The diagnostic code is designed to appear three times in 10 seconds. A short beep will
when the ignition key is turned on. be heard if the cancellation is successfully
finished.
NOTICE

If the diagnostic system activates while you

are operating your outboard motor, there is an
abnormal condition in one of the sensor sig-
nals of the control system.

Consult your authorized Suzuki marine dealer

for repair of the control system.

NOTE:
Remote control model: 4. Turn the ignition key to the “OFF” position.
The buzzer sound with diagnostic system acti- 5. Set the plate 1 in the original position.
vating will be canceled by pushing the ignition
key in.

26
NOTE: ENGINE STALLING
• Canceling of the system activation is possible
regardless of whether or not the engine oil
CAUTION SYSTEM
has been replaced. Once the system has
This system informs the operator when the
operated, however, Suzuki strongly recom-
motor stalls while it is operating.
mends that the engine oil be replaced before When the engine stalls for any reason, the cau-
canceling the system activation. tion buzzer sounds three times.
• Even if the engine oil has been replaced with
the system not operating, it is still necessary
to perform the cancellation.

27
OPERATION OF TILTING “RELEASE” Position (UP)
Use this position only when you tilt the motor
SYSTEMS up.

TILT LOCK LEVER

DF40A (QH) MODEL
The tilt lock lever A has two positions.

“LOCK” Position (DOWN)

Use this position always when you operate the
motor.

 WARNING

When you operate the motor with the tilt lock

lever in the “Release” position, the tilt lock
will not work. As a result, forces such as from
propeller thrust during operation in
“REVERSE” gear, rapid deceleration, and
NOTICE striking an underwater object can cause the
motor to lift out of the water, resulting in per-
sonal injury.
If you strike an underwater object with the tilt
lock lever in the “LOCK” position, your out- When using the “Release” position, proceed
board motor or boat may be damaged. with caution and only at very low speed.

When operating the motor in an area where

you may encounter underwater objects, move
the tilt lock lever to the “RELEASE” position TILT BRACKET
and operate the motor only at very low DF40A (QH) MODEL
speeds. The Tilt Bracket is provided so you can support
the motor in a tilted position for non-moving
engine support.

 WARNING

If you place your hands near the mounting

bracket or under the motor when tilting it,
your hands can be crushed if the motor slips
from your grasp.

Never place your hands near the mounting

bracket or under the motor when tilting it.

28
To hold the motor in the fully raised position: 4. Move the tilt lock lever 1 to the “lock” posi-
1. Shift into “NEUTRAL”. tion, then pull down the tilt bracket 2 as
2. Move the tilt lock lever 1 to the “release” shown.
position.

To lower the motor:

3. Grab the handle on the back of the motor 1. Pull up the tilt bracket 2, then move the tilt
cover and tilt the motor all the way up. lock lever 1 to the “release” position as
shown.

2. Lower the motor by pushing the motor cover

NOTICE
down.
3. Move the tilt lock lever 1 to the “lock” posi-
If you use the throttle grip handle to raise or tion.
lower the motor, the handle may break.
 WARNING
Never use the throttle grip handle to raise or
lower the motor.
If you do not take proper precautions when
tilting up the motor, fuel may leak out.
NOTICE
Disconnect the fuel line whenever you leave
If the tiller handle contacts any objects when the motor tilted up for a long period of time.
tilting motor up, the outboard motor or boat
could be damaged. NOTICE
When tilting the motor up, position the motor
If you use the tilt bracket to hold the motor in
so the tiller handle will not contact such as a
the fully tilted position for trailering, the tilt
tackle box, ice chest, or the motor well.
bracket could release resulting in damage to
the motor.

When trailering your boat, never use the tilt

bracket to hold the motor in the fully tilted
position.

29
POWER TRIM AND TILT MANUAL TILTING
DF40A (T/TH), DF50A (T/TH), DF50AV DF40A (T/TH), DF50A (T/TH), DF50AV
(T/TH), DF60A (T/TH), DF60AV (T) MODEL (T/TH), DF60A (T/TH), DF60AV (T) MODEL
The “Power Trim and Tilt” is operated by press- If you are unable to tilt the motor using the
ing the switch. To tilt the motor up, press the “Power Trim and Tilt” because of an electrical
upper part of the switch. To tilt the motor down, problem or some other problem, you can move
press the lower part of the switch. the motor manually. To tilt the motor up or
down, turn the manual release valve A four
turns counterclockwise, move the motor to the
desired position, then retighten the release
screw.
UP
UP
DOWN
DOWN

UP
DOWN

 CAUTION

The motor is very heavy. When you tilt it man-

ually, you could injure your back or slip and
fall causing injury.

When you tilt the motor manually, ensure that

 WARNING your grip and footing are secure and that you
are able to support the weight of the engine.
The power trim and tilt (PTT) switch can be
accidentally activated when the ignition key is
off, resulting in injury.

Keep all persons away from the outboard

motor to help prevent accidental activation of
the PTT system.

NOTICE

If the tiller handle contacts any objects when

tilting motor up, the outboard motor or boat
could be damaged.

When tilting the motor up, position the motor

so the tiller handle will not contact such as a
tackle box, ice chest, or the motor well.

30
TILT BRACKET
DF40A (T/TH), DF50A (T/TH), DF50AV
NOTICE
(T/TH), DF60A (T/TH), DF60AV (T) MODEL
The Tilt Bracket is provided so you can support Damage can occur if you use the tilt bracket
the motor in a tilted position for non-moving other than when the boat is moored or is oth-
engine support. erwise stationary.

To set the Tilt Bracket: The tilt bracket relieves pressure from the
1. Tilt the motor all the way up using the Power power trim and tilt and should only be used
Trim and Tilt. when the boat is stationary. Do not use the tilt
2. Pull down the Tilt Bracket as shown in the bracket when trailering your boat and motor.
illustration. Refer to the TRAILERING section of this man-
ual.
DF50AV/60A/60AV

DF40A/50A

3. Lower the motor using the Power Trim and

Tilt, until the motor is supported by the Tilt
Bracket.

 CAUTION

The remote Power Trim and Tilt switch will

work when the ignition switch is off. If some-
one activates the switch while you are moving
the tilt bracket your hand could be injured.

Keep all persons away from the remote Power

Trim and Tilt switch while you are moving the
tilt bracket.

31
INSPECTION BEFORE 2. Pull out the oil dipstick 3 and wipe oil off
with a clean cloth.
BOATING
 WARNING

Failure to inspect your boat and motor before

beginning a trip can be hazardous.

Before boating, always perform the inspec-

tions described in this section.

It is important to make sure that your boat and

motor are in good condition and that you are NOTE:
properly prepared for an emergency. If the engine oil is contaminated or discolored,
Always perform the following checks before you replace with fresh engine oil (Refer to Inspec-
begin boating: tion and maintenance/engine oil section).

• Make sure that you have enough fuel for 3. Insert the dipstick all the way into the engine,
the intended run. then remove it again.

• Check the level of engine oil in the sump.

NOTICE

Running the engine with an insufficient

amount of oil can cause serious engine dam- UPPER LIMIT
age.
LOWER LIMIT
Always check the oil level before each trip and
add oil if necessary.
The oil on the dipstick should be between the
To check the oil level: upper and lower limits shown on the dipstick. If
the oil level indication is near the lower limit,
NOTE: add enough oil to raise the level to the upper
To avoid an incorrect assessment of engine oil limit.
level, check the level only when the engine has
cooled.

1. Place the motor in a vertical position, then

remove the motor cover 1 by unlocking the
lever 2.

32
To fill the engine oil: BREAK-IN
1. Remove the oil filler cap.
2. Fill the recommended engine oil to the upper Proper operation during this break-in period will
level. help ensure maximum life and performance
from your engine. The following guidelines will
explain proper break-in procedures.

NOTICE

Failure to follow the break-in procedures

described below can result in severe engine
damage.

Be sure to follow the engine break-in proce-

dures described below.

NOTICE Break-in period: 10 hours

Running the engine with an excessive amount Break-in procedure

of oil can damage the engine. 1. For the initial 2 hours:
Allow sufficient idling time (about 5 minutes)
Do not overfill the engine with oil. for the engine to warm up after cold engine
starting.
3. Tighten the oil filler cap securely.
NOTICE
• Check the battery solution level.
The level should be kept between the MAX Running at high speed without sufficient
and the MIN level lines at all times. If the warm-up may cause severe engine damage
level drops below the MIN level line, refer such as piston seizure.
to MAINTENANCE section.
Always allow sufficient idling time (5 minutes)
• Make sure that the battery leads are for the engine to warm-up before running at
securely connected to the battery termi- high speed.
nals.
After warming up, run the engine at idling
• Visually check the propeller to make sure speed or the lowest in-gear speed for about
it is not damaged. 15 minutes.
During the remaining 1 hour and 45 minutes,
• Make sure that the motor is securely if safe boating conditions permit, operate the
mounted to the transom. engine in gear at less than 1/2 (half) throttle
(3000 r/min.).
• Check for proper operation of the Power
Trim and Tilt.

• Make sure you have the boating safety

and emergency equipment on board.

• Make sure that the emergency stop switch

operates properly.

• Make sure the obstacle is not attached to

water intake hole.

33
NOTE: OPERATION
You may throttle up beyond the recommended
operating range to plane your boat, then imme- BEFORE ATTEMPTING TO START THE
diately reduce the throttle to the recommended
operating range.
ENGINE
1. The motor has been lowered into the water.
2. Make sure that the motor fuel hose and the
2. For the next 1 hour:
hose from the boat’s fuel tank are securely
Safe boating conditions permitting, operate
attached and clamped.
the engine in gear at 4000 r/min. or at three-
quarter throttle. Avoid running the engine at
full throttle.
3. Remaining 7 hours:
Safe boating conditions permitting, operate
the engine in gear at desired engine speed.
You may occasionally use full throttle; how-
ever do not operate the engine continuously
at full throttle for more than 5 minutes at any
time.

NOTICE
3. Twist the air-vent screw 1 on the fuel tank
Running continuously at full throttle for more cap counterclockwise to open the vent.
than 5 minutes at a time during the last 7
hours of break-in operation may cause severe
engine damage such as seizure.

During the last 7 hours of break-in operation,

do not operate at wide open throttle for more
than 5 minutes at a time.

4. Make sure that the motor is in “NEUTRAL”.

34
5. Make sure the lock plate is in place and NOTE:
attach the emergency stop switch cord to a A spare plastic lock plate is provided for tempo-
part of your body. rary use only. Remove it from the cord and
place it in a safe place on board your boat. If
you lose or break the emergency stop switch
cord/lock plate assembly, replace it as soon as
possible so that you can resume normal use of
the emergency stop switch.

6. Set the tilt lock lever 2 to the “Lock” posi-

tion. (DF40AQH model)

STARTING THE ENGINE

 WARNING  WARNING

Failure to properly attach the emergency stop Exhaust gas contains carbon monoxide, a
switch cord or to take proper precautions to dangerous gas that is difficult to detect
help ensure that the emergency stop switch because it is colorless and odorless. Breath-
works as intended may result in serious injury ing carbon monoxide can cause death or
or death to the operator or passengers. severe injury.

Always take the following precautions: Never start the engine or let it run indoors or
• Make sure that the emergency stop switch where there is little or no ventilation.
cord is fastened securely to the operator’s
wrist or to an appropriate clothing area (belt NOTE:
etc.). If the emergency stop switch lock plate is not in
• Ensure that no obstructions impede or position, the starter motor cannot operate.
restrict emergency stop switch operation.
• Be careful not to pull the stop switch cord
or knock out the lock plate during normal
operation. The motor will stop abruptly, and
the loss of forward motion may unexpect-
edly throw occupants forward.

35
1. Squeeze the fuel line priming bulb several NOTICE
times until you feel resistance.

If you hold the ignition key at the “START”

position to start the engine, the starter system
can be damaged.

Turn the ignition key to the “START” position

once and release it to start the engine. The
engine will crank continuously for 4 seconds
or until the engine starts.

NOTE:
The continuous operating time of the starter
2. Remote control model: motor is set at five seconds.
Make sure that the warm-up lever is in the When this time is exceeded, the starter motor
fully closed position. will automatically stop.
If the motor stops, wait about ten seconds for
Tiller handle model: the motor to cool down and try again.
Make sure that the throttle control grip is in
the fully closed position. NOTICE

If the OIL lamp remains lit while operating the

outboard, the oil level may be low enough to
damage the engine.

Stop the engine and check the oil level.

5. Warm up the engine for about 5 minutes.

NOTICE
3. Turn the ignition key to the “ON” position.
Operating the engine at high RPM or “wide
4. Turn the ignition key to the “START” position.
open throttle” immediately after starting the
After returning the ignition key to “ON” posi- engine without allowing the engine to warm
tion from “START” one, starter motor con- up may cause engine failure.
tinue to turn for 4 seconds until engine start.
Always allow the engine to warm up suffi-
ciently before operating it at high speeds.

36
Cooling water check EMERGENCY STARTING
As soon as the engine starts, water should If you must get the engine running, but are
spray out of the pilot water hole 1, indicating unable to do so because of starter system fail-
that the water pump and cooling system are ure or battery discharge, you can use the emer-
working properly. If you notice that water does gency starting procedure to start the engine.
not spray out of the pilot water hole, stop the
engine as soon as possible and consult your  WARNING
authorized Suzuki Marine Dealer.
If you touch electrical components when rope-
starting the engine, you can get a severe elec-
trical shock.

When rope-starting the engine, be careful not

to touch electrical components such as igni-
tion coils or spark plug leads.

1. Make sure that the motor is in “NEUTRAL”

and the emergency stop switch lock plate is
removed.

NOTICE

Never operate your outboard motor when

there is no water coming out of the pilot water
hole, or severe damage can result.

After starting the engine, check to make sure

that there is water coming out of the pilot
water hole.

 WARNING
 WARNING
Operating the boat when the emergency stop
switch is not operating properly can be haz- When you use the emergency starting proce-
ardous. dure, the start-in-gear protection system will
not work. If the shift lever is not in the “NEU-
Before starting off, check to make sure that TRAL” position, the boat can start off unex-
the emergency stop switch operates properly. pectedly when the engine is started, throwing
occupants or causing an accident.

Make sure that the shift lever is in the “NEU-

TRAL” position before attempting to start the
motor using the emergency starting proce-
dure.

37
2. Remove the motor cover.  WARNING
3. Remove the flywheel cover.

If you attempt to reinstall the ring gear cover

or motor cover after starting the engine you
can be injured.

Do not attempt to reinstall the ring gear cover

or motor cover after starting the engine.

 WARNING

When the engine is running, there are many

4. Squeeze the fuel line priming bulb several moving parts that could cause severe per-
times until resistance is felt. sonal injury.
5. Put the emergency stop switch lock plate in
place. When the engine is running, keep your hands,
6. Turn the ignition key to the “ON” position and hair, clothing, etc., away from the engine.
listen for the electric fuel pump to cycle.
NOTE:
NOTE: Be sure to have the starter system repaired as
The initial fuel pump cycle is for a period of 3 soon as possible. You should not continue to
seconds after the ignition key is first turned on. use the emergency starting procedure for rou-
If the battery voltage is too low to operate the tine engine starting.
electric fuel pump, sufficient fuel will not be sup-
plied to start the engine. If you are not sure
about fuel pump operation, you may turn the SHIFTING AND SPEED CONTROL
key off, then repeat step #6.
NOTICE
7. Tie a knot in one end of the emergency
starter rope located in the tool kit. Tie the
other end around the screw-driver handle in Severe engine damage may occur if (a) engine
the tool kit. speed is not allowed to return to idle and boat
8. Hook the knotted end of the rope in the pul- speed is not reduced when shifting from
ley notch and wind the rope around the pul- “FORWARD” to “REVERSE” or from
ley in a clockwise direction. “REVERSE” to “FORWARD”, or (b) care is not
9. After following steps of the normal starting taken when operating the boat in reverse.
procedure, pull the emergency starter rope
sharply to start the engine. Always allow the engine speed to return to
idle before shifting. Exercise caution and use
minimal speed when operating the boat in
reverse. Be sure the handle/shift lever is in the
desired position before accelerating.

NOTICE

If you shift gears when the engine is not run-

ning, the shifting mechanism can be dam-
aged.

Avoid shifting gears when the engine is not

running.

38
TILLER HANDLE MODEL REMOTE CONTROL MODEL
Shifting Shifting
To shift the motor into “FORWARD”, set the To shift into “FORWARD”, squeeze the lock-out
throttle control grip to the idle position and pull lever on the control handle and move the con-
the shift lever towards you firmly. trol handle forward to approximately position A,
as shown in the illustration.
To shift into “REVERSE”, set the throttle to the
idle position, and push the shift lever away from To shift into “REVERSE”, squeeze the lock-out
you firmly. lever on the control handle and move the con-
trol handle rearward to approximately position
B, as shown in the illustration.

REVERSE FORWARD
NEUTRAL

32˚ 32˚
REVERSE
FORWARD

Speed Control
After shifting, control the engine speed by twist-
ing the throttle control grip. Speed Control
To increase speed after you have shifted into
gear, continue moving the control handle for-
ward or rearward.
FASTER
 WARNING

Since the same handle is used for shifting and

SLOWER speed control it is possible to move the han-
dle past the detent and engage the throttle.
This can cause the boat to move suddenly
resulting in personal injury or property dam-
age.

You must be careful not to move the control

handle too far forward or rearward when shift-
ing.

39
STOPPING THE ENGINE
 WARNING
NOTE:
When it is necessary to stop the engine in an
emergency, pull the emergency stop switch lock Unauthorized use of your boat could lead to
plate out of the emergency stop switch by pull- an accident or damage to your boat.
ing the emergency stop switch cord.
To prevent unauthorized use of your boat, be
To stop the engine: sure to remove the key and emergency stop
1. Tiller handle model: switch lock plate when the boat is unattended.
Turn the throttle control grip to the idle posi-
tion. 4. After stopping the engine, disconnect the
Shift into “NEUTRAL”. fuel line from the outboard motor if there is a
fuel connector.
Remote control model:
Shift into “NEUTRAL”.  WARNING
2. After operating at full throttle, cool off the
engine a few minutes by allowing it to idle or
If you leave the motor stopped for a long
troll at low speed.
period of time with the fuel line connected,
fuel can leak out.

Disconnect the fuel line from fuel tank, if there

is a fuel connector, whenever you leave the
motor stopped for a long period of time.

5. Turn the air-vent screw on the fuel tank cap

clockwise to shut the vent (if equipped).

NOTE:
To make sure that the emergency stop switch
3. Turn the ignition key to the “OFF” position. operates properly, stop the engine occasionally
Always leave the ignition key in the “OFF” by pulling out the lock plate, while operating the
position when the motor is not running, or engine at idling speed.
the battery can discharge.

MOORING
The motor should be tilted up out of the water
when you moor the boat in shallow water or if
the motor will not be used for some time, to pro-
tect it from damage by underwater obstacles at
low tide or corrosion from salt water.
Refer to the TILT BRACKET section for details
on how to tilt up the motor.

NOTICE

NOTICE Improperly securing your boat may cause

damage to your boat or motor, or other prop-
erty damage.
If the ignition key is left ON when the engine is
not running, the battery will discharge. Do not allow your motor to rub against quay
walls, piers or other boats when the boat is
Always turn the ignition key OFF when the tied up.
engine is not running.

40
OPERATING THE TROLL MODE Remote control model Tiller handle model
(Remote control model: Option Item,
Tiller handle model: Standard Item)
On the remote control model, trolling speed can
be controled to install the optional Troll Mode
switch.
Please contact your authorized Suzuki Marine
Dealer for more information.

NOTE:
Troll mode switch
To monitor engine speed correctly during the
troll mode operation, Suzuki recommends the NOTE:
use of the Suzuki 2-scale Monitor Tachometer. The troll mode system will not operate if the
(Remote control model) switch is depressed when the handle/shift lever
is in the neutral position.
Usual scale
Adjusting trolling speed:
• When pressing the “UP” switch, one short
beep sounds and the engine speed
increases by 50 r/min.
• When pressing the “DN” switch, one short
beep sounds and the engine speed
decreases by 50 r/min.
Trolling mode scale
NOTE:
• When pressing the “DN” switch at the lower
System Outline limit of trolling speed, the engine speed will
The “Troll Mode System” is activated by press-
not change and three long beeps will sound.
ing the troll mode switch, when the motor is run-
• When pressing the “UP” switch at the upper
ning at in-gear idle speed. By using this system,
you can set and maintain a desired engine limit of trolling speed, the engine speed will
speed with the control switch in a range from not change and three long beeps will sound.
in-gear idle speed (approx. 800 r/min) to 1200 • Shift operation and throttle control remain
r/min. operational, even in troll mode.

How to use the Troll Mode Cancelling the troll mode:

Setting the troll mode: The troll mode can be cancelled by shifting the
1. Shift into forward or reverse gear and make handle/shift lever to the neutral position, or by
sure that the throttle is fully closed (in-gear increasing the engine speed to 3000 r/min or
idle speed). more. In both cases, two short beeps sound
2. Press the “UP” or “DN” position of the troll when cancelling the troll mode.
mode switch, until you hear one beep.
On the remote control model, the REV/TRL
(or REV) lamp on the monitor gauge will
flash indicating that the motor has been set
to the troll mode. The REV/TRL (or REV)
lamp will continue to flash while the motor is
in the troll mode.

41
OPERATION IN SHALLOW WATER DF40A (T/TH), DF50A (T/TH), DF50AV
When operating your boat in shallow water, it (T/TH), DF60A (T/TH), DF60AV (T) MODEL
may be necessary to tilt the motor higher than To tilt the motor higher than the normal trim
the normal trim angle. When you tilt the motor angle, use the Power Trim and Tilt switch.
beyond the normal trim angle, however, you
should only operate the boat at slow speeds.  WARNING
After returning to deep water, be sure to lower
the motor to the normal trim angle.
When the motor is beyond the maximum trim
DF40A (QH) MODEL position, the swivel bracket will not have side
To tilt the motor higher than the normal trim support from the clamp bracket and the tilt
angle: system will be unable to cushion the engine if
1. Stop the engine. the lower unit strikes an obstruction. This
2. Move the tilt lock lever 1 to the release posi- could lead to occupant injury. In addition,
tion. beyond the maximum trim position, the water
intake holes may be above the water line,
which can result in severe engine damage
from overheating.

Do not operate the engine above 1500 r/min or

RELEASE operate the boat in a planing attitude with the
engine beyond the maximum trim position.
LOCK
NOTICE

If the motor hits bottom, serious damage can

3. Slowly tilt the motor up to appropriate trim occur.
angle.
Do not allow the motor to hit bottom. If the
motor does strike bottom, inspect it immedi-
ately for damage.

OPERATION IN SALT WATER

After operating the motor in salt water, you
should flush the water passages with clean,
fresh water as outlined in the FLUSHING THE
WATER PASSAGES section. If you do not flush
the water passages, salt can corrode the motor
and shorten its life.
4. Move the tilt lock lever 1 to the lock position.

To lower motor back down:

1. Shift into “NEUTRAL”.
2. Move the tilt lock lever 1 to the release posi-
tion.
3. Push the handle on the back of motor cover
and slowly let the motor down.
4. Move the tilt lock lever 1 to the lock position.

42
OPERATION IN FREEZING WEATHER MOTOR REMOVAL AND
When operating your outboard motor in freez-
ing temperatures, you should keep the lower TRANSPORTING
unit submerged in the water at all times.
When taking motor out of the water, stand it up MOTOR REMOVAL
in a vertical position until the cooling system If it is necessary to remove the outboard motor
drains completely. from your boat, we recommend that you ask
your authorized Suzuki Marine Dealer to do the
NOTICE work for you.

If you leave your outboard motor out of the

water in freezing temperatures with water still
MOTOR TRANSPORTING
in the cooling system, the water can freeze When transporting the motor, place the motor
and expand, causing severe damage to the either vertically or horizontally.
motor.
Vertical transport:
When your outboard is in the water in freezing Attach the motor to the carrier by securing
temperatures, keep the lower unit submerged clamp bracket with two sets of transom bolt and
in the water at all times. When the motor is nut.
stored out of the water in freezing tempera- Never use display stand for transportation of the
tures stand it up in the vertical position so motor.
that the cooling system drains completely.

Horizontal transport:
1. Drain the engine oil. Refer to the ENGINE
OIL section.
2. Drain the gasoline from the vapor separator
as follows:
(1) Fully steer the motor to the starboard side.
(2) Pull the drain hose end 1 out.
(3) Loosen the vapor separator drain screw 2
and drain the gasoline into a suitable con-
tainer.

43
  WARNING  WARNING

Gasoline is extremely flammable and toxic. It Spilled fuel or fuel vapor can cause a fire and
can cause a fire and can be hazardous to peo- is hazardous to health.
ple and pets.
Always take the following precautions:
Use a proper, safe container to store any gas- • Drain the fuel from the fuel line and fuel
oline drained from the outboard motor. Keep vapor separator before transporting the
gasoline away from sparks, flames, people, boat/outboard motor and before removing
and pets. the motor from the boat.
• DO NOT lay motor on its side without drain-
NOTICE ing fuel.
• Keep the motor away from open flames or
sparks.
If spilled gasoline is just left on painted sur- • Wipe up spilled fuel immediately.
face, it may cause a stain or discoloration of
the surface coating.
NOTICE
Wipe off any spilled gasoline immediately with
a soft cloth etc. If you are not careful when resting the out-
board on its side and do not take proper pre-
(4) After draining, retighten the drain screw and cautions such as first draining the engine oil
put the drain hose back. and cooling water completely, damage can
occur. Engine oil may enter the cylinder from
3. Rest the motor on a case protector with the the sump, water may enter the cylinder
starboard side downwards as shown. through the exhaust port, or the outer casings
may be damaged.

Always drain the engine oil and cooling water

completely before laying the motor on its side,
and be careful laying the motor down.

NOTICE

If you let the lower unit of your outboard sit

higher than the power head during transport-
ing or storing, water may trickle into the
power head, causing damage to the engine.

Never let the lower unit sit higher than the

power head when transporting or storing your
outboard.

44
TRAILERING
When trailering your boat with the motor
attached, keep the motor in the normal operat-
ing position unless there is not enough ground
clearance. If you need more ground clearance,
trailer the motor in a tilted position using a tran-
som saver bar or similar device to support the
weight of the motor.

NOTICE

If you use the tilt bracket to hold the motor in

the fully tilted up position when trailering the
boat, towing motion or poor road surfaces
may cause unexpected tilt lock release, result-
ing in damage to the motor and the tilt lock
mechanism.

Never use the tilt bracket to hold the motor in

the fully tilted up position when trailering the
boat. Use a transom saver bar or similar
device to support the weight of the motor.

45
INSPECTION AND MAINTENANCE
MAINTENANCE SCHEDULE
It is important to inspect and maintain your out-  WARNING
board motor regularly. Follow the chart below.
At each interval, be sure to perform the indi- Exhaust gas contains carbon monoxide, a
cated service. Maintenance intervals should be dangerous gas that is difficult to detect
judged by number of hours or number of because it is colorless and odorless. Breath-
months, whichever comes first. ing carbon monoxide can cause death or
severe injury.

Never start the engine or let it run indoors or

where there is little or no ventilation.

Interval Every 100 hrs. Every 200 hrs. Every 300 hrs.
Initial 20 hrs.
or every or every or every
or 1 month 12 months 12 months 36 months
Item to be serviced
Spark plug I
Breather & Fuel line I I
Engine oil R R
Gear oil R R
Lubrication I I
Anodes (external) I I
* Anodes (internal cylin-
I
der block/cylinder head)
Bonding wire I I
Battery I I
* Engine oil filter R R
I I
Low pressure fuel filter
Replace every 400 hours or every 2 years.
* Idle speed I I
* Valve clearance (lash) I
* Water pump I
* Water pump impeller I R
* Propeller nut & pin I I
* Bolts & Nuts T T
* Thermostat I
I: Inspect and clean, adjust, lubricate, or replace, if necessary T: Tighten R: Replace

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

46
  WARNING • Frequent abrupt acceleration and decelera-
tion
Improper maintenance or failure to perform • Frequent shift operation
recommended maintenance can be hazard- Failure to perform maintenance more fre-
ous. Poor maintenance or lack of maintenance quently could result in damage.
increases the chance of an accident or equip-
ment damage. Consult your authorized Suzuki marine dealer
regarding appropriate maintenance intervals
Be sure to have maintenance performed for your usage conditions. When replacing
according to the schedule in the above chart. parts on your outboard motor, Suzuki strongly
Suzuki recommends that only your authorized recommends that you use genuine Suzuki
Suzuki marine dealer or a qualified service parts or their equivalent.
mechanic perform maintenance on those
items in the chart above which are marked
with an asterisk (*). You may perform mainte- TOOL KIT
nance on the unmarked items by referring to A tool kit is provided with your outboard motor.
the instructions in this section if you have Keep the kit on board your boat and make sure
mechanical experience. If you are not sure that all of the items provided remain in the kit.
whether you can successfully complete any of The tool kit contains the following items:
the unmarked maintenance jobs, ask your
authorized Suzuki marine dealer to do the 1 Tool bag
maintenance for you. 2 8 × 10 mm Box wrench
3 16 mm Box wrench
 WARNING 4 Combination screw driver
5 Screwdriver handle
6 Pliers
The safety of you and your passengers 7 Hexagon wrench 8 mm
depends on how well you maintain your out- 8 Engine oil drain plug gasket (spare)
board motor. 9 Emergency starter rope

Follow all inspection and maintenance

instructions carefully. If you do not have prior
mechanical experience, do not attempt to per-
form maintenance on your outboard motor.
You could be injured or may damage the
motor.

NOTICE

The maintenance intervals in the chart are

designed for normal usage of your outboard
motor. If your outboard motor is used under
severe conditions as outlined below, you may
need to perform maintenance more often than
indicated in the chart.
• Frequent full throttle operation
• Prolonged continuous operation at the
maximum speed
• Prolonged continuous operation at idling
speed or trolling speed
• Frequent operation in muddy, silty, sandy,
acidic or shallow water
• Operation without appropriate warmup

47
SPARK PLUG A normally operating spark plug is very light-
Remove the spark plugs as follows: brown in color. If the standard plug is not suit-
1. Remove the bolts securing the fuel hose able for your operating, consult your authorized
guard A. Suzuki Marine Dealer.

2. Remove the bolt securing the ignition coil.

3. Pull out the ignition coil. NOTICE
4. Loosen and remove the spark plug using the
box wrench in the tool bag. Use of improper spark plugs or improperly
tightening spark plugs can cause severe
engine damage.

• Do not experiment with other spark plug

brands unless you can determine that they
are directly equivalent to the specified
brand, or you may experience engine dam-
age which will not be covered under war-
ranty. Note that aftermarket cross-reference
charts may not be accurate.
• To install a spark plug; seat it as far as pos-
sible by hand, then use a wrench to tighten
Your outboard motor comes equipped with the it to either the recommended torque setting
following “standard” spark plug for normal or the specified rotation angle.
usage.
Tightening torque
NGK DCPR6E Standard 15 – 19 N·m
(1.5 – 1.9 kgf-m, 11 – 14 lbf-ft)
Rotation angle
NOTICE New plug 1/2 – 3/4 of a turn
Re-use plug 1/12 – 1/8 of a turn
Non-resistor types of spark plugs will inter-
fere with the function of the electronic igni- • Do not overtighten or cross-thread a spark
tion, causing misfiring, or causing problems plug, as this will damage the aluminum
with other electronic boat equipment and threads of the cylinder head.
accessories.

Use ONLY resistor type spark plugs in your

outboard motor.

48
To maintain a strong spark, you should clean BREATHER AND FUEL LINE
and adjust the plugs at the intervals shown in Inspect the breather and fuel line for leaks,
the maintenance chart. Remove carbon depos- cracks, swelling, or other damage. If the
its from the spark plugs using a small wire breather and fuel line is damaged in any way, it
brush or spark plug cleaner, and adjust the gap must be replaced. Consult your authorized
according to the following chart: Suzuki Marine Dealer if it is necessary to
replace them.
0.8 – 0.9 mm
Spark plug gap Fuel line Breather line
(0.031 – 0.035 in)

 WARNING

1 2 3 Fuel leakage can contribute to an explosion or

fire, resulting in serious personal injury.

Have your authorized Suzuki Marine Dealer

replace the fuel line if there is any evidence of
4 5 6 leaking, cracking or swelling.

1. Excessive wear 2. Breakage 3. Melting

4. Erosion 5. Yellow deposits 6. Oxidation

NOTE:
If the spark plug condition is found as shown in
the illustration above, ensure it is replaced with
new one. Otherwise, it will cause difficulty in
starting the engine, increase fuel consumption,
and result in engine troubles.

49
ENGINE OIL 3. Place a drain pan under the engine oil drain
screw.
 WARNING
 CAUTION
Never perform any ENGINE OIL procedure
with the motor running, as serious injury can The engine oil temperature may be high
occur. enough to burn your fingers when the drain
plug is loosened.
The motor must be shut off before any
ENGINE OIL procedures are performed. Wait until the drain plug is cool enough to
touch with bare hands before removing it.
NOTICE
4. Remove the engine oil drain screw 1 and
Extended trolling can reduce oil life. Your gasket 2, then let the engine oil drain.
engine may be damaged if you do not change
engine oil more frequently under this type of
use.

Change your engine oil more frequently if

your engine is used for extended trolling.

Engine oil change

The oil should be changed when engine is
warm so that the oil will drain thoroughly from
the engine.
5. After draining, secure the engine oil drain
To change the engine oil: screw with a new gasket.
1. Place the motor in a vertical position and
remove the motor cover.
2. Remove the oil filler cap.
NOTICE

A previously-used gasket may leak, resulting

in engine damage.

Do not re-use gaskets. Be sure to always use

new gaskets.

NOTE:
There are spare gaskets in the tool bag.

6. Fill with recommended engine oil to the

upper level.

Oil capacity: 2.7 L

50
7. Check the engine oil level. GEAR OIL
To check the gear oil level, remove the upper oil
level plug and look into the hole. The oil level
should be at the bottom edge of the hole. If the
oil level is low, add the specified gear oil until
the level reaches the bottom edge of the hole.
Then, reinstall and tighten the plug.
UPPER LIMIT
To change the gear oil:
1. Make sure the motor is in an upright posi-
LOWER LIMIT tion. Place a drain pan under the lower cas-
ing.
2. Remove the gear oil drain plug 1, then
NOTE: remove the gear oil level plug 2.
To avoid incorrect measurement of engine oil
level, check oil level only when the engine has DF40A/50A/60A
cooled.

8. Reinstall the oil filler cap.

 WARNING

Engine oil can cause injury to people or pets.

Repeated, prolonged contact with used
engine oil may cause skin cancer. Even brief
contact with used oil may irritate skin.
DF50AV/60AV
• Keep new and used oil away from children
and pets.
• Wear a long-sleeve shirt and waterproof
gloves when handling oil.
• Wash with soap if oil contacts your skin.
• Launder any clothing or rags that are wet
with oil.

NOTE:
Recycle or properly dispose of used engine oil. 3. After the oil has drained completely, inject
Do not throw it in the trash, or pour it on the the specified gear oil into the lower drain
ground, down a drain, or into the water. hole until it just starts to come out of the
upper level hole.

DF40A/50A/60A MODEL:
Approximately 0.61 L (0.64/0.54 US/lmp. qt.)
will be required.

DF50AV/60AV MODEL:
Approximately 1.05 L (1.11/0.92 US/lmp. qt.)
will be required.
4. Reinstall and tighten the gear oil level plug
2, then quickly reinstall and tighten the gear
oil drain plug 1.

51
NOTE: LUBRICATION
To avoid insufficient injection of gear oil, check Proper lubrication is important for the safe,
the gear oil level 10 minutes after doing the pro- smooth operation and long life of each working
cedure in the step 4. If the oil level is low, slowly part of your outboard motor. The following chart
inject the gear oil up to the correct level. shows the lubrication points of your motor and
the recommended lubricant:
 WARNING
LOCATION LUBRICANT
Gear oil can cause injury to people or pets.
Repeated, prolonged contact with used gear
oil may cause skin cancer. Even brief contact
with used oil may irritate skin.

• Keep new and used oil away from children

and pets.
• Wear a long-sleeve shirt and waterproof Marine-grade
Throttle/Shift linkage
gloves when handling oil. water resistant
• Wash with soap if oil contacts your skin. grease
• Launder any clothing or rags that are wet
with oil.

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

If fishing line wraps around the rotating pro-

peller shaft, the propeller shaft oil seal can
become damaged and can allow water to enter
the gear case causing severe damage.
Swivel bracket
If the gear oil has a milky color, it is contami-
nated with water. Immediately contact your
authorized Suzuki marine dealer for advice.
Do not operate your outboard until the oil is Marine-grade
changed and the cause of the contamination water resistant
is corrected. grease
(Grease Gun)
Swivel bracket
(DF40AQH/50ATH)

Steering bracket

52
NOTE: DF50AV/60AV
Before applying grease through the steering
bracket grease nipple, lock the motor in the fully
tilted up position.

ANODES AND BONDING WIRES

Anodes
The motor is protected from exterior corrosion
by anodes. These pieces of anodes control
electrolysis and prevent corrosion. The anodes
will corrode in place of the parts they are pro-
tecting. You should periodically inspect each of NOTICE
the anodes and replace them when 2/3 of the
metal has corroded away. If anodes are not properly maintained, under-
water aluminum surfaces (such as the lower
DF60A (T/TH) unit) will suffer galvanic corrosion damage.

• Periodically inspect anodes to make sure

they have not become detached.
• Do not paint anodes, as this will render
them ineffective.
• Periodically clean anodes with a wire brush
to remove any coating which might
decrease their protective ability.

NOTE:
DF40A/50A/50AV/60AV Consult your authorized Suzuki Marine Dealer
for inspection and replacement of internal
anodes attached to the cylinder block/cylinder
head.

Bonding wires
Bonding wires are used to electrically connect
the engine components so they exist in a com-
mon ground circuit. This allows them to be pro-
tected against electrolysis by the anodes.
These wires and their terminals should be
DF40A/50A/60A checked periodically to be sure they have not
been damaged.

53
BATTERY ENGINE OIL FILTER
The battery solution level must be kept between The engine oil filter must be changed by an
the MAX and the MIN level lines at all times. If authorized Suzuki Marine Dealer periodically.
the level drops below the MIN level line, add Replace engine oil filter with a new one at initial
DISTILLED WATER ONLY until the battery 20 hours (1 month).
solution level reaches the MAX level line. Replace engine oil filter with a new one at every
200 hours (12 months).
 WARNING

Battery acid is poisonous and corrosive, and

FUEL FILTER
The fuel filter must be inspected by authorized
can cause severe injury.
Suzuki Marine Dealer periodically.
Avoid contact with eyes, skin, clothing, and
painted surfaces. If battery acid comes in con- Low pressure fuel filter
tact with any of these, flush immediately with Inspect low pressure fuel filter at initial 20 hours
large amounts of water. If acid contacts the (1 month).
eyes or skin, get immediate medical attention. Inspect low pressure fuel filter at every 100
hours (12 months).
Replace low pressure fuel filter with a new one
 WARNING at every 400 hours (2 years).

If you are not careful when checking or servic-

ing the battery, you can cause a short circuit,
which could result in an explosion, fire, or cir-
cuit damage.

Disconnect the negative (black) cable when

checking or servicing the battery. Be careful
not to allow a metal tool or other metal object
to touch the battery’s positive terminal and
the motor at the same time.

 WARNING

Battery posts, terminals, and related accesso-

ries contain lead and lead compounds that
may be hazardous.

Wash hands after handling.

NOTICE

If you add diluted sulphuric acid to the battery

after it has been initially serviced, you will
damage the battery.

NEVER add diluted sulphuric acid to the bat-

tery after it has been initially serviced. Follow
the battery manufacturer’s instructions for
specific maintenance procedures.

54
FLUSHING THE WATER To flush the water passages, you must obtain a
commercially available engine flush device.
PASSAGES 1. Make sure that the motor is stopped.
2. Plug the water intake hole 1 with a piece of
After operation in muddy, brackish, or salt duct tape. (except DF50AV/60AV model)
water, you should flush the water passages and
motor surface with clean, fresh water.
If you do not flush the water passages, salt can
corrode the motor and shorten its life. Flush the
water passages as follows.

ENGINE RUNNING – Vertical position –

Suzuki recommends that you flush the water
passages by using this method.

 WARNING
3. Install the flushing attachment 2 so that the
Exhaust gas contains carbon monoxide, a water intake holes are covered by the rubber
dangerous gas that is difficult to detect cups on the attachment.
because it is colorless and odorless. Breath-
ing carbon monoxide can cause death or
severe injury.

Never start the engine or let it run indoors or

where there is little or no ventilation.

 WARNING

Failure to take proper precautions when flush-

ing the water passages can be hazardous.
4. Connect a garden hose to the flushing
When flushing the water passages, always attachment and turn on the water to obtain
take the following precautions: enough flow so that plenty of excess water
• Make sure that the engine remains in NEU- is flowing out from around the rubber cups
TRAL. If shifted into gear, the propeller on the attachment.
shaft will turn and could cause severe per- 5. Shift the motor into “NEUTRAL” and remove
sonal injury. the propeller. Start the motor and allow it to
• Make sure the motor is properly clamped to run at idle.
a secure stand or boat, and remain in atten- 6. Readjust the water flow, if necessary, so
dance until flushing is completed. that there is still plenty of excess water flow-
• Keep children and pets away from the area, ing out from around the rubber cups.
and stay clear of all moving parts. 7. Allow the water to continue circulating for a
few minutes.
NOTICE 8. Stop the motor, then turn off the water.
9. Remove the flushing attachment and
remove the duct tape from the water intake
Severe engine damage can occur in as little as
hole.
15 seconds if the engine is started without
10. Clean the motor surface and apply a coat of
supplying water to the cooling system.
automotive wax on the external finish of the
motor.
Never start the motor without supplying water
to the cooling system.

55
ENGINE NOT RUNNING ENGINE NOT RUNNING
– Vertical position – – Full tilt up position –
1. Make sure that the motor is stopped. 1. Raise the engine to the full tilt up position.
2. Remove the plug A from the flushing port. 2. Follow the “ENGINE NOT RUNNING – Verti-
cal position” instructions.
DO NOT RUN ENGINE IN THE FULL TILT
UP POSITION.
3. Lower the motor to a vertical position until
the engine is drained completely.

3. Install garden hose by using a hose connec-

tor matched to flushing port thread B.
Thread B: 0.75 – 11.5 NHR (American stan-
dard hose coupling threads for garden hose
applications.)

NOTE:
The hose connector (flushing attachment)
matched to the flushing point thread B is
included in the crate parts.

4. Turn on the water to obtain a good water

flow. Flush the engine for about five minutes.
5. Turn off the water.
6. Remove the hose and connector (if used)
then reinstall the plug into the flushing port.
7. Leave the motor in a vertical position until
the engine is drained completely.

56
SUBMERGED MOTOR 7. Take the motor to your authorized Suzuki
Marine Dealer as soon as possible to be
A motor that has been accidentally submerged overhauled.
in water must be overhauled as soon as possi-
ble to prevent corrosion. In the event that your NOTICE
motor is accidentally submerged, take the fol-
lowing steps:
If the fuel supply is contaminated with water,
engine damage may occur.
1. Get the motor out of the water as soon as
possible.
If the boat’s fuel tank filler and vent were sub-
2. Wash it thoroughly with fresh water to com-
merged, inspect the fuel supply to make sure
pletely remove all salt, mud, and seaweed.
it is not contaminated with water.
3. Remove the spark plugs. Drain the water
from the cylinders through the spark plug
holes by manually turning the flywheel sev-
eral times.
4. Check if any water is evident in the engine
oil. If water is seen, remove the oil drain plug
and drain the oil. After draining, tighten the
oil drain plug.
5. Drain the fuel line.

 WARNING

Gasoline is extremely flammable and toxic. It

can cause a fire and can be hazardous to peo-
ple and pets.

Keep flames and sparks away from gasoline.

Dispose of unwanted fuel properly.

6. Pour engine oil into the engine through the

spark plug holes. Coat the engine inner
parts with oil by turning the engine over with
the emergency starter rope.

NOTICE

Severe engine damage may occur if you con-

tinue cranking the engine when you encounter
friction or resistance.

If you encounter friction or resistance while

cranking the engine, stop at once and do not
attempt to start the engine until you find and
correct the problem.

57
STORAGE PROCEDURE NOTICE
MOTOR STORAGE
Severe engine damage can occur in as little as
When storing your motor for a long period of
15 seconds if the engine is started without
time (for example, at the end of the boating sea-
supplying water to the cooling system.
son), it is recommended that you take your
motor to your authorized Suzuki Marine Dealer.
Never start the motor without supplying water
However, if you choose to prepare the motor for
to the cooling system.
storage yourself, follow the procedure outlined
below:

1. Change the gear oil as outlined in the BATTERY STORAGE

GEAR OIL section. 1. When the outboard motor will not be used
2. Change the engine oil as outlined in the for a month or longer, remove the battery
ENGINE OIL section. and store it in a cool, dark place. Completely
3. Fill a fuel stabilizer to the fuel tank accord- recharge the battery before reusing it.
ing to the instructions on the stabilizer can. 2. If the battery will be stored for a long period
4. Flush the water passages in the motor thor- of time, check the specific gravity of the bat-
oughly. Refer to the FLUSHING THE tery solution at least once a month and
WATER PASSAGES (Engine running) sec- recharge the battery when low.
tion.
5. Readjust the water flow, run the engine at  WARNING
about 1500 r/min in neutral for five minutes
to distribute the stabilized fuel through the
engine.
Failure to take proper precautions when
6. Stop the engine. Then turn off the water and
charging the battery can be hazardous. Bat-
disconnect the flushing attachment.
teries produce explosive vapors that can
7. Lubricate all other specified parts. Refer to
ignite. Battery acid is poisonous and corro-
the LUBRICATION section.
sive, and can cause severe injury.
8. Wash the exterior of the engine with fresh
water. After washing, the water remaining
• Do not smoke and keep battery away from
on the engine should be wiped off with dry
open flames and sparks.
clothes.
• To avoid creating a spark when charging
High pressure washer should be used only
the battery, connect the battery charger
for washing exterior. And the nozzle of the
cables to the proper terminals before turn-
high pressure washer should be well away
ing the charger on.
from the engine.
• Handle the battery with extreme care and
9. Apply a coat of automotive wax on the
avoid skin contact with battery acid.
external finish of the motor. If paint damage
• Wear proper protective clothing (Safety
is evident, apply touch up paint before wax-
glasses, gloves, etc.)
ing.
10. Store the motor in an upright position in a
dry, well-ventilated area.

 WARNING

When the engine is running, there are many

moving parts that could cause severe per-
sonal injury.

When the engine is running, keep your hands,

hair, clothing, etc., away from the engine.

58
AFTER STORAGE TROUBLESHOOTING
When taking your motor out of storage, follow This troubleshooting guide is provided to help
the procedure below to return it to operating you find the cause of common complaints.
condition:
1. Thoroughly clean the spark plugs. Replace NOTICE
them if necessary.
2. Check the gear-case oil level and if neces-
sary, add gear oil according to the procedure Failure to troubleshoot a problem correctly
outlined in the GEAR OIL section. can damage your outboard motor. Improper
3. Lubricate all moving parts according to the repairs or adjustments may damage the out-
LUBRICATION section. board motor instead or fixing it. Such damage
4. Check the engine oil level. may not be covered under warranty.
5. Clean the motor and wax the painted sur-
faces. If you are not sure about the proper action to
6. Recharge the battery before installing it. correct a problem, consult your Suzuki marine
dealer.

Starter motor will not operate:

• Shift lever is not in NEUTRAL.
• Fuse is blown out.
• Emergency stop switch lock plate is not in
position.

Engine will not start (hard to start):

• Fuel tank is empty.
• Fuel hose is not properly connected to
engine.
• Fuel hose is kinked or pinched.
• Spark plug is fouled.

Engine idles unstably or stalls:

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

Engine speed will not increase (Engine

power is low):
• Engine is overloaded.
• Caution/Diagnostic system is activated.
• Propeller is damaged.
• Propeller is not properly matched to loads.

Engine vibrates excessively:

• Engine mounting bolts or clamp screws are
loose.
• Foreign object (seaweed etc.) is tangled on
propeller.
• Propeller is damaged.

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

59
FUSE 4. Inspect the fuse and replace with the new
1. Turn the ignition key to the “off” position. fuse if needed.
2. Remove the motor cover.
3. Remove the fuse box cover and pull off the
fuse. Main fuse (30A)

Fuse box
cover

Normal fuse Blown fuse

Normal fuse Blown fuse

NOTE:
If a fuse is blown, try to determine the root
cause and correct it.
NOTE: If the cause is not corrected, the fuse may be
Use the fuse puller at the back of fuse box blown again.
cover, when the fuse is pulled off and installed.
 WARNING

If you replace a blown fuse with a fuse having

a different amperage rating or with a substi-
tute such as aluminum foil or a wire, extensive
electrical system damage and a fire may
result.

Fuse puller Always replace a blown fuse with a fuse of the

same type and rating.

NOTICE

If a new fuse blows in a short time after instal-

lation, you may have a major electrical system
problem.

Consult your SUZUKI marine dealer.

60
 1 Main fuse: 30A
2 PTT switch fuse: 15A
3 Ignition coil/Injector/ECM/IAC fuse: 30A
4 Starter motor relay fuse: 30A
30A 5 Spare fuse: 30A

15A

30A
30A
MAIN
6 Fuel pump fuse: 15A
MAIN STARTER
7 Spare fuse: 30A

15A
SPARE
RELAY RELAY
8 Spare fuse: 15A

NOTE:
Spare fuses 7 and 8 are provided for the back
of fuse box cover.

Fuse box cover

SPECIFICATIONS
DF50A/ DF60A/
Item DF40A DF40AS 50AV 60AV
Engine Type 4 Stroke
Number of Cylinders 3
Bore and Stroke 72.5 × 76.0 mm (2.85 × 2.99 in)
Piston Displacement 941 cm3 (57.4 cu. in)
Maximum output 36.8 kW 44.1 kW
29.4 kW (40PS)
(50PS) (60PS)
5000 – 6000 5300 – 6300
Full Throttle Operating Range
r/min. (min–1) r/min. (min–1)
Ignition System Full-transistor
Engine Lubrication Trochoid pump pressure lubrication
Engine Oil Capacity 2.7 L (2.9/2.4 US/lmp. qt.)
Gear Oil Capacity DF40A/50A/60A model:
0.61 L (0.64/0.54 US/Imp. qt.)
DF50AV/60AV model:
1.05 L (1.11/0.92 US/Imp. qt.)
Spark Plug NGK DCPR6E
Spark Plug Gap 0.8 – 0.9 mm (0.031 – 0.035 in)
Valve Clearance (Lash) IN. : 0.18 – 0.22 mm (0.007 – 0.009 in)
EX.: 0.28 – 0.32 mm (0.011 – 0.013 in)
Fuel Type Alcohol-free unleaded gasoline
Minimum Fuel Octane Rating 91 (Research method)

61
INFORMATION REGARDING EC – DIRECTIVE
(For European countries)

Sound Pressure Level

Regulation Sound pressure level limit
72 dB (A): DF40A/50A
2013 / 53 / EU
75 dB (A): DF60A
Sound pressure level is measured according to ISO 14509-1:2008.

Vibration on tiller handle grip

Tiller handle grip vibration total value of this motor measured under related EC Directive does not
exceed 2.5m/s2. The vibration measurement is performed specified in ISO 5349-1986.

CHART OF TOTAL OPERATING HOURS INDICATION

(REMOTE CONTROL MODEL)
Total MONITOR-TACHOMETER
operating Needle 1 REV-LIMIT
hours indication lamp 2 flashing *
0h-(49h) No No
50 h- 500 r/min No
60 h- 600 r/min No
: : :
: : :
540 h- 5400 r/min No
550 h- 500 r/min 1 time
560 h- 600 r/min 1 time
: : :
: : :
1040 h- 5400 r/min 1 time
1050 h- 500 r/min 2 times
: : :
: : :
1540 h- 5400 r/min 2 times
1550 h- 500 r/min 3 times
: : :
: : :
2030 h- 5300 r/min 3 times
2040 h or over 5400 r/min 3 times
*: One flashing is corresponded to 500 hours.

62
(TILLER HANDLE MODEL)
Tachometer 1 indication
2nd indication
1st indication
(The hours subtracted
Total (Indication of number
the hours indicated in
operating of time in which the
the first step indication
hours operating hours attain
from the total operat-
to 500 hours in the 3rd
ing hours. [Indicated
digit.)
in units of 10 hours])
0h - 50h 0
51h - 59h 50
: :
: :
0
300h - 309h 300
: :
: :
540h - 549h 540
550h - 559h 50
: :
: :
100
800h - 809h 300
(1 time)
: :
: :
1040h - 1049h 540
1050h - 1059h 50
: :
: :
200
1300h - 1309h 300
(2 times)
: :
: :
1540h - 1549h 540
1550h - 1559h 50
: :
: :
300
1800h - 1809h 300
(3 times)
: :
: :
2040h and over remaining at 540

Tachometer indication procedure

Lapse of Time Tachometer indication
First 2 seconds after main switch is turned on “0”
Next 2.5 seconds (1st indication) Indication of number of time in which the operat-
ing hours attain to 500 hours in the 3rd digit.
Next 1 second “0”
Next 3 seconds (2nd indication) The hours subtracted the hours indicated in the
first step indication from the total operating
hours. (Indicated in units of 10 hours)

63
NOTE:
“0” of the first step indication signifies 0 time, “100” means 1 time (500 hours), “200” means 2 times
(1000 hours = 500 × 2), and “300” means 3 times (1500 hours = 500 × 3).
The total operating hours are the sum of hours indicated in the first step indication, and the indi-
cated hours of second step indication (indicated in units of 10 hours).

FLOWCHART OF OIL CHANGE REMINDER SYSTEM

Action
Starting operation
(*1) (*4)

Indication Cancellation
(*2) (*4)

Indication Cancellation
(*3) (*4)

Indication Cancellation
(*3) (*4)

Indication Cancellation *1: Lapse of initial 20 hour’s operation

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

64
 WIRE COLOR
B : Black Lg/B : Light green with Black
Bl : Blue Lg/W : Light green with White
Br : Brown O/B : Orange with Black
G : Green O/Y : Orange with Yellow
Gr : Gray P/B : Pink with Black
Lbl : Light blue P/W : Pink with White
O : Orange R/B : Red with Black
P : Pink R/G : Red with Green
R : Red R/W : Red with White
V : Violet R/Y : Red with Yellow
W : White W/B : White with Black
Y : Yellow W/Bl : White with Blue
B/Bl : Black with Blue W/R : White with Red
B/Br : Black with Brown W/Y : White with Yellow
B/G : Black with Green Y/B : Yellow with Black
B/R : Black with Red Y/Bl : Yellow with Blue
B/W : Black with White Y/G : Yellow with Green
Bl/B : Blue with Black
Bl/R : Blue with Red
Bl/W : Blue with White
Br/Y : Brown with Yellow
G/W : Green with White
NEUTRAL SWITCH G/Y : Green with Yellow
R
B/W THROTTLE & IAT & MAP
N ON Br/Y Gr/Y : Gray with Yellow
Lg/B SENSOR
W Lbl/W : Light blue with White
F, R OFF
PTT SWITCH IAC
DN UP

R/G OIL PRESSURE

W/B

P
Gr

Lbl
SWITCH

W/R
Gr
W/Bl
R/Y HI
Bl
LO

P
Lbl
FUEL PUMP

W/R
STARTER

Br
RECTIFIER & MOTOR

Y/B
REGULATOR MAGNETO M
CMP
SENSOR #1 Y
Y
Y

B/R
R
B/W R

W
Y/Bl B

B/Bl
Lbl Lbl

R
W/R W/R B/Bl
P P R/G

Y/G
B

B
Gr

R
B LIGHTING
IGNITION COIL #1 CKP SENSOR TROLL MODE B SWITCH
DF40AT/40AST/50AT/50AVT/60AT/60AVT

FUEL INJECTOR DIGITAL GAUGE Gr

Gr SWITCH
#1 O/B O DIAGRAM R/G
Gr B STARTER B
FUSE BOX (OPTION)
UP DN
MAIN MOTOR
B
R/G

RELAY RELAY B
GAUGE Gr Gr Gr

P/W
O/Y
B/G

B Lg/W METER
CONNECTOR B B
R/G

B B/W
Y

G/W
Bl/B
FUSE

R/B
ENGINE CONTROL MODULE CAP
R/G
15A 30A 30A 15A 30A B

B/G
R/G

CYLINDER TEMP SDS

Bl/B
B

2.2μ F
R/G

SENSOR CONNECTOR TRIM Gr

450 V W/Y W/Y W/Y Gr
P/W
G/W

B V B METER B B

W
B/R

R/B
R
SDS

Gr
R/G R/G

Y/G
R/Y
W
W
W

R/W
G
R
R

B/W
W/R
B B

R/Y
CONNECTOR

Gr
W
R

W
B

Y/G
R
B
Y
Y

B
R

Bl
Bl

Br
Gr

R/G
B/R
Gr R/G

Lbl

O/B
Y/B

W/Bl
G/Y

R/W
P/W

Y/Bl
B/Bl
IGNITION COIL #2

Lg/B
CAP

Lbl/W
FUEL INJECTOR Bl/B Bl/B TACHOMETER Gr
G/Y G/Y B B

O
B
P
V

O
W
B
Y

R/Y
P P B

P/W

W/B
R/B
Y/G
O/Y
B/G

Gr/Y
B/Br
R/W
W/Y

B/W

G/W
Bl/B
Bl/R

Br/Y
B/Br

Bl/W
WITH LED

Lg/W
#2 Gr
G/W G/W Y Y
Gr
O/Y
B/G

Bl
Gr

B
10A
GAUGE
P/W

CONNECTOR PTT SWITCH

UP DN
G/W
Bl/B

NEUTRAL SWITCH
N ON
F, R OFF
P/W
G/W
Bl/B

2.2 kΩ OFF IG ST FREE PUSH

(DF60AT/
B GND
DF60AVT IGNITION SWITCH
IGNITION COIL #3 only) G STOP
FUEL INJECTOR W BATT
Gr
R/W Gr/Y
SUZUKI

#3 B Gr IG
Gr
Y W/Y Br Br
V B Br Br Br START
Bl/B Bl/B
G/Y G/Y BZ EMERGENCY
P/W P Lbl Lbl O RESET
G/W G/W W/R W/R CAUTION STOP SWITCH
Lbl Lbl P P TURN PUSH
P P BUZZER
O O O O LOCK PLATE IN RUN
W W W W
Br Br Br Br Bl Bl BZ Gr Gr LOCK PLATE OFF STOP
Y/B Y W/R W/R
Bl/R G G G G
B/G Gr Gr Gr G
Bl/W Bl/W Bl/W Bl B B
B B B B

W
Lbl/W
P/W

Bl B/W
B/Bl
Lbl
R

G B
W
P

B/G

B/Bl Lbl P Gr, W B

B/W B Gr W B/G
B

JOINT JOINT PTT

CONNECTOR #2 CONNECTOR #1 RELAY BATTERY
TRIM
SENSOR PTT MOTOR
R

W/Y
R
B/W
W/Y

B/W
 WIRE COLOR
B : Black Lg/B : Light green with Black
Bl : Blue Lg/W : Light green with White
Br : Brown O/B : Orange with Black
G : Green O/Y : Orange with Yellow
Gr : Gray P/B : Pink with Black
Lbl : Light blue P/W : Pink with White
Lg : Light green R/B : Red with Black
O : Orange R/G : Red with Green
P : Pink R/W : Red with White
R : Red R/Y : Red with Yellow
V : Violet W/B : White with Black
W : White W/Bl : White with Blue
Y : Yellow W/R : White with Red
B/Bl : Black with Blue W/Y : White with Yellow
B/Br : Black with Brown Y/B : Yellow with Black
B/G : Black with Green Y/Bl : Yellow with Blue
B/R : Black with Red Y/G : Yellow with Green
B/W : Black with White
Bl/B : Blue with Black
Bl/R : Blue with Red
Bl/W : Blue with White
Br/Y : Brown with Yellow
NEUTRAL SWITCH G/W : Green with White
R
B/W THROTTLE & IAT & MAP
N ON Br/Y G/Y : Green with Yellow
Lg/B SENSOR
W Gr/Y : Gray with Yellow
F, R OFF Lbl/W : Light blue with White
PTT SWITCH IAC
DN UP

R/G OIL PRESSURE

W/B

P
Gr

Lbl
SWITCH

W/R
Gr
W/Bl
R/Y HI
Bl
LO

P
Lbl
DF40ATH/50ATH/50AVTH/60ATH

FUEL PUMP

W/R
STARTER

Br
RECTIFIER & MOTOR

Y/B
CMP REGULATOR MAGNETO M
SENSOR #1 Y
Y
Y

B/R
B/W R

W
Y/Bl B

B/Bl
Lbl Lbl B/Bl

R
W/R W/R
P P

Y/G
B
B

R
IGNITION COIL #1 CKP SENSOR
FUEL INJECTOR DIGITAL GAUGE
Gr DIAGRAM
O/B O
#1 Gr B STARTER TILLER HANDLE
MAIN MOTOR FUSE BOX (OPTION)
RELAY RELAY GAUGE
P/W
O/Y
B/G

B Lg/W
CONNECTOR
B

B
Y

B/W
G/W
Bl/B

FUSE

R/B
ENGINE CONTROL MODULE CAP Bl/B Bl/B
15A 30A 30A 15A 30A G/Y G/Y TACHOMETER/
G/W G/W

B/G
CYLINDER TEMP Y Y INDICATOR
SDS Gr Gr
Bl/B

2.2μ F CONNECTOR B B
SENSOR 450 V
P/W
G/W

W
EMERGENCY

B/R

R/B
STOP SWITCH

R
SDS

Gr
B B

Y/G
R/Y
LOCK PLATE IN RUN

W
W
W
R
R

R/W
G

B/W
G G

W/R

R/Y
CONNECTOR

Gr
W
R

W
LOCK PLATE OFF STOP

Y/G
B

Bl
Y
Y

B
R

G
Bl

Br

R/Y
Gr

O/B

W/R
R/W
Lbl

Y/B
G/Y
P/W

Y/Bl
B/Bl

Lbl/W
Lg/B
FUEL INJECTOR IGNITION COIL #2 CAP
UP

P
V

O
O
W
Y

Lbl Lbl
B

R/W

B/R
R/B
Y/G
O/Y

R/G
B/G

P/W
W/Y

B/W

G/W
Bl/B
Bl/R

Br/Y

Gr/Y
B/Br

W/Bl
Bl/W
B/Br Lg/W
#2 Gr Gr W/R Lg
O/Y
B/G

Bl PTT SWITCH
B
P R DN

GAUGE
P/W

CONNECTOR UP
G/W
Bl/B

Gr Lbl
TROLL MODE
V Lg SWITCH
B R DN
P/W
G/W
Bl/B
Gr, O

2.2 kΩ JOINT
(DF60ATH/
CONNECTOR
B

DF60AVTH
IGNITION COIL #3 only)

FUEL INJECTOR
Gr OFF IG ST FREE PUSH
R/W Gr/Y IGNITION
#3 Gr B B GND
Y SWITCH
V V
Bl/B Bl/B G STOP
G/Y G/Y
P/W
G/W G/W B B W BATT
Lbl Lbl G G
P P W/R W
SUZUKI

O O W W Gr IG
W W Gr Gr
Br Br Br Br Br START
Y/B Y Bl Bl
Bl/R G B. Z
B/G Gr O RESET
Bl/W Bl
B B TURN PUSH

Gr Gr BZ
Bl Bl

CAUTION BUZZER
Lbl/W
P/W

Bl B/W
B/Bl
Lbl
R

G B
W

B/G
P

B/Bl Lbl P Gr, W B

B/W B Gr W B/G
B

JOINT JOINT PTT

CONNECTOR #2 CONNECTOR #1 RELAY BATTERY
TRIM
SENSOR PTT MOTOR
R

W/Y
R
B/W
W/Y

B/W
 WIRE COLOR
B : Black Lg/B : Light green with Black
Bl : Blue Lg/W : Light green with White
DF40AQH

Br : Brown O/B : Orange with Black

G : Green O/Y : Orange with Yellow
Gr : Gray P/B : Pink with Black
Lbl : Light blue P/W : Pink with White
O : Orange R/B : Red with Black
P : Pink R/G : Red with Green
R : Red R/W : Red with White
V : Violet R/Y : Red with Yellow
W : White W/B : White with Black
Y : Yellow W/Bl : White with Blue
B/Bl : Black with Blue W/R : White with Red
B/Br : Black with Brown Y/B : Yellow with Black
B/G : Black with Green Y/Bl : Yellow with Blue
B/R : Black with Red Y/G : Yellow with Green
B/W : Black with White
Bl/B : Blue with Black
Bl/R : Blue with Red
Bl/W : Blue with White
Br/Y : Brown with Yellow
G/W : Green with White
NEUTRAL SWITCH G/Y
R : Green with Yellow
B/W THROTTLE & IAT & MAP
N ON Br/Y Gr/Y : Gray with Yellow
Lg/B SENSOR
W
F, R OFF
IAC

R/G OIL PRESSURE

W/B
Gr SWITCH
Gr
W/Bl
R/Y HI
Bl
LO

FUEL PUMP
STARTER

Br
RECTIFIER & MOTOR

Y/B
CMP REGULATOR MAGNETO M
SENSOR #1 Y
Y
Y

B/R
B/W

R
R
R

W
Y/Bl B

B/Bl
B/Bl

Y/G
B
B

R
IGNITION COIL #1 CKP SENSOR
FUEL INJECTOR DIGITAL GAUGE
Gr DIAGRAM
#1 O/B O TILLER HANDLE
Gr B STARTER
MAIN MOTOR FUSE BOX (OPTION)
RELAY RELAY GAUGE
P/W
O/Y
B/G

B Lg/W
CONNECTOR
B
Y

B B/W
G/W
Bl/B

FUSE

R/B
ENGINE CONTROL MODULE CAP Bl/B Bl/B
15A 30A 30A 30A G/Y G/Y TACHOMETER/
G/W G/W

B/G
CYLINDER TEMP Y Y INDICATOR
SDS Gr Gr
Bl/B

2.2μ F B B
SENSOR CONNECTOR
450 V
P/W
G/W

W
EMERGENCY

B/R

R/B
SDS STOP SWITCH

Gr
B B

Y/G
R/Y
W
W
W

R/W
G
R
R
LOCK PLATE IN RUN

B/W
G G

R/Y
CONNECTOR

Gr
W
R

W
LOCK PLATE OFF STOP

Y/G
Y

B
R

B
Bl

Bl
Br
Gr

Y/B
G/Y

R/Y
B/G

O/B
P/W

Y/Bl
B/Bl

W/R
R/W
Lg/B
FUEL INJECTOR IGNITION COIL #2 CAP
V

O
W

O
Lbl

R/B
Y/G
O/Y
B/G
B/G

R/W
B/W
Y
B

G/W
Bl/B
Bl/R

Br/Y

Bl/W

B/R

R/G
Lg/W

Gr/Y
B/Br

W/Bl
B/Br
#2 Gr Gr W/R
O/Y
B/G

Bl
B
P

GAUGE
P/W

CONNECTOR UP
G/W
Bl/B

TROLL MODE
Gr Lbl SWITCH
V Lg
B R DN
P/W
G/W
Bl/B
Gr, O

JOINT
CONNECTOR
B

IGNITION COIL #3
FUEL INJECTOR OFF IG ST FREE PUSH
Gr
R/W Gr/Y IGNITION
#3 Gr B B GND
V V SWITCH
Bl/B Bl/B G STOP
G/Y G/Y
2.2 kΩ
P/W W BATT
G/W G/W B B
(DF60AQH Lbl G G
P W/R W
SUZUKI

only) O Gr IG
O W W
W W Gr Gr
Br Br Br Br Br START
Y/B Y Bl Bl
Bl/R G O B. Z
B/G Gr RESET
Bl/W Bl
B B TURN PUSH

Gr Gr BZ
Bl Bl

CAUTION BUZZER
B

B/Bl
R

B/G

B/Bl Gr, W B
B/W Gr W B/G

JOINT JOINT
CONNECTOR #2 CONNECTOR #1 BATTERY
 Prepared by

September, 2019
Part No. 99011-88L90-054
Printed in Japan

© COPYRIGHT SUZUKI MOTOR CORPORATION 2019