Suzuki Marine DF40A Owner'S Manual Download | Manualshive

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

WARNING

Improper maintenance or failure to per-
form recommended maintenance can be
hazardous. Poor maintenance or lack of
maintenance increases the chance of an
accident or equipment damage.

Be sure to have maintenance performed
according to the schedule in the above
chart. Suzuki recommends that only your
authorized Suzuki marine dealer or a
qualified service mechanic perform main-
tenance on those items in the chart above
which are marked with an asterisk (*). You
may perform maintenance on the
unmarked items by referring to the
instructions in this section if you have
mechanical experience. If you are not
sure whether you can successfully com-
plete any of the unmarked maintenance
jobs, ask your authorized Suzuki marine
dealer to do the maintenance for you.



WARNING

The safety of you and your passengers
depends on how well you maintain your
outboard motor.

Follow all inspection and maintenance
instructions carefully. If you do not have
prior mechanical experience, do not
attempt to perform maintenance on your
outboard motor. You could be injured or
may damage the motor.

NOTICE

The maintenance intervals in the chart
were established for normal usage of
your outboard motor. If your outboard
motor is used under severe conditions
such as frequent full throttle operation or
frequent operation in muddy, silty, sandy,
acidic, or shallow water, you may need to
perform maintenance more often than
indicated in the chart. Failure to perform
maintenance more frequently could
result in damage.

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

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Summary of Contents for DF40A

Page 1: ...1 ENGLISH DF40A DF50A DF50AV DF60A DF60AV OWNER S MANUAL EN ...

Page 2: ... BEFORE BOATING section for important items Become thoroughly familiar with all operating and handling characteristics of your boat and motor Practice at low and moderate speeds until you are competent at handling the boat and motor Do not attempt to operate at max imum performance until you are com pletely familiar with all of these characteristics Carry boating safety and emergency equipment Thi...

Page 3: ...m time to time It contains important infor mation on safety operation and mainte nance FOREWORD The proper care and maintenance that your outboard motor requires is outlined in this man ual By following these instructions explicitly you will ensure a long trouble free operating life for your outboard motor This outboard motor also conforms to the U S Environmental Protection Agency emission regula...

Page 4: ...njoy boating more and will be a safer boater We recommend that you take a boating safety class Classes explaining required and recommended equipment for small boats and offering training in 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 depart...

Page 5: ...YSTEMS 25 POWER TRIM AND TILT 25 MANUAL TILTING 26 TILT LEVER 26 INSPECTION BEFORE BOATING 27 BREAK IN 29 OPERATION 30 BEFORE ATTEMPTING TO START THE ENGINE 30 STARTING THE ENGINE 32 EMERGENCY STARTING 34 SHIFTING AND SPEED CONTROL 36 STOPPING THE ENGINE 37 MOORING 38 OPERATION IN SHALLOW WATER 38 OPERATING THE TROLL MODE Optional Item 38 OPERATION IN SALT WATER 39 OPERATION IN FREEZING WEATHER 39...

Page 6: ...s oxygenated fuel does not con tain alcohol Gasoline Ethanol Blends Blends of unleaded gasoline and ethanol grain alcohol also known as gasohol may be used in your outboard motor if the ethanol content is not greater than 10 Gasoline Methanol Blends Avoid using blends of unleaded gasoline and methanol wood alcohol whenever possible DO NOT USE fuels containing more than 5 methanol under any circums...

Page 7: ...nk from the boat to refill it Do not fill the fuel tank all the way to the top or fuel may overflow when it expands due to heating by the sun Be careful not to spill fuel If you do wipe it up immediately Do not smoke and keep away from open flames and sparks NOTICE Fuels containing alcohol can cause paint damage which is not covered under the New Outboard Motor Limited Warranty Be careful not to s...

Page 8: ...NE OIL If SUZUKI MARINE 4 CYCLE ENGINE OIL is not available select a NMMA certified FC W oil or good quality 4 cycle motor oil from the following chart according to the average temperatures in your area NOTE In very cold weather below 5 C 41 F use SAE or NMMA FC W 5W 30 for easier start ing and smooth operation GEAR OIL Suzuki recommends the use of SUZUKI HYPOID GEAR OIL If it is not available use...

Page 9: ... le carburant du séparateur de vapeurs ou du carburateur avant de procéder Pour plus de détail voir le manuel du propriétaire WARNING AVERTISSEMENT 8 To avoid injury when engine is running keep your hands hair clothing etc away from engine See owner s manual for details Pour éviter toute blessure quand le moteur est en marche éloigner les mains les cheveux les vêtements etc du moteur Pour plus de ...

Page 10: ... 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 Emergen...

Page 11: ...nd 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 ...

Page 12: ... installed by your authorized Suzuki marine dealer He has the tools the facilities and the know how to do the job correctly BATTERY INSTALLATION BATTERY REQUIREMENT Choose 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 SAE or 160 Reserve Capacity RC Minutes SAE NOTE The specifications listed above...

Page 13: ...nnecting and disconnecting the battery as described above will help minimize the chance of creating an accidental short circuit and sparks Suzuki recommends that you install the termi nal cap on the positive battery terminal to pre vent an accidental short circuit of battery terminals If a terminal cap is required contact your autho rized Suzuki marine dealer WARNING Batteries produce flammable hy...

Page 14: ...ance Your operating load will also affect propeller selec tion Smaller loads generally require larger pitch propellers larger loads generally require smaller pitch propellers Your authorized Suzuki Marine 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 w...

Page 15: ...nal injury When installing or removing the propeller Always shift into Neutral and remove the emergency stop switch lock plate so that the motor cannot be started accidentally Wear gloves to protect hands and lock the propeller by placing a block of wood between the blades and the anti cavitation plate ADJUSTMENTS TRIM ANGLE ADJUSTMENT To help maintain steering stability and good performance alway...

Page 16: ...tilted beyond the maxi mum trim position the swivel bracket will not have side support from the clamp bracket and the tilt system will be unable to cushion the engine if the lower unit strikes an obstruction This could lead to occupant injury Do not operate the engine above 1500 r min or operate the boat in a planing atti tude with the motor tilted beyond the maximum trim position Tilt range Trim ...

Page 17: ...at holds the trim tab in place After adjusting the trim tab check to see if the boat still tends to veer to one side If necessary readjust the trim tab THROTTLE TENSION ADJUSTMENT The tension of the remote control handle can be adjusted according to your preference To increase the tension turn the adjuster A clock wise To decrease the tension turn the adjuster counterclockwise NOTE Top mount type ...

Page 18: ...ree seconds and the buzzer will sound twice briefly indicating the setting has been canceled 6 Return the throttle to the fully closed posi tion SETTING THE TILT UPPER POSITION LIMIT 7 Press the UP side of the PTT switch so that the optimum full tilt up position for the boat can be obtained 8 Using the throttle only function of the remote control box move the warm up lever upward until the caution...

Page 19: ...ccupants Keep all occupants away from the motor when operating at high speed CAUTION SYSTEM The caution systems are designed to alert you to certain situations which may cause damage to your outboard motor NOTICE Your outboard motor may become dam aged if you rely on the Caution System to alert you to any malfunction that may occur or to give you an indication of the need for maintenance To avoid ...

Page 20: ...ur out board motor If any of the four lamps does not come on or the buzzer does not sound when the ignition key is turned to the ON posi tion the lamps or buzzer may be broken or a failure may exist in the system cir cuit Consult your authorized Suzuki marine dealer OVER REVOLUTION CAUTION SYSTEM This system is activated when engine speed exceeds maximum recommended speed for more than 10 seconds ...

Page 21: ...the oil level stop the engine and then remove the motor cover COOLING WATER CAUTION SYSTEM This system is activated when the cylinder wall temperature is too high due to insufficient water cooling NOTE The cooling water caution system will not detect high combustion chamber temperature caused by for example an oil system malfunction poor quality fuel or spark plugs with an incorrect heat range If ...

Page 22: ...ses abnormally If either of the above situations arises your authorized Suzuki Marine Dealer must be con sulted as soon as possible NOTE If pilot hole water discharge is sufficient buzzer and TEMP lamp may still operate until engine temperature 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 overheati...

Page 23: ...pect or service the battery without first reading the warn ings cautions and instructions in the BATTERY INSTALLATION section of this 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 CHECK ENGINE lamp will flash and a buzzer will sound Also incorpor...

Page 24: ...is indication will repeat until you cancel the system activation CANCELLATION 1 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 will be heard if the cancellation is successfully finished 4 Turn the ignition key to the OFF position 5 Set the plate 1 in the original position NOTE C...

Page 25: ...r Trim and Tilt is operated by press ing the switch To tilt the motor up press the upper part of the switch To tilt the motor down press the lower part of the switch WARNING The power trim and tilt PTT switch can be accidentally activated when the igni tion key is off resulting in injury Keep all persons away from the outboard motor to help prevent accidental activa tion of the PTT system UP DOWN ...

Page 26: ...ausing injury When you tilt the motor manually ensure that your grip and footing are secure and that you are able to support the weight of the engine TILT LEVER The tilt lever is provided so you can support the motor in a tilted position for non moving engine support 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...

Page 27: ...ILERING sec tion of this manual INSPECTION BEFORE BOATING It is important to make sure that your boat and motor are in good condition and that you are properly prepared for an emergency Always perform the following checks before you begin boating Check that you have enough fuel for the intended run Check the level of engine oil in the sump To check the oil level NOTE To avoid an incorrect assessme...

Page 28: ...to the engine then remove it again UPPER LIMIT LOWER LIMIT The oil on the dipstick should be between the upper and lower limits shown on the dipstick If the oil level indication is near the lower limit add enough oil to raise the level to the upper limit 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 secure...

Page 29: ...iod 10 hours Break in procedure 1 For the initial 2 hours Allow sufficient idling time about 5 minutes for the engine to warm up after cold engine starting After warming up run the engine at idling speed or the lowest in gear speed for about 15 minutes During the remaining 1 hour and 45 minutes if safe boating conditions permit operate the engine in gear at less than 1 2 half throttle 3000 r min N...

Page 30: ...zure During the last 7 hours of break in opera tion do not operate at wide open throttle for more than 5 minutes at a time OPERATION BEFORE ATTEMPTING TO START THE ENGINE 1 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 tank cap fully counterclockwise to open the vent NOTE SUZUKI genuine portable fuel tanks have a semi auto air...

Page 31: ... securely attached and clamped 4 Make sure the motor is in NEUTRAL Side mount type Top mount type 5 Make sure the lock plate is in place and the emergency stop switch cord is fastened securely to your wrist or appropriate clothing area such as your belt Side mount type Top mount type ...

Page 32: ...mergency stop switch opera tion Be careful not to pull the stop switch cord or knock out the lock plate during normal operation The motor will stop abruptly and the loss of forward motion may unexpectedly throw occu pants forward WARNING Exhaust gas contains carbon monoxide a dangerous gas that is difficult to detect because it is colorless and odorless Breathing carbon monoxide can cause death or...

Page 33: ...age the engine Stop the engine and check the oil level Cooling water check As soon as the engine starts water should spray out of the pilot water hole 1 indicating that the water pump and cooling system are working properly If you notice that water does not spray out of the pilot water hole stop the engine as soon as possible and consult your authorized Suzuki Marine Dealer NOTICE Operating the en...

Page 34: ...ll not be supplied to the engine 1 Make sure that the motor is in NEUTRAL and the emergency stop switch lock plate is removed 2 Remove the motor cover WARNING If you touch electrical components when rope starting the engine you can get a severe electrical shock When rope starting the engine be careful not to touch electrical components such as ignition coils or spark plug leads WARNING When you us...

Page 35: ...ndle in the tool kit 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 rope sharply to start the engine Repeat if the motor has not started NOTE Be sure to have the starter system repaired as soon as possib...

Page 36: ... operating the boat in reverse Always allow the engine speed to return to idle before shifting Exercise caution and use minimal speed when operating the boat in reverse Be sure the handle shift lever is in the desired position before accelerating NOTICE If you shift gears when the engine is not running the shifting mechanism can be damaged Avoid shifting gears when the engine is not running NOTE T...

Page 37: ...nning Side mount type Top mount type 4 After stopping the engine disconnect the fuel line from the outboard motor if there is a fuel connector 5 Turn the air vent screw on the fuel tank cap clockwise to shut the vent if equipped NOTE To make sure that the emergency stop switch operates properly stop the engine occasionally by pulling out the lock plate while operating the engine at idling speed WA...

Page 38: ...amp bracket and the tilt system will be unable to cush ion the engine if the lower unit strikes an obstruction This could lead to occupant injury In addition beyond the maximum trim position the water intake holes may be above the water line which can result in severe engine damage from overheat ing Do not operate the engine above 1500 r min or operate the boat in a planning attitude with the engi...

Page 39: ...ain operational even in troll mode Troll mode switch Cancelling the troll mode The troll mode can be cancelled by shifting the remote control lever to the neutral position or by increasing the engine speed to 3000 rpm or more In both cases two short 0 1 sec beeps sound when cancelling the troll mode OPERATION IN SALT WATER After operating the motor in salt water you should flush the water passages...

Page 40: ...ortation of the motor Horizontal transport 1 Drain the engine oil Refer to the ENGINE OIL section 2 Drain the gasoline from the vapor separator as follows 1 Fully steer the motor to the starboard side 2 Pull the drain hose end 1 out 3 Loosen the vapor separator drain screw 2 and drain the gasoline into a suitable container 4 After draining retighten the drain screw and put the drain hose 1 back WA...

Page 41: ...ful when resting the outboard on its side and do not take proper precautions such as first draining the engine oil and cooling water com pletely damage can occur Engine oil may enter the cylinder from the sump water may enter the cylinder through the exhaust port or the outer casings may be damaged Always drain the engine oil and cooling water completely before laying the motor on its side and be ...

Page 42: ...ar device to support the weight of the motor NOTICE If you use the tilt lever to hold the motor in the fully tilted up position when traile ring the boat towing motion or poor road surfaces may cause unexpected tilt lock release resulting in damage to the motor and the tilt lock mechanism Never use the tilt lever to hold the motor in the fully tilted up position when traile ring the boat Use a tra...

Page 43: ...WHICH HAS BEEN CERTIFIED UNDER THE PROVISIONS IN THE CLEAN AIR ACT Sec 207 a 2 WARNING Exhaust gas contains carbon monoxide a dangerous gas that is difficult to detect because it is colorless and odorless Breathing carbon monoxide can cause death or severe injury Never start the engine or let it run indoors or where there is little or no ventilation Interval Item to be serviced Initial 20 hrs or 1...

Page 44: ...RNING The safety of you and your passengers depends on how well you maintain your outboard motor Follow all inspection and maintenance instructions carefully If you do not have prior mechanical experience do not attempt to perform maintenance on your outboard motor You could be injured or may damage the motor NOTICE The maintenance intervals in the chart were established for normal usage of your o...

Page 45: ... center electrode insulator after operation If the plug tends to run hot usually evidenced by whitening of the insulator or a burnt elec trode stop using your motor immediately as severe engine damage may result If the plug tends to run cold usually evidenced by black ening of the insulator or a wet electrode per formance may suffer Ask your authorized Suzuki Marine dealer to evaluate either of th...

Page 46: ...ecommended torque setting or the specified rotation angle 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 a spark plug as this will damage the alu minum threads of the cylinder head To maintain a strong spark you should clean and adjust the plug at the interval shown in the maintena...

Page 47: ...ng Fuel line Breather line ENGINE OIL Engine oil change The oil should be changed when engine is warm so that the oil will drain thoroughly from the 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 serious injury can occur The motor must be shut o...

Page 48: ...CE A previously used gasket may leak resulting in engine damage Do not re use gaskets Be sure to always use new gaskets 7 Check the engine oil level NOTE To avoid incorrect measurement of engine oil level check oil level only when the engine has cooled 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 the ground down a dra...

Page 49: ...install and tighten the gear oil drain plug 2 NOTE To avoid insufficient injection of gear oil check the gear oil level 10 minutes after doing the pro cedure in the step 4 If the oil level is low slowly inject the gear oil into the gear oil level hole 1 up to the correct level NOTE Recycle or properly dispose of used gear oil Do not throw it in the trash or pour it on the ground down a drain or in...

Page 50: ...LUBRICANT Throttle Shift linkage Marine grade water resistant grease Propeller shaft Swivel bracket Marine grade water resistant grease Grease Gun Steering bracket CORROSION PREVENTION ANODES The motor is protected from exterior corrosion by anodes These anodes control electrolysis and help prevent corrosion The anodes will corrode in place of the parts they are protect ing You should periodically...

Page 51: ...s These wires and their terminals should be checked periodically to be sure they have not been damaged BATTERY If you are using a maintenance free battery inspect the window area according to the instructions 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 every 100 hours of operation or 12 mont...

Page 52: ... initially serviced you will damage the battery NEVER add diluted sulphuric acid to the battery after it has been initially serviced Follow the battery manufacturer s instructions for specific maintenance procedures ENGINE OIL FILTER The engine oil filter must be changed by an authorized Suzuki Marine Dealer periodically Replace engine oil filter with a new one at initial 20 hours 1 month Replace ...

Page 53: ... 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 cause severe personal injury Make sure the motor is properly clamped to a secure stand or boat and remain in attendance until flushing is completed Keep children and pets away from the area and stay clea...

Page 54: ...nish of the motor ENGINE NOT RUNNING Vertical position 1 Remove the plug A from the flushing port 2 Install garden hose directly or by using a hose connector matched to flushing point thread B Thread B 0 75 11 5 NHR American stan dard hose coupling threads for garden hose applications NOTE The hose connector flushing attachment matched to the flushing point thread B is included in the crate parts ...

Page 55: ...ning tighten the oil drain plug 5 Drain the fuel line and all filters 6 Pour one tablespoon of engine oil in through each spark plug hole Coat the engine inner parts with oil by manually turning the fly wheel several times Don t use the electric starter as this may bend the connecting rods WARNING Gasoline is extremely flammable and toxic It can cause a fire and can be haz ardous to people and pet...

Page 56: ...ed fuel through the engine 6 Stop the engine Then turn off the water and disconnect the flushing attachment 7 Lubricate all other specified parts Refer to the LUBRICATION section Spray entire powerhead with a rust preventative not a penetrating 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 th...

Page 57: ...arg ing the battery connect the battery charger cables to the proper terminals before turning the charger on Handle the battery with extreme care and avoid skin contact with battery acid Wear proper protective clothing Safety glasses gloves etc AFTER STORAGE When taking your motor out of storage follow the procedure below to return it to operating condition 1 Thoroughly clean the spark plugs Repla...

Page 58: ...r 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 87 OCTANE R ...

Page 59: ...ake s are blocked Engine is overloaded Propeller is not properly matched to loads FUSE 1 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 box cover when the fuse is pulled off and installed Fuse box cover 4 Inspect the fuse and replace with new fuse if needed NOTE If a fuse is blown try...

Page 60: ... RELAY STARTER RELAY SPARE 15A 30A 30A SPARE 30A MAIN 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 Range 5000 6000 r min min 1 5300 6300 r min ...

Page 61: ...ill activate up to 2100 hour s operation Total operating hours MONITOR TACHOMETER Needle 1 indication REV LIMIT lamp 2 flashing 0h 49h No No 50h 500rpm No 60h 600rpm No 540h 5400rpm No 550h 500rpm 1 time 560h 600rpm 1 time 1040h 5400rpm 1 time 1050h 500rpm 2 times 1540h 5400rpm 2 times 1550h 500rpm 3 times 2030h 5300rpm 3 times 2040h or over 5400rpm 3 times Action Starting operation Cancellation I...

Page 62: ... Y G B Bl V V V V V V B G B G B Bl B Bl B B B G B Bl B W Y W Y R R B W B W W Y R R R B W B W B W B W P W P W Lbl W Lbl W P W Lbl W B B B G W G W P W P W Bl B Bl B G W G W P W P W Bl B Bl B G W P W Bl B G W P W Bl B O Y O Y B B B G B G O Y B B G EMERGENCY STOP SWITCH LOCK PLATE IN RUN LOCK PLATE OFF STOP Gr Gr Gr Gr Bl Bl Bl Bl Gr Gr Bl Bl W Y W Y B B Bl B Bl B G Y G Y P P G W G W Lbl Lbl P P O O W...

Page 63: ...Prepared by Outboard Motor Engineering Department June 2015 Part No 99011 88L50 03B Printed in Japan COPYRIGHT SUZUKI MOTOR CORPORATION 2015 ...

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