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ENGLISH

DF40ADF50ADF50AVDF60ADF60AV

OWNER’S MANUAL

EN

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

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

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

IMPORTANT NOTICE TO OWNERS

WARNING

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

CAUTION

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

NOTICE

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

WARNING

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

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

• Inspect the boat and motor before eachtrip. See the INSPECTION BEFOREBOATING section for important items.

• Become thoroughly familiar with alloperating and handling characteristicsof your boat and motor. Practice at lowand moderate speeds until you arecompetent at handling the boat andmotor. Do not attempt to operate at max-imum performance until you are com-pletely familiar with all of thesecharacteristics.

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

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

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

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

• Ensure that everyone wears a life jacketon board.

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

• Distribute all weight load evenly in theboat.

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

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

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

• Learn and obey all applicable naviga-tion rules.

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

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

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

FOREWORD

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

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

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

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

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

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

California Proposition 65 Warning

WARNING

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

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TABLE OF CONTENTS

FUEL AND OIL....................................... 6GASOLINE............................................ 6FILLING THE FUEL TANK ................... 7ENGINE OIL .......................................... 8GEAR OIL ............................................. 8

LOCATION OF SAFETY LABELS ..... 9LOCATION OF PARTS....................... 10MOTOR INSTALLATION .................. 12BATTERY INSTALLATION .............. 12

BATTERY REQUIREMENT ................ 12BATTERY INSTALLATION ................ 13USE OF ELECTRICAL ACCESSORIES................................... 14

PROPELLER SELECTION AND INSTALLATION................................... 14

PROPELLER SELECTION ................. 14PROPELLER INSTALLATION ........... 15

ADJUSTMENTS.................................... 15TRIM ANGLE ADJUSTMENT............. 15TRIM TAB ADJUSTMENT.................. 17THROTTLE TENSION ADJUSTMENT .................................... 17IDLE SPEED ADJUSTMENT.............. 17SETTING OF TILT UPPER LIMIT POSITION <DF50AV/60A/60AV>....... 18MOTOR COVER FASTENING ADJUSTMENT .................................... 19

CAUTION SYSTEM............................. 19INDICATOR CHECK........................... 20OVER-REVOLUTION CAUTION SYSTEM.............................................. 20OIL PRESSURE CAUTION SYSTEM.............................................. 21COOLING WATER CAUTION SYSTEM.............................................. 21BATTERY VOLTAGE CAUTION SYSTEM.............................................. 23

DIAGNOSTIC SYSTEM ...................... 23OIL CHANGE REMINDER SYSTEM................................................. 24

SYSTEM ACTIVATION....................... 24CANCELLATION ................................ 24

ENGINE STALLING CAUTION SYSTEM................................................. 25OPERATION OF TILTING SYSTEMS............................................... 25

POWER TRIM AND TILT .................... 25MANUAL TILTING .............................. 26TILT LEVER ........................................ 26

INSPECTION BEFORE BOATING ... 27BREAK-IN ............................................. 29

OPERATION ......................................... 30BEFORE ATTEMPTING TO START THE ENGINE....................................... 30STARTING THE ENGINE ................... 32EMERGENCY STARTING .................. 34SHIFTING AND SPEED CONTROL ... 36STOPPING THE ENGINE ................... 37MOORING ........................................... 38OPERATION IN SHALLOW WATER................................................ 38OPERATING THE TROLL MODE(Optional Item) ................................... 38OPERATION IN SALT WATER .......... 39OPERATION IN FREEZING WEATHER........................................... 39

MOTOR REMOVAL AND TRANSPORTING ................................. 40

MOTOR REMOVAL ............................ 40MOTOR TRANSPORTING.................. 40

TRAILERING ....................................... 42INSPECTION AND MAINTENANCE................................... 43

MAINTENANCE SCHEDULE ............. 43SPARK PLUG ..................................... 45BREATHER AND FUEL LINE ............ 47ENGINE OIL ........................................ 47GEAR OIL ........................................... 49LUBRICATION.................................... 50CORROSION PREVENTION .............. 50

ANODES.............................................. 50BONDING WIRES ............................... 51

BATTERY............................................ 51ENGINE OIL FILTER .......................... 52FUEL FILTER...................................... 52

FLUSHING THE WATER PASSAGES............................................. 53SUBMERGED MOTOR....................... 55STORAGE PROCEDURE ................... 56

MOTOR STORAGE............................. 56BATTERY STORAGE......................... 57

AFTER STORAGE ............................... 57GENERAL INFORMATION............... 57

WARRANTIES (For U.S.A)................. 57IDENTIFICATION NUMBER LOCATION.......................................... 58

EMISSION CONTROLINFORMATION.................................... 58TROUBLESHOOTING........................ 58SPECIFICATIONS ............................... 60CHART OF TOTAL OPERATING HOURS INDICATION ......................... 61FLOWCHART OF OIL CHANGE REMINDER SYSTEM.......................... 61

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FUEL AND OIL

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

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

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

NOTICE

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

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

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

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

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

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

NOTE:• Be sure that any oxygenated fuel blend you

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

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

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

• Unleaded gasoline will extend spark plug life.

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FILLING THE FUEL TANKTo fill the fuel tank:1. Always stop the engine before refilling the

tank.2. Remove the portable fuel tank from the boat

to refill it.

NOTICE

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

Always use fresh gasoline.

WARNING

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

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

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

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

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

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

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

NOTICE

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

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

3. Turn the air-vent screw 1 on top of the fueltank cap 2 fully counterclockwise to openthe vent.

NOTE:VENT SCREW should be CLOSED for trans-portation and OPEN for OPERATlON and CAPREMOVAL.

4. Locate the pressure relief tab 3 under thefuel tank cap and turn the cap counterclock-wise until the tab engages the first lock.

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5. Press down on the tab, and release the lock,then rotate the fuel tank cap 1/4 turn. Thetab will engage the second lock.

6. Press the tab down again and turn toremove the fuel tank cap.

7. Carefully refill the fuel tank with gasoline.

Do not over fill.

8. Tighten the fuel tank cap until an audible“click” is heard.

9. Tighten the air-vent screw on top of the fueltank cap.

ENGINE OIL

Oil quality is a major contributor to yourengine’s performance and life. Always selectgood quality engine oil.Suzuki recommends the use of SAE 10W-40 or10W-30 SUZUKI MARINE 4-CYCLE ENGINEOIL. If SUZUKI MARINE 4-CYCLE ENGINEOIL is not available, select a NMMA certifiedFC-W oil or good quality 4-cycle motor oil fromthe following chart according to the averagetemperatures in your area.

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

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

NOTICE

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

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

–20 –10 0 10 20 30

–4 14 32 50 68 86

40

104TEMP.

API Classification SAE Viscosity Grade

10W–40

10W–30

˚F

˚C

SGSHSJSLSM

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LOCATION OF SAFETY LABELS

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

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

WARNING AVERTISSEMENT

• Fuel can leak creating a fire hazard if you lay motor on its side. Drain fuelcompletely from vapor separator orcarburetor 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 lemoteur est placé sur le côté.Vidanger entièrement le carburant duséparateur de vapeurs ou du carburateur avant de procéder.

• Pour plus de détail, voir le manueldu propriétaire.

WARNING AVERTISSEMENT• To avoid injury, when engine is running,

keep your hands, hair, clothing, etc., awayfrom engine.

• See owner’s manual for details. • Pour éviter toute blessure, quand le moteur

est en marche, éloigner les mains, lescheveux, les vêtements, etc. du moteur.

• Pour plus de détail, voir le manuel du propriétaire.

Label symbol meaningsThese symbols mean as follows;

: General warning symbol (Caution or Warning)

: Read owner’s manual carefully

: Remote control lever/gear shift lever operation-two direction; Forward/Neutral/Reverse

: Engine start

: Hazard caused by fire

: Hazard caused by laying the motor on its side

: Hazard caused by rotating parts

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LOCATION OF PARTS

MONITOR-TACHOMETER

Priming bulb

FUEL HOSE

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

Remote control handle

Warm-up leverLock-out lever Ignition key

Emergency stop switch

Throttle tension adjuster

SIDE MOUNT TYPE TOP MOUNT TYPE

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

Remote control handle

Free accelerator button

REMOTE CONTROL BOX (Option)

Motor cover

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

Engine oil drain plug

Clamp bracket

Anode

Gear oil level plug

Water intake hole

Gear oil drain plug

Pilot water hole

Flush plug

Anti-cavitation plate

Trim tab(Anode)

Flush plug

DF40A/50A/60A

Ignition key

Emergencystop switch

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Motor cover

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

Engine oil drain plug

Clamp bracket

Anode

Pilot water hole

Flush plug

Anode

Gear oil level plug

Water intake hole

Gear oil drain plug

Anti-cavitation plate

Trim tab

DF50AV/60AV

Anode(Reverse side)

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MOTOR INSTALLATION

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

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

WARNING

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

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

WARNING

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

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

BATTERY INSTALLATION

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

650 Marine Cranking Amps (MCA)/ABYC,or 512 Cold Cranking Amps (CCA)/SAEor 160 Reserve Capacity (RC) Minutes/SAE

NOTE:• The specifications listed above are the mini-

mum battery rating requirements for startingthe engine.

• Additional electrical loads from the boat willrequire larger capacity batteries. Consultyour Suzuki dealer to determine the properbattery sizing for your boat and engine com-bination.

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

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

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

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

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

NOTE:• It is recommended that the battery be

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

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

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

WARNING

If you place the battery near the fuel tank,a spark from the battery may ignite thegasoline, causing a fire and/or an explo-sion.

Do not place the fuel tank in the samecompartment/area as the battery.

Red lead

Hexagon-nut

Black lead

Hexagon-nut

Hexagon-nut

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

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

Suzuki recommends that you install the termi-nal cap on the positive battery terminal to pre-vent an accidental short circuit of batteryterminals.If a terminal cap is required, contact your autho-rized Suzuki marine dealer.

WARNING

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

Never smoke or cause sparks when work-ing near the battery. Keep the batteryaway from open flames. To avoid creatinga spark when charging the battery, con-nect the battery charger cables to theproper terminals before turning thecharger on.

WARNING

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

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

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

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

NOTICE

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

• Be sure to attach battery leads cor-rectly.

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

PROPELLER SELECTION AND INSTALLATION

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

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

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

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

NOTICE

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

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

DF40A5000 – 6000r/min. (min–1)

DF50A/50AVDF60A/60AV

5300 – 6300r/min. (min–1)

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PROPELLER INSTALLATION

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

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

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

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

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

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

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

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

WARNING

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

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

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

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

ADJUSTMENTS

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

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

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

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

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

• Proper trim angle

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WARNING

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

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

WARNING

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

Do not operate the engine above 1500r/min or operate the boat in a planing atti-tude with the motor tilted beyond themaximum trim position.

Tilt range

Trim range

NOTICE

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

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

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

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

place.

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

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

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

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

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

IDLE SPEED ADJUSTMENTThe idle speed has been factory adjustedbetween 750 – 850 r/min. in neutral.

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

Side mounttype

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SETTING OF TILT UPPER LIMIT POSITION <DF50AV/60A/60AV>If the outboard motor contacts the motor well ofthe boat during full tilt up operation, the upperlimit setting should be reset.Perform this set-up after the current positionsetting has been canceled, as explained in thefollowing procedure.

CANCELING THE TILT UPPER POSITION LIMIT SETTING1. Turn the ignition key to the “ON” position.2. Pull out the emergency stop switch lock

plate.

3. Make sure that remote control handle is in“NEUTRAL”.

4. Using the throttle only function of the remotecontrol box, move the warm-up lever upwarduntil the caution buzzer sounds one time.

“NEUTRAL”

5. Press the “UP” side of the PTT switch forthree seconds and the buzzer will soundtwice briefly indicating the setting has beencanceled.

6. Return the throttle to the fully closed posi-tion.

SETTING THE TILT UPPER POSITION LIMIT7. Press the “UP” side of the PTT switch so

that the optimum full tilt up position for theboat can be obtained.

8. Using the throttle only function of theremote control box, move the warm-up leverupward until the caution buzzer sounds onetime.

9. Press the “UP” side of PTT switch threetimes within three seconds. The buzzer willsound one time briefly indicating the settinghas been accepted.

10. Return the throttle to the fully closed posi-tion and install the lock plate on the emer-gency switch. Operate the full tilt up and fulldown operations several times by pressingthe PTT switch and check that the setting ofboth the trim lower limit and tilt upper limitare properly set.

UP

PTT switch

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MOTOR COVER FASTENING ADJUST-MENTIf you feel the motor cover fastening is loose ortoo tight when locking the levers, adjust as fol-lows:

1. Loosen the bolt 1. 2. Adjust the position of bracket 2. To increase

the fastening, move the bracket to the direc-tion A. To decrease the fastening, move thebracket to the direction B.

3. Tighten the bolt 1.

WARNING

Setting of the tilt upper limit position willnot prevent the outboard motor from tilt-ing fully up and contacting the motor wellif the motor’s lower unit hits an object athigh speed. Such tilting could damageyour motor and boat and injure boatoccupants.

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

CAUTION SYSTEM

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

NOTICE

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

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

NOTICE

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

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

20

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

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

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

NOTICE

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

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

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

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

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

NOTICE

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

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

21

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

If this system activates, the red OIL lamp willlight and a buzzer will begin a series of beeps.In addition, when this system is activated at1000 r/min. or higher, engine speed will auto-matically be reduced to approximately 1000 r/min. with REV LIMIT lamp lit.

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

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

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

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

WARNING

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

To check the oil level, stop the engine andthen remove the motor cover.

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

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

If this system activates, the red TEMP lampwill light and the buzzer will begin a series ofbeeps. In addition, when this system is acti-vated at 3000 r/min. or higher, engine speedwill automatically be reduced to approximately3000 r/min. with REV LIMIT lamp lit.

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

NOTICE

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

Check the engine oil level periodicallyand add oil as necessary.

NOTICE

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

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

22

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

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

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

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

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

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

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

NOTICE

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

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

23

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

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

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

NOTE:• A marginal battery may have enough power

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

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

WARNING

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

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

DIAGNOSTIC SYSTEM

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

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

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

NOTE:• The CHECK ENGINE lamp will light briefly

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

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

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

NOTICE

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

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

24

OIL CHANGE REMINDER SYSTEM

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

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

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

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

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

NOTE:• Canceling of the system activation is possible

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

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

25

ENGINE STALLING CAUTION SYSTEM

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

OPERATION OF TILTING SYSTEMS

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

WARNING

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

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

UP

DOWN

UP

DOWN

Side mounttype

Top mounttype

UP

DOWN

26

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

CAUTION

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

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

TILT LEVERThe tilt lever is provided so you can support themotor in a tilted position for non-moving enginesupport.

To set the tilt lever:1. Tilt the motor all the way up using the power

trim and tilt.2. Pull down the tilt lever as shown in the illus-

tration.

3. Lower the motor using the power trim andtilt, until the motor is supported by the tiltlever.

To release the lever, tilt the motor all the way upusing the power trim and tilt, and pull up the tiltlever.

DF50AV/60A/60AV

DF40A/50A

27

CAUTION

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

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

NOTICE

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

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

INSPECTION BEFORE BOATING

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

• Check that you have enough fuel for theintended run.

• Check the level of engine oil in the sump.

To check the oil level:

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

WARNING

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

Before boating, always perform theinspections described in this section.

NOTICE

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

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

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1. Place the motor in a vertical position, thenremove the motor cover 1 by unlocking thelever 2.

2. Pull out the oil dipstick 3 and wipe oil offwith a clean cloth.

NOTE:If the engine oil is contaminated or discolored,replace with fresh engine oil. Refer to theENGINE OIL section.

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

UPPER LIMIT

LOWER LIMIT

The oil on the dipstick should be between theupper and lower limits shown on the dipstick. Ifthe oil level indication is near the lower limit,add enough oil to raise the level to the upperlimit.

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

upper level.

3. Tighten the oil filler cap securely.

NOTICE

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

Do not overfill the engine with oil.

29

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

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

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

• Make sure the motor is securely mountedto the transom.

• Check for proper operation of the PowerTrim and Tilt.

• Check for proper trim angle.

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

BREAK-IN

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

Break-in period: 10 hours

Break-in procedure1. For the initial 2 hours:

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

After warming up, run the engine at idlingspeed or the lowest in-gear speed for about15 minutes.During the remaining 1 hour and 45 minutes,if safe boating conditions permit, operate theengine in gear at less than 1/2 (half) throttle(3000 r/min.).

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

NOTICE

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

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

NOTICE

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

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

30

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

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

NOTICE

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

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

OPERATION

BEFORE ATTEMPTING TO START THE ENGINE1. Lower the motor into the water.2. If there is a manual fuel tank air-vent, turn

the air-vent screw 1 on top of the fuel tankcap fully counterclockwise to open the vent.

NOTE:SUZUKI genuine portable fuel tanks have asemi-auto air vent.

WARNING

When connecting the fuel hose to theportable fuel tank or motor, the fuel maybe under pressure and may spray outaround the connector, causing seriousinjury.

Before connecting the fuel hose, loosenand retighten the fuel tank cap once torelieve the fuel pressure in fuel tank.For handling the fuel tank cap, refer tothe “FUEL AND OIL/FILLING FUEL TANK”section in this manual.

31

3. Make sure that the motor fuel hose and thehose from the boat’s fuel tank are securelyattached and clamped.

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

Side mounttype

Top mounttype

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

Side mounttype

Top mounttype

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

STARTING THE ENGINE

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

WARNING

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

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

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

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

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

WARNING

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

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

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

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

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

After returning the ignition key to “ON” posi-tion from “START” one, the starter motorcontinues to turn for 4 seconds until theengine start.

33

NOTE:The continuous operating time of the startermotor is set at five seconds.When this time is exceeded, the starter motorwill automatically stop.If the motor stops, wait about ten seconds forthe motor to cool down and try again.

4. Warm up the engine for about 5 minutes.

NOTICE

If you hold the ignition key at the“START” position to start the engine, thestarter system can be damaged.

Turn the ignition key to the “START” posi-tion once and release it to start theengine.The engine will crank continuously for 4seconds or until the engine starts.

NOTICE

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

Stop the engine and check the oil level.

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

NOTICE

Operating the engine at high RPM or“wide open throttle” immediately afterstarting the engine without allowing theengine to warm up may cause engine fail-ure.

Always allow the engine to warm up suffi-ciently before operating it at high speeds.

NOTICE

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

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

34

WARNING

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

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

EMERGENCY STARTINGIf you must get the engine running, but areunable to do so because of starter system fail-ure or battery discharge, you can use the emer-gency starting procedure to start the engine.

NOTE:If the battery voltage is too low to operate theelectric fuel pump, you will not be able to startthe engine using the EMERGENCY STARTINGprocedure because sufficient fuel will not besupplied to the engine.

1. Make sure that the motor is in “NEUTRAL”and the emergency stop switch lock plate isremoved.

2. Remove the motor cover.

WARNING

If you touch electrical components whenrope-starting the engine, you can get asevere electrical shock.

When rope-starting the engine, be carefulnot to touch electrical components suchas ignition coils or spark plug leads.

WARNING

When you use the emergency startingprocedure, the start-in-gear protectionsystem will not work. If the shift lever isnot in the “NEUTRAL” position, the boatcan start off unexpectedly when theengine is started, throwing occupants orcausing an accident.

Make sure that the shift lever is in the“NEUTRAL” position before attempting tostart the motor using the emergencystarting procedure.

35

3. With the ignition key turned off, loosen thescrews securing the ring gear cover andremove the ring gear cover.

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

5. Put the emergency stop switch lock plate inplace.

6. Turn the ignition key to the “ON” position andlisten for the electric fuel pump to cycle.

NOTE:The initial fuel pump cycle is for a period of 3seconds after the ignition key is first turned on.If you are not sure about fuel pump operation,you may turn the key off, then repeat step #6.

7. With the ignition key turned off, tie a knot inone end of the emergency starter ropelocated in the tool kit. Tie the other endaround the screw-driver handle in the toolkit.

8. Hook the knotted end of the rope in the pul-ley notch and wind the rope around the pul-ley in a clockwise direction.

9. Turn the ignition key to the “ON” position.10. After following steps for normal starting pro-

cedure, pull the emergency starter ropesharply to start the engine. Repeat, if themotor has not started.

NOTE:Be sure to have the starter system repaired assoon as possible. You should not continue touse the emergency starting procedure for rou-tine engine starting.

WARNING

If you attempt to reinstall the ring gearcover or motor cover after starting theengine you can be injured.

Do not attempt to reinstall the ring gearcover or motor cover after starting theengine.

WARNING

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

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

36

SHIFTING AND SPEED CONTROL

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

To shift into “REVERSE”, squeeze the lock-outlever on the control handle and move the con-trol handle rearward to approximate position B,as shown in the illustration.

A detent or notch is present on all Suzuki con-trol boxes to provide a “feel” for positions A, B,and neutral. Always shift quickly and firmly fromneutral to position A or B to prevent abnormalwear on the gear and clutch engagement sur-faces.

NOTICE

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

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

NOTICE

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

Avoid shifting gears when the engine isnot running.

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

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

WARNING

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

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

NEUTRAL

32˚ 32˚

FORWARD

REVERSE

Top mounttype

FORWARD

35˚ 35˚

REVERSE

NEUTRAL

37

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

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

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

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

NOTICE

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

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

Side mounttype

Top mounttype

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

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

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

WARNING

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

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

WARNING

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

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

38

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

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

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

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

NOTICE

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

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

WARNING

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

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

OPERATING THE TROLL MODE(Optional Item)Trolling speed can be controlled to install theoptional Troll Mode switch.Please contact your authorized Suzuki MarineDealer for more information.

NOTE:To monitor engine speed correctly during thetroll mode operation, Suzuki recommends theuse of the Suzuki 2-scale Monitor Tachometer.

System OutlineThe “Troll Mode System” is activated by press-ing the troll mode switch, when the motor is run-ning at in-gear idle speed. By using this system,you can set and maintain a desired enginespeed with the control switch in a range from in-gear idle speed (approx. 800 rpm) to 1200 rpm.

NOTICE

If the motor hits bottom, serious damagecan occur.

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

Usual scale

Trolling mode scale

39

How to use the Troll ModeSetting the troll mode:1. Shift into forward or reverse gear and make

sure that the throttle is fully closed (in-gearidle speed).

2. Press the “UP” or “DN” position of the trollmode switch, until you hear one beep.The REV/TRL (or REV) lamp on the monitorgauge will flash indicating that the motor hasbeen set to the troll mode. The REV/TRL (orREV) lamp will continue to flash while themotor is in the troll mode.

NOTE:The troll mode system will not operate if theswitch is depressed when the remote controllever is in the neutral position.

Adjusting trolling speed:• When pressing the “UP” switch, one short

beep sounds and the engine speedincreases by 50 rpm.

• When pressing the “DN” switch, one shortbeep sounds and the engine speeddecreases by 50 rpm.

NOTE:• When pressing the “DN” switch at the lower

limit of trolling speed, the engine speed willnot change and three long (0.8 sec.) beepswill sound.

• When pressing the “UP” switch at the upperlimit of trolling speed, the engine speed willnot change and three long (0.8 sec.) beepswill sound.

• Shift operation and throttle control remainoperational, even in troll mode.

Troll mode switch

Cancelling the troll mode:The troll mode can be cancelled by shifting theremote control lever to the neutral position, orby increasing the engine speed to 3000 rpm ormore. In both cases, two short (0.1 sec.) beepssound when cancelling the troll mode.

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

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

NOTICE

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

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

40

MOTOR REMOVAL AND TRANSPORTING

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

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

Vertical transport:Attach the motor to the carrier by securingclamp bracket with two sets of transom bolt andnut.Never use display stand for transportation of themotor.

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 suitablecontainer.

(4) After draining, retighten the drain screwand put the drain hose 1 back.

WARNING

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

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

41

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

WARNING

Spilled fuel or fuel vapor can cause a fireand is hazardous to health.

Always take the following precautions:• Drain the fuel from the fuel line and fuel

vapor separator before transporting theboat/outboard motor and before remov-ing the motor from the boat.

• DO NOT lay motor on its side withoutdraining fuel.

• Keep the motor away from open flamesor sparks.

• Wipe up spilled fuel immediately.

NOTICE

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

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

NOTICE

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

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

42

TRAILERING

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

NOTICE

If you use the tilt lever to hold the motorin the fully tilted up position when traile-ring the boat, towing motion or poor roadsurfaces may cause unexpected tilt lockrelease, resulting in damage to the motorand the tilt lock mechanism.

Never use the tilt lever to hold the motorin the fully tilted up position when traile-ring the boat. Use a transom saver bar orsimilar device to support the weight ofthe motor.

43

INSPECTION AND MAINTENANCENOTICE

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

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

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

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

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

WARNING

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

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

Interval

Item to be serviced

Initial 20 hrs.or 1 month

Every 100 hrs.or 12 months

Every 200 hrs.or 12 months

Every 300 hrs.or 36 months

Spark plug – I I I

Breather & Fuel line I I I I

Engine oil R R R R

Gear oil R R R R

Lubrication I I I I

Anodes (external) I I I I

* Anodes (internal Powerhead)

– I I I

Bonding wires I I I I

Battery I I I I

* Engine oil filter R – R –

* Low pressure fuel filterI I I I

Replace every 400 hours or 2 years.

* Idle speed I – I –

* Valve lash – – – I

* Water pump – – I –

* Water pump impeller – – I R

* Propeller nut & pin I I I I

* Bolts & Nuts T T T T

* Thermostat – I I I

44

WARNING

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

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

WARNING

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

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

NOTICE

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

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

45

SPARK PLUGRemove the spark plugs as follows:1. Remove the bolts securing the fuel hose

guard A.

2. Remove the bolt securing the ignition coil.3. Pull out the ignition coil.4. Loosen and remove the spark plug using the

box wrench in the tool bag.

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

Standard spark plug NGK DCPR6E

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

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

NOTICE

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

Use ONLY resistor type spark plugs inyour outboard motor.

Centerelectrode

Insulator

Ground electrode

Gap

46

NOTICE

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

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

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

Tightening torque

15 – 19 N·m (1.5 – 1.9 kg-m, 10.8 – 13.7 lb-ft)

Rotation angle

New plug 1/2 – 3/4 of a turn

Re-use plug 1/12 – 1/8 of a turn

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

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

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

Spark plug gap0.8 – 0.9 mm

(0.031 – 0.035 in.)

47

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

WARNING

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

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

Fuel line Breather line

ENGINE OIL

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

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

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

WARNING

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

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

NOTICE

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

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

48

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

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

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

NOTE:There are spare gaskets in the tool bag.

6. Fill with recommended engine oil to theupper level.

Oil capacity: 2.7 L (2.9/2.4 US/Imp. qt.)Engine oil: SAE (or NMMA FC-W) 10W-40,

10W-30API (or NMMA FC-W) Classifica-tion SG, SH, SJ, SL, SM

CAUTION

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

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

NOTICE

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

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

7. Check the engine oil level.

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

8. Reinstall the oil filler cap.

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

WARNING

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

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

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

• Wash with soap if oil contacts yourskin.

• Launder any clothing or rags that arewet with oil.

UPPER LIMIT

LOWER LIMIT

49

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

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

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

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

2. Remove the gear oil drain plug 2, thenremove the gear oil level plug 1.

3. After the oil has drained completely, injectthe specified gear oil into the gear oil drainhole 2 until it just starts to come out of thegear oil level hole 1.

DF40A/50A/60A MODELApproximately 610 ml (20.6/21.5 US/lmp oz.)will be required.

DF40A/50A/60A

DF50AV/60AV

DF50AV/60AV MODELApproximately 1050 ml (35.5/37.0 US/lmpoz.) will be required.

4. Reinstall and tighten the gear oil level plug1, then quickly reinstall and tighten the gearoil drain plug 2.

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

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

WARNING

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

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

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

• Wash with soap if oil contacts yourskin.

• Launder any clothing or rags that arewet with oil.

NOTICE

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

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

50

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

NOTE:Before applying grease through the steeringbracket grease nipple, lock the motor in the fullytilted up position.

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

LOCATION LUBRICANT

Throttle/Shift linkage Marine-grade water resistant grease

Propeller shaft

Swivel bracketMarine-grade water resistant grease(Grease Gun)

Steering bracket

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

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

DF60A

DF40A/50A/50AV/60AV

51

NOTE:Consult your authorized Suzuki Marine Dealerfor inspection and replacement of internalanodes attached to the powerhead.

NOTICE

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

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

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

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

DF40A/50A/60A

DF50AV/60AV

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

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

If you are not using a maintenance-free battery,the battery fluid level should be checked every100 hours of operation or 12 months. The bat-tery solution level must be kept between theMAX and the MIN level lines at all times. If thelevel drops below the MIN level line, add DIS-TILLED WATER ONLY until the battery solutionlevel reaches the MAX level line.

WARNING

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

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

52

WARNING

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

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

WARNING

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

Wash hands after handling.

NOTICE

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

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

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

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

Low pressure fuel filterInspect low pressure fuel filter at initial 20 hours(1 month).Inspect low pressure fuel filter at every 100hours (12 months).Replace low pressure fuel filter with a new oneat every 400 hours (2 years).

53

FLUSHING THE WATER PASSAGES

After operation in muddy, brackish, or saltwater, you should flush the water passages andmotor surface with clean, fresh water. If you donot flush the water passages, salt can corrodethe motor and shorten its life.Flush the water passages as follows:

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

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

WARNING

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

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

WARNING

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

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

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

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

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

1. Cover the auxiliary water intake hole 1 witha piece of duct tape. (except DF50AV/60AVmodel)

2. Install the flushing attachment 2 so that thewater intake holes are covered by the rubbercups on the attachment.

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

NOTICE

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

Never start the motor without supplyingwater to the cooling system.

54

4. Place the remote control lever in the “NEU-TRAL” position with the propeller removedand start the motor. As soon as the enginestarts, water should spray out of the pilotwater hole 3, indicating proper water pumpoperation. If no water spray is evident, stopthe motor immediately and consult yourdealer.

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

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

7. Stop the motor, then turn off the water.8. Remove the flushing attachment and

remove the duct tape from the water intakehole.

9. Clean the motor surface and apply a coat ofautomotive wax on the external finish of themotor.

ENGINE NOT RUNNING – Vertical position –1. Remove the plug A from the flushing port.

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

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

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

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

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

the engine is drained completely.

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

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

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

55

SUBMERGED MOTOR

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

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

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

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

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

5. Drain the fuel line and all filters.

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

WARNING

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

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

7. Have your authorized Suzuki Marine Dealerinspect the engine as soon as possible.

NOTICE

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

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

NOTICE

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

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

56

STORAGE PROCEDURE

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

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

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

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

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

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

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

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

8. Apply a coat of automotive wax on the exter-nal finish of the motor. If paint damage is evi-dent, apply touch up paint before waxing.

9. Store the motor in an upright position in adry, well-ventilated area. Select an area withconstant temperature to avoid corrosioncaused by condensation. Do not store nextto furnaces, heaters, etc.

WARNING

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

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

NOTICE

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

Never start the motor without supplyingwater to the cooling system.

57

BATTERY STORAGE1. When the outboard motor will not be used

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

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

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

WARNING

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

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

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

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

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

AFTER STORAGE

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

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

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

3. Lubricate all moving parts according to theLUBRICATION section.

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

faces.6. Recharge the battery before installing it.

GENERAL INFORMATION

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

58

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

Model Number:

Identification Number:

Ignition Key Number:

Ignition key numberstamped position

Spare key

EMISSION CONTROLINFORMATION

NOTICE

TROUBLESHOOTING

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

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

position.

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

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

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

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

• EXHAUST EMISSION CONTROLSYSTEM:ECM, MFI

NOTICE

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

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

59

Engine speed will not increase (Engine power is low):• Engine is overloaded.• Caution/Diagnosis system is activated.• Propeller is damaged.• Propeller is not properly matched to loads.

Engine vibrates excessively:• Engine mounting bolts or clamp screws are

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

propeller.• Propeller is damaged.

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

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

fuse.

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

Fuse box cover

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

NOTE:If a fuse is blown, try to determine the rootcause and correct it.If the cause is not corrected, the fuse may beblown again.

Normal fuse

Main fuse (30A)

Blown fuse

Normal fuse Blown fuse

60

WARNING

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

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

NOTICE

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

Consult your SUZUKI marine dealer.

1 Main fuse: 30A2 Spare fuse: 30A3 Spare fuse: 15A4 Starter motor relay fuse: 30A5 PTT switch fuse: 15A6 Ignition coil/Injector/ECM/IAC fuse: 30A7 Fuel pump fuse: 15A8 Spare fuse: 30A

15AMAINRELAY

STARTERRELAY

SPARE15A

30A

30A

SPARE

30AMAIN

SPARE

SPECIFICATIONS

Power rated in accordance with NMMA procedure.

Item DF40A DF50A/50AV DF60A/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 29.4 kW (40PS) 36.8 kW (50PS) 44.1 kW (60PS)

Full Throttle Operating Range5000 – 6000 r/min.

(min–1)5300 – 6300 r/min. (min–1)

Idle speed (in Neutral) 800 ± 50 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/Imp. qt.)

Spark Plug NGK DCPR6E

Spark Plug Gap 0.8 – 0.9 mm (0.031 – 0.035 in.)

Valve 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 87 Pump ((R+M)/2 method)

61

CHART OF TOTAL OPERATING HOURS INDICATION

*: One flashing is corresponded to 500 hours.

FLOWCHART OF OIL CHANGE REMINDER SYSTEM

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

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

Totaloperating

hours

MONITOR-TACHOMETERNeedle 1indication

REV-LIMITlamp 2 flashing *

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

::

::

::

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

::

::

::

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

::

::

::

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

::

::

::

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

Action

Starting operation

CancellationIndication

(*1) (*4)

CancellationIndication

CancellationIndication

CancellationIndication

Repeat

(*2) (*4)

(*3) (*4)

(*3) (*4)

WIRING DIAGRAM

10A

UP

DN

DN

UP

M

GA

UG

EC

ON

NE

CTO

R

SD

SC

ON

NE

CTO

R

DIG

ITA

L G

AU

GE

D

IAG

RA

M(O

PT

ION

)

GA

UG

EC

ON

NE

CTO

R

SD

SC

ON

NE

CTO

R

CA

P

CA

P

PUSH

PU

SH

TU

RN

FREE

ST

IGO

FF

B G W Gr

Br O

GND

STOP

BATT

STAR

T

BZ RESE

T

IG

SUZUKI

UP

DN

IGN

ITIO

N S

WIT

CH

CA

UT

ION

B

UZ

ZE

RB

Z

W/B W/BR/Y R/Y

B/R B/ROO

O/B O/BR/WR/W

Bl Bl

W/B

Gr/Y Gr/YB/Br B/Br

P/WP/W

BBBB

Lbl/W Lbl/W

W/Bl W/Bl

BA

TT

ER

Y

MAG

NETO

CK

P S

EN

SO

R

STA

RT

ER

MO

TOR R

B

LIG

HT

ING

SW

ITC

HT

RO

LL

MO

DE

SW

ITC

H

ME

TER

TRIM

ME

TER

TACHO

METER

WITH L

EDB Y

B BBBBBBB

Gr

B YGr

Bl/B

Bl/B

G/Y

G/Y

PP

G

/W

G

/W

Bl/B

G/Y

P

G

/W

W/Y

W/Y

W/Y

W/Y

W/Y

W/Y

W/Y

W/Y

W/Y

Bl/B

Bl/B

G

/Y

G/Y

PP

G/W

G

/W

Bl/B

G

/YP

G

/W

R/G R/GR/G R/G R/GR/G

R/G

R/G BB BBGr

Gr

R/G B BGr

R/G

R/G BB

R/G R/GBB

R/G B

BBB

BBB

R/GB

BBGr

Gr

BBGr

Gr

BGr

BGr

Gr

Gr

Gr

Gr

Gr

Gr

R/G

R/G BB

R/G R/GBB

R/G B

R/GB

R/G

R/G BB

R/G

R/G BB

BBGr

Gr

BBGr

Gr

R/G B

R/G B

BGr

BGr

GGGGG

PT

T S

WIT

CH

BBBBBB

G

Bl

Bl

G

G

PT

TR

EL

AY

TR

IM

SE

NS

OR

PT

T M

OTO

R

B/W

B/W

B

B

Bl

G

RR

BB

R

MA

IN

RE

LA

Y

STA

RT

ER

MO

TOR

RE

LA

YF

US

E B

OX

FU

SE

15A

15A

30A

30A

30A

CM

PS

EN

SO

R #

1

B

/W

B

/WY

/Bl

Y/B

l

B

/Bl

B/B

l

B/W

Y/B

l

B

/Bl

WW B/R B/R

W B/R

Gr

Gr

OO

B

B

Gr

O

B

IGN

ITIO

N C

OIL

#1

Gr

Bl

B

IGN

ITIO

N C

OIL

#2

Gr

Gr/

Y

B

IGN

ITIO

N C

OIL

#3

#3#2#1

FU

EL

INJE

CTO

R

FU

EL

INJE

CTO

R

FU

EL

INJE

CTO

R

CY

LIN

DE

R T

EM

PS

EN

SO

RBB

B

BB

B

Lg

/W

Lg

/WB

/WB

/W

Lg

/WB

/W

OIL

PR

ES

SU

RE

SW

ITC

H

RE

CT

IFIE

R &

RE

GU

LA

TOR

TH

RO

TT

LE

& IA

T &

MA

PS

EN

SO

R

JOIN

T

CO

NN

EC

TOR

#2

JOIN

T

CO

NN

EC

TOR

#1

EN

GIN

E C

ON

TR

OL

MO

DU

LE

B

W P/B

B/G B/G R/B R/B

B/G R/B

Gr Gr

W

R W

W

W

WW

R

RR

W

W/R

GY/G

Y/G

Bl

Bl

Bl

YY

Y

YYY

R

R

BBY

Y

Y

R

B

BBB

RRR

Gr,

WB

BW

B/G

Gr

B/W

PL

bl

B/B

l

Lb

lW

/R

P

PW/R

Lbl

Lb

lW

/R

P

B/B

rB

/Br

G

r

Gr

B/B

r

Gr

O/B

O/B

G

r

Gr

O/B

G

r

1.0

± 0.

3 kg

f/cm

2

O

N

R/G R/GW/Bl

R/Y B/R

O

PT

T S

WIT

CH

NE

UT

RA

L S

WIT

CH

N

ON

F, R

OF

F

Lbl Lbl

W/R W/R

PP

Lbl

W/R

P

IAC

FUE

L P

UM

P

R/G

R/G

W/B

W/B

G

r

Gr

Gr

Gr

W

/Bl

W

/Bl

R/Y

R/Y

R/G

W/B

G

rG

r

W/B

lR

/Y

R

R

B/W

B/W

Br/

Y

B

r/Y

Lg

/BL

g/B

W

W

RB

/W

B

r/Y

Lg

/B

W

B/WB/W R/B R/B

B/W R/B

Y/B Y/B Br Br

Y/G Y/G B/Bl B/Bl

Y/B Br

Y/G B/Bl

VVV

VVV

B/G B/G B/Bl B/Bl

B B

B/G B/Bl

B

W/Y W/Y R R

B/W B/WW/Y

R

RR

B/W

B/W

B/W

B/W

P/WP/W Lbl/W Lbl/W

P/W Lbl/W

BBB

G/WG/W P/W P/W

Bl/B Bl/BG/WG/W

P/W P/WBl/B Bl/B

G/W P/W

Bl/BG/W

P/WBl/B

O/Y O/Y B B

B/G B/GO/Y

BB/G

EM

ER

GE

NC

YS

TOP

SW

ITC

HL

OC

K P

LA

TE

IN

RU

NL

OC

K P

LA

TE

OF

F

STO

PG

rG

rG

rG

rB

lB

lB

lB

lG

rG

rB

lB

l

W/Y

W/Y

B

B

Bl/B

Bl/B

G

/Y

G/Y

PP

G/W

G

/WL

bl

Lb

l

P

POO

W

W

Br

Br

Y

Y

GG

Gr

G

rB

l/WB

l/W

B

B

W/Y

B

Bl/B

G

/YP

G

/WL

bl

P

O

WB

r

YG

G

rB

l/W

B

YY

B

l/BB

l/B

G/Y

G

/YP

/WP

/W

G/W

G

/WL

bl

Lb

l

P

POO

W

W

Br

Br

Y

/B

Y/B

Bl/R

Bl/R

B

/G

B/G

Bl/W

Bl/W

B

B

Y

Bl/B

G

/YP

/W

G/W

Lb

l

PO

W

Br

Y

/BB

l/R

B/G

Bl/W

B

WWW

Lb

lL

bl

OOWW

Br

Br W

/RW

/RGG

Gr

Gr

Bl/W

Bl/W

BB

W/R

W/R

PP

Lb

lL

bl

OOWW

Br

Br

W/R

W/R

GGG

rG

rB

lB

l BB

W/R

W/R PP

Lb

l

OW

Br W

/RG

Gr

Bl/W

B

W/R

P

Lb

l

OW

Br

W/R

GG

rB

l B

W/R P

G/WG/W P/W P/W

Bl/B Bl/B

P/WP/W Bl/B Bl/B

G/WG/W O/Y O/Y

BB B/G B/G

G/W P/W

Bl/B

P/W Bl/B

G/W O/Y

B B/G

R/W

R/W

G

r

Gr

R/W

G

r

RR

PPPLbl Lbl Lbl

B/W

B

R/B R/B

Y/G Y/GBl/W Bl/W

Bl/B Bl/B

OO

WWBr/Y Br/YB/WB/W

W/Y W/Y

Bl/R Bl/R

B/G B/GVV

PPLg/W Lg/W

O/Y O/YG/WG/W

P/B P/B

Y/Bl Y/BlBr Br

Bl Bl

Lg/B Lg/B

Y/B Y/BG/Y G/YYY

GG

BBB/Bl B/BlLbl LblGr Gr

RR

YY

P/WP/W

R/B

Y/GBl/W

Bl/B

O

WBr/YB/W

W/Y

Bl/R

B/GV

PLg/W

O/YG/W

P/B

R/G

O/BR/W

BlGr/YB/Br

P/W

BB

Lbl/W

Y/BlBr

Bl

Lg/B

Y/BG/YY

G

BB/BlLblGr

R

Y

YY

P/W

YYY

Br B

rB

r Br

NE

UT

RA

L S

WIT

CH

N

O

NF,

R

OF

F

B Bl

Br

G Gr

Lb

l

: Bla

ck: B

lue

: Bro

wn

: G

reen

: Gra

y: L

igh

t b

lue

Lg

/B: L

igh

t g

reen

wit

h B

lack

WIR

E C

OL

OR

O P R V W Y B/B

rB

/G

: Ora

ng

e: P

ink

: Red

: Vio

let

: Wh

ite

: Yel

low

: Bla

ck w

ith

Bro

wn

B/B

l: B

lack

wit

h B

lue

: Bla

ck w

ith

Gre

enB

/RB

/W: B

lack

wit

h R

ed: B

lack

wit

h W

hit

eB

l/BB

l/RB

l/WB

r/Y

: Blu

e w

ith

Bla

ck

: Blu

e w

ith

Red

: B

lue

wit

h W

hit

e: B

row

n w

ith

Yel

low

G

/WG

/YG

r/Y

: Gre

en w

ith

Wh

ite

: Gre

en w

ith

Yel

low

: G

ray

wit

h Y

ello

w

Lg

/WO

/B: L

igh

t g

reen

wit

h W

hit

e : O

ran

ge

wit

h B

lack

O/Y

P/B

P/W

R/B

R/G

R/W

R/Y

: Ora

ng

e w

ith

Yel

low

: Pin

k w

ith

Bla

ck

: Pin

k w

ith

Wh

ite

: Red

wit

h B

lack

: Red

wit

h G

reen

: R

ed w

ith

Wh

ite

: Red

wit

h Y

ello

wW

/BW

/Bl

W/G

W/R

W/Y

Y/B

lY

/G

: Wh

ite

wit

h B

lack

: W

hit

e w

ith

Blu

e : W

hit

e w

ith

Gre

en

: Wh

ite

wit

h R

ed

: Wh

ite

wit

h Y

ello

w

: Yel

low

wit

h B

lue

Y/B

: Yel

low

wit

h B

lack

: Yel

low

wit

h G

reen

W/Y W/Y W/Y

Prepared by

Outboard Motor Engineering Department

June, 2015

Part No. 99011-88L50-03B

Printed in Japan

© COPYRIGHT SUZUKI MOTOR CORPORATION 2015