DF2.5

OWNER'S MANUAL

ENGLISH

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FOREWORD

Thank you for choosing a Suzukioutboard motor. Please read thismanual carefully and review it fromtime to time. It contains importantinformation on safety, operation,and maintenance. A thoroughunderstanding of the informationpresented in this manual will helpyou experience safe, enjoyableboating.

All information in this manual isbased on the latest productinformation available at the time ofpublication. Due to improvementsor other changes, there may be

TABLE OF CONTENTS

WARNING/CAUTION/NOTE.......................3IMPORTANT NOTICE TO OWNERS……..3

IDENTIFICATION NUMBERLOCATION.................................................4FUEL AND OIL.........................................4LOCATION OF SAFETY LABELS ……...6LOCATION OF PARTS............................7MOTOR MOUNTING.................................8

PROPELLER SELECTION ANDINSTALLATION..........................................9

ADJUSTMENT...........................................10

OPERATION OF TILTINGSYSTEMS...................................................12INSPECTION BEFORE BOATING............14BREAK-IN..................................................15OPERATION...............................................16

MOTOR REMOVAL ANDTRANSPORTING.......................................21

INSPECTION ANDMAINTENANCE.........................................23

FLUSHING THE WATERPASSAGES................................................29SUBMERGED MOTOR.............................30STORAGE PROCEDURE.........................30AFTER STORAGE....................................31TROUBLESHOOTING................................32SPECIFICATIONS........................................32

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IMPORTANT

WARNING/CAUTION/NOTE

Please read this manual and follow its instructionscarefully. To emphasize special information, thesymbol and the words WARNING, CAUTION andNOTE have special meanings. Pay special attentionto the messages highlighted by these signal words.

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indicates a potential hazard that could result in death or injury.

! WARNING! WARNING

CAUTIONCAUTION indicates a potential hazard that couldresult in motor damage.

NOTE:Indicates special information to makemaintenance easier or instructions clearer.

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IMPORTANT NOTICE TOOWNERS

! WARNINGYou must take precautions to reduce the chance ofaccidents and injuries resulting from the use of youroutboard motor and boat. Some of the importantsafety precautions you should take are:

� Before first use of your outboard motor, readthis owner's manual carefully to become fa-miliar with the outboard motor's features, safetyrequirements, and maintenance requirements.

� Before each use of your boat, perform a dailyinspection. Specific items to check are listed inthe INSPECTION BEFORE BOATING section.

� Never run the outboard motor indoors or in anenclosed area. Exhaust emissions containpoisonous carbon monoxide fumes which cancause unconsciousness and may lead to death.

� Never operate your boat while under the

influence of alcohol or other drugs.

� Practice operating your boat at slow andmoderate speeds until you become thor-oughly familiar with the operating and han-dling characteristics of your motor/boatcombination. Do not operate your outboardmotor at maximum performance until you arethoroughly familiar with these characteristics.

� Be sure that you and your passengers alwayswear life jackets on board.

� When loading your boat, distribute weightevenly between the bow and stern, and theport and starboard sides.

� Observe periodic maintenance require-ments-your authorized Suzuki Marine Dealer istrained and equipped to perform this service.

� Do not modify your outboard motor. Modifi-cations or removal of original equipment maymake the motor unsafe.

� Learn and obey the navigation rules of thelocality in which you operate your boat.

� Make sure you have the necessary emer-gency equipment on board such as a flotationdevice for each passenger, fire extinguisher,signaling devices, anchor, paddles, bilgepump, rope, first-aid kit, tool kit, emergencystarter rope, flashlight, extra fuel and oil, etc.

� Instruct your passengers about emergencyprocedures. Make sure they understand thebasics of how to operate the boat, how to useemergency equipment, and what to do in caseof trouble.

� Do not hold onto the motor cover or any otherparts of your outboard motor while getting onor off your boat.

� Check the weather forecast before boating toavoid bad weather.

� Use extreme caution when replacing a parton your outboard motor or selecting andinstalling accessories. Use of inappropriateor poor quality replacement parts or accesso-ries can create unsafe operating conditions,or result in damage to the motor. Suzukistrongly recommends that you use genuineSuzuki replacement parts and accessories asdamage caused by use of parts and ac-cessories other than genuine Suzuki re-placement parts and accessories will not becovered under warranty.

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IDENTIFICATION NUMBERLOCATIONThe model and identification numbers of youroutboard motor are stamped on a plate attachedto the clamp bracket. It is important to know thesenumbers when you place a parts order or if yourmotor is stolen.

FUEL AND OILGASOLINESuzuki highly recommends that you use alco-hol-free unleaded gasoline whenever possible,with a minimum octane rating of 91 (Researchmethod). However, blends of unleaded gasolineand alcohol with equivalent octane content maybe used, provided the guidelines that follow aremet.

CAUTION

If leaded gasoline is used, enginedamage may result. Use only unleadedgasoline.

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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 containalcohol.

Gasoline/Ethanol BlendsBlends of unleaded gasoline and ethanol (grainalcohol), also known as gasohol, are commer-cially available in some areas. Gasoline contain-ing a maximum of 10% ethanol may be used inyour outboard motor without jeopardizing theNew Outboard Motor Limited Warranty.

Gasoline/Methanol BlendsBlends of unleaded gasoline and methanol (woodalcohol) are also commercially available in someareas. DO NOT USE fuels containing more than5% methanol under any circumstances. Fuelsystem damage or outboard motor performanceproblems resulting from the use of such fuels arenot the responsibility of Suzuki and may not becovered under the New Outboard Motor LimitedWarranty. Fuel containing 5% or less methanolmay be suitable for use in your outboard motor ifthey contain cosolvents and corrosion inhibitors.

Pump Labelling for Gasoline/AlcoholBlendsIn some states, pumps that dispense gasoline/alcohol blends are required to be labelled for thetype and percentage of alcohol content, andwhether important additives are present. Suchlabels may provide enough information for you todetermine if a particular blend of fuel meets therequirements listed above. In other states, pumpsmay not be clearly labeled as to the content ortype of alcohol and additives. If you are not surethat the fuel you intend to use meets theserequirements, check with the service stationoperator or the fuel suppliers.

NOTE:If you are not satisfied with the operation orfuel economy of your outboard motor whenyou are using gasoline/alcohol blends, youshould switch back to unleaded gasolinecontaining no alcohol. Be sure that anygasoline/alcohol blend you use has octaneratings of at least 91 octane (Researchmethod).If engine pinging is experienced, substituteanother brand as there are differences

CAUTION

Be careful not to spill fuel containing alcohol whilerefuelling. Fuels containing alcohol can causepaint damage, which is not covered underwarranty.

! WARNINGGasoline is extremely flammable and toxic.Always observe the following precautionswhen refuelling.

• Never permit anyone other than an adult torefill the fuel tank.• To refill the fuel tank, always stop the motor.• Do not fill the fuel tank all the way to the topor fuel may overflow when it expands due toheating by the sun.• Be careful not to spill fuel. If you do, wipeit up immediately.• Do not smoke, and keep away from openflames and sparks.• Refuel in a well ventilated area.• Avoid prolonged contact with skin and

CAUTION

Always use fresh gasoline. Gasoline kept in thefuel tank for long periods of time will producevarnish and gum, which can damage the engine.

ENGINE OILUsing a premium quality four stroke motor oil willincrease the service life of your motor. Use only oilswhich are rated SE, SF, SG, SH or SJ under the APIclassification system. The viscosity rating should beSAE 10W-40. If an SAE 1OW-40 motor oil is notavailable, select an alternative according to the chartbelow.

CAUTION

The choice of engine oil is major factor affectingengine performance and life.

GEAR OIL

Use SUZUKI OUTBOARD MOTOR GEAR OIL, oran equivalent high quality SAE90 hypoid gear oil.

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LOCATION OF SAFETY LABELS

Read and follow all of the labels on your outboardmotor or fuel tank. Make sure you understand all ofthe labels.

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

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LOCATION OF PARTSAir-vent screw

Starter grip

Choke knobThrottle tensionadjuster

Throttlecontrol grip

Combination emergencystop switch & normal stopbutton

Clamp screw

Water intake holeGear oil level plug

Gear oil drain plug

Oil level inspection window

Steering tension adjuster

Anode

Pilot water hole

Shift lever

Fuel cock lever

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MOTOR MOUNTING

! WARNINGNever overpower your boat. Do not install anoutboard motor that exceeds the maximumhorsepower listed on the boat's "CertificationPlate". If you are unable to locate the "Certifi-cation Plate", consult your authorized SuzukiMarine Dealer.

Proper transom height is important for good per-formance. A motor mounted on a transom that is toohigh causes the propeller to slip resulting in wastedpower or overheating. A motor mounted on atransom that is too low will increase drag, causingreduced speed. Make sure that when the motor islowered all the way down, the anti-cavitation plateis located 0 -25 mm (0 - 1.0 in) below the bottom of

CAUTION

If the anti-cavitation plate is above the watersurface, this may induce overheating and theoutboard motor will sustain damage.

Center the motor on the transom and secure it byalternately tightening the clamp bracket screws byhand. Make sure you accurately center the motor,or the boat will pull to one side during operation.

After installing the motor, check to make sure thatsteering and tilt movement are not obstructed byany part of the boat.

CAUTION

The motor may come off if it is held onlyby the clamp screws. Occasionally checkthe clamp screws for tightness.

Run a sturdy rope or cable through thehole on the clamp bracket and fasten theends securely to the boat.

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PROPELLER SELECTIONAND INSTALLATION

PROPELLER SELECTIONIt is essential to use a propeller on your outboardmotor that is properly matched to your boat'soperating characteristics. The speed of theengine when you operate your boat at full throttledepends on the propeller you use.

CAUTION

Installing a propeller with much or toolittle pitch will cause incorrect maximumengine RPM, which may result insevere damage to the motor.

Full throttleoperating range

5250 - 5750r/min. (min'1 )

PROPELLER INSTALLATION

! WARNINGWhen installing or removing the propeller, besure to shift into "NEUTRAL" and disconnectthe spark plug wires so the motor can'taccidentally be started. To prevent being cutby the propeller blades, wear gloves and placea block of wood between the anti-cavitationplate and propeller to hold the propeller in place.

To install a propeller on your outboard motor,use the following procedure:1. Coat the propeller shaft liberally withSuzuki water resistant grease to help preventcorrosion.2. Install the shear pin as illustrated.3. Slide the propeller onto the shaft.4. Insert the cotter pin and bend it so thatthe propeller can not come off.

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To remove the propeller, reverse the aboveprocedure.

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ADJUSTMENT

To help maintain steering stability and good per-formance, always maintain the proper trim angle asshown in the illustration. The appropriate trim anglevaries depending on the combination of the boat,engine, and propeller, as well as operatingconditions.

TRIM ANGLE ADJUSTMENT

Trim angle too small (Boat tends to "plough")

Trim angle too large (Boat tends to "porpoise")

Proper trim angle

To adjust the trim angle;1. Hold the motor in the fully tilted up position.(Refer to the TILT UP LOCK ARM section.)2. Turn the nut counterclockwise.1

3. Pull the spacer and tilt pin out to the limiton both sides of the swivel bracket.

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4. Reposition the tilt pin in the desired holes.5. Push the spacer and tilt pin back in andtighten the nut .6. Lower the motor back down.To lower the bow, move the pin towards the boat.To raise the bow, move the pin away from theboat.

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STEERING TENSION ADJUSTMENT

The steering on your outboard motor should besmooth and not tight. Adjust the steering tension sothat there is only a slight resistance to steeringmovement.To increase the steering tension, turn the steeringtension adjuster clockwise. To decrease thesteering tension, turn the steering tension adjustercounterclockwise.

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THROTTLE TENSION ADJUSTMENT

The tension of the throttle control grip can beadjusted according to your preference. To increasethe tension, turn the throttle tension adjuster clockwise. To decrease the tension, turn theadjuster counterclockwise.A

IDLE SPEED ADJUSTMENTThe idle speed of your outboard motor has been setby your dealer. If it is necessary to adjust the idlespeed, use the following procedure:The part of motor cover on DF2.5 is used as theholder of recoil starter grip, too. Idle speed ad-justment is recommended to be made by the Suzukiauthorized dealer. The motor cover can not becompletely removed unless you first remove thestarter grip. Please refer to the steps mentionedbelow.

1. Slightly remove the motor cover.2. Tie a knot in the rope inside of the motorcover, in order to prevent the rope binding ontothe recoil reel when the starter grip is off.

3. Take of the starter grip.4. Completely remove the motor cover.

5. Install the starter grip holder to the end of rope.6. Loosen a knot in the rope.

7. Starter the engine.(Refer to starting the enginesection)8. Warm up the engine for about 5 minutes.

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9. Turn the idle adjustment screw clockwiseto increase idle speed or counterclockwise todecrease idle speed.

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10. Stop the engine.11. Reinstall the motor cover by the oppositesteps of the above 1 to 6.

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

OPERATION OF TILTING SYSTEMS

TILT UP LOCK ARMThe tilt up lock arm is used to hold the motor inthe fully tilted up position.

! WARNINGBefore tilting up the motor, be sure to turnthe fuel cock lever to the right and tightenthe air-vent screw on the fuel filler cap ofthe built-in tank to prevent fuel from leakingout.

FULL TILT UP POSITIONTo hold the motor in the fully raised position:

! WARNINGNever place your hands near the mountingbracket or under the motor when tilting, orthey could be crushed if the motor slipsfrom your grasp.

1. Shift into "NEUTRAL".2. Turn the motor to the front, to free the re-verse thrust stopper .A

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3. Grab the handle on the back of the motor lowercover and tilt the motor all the way up until it isautomatically locked in the fully tilted up positionby the tilt up lock arm .1

CAUTIONNever use the throttle grip handleto raise or lower the motor. Thehandle may break.

CAUTIONNever use the throttle grip handleto raise or lower the motor. Thehandle may break.

To lower the motor back down, pull the motor slightlytoward you, pull up on the till up lock arm andslowly let the motor down.

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INSPECTION BEFOREBOATING

! WARNINGFor the safety of you and your passengers,always perform an inspection as describedbelow before you begin boating.

Make sure that you have enough fuel for theintended run.Fuel capacity : 1.0 L (0.26/0.22 US/lmp.gal.)

Check the level of engine oil in the sump.

Running the engine with insufficient oil cancause serious engine damage.

CAUTION

To check the engine oil level:

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

1. Place the motor in a vertical position.2. Check the engine oil level through the oil levelinspection window .The oil should be between the upper and lower

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Upper limit

Lower limit

NOTE:If the engine oil is contaminated or discoloured,replace with fresh engine oil (Refer to INSPEC-TION AND MAINTENANCE/Engine oil section).

Seeing the window , add enough oil to raise thelevel to the upper limit.

To add the engine oil:1. Remove the motor cover by unlocking thefasteners and .

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2. Remove the oil filler cap .4

3. Add the recommended engine oil until the oillevel reaches the upper limit.

Do not overfill, as excessive oil can damagethe engine.

CAUTION

4. Tighten the oil filler cap securely.

• Visually check the propeller to make sure itis not damaged.

• Make sure that the motor is securelymounted to the transom.

• Make sure that the tilt pin is securely in-stalled in the proper position.

• Make sure the starter rope is free from anyevidence of fraying or wear.

• Make sure you have the boating safety andemergency equipment on board.

BREAK-INProper operation during the break-in period willhelp ensure maximum life and performance fromyour engine. The following guidelines will explainproper break-in procedures.

Failure to follow the break-in proceduresdescribed below can result in severe enginedamage.

CAUTION

Break-in period: 10 hours

Break-in procedure

1. For the initial 2 hours:Allow sufficient idling time (about 5 minutes) forthe engine to warm up after cold engine starting.

High rpm without sufficient warm-up maycause severe engine damage such as pistonseizure.

CAUTION

After warming up, run the engine at idling speed orthe lowest in-gear speed for about 15 minutes.During the remaining 1 hour and 45 minutes, if safeboating conditions permit, operate the engine ingear at less than 1/2 (half) throttle (3000 r/min.).

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NOTE:You may throttle up beyond therecommended operating range to plane yourboat, then immediately reduce the throttle tothe recommended operating range.

2. For the next 1 hour:Safe boating conditions permitting, operate theengine in gear at 4000 r/min. or at three-guarterthrottle. Avoid running the engine at full throttle.

3. Remaining 7 hours:Safe boating conditions permitting, operate theengine in gear at the desired engine speed.You may occasionally use full throttle; however donot operate the engine continuously at full throttlefor more than 5 minutes at any time.

NOTE:For the remaining 7 hours of break-inoperation, you may use full throttle howeverdo not operate the engine continuously at fullthrottle for more than 5 minutes at a time orsevere engine damage such as seizure mayresult.

OPERATION

BEFORE ATTEMPTING TO STARTTHE ENGINE

1. Make sure the motor has been lowered into thewater.2. Twist the air-vent screw on the fuel tank capcounterclockwise to open the vent.

3. Turn the fuel cock lever to the left.

NOTE:When turning the fuel cock lever to theleft, fuel can flow from the built-in tank.