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Suzuki DF150AP, Owner'S Manual

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Suzuki DF150AP Owner'S Manual Download Page 99

99

EMISSION CONTROL
INFORMATION

NOTICE

Emergency key Number:

• THIS ENGINE IS CERTIFIED TO OPER-

ATE ON UNLEADED GASOLINE OF 87
OCTANE ((R+M)/2 METHOD) OR
GREATER.

• EXHAUST EMISSION CONTROL

SYSTEM:
ECM, MFI,  HO2S

Emergency key
number stamped  
position

TROUBLESHOOTING

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

Starter motor will not operate:

• Emergency stop switch lock plate is not in

position.

• Starter relay fuse is blown out.
• Sub battery cable fuse is blown out.
• Control handle is not in NEUTRAL.
• Battery terminal connection is corroded or

lost.

• Battery power is lost.
• Starter motor is failed.
• Main switch or start & stop switch is failed.
• Electric wiring connection is loose.

Engine will not start (hard to start):

• Fuel tank is empty.
• Fuel is deteriorated.
• Engine starting procedure is not correct.
• Fuel tank air vent is not opened.
• Fuel hose is not properly connected to

engine.

• Fuel hose is kinked or pinched.
• Fuel filter is clogged.
• Fuel pump is failed.
• Fuel tank filter is clogged.
• Spark plug is fouled.
• Ignition system is fouled.
• Electric wiring connection is loose.

NOTICE

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

If you are not sure about the proper
action to correct a problem, consult your
Suzuki marine dealer.

Summary of Contents for DF150AP

Page 1: ...1 ENGLISH DF150AP DF175AP DF200AP OWNER S MANUAL EN ...

Page 2: ...FOR YOUR OUTBOARD MOTOR The first 10 hours are the most important in the life of your engine Proper operation during this break in period is essential to help ensure max imum life and performance Refer to the BREAK IN section of this manual for specific break in recommendations IMPORTANT NOTICE TO OWNERS WARNING Failure to take the proper precautions may increase the risk of death or severe injury...

Page 3: ...ine cowling can cause electrical noise interference Suzuki recommends that antennae be mounted at least one meter 40 inches away from the engine cowling 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 c...

Page 4: ...f boating and your Suzuki Marine dealer can supply you with addi tional information on boating safety and regula tions or you can call the U S Coast Guard Boating Safety Hotline toll free at 1 800 368 5647 TABLE OF CONTENTS FUEL AND OIL 6 GASOLINE 6 ENGINE OIL 7 GEAR OIL 7 LOCATION OF SAFETY LABELS 8 LOCATION OF PARTS 9 MOTOR INSTALLATION 11 EMISSION RELATED INSTALLATION INSTRUCTIONS 11 MOTOR INST...

Page 5: ...T 51 TILT LIMITER CAM 52 MANUAL TILTING 52 TILT LEVER 53 INSPECTION BEFORE BOATING 54 BREAK IN 56 OPERATION 57 MAIN SWITCH OPTION 57 CONTROL PANEL OPTION 58 BEFORE ATTEMPTING TO START THE ENGINE 61 STARTING THE ENGINE 62 EMERGENCY START 65 SHIFTING AND SPEED CONTROL 69 STOPPING THE ENGINE 70 MOORING 72 OPERATION IN SHALLOW WATER 73 OPERATING THE TROLL MODE 73 OPERATION IN SALT WATER 76 OPERATION I...

Page 6: ...ance and may damage your motor and fuel system Use only unleaded gasoline Do not use fuel having lower than the recommended octane or fuel that may be stale or con taminated by dirt water etc 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 Fuel Pump Labeling In some ...

Page 7: ... fuel containing alcohol while refueling If fuel is spilled wipe it up immediately ENGINE OIL Oil quality is a major contributor to your engine s performance and life Always select good quality engine oil Suzuki recommends the use of SAE 10W 40 or 10W 30 SUZUKI MARINE 4 CYCLE ENGINE OIL If SUZUKI MARINE 4 CYCLE ENGINE OIL is not available select a NMMA certified FC W oil or good quality 4 cycle mo...

Page 8: ...ng motor on its side See owner s manual for details Le carburent risque de fuir et de présenter un danger d incendie si le moteur est placé sur le côté Vidanger entièrement le carburant du séparateur de vapeurs ou du carburateur avant de procéder Pour plus de détail voir le manuel du propriétaire Label symbol meanings These symbols mean as follows General warning symbol Caution or Warning Read own...

Page 9: ...lamp bracket Manual release screw Water intake hole Air vent hole plug Power trim and tilt P T T switch Anti cavitation plate Trim tab Motor cover Anode Anode Gear oil level plug Gear oil drain plug Anode Engine oil drain plug Pilot water hole Flush plug ...

Page 10: ...10 KEY FOB IF EQUIPPED WITH KEYLESS START SYSTEM MULTI FUNCTION GAUGE Option PRIMING BULB REMOTE CONTROL BOX Option Power trim and tilt P T T switch Remote control handle Shift lock button Type B Type A ...

Page 11: ...orsepower exceeding the manufac turer s recommended maximum horse power listed on the boat s Certification Plate Contact your authorized Suzuki marine dealer if you are unable to locate the hull Certificate Plate SELECTION OF LOWER UNIT ROTATION Lower unit of this product can be used for both regular rotation or counter rotation without changing itself The motor will be shipped as regular rotation...

Page 12: ...isted above are the mini mum battery rating requirements for starting the engine If your boat application requires additional battery loads it is recommended that an aux iliary battery or batteries be installed Consult your Suzuki dealer for proper battery installa tion information Dual purpose Cranking Deep cycle batter ies can be used if they meet the minimum specifications listed above MCA CCA ...

Page 13: ... Connecting 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...

Page 14: ...position is blown when the second battery for accesso ries will not be charged Please ask your authorized Suzuki Marine Dealer for installation of the isolator lead assembly NOTICE The electrical system or its components may be damaged if proper battery pre cautions are not followed Be sure to attach battery leads cor rectly Do not disconnect battery leads from the battery while the engine is runn...

Page 15: ...ed operating instructions IMMOBILIZER SYSTEM In this system the key fob and the keyless con trol unit uses radio communication to check if the key fob ID is registered in the Keyless Start System If the key fob ID is not registered the system prevents the engine from starting using the key fob Key fob Keyless control unit KEY FOB Two 2 key fobs are supplied with the Keyless Start System WARNING Ra...

Page 16: ... the conform ance certification mark A maximum of six 6 key fobs can be regis tered in one keyless control unit The battery life of the key fob is about two 2 years which can vary depending on use The key fob is always in transmission mode in order to communicate with the keyless control unit For this reason the battery may run down quickly if it receives strong radio waves from televisions or per...

Page 17: ...stem Switching the communication mode of the key fob Press and hold the lock button 1 on the key fob for more than one second to switch between ON mode and OFF mode NOTE If the lock button is pressed briefly while in com munication ON mode the LED 2 on the key fob briefly flashes once KEY FOB BATTERY REPLACEMENT WARNING This product contains a coin button cell battery If swallowed the coin button ...

Page 18: ...the battery Install the lithium disc type battery with the electrodes facing the proper direc tion Do NOT touch the internal circuit of the key fob when replacing the battery 2 Remove the O ring 1 NOTE The O ring may be fitted on the cover side 3 Insert a flat blade screwdriver into the slot at the mark on the cover to remove the bat tery NOTICE If the O ring is damaged the waterproof performance ...

Page 19: ... key fob is lost NOTE When the passcode has been updated or changed the previous passcode is deleted and updated to the new passcode Use the following procedure to set or change the passcode 1 Confirm that the engine is stopped 2 Make sure the emergency switch lock plate is in place 3 Confirm the key fob is within the communi cation range of the Keyless Start System 4 Confirm that the key fob is i...

Page 20: ...s emitting short sounds Briefly turn the switch after the number of sounds that is the same as the first pass code digit For example if the first passcode digit is seven turn the switch after the sev enth sound To set or select zero 0 turn the switch after the 10th sound NOTE If the operation in Step 2 is not performed within 60 seconds after performing Step 1 the passcode input operation will be ...

Page 21: ...on the emergency stop switch Buzzer sound When entering the 1st digit When entering the 2nd digit When entering the 3rd digit When entering the 4th digit Hold it for five 5 seconds NOTE When performing the passcode input operation again after the operation has been cancelled due to passcode input failure or after having interrupted the operation 1 Install the emergency switch lock plate 2 Turn the...

Page 22: ... it for five 5 seconds or longer then release it to the position Repeat this operation for two more times 2 The LED on the key fob blinks once and the buzzer sounds once After that the LED on the key fob blinks to indicate the passcode by the number of blinks as shown in the illustration This is indicated repeatedly NOTE The passcode indication will not start if Step 1 is not performed within eigh...

Page 23: ...a counter rotation lower unit or a left hand rotation propeller on a regu lar rotation lower unit the boat could go in the opposite direction expected which could lead to an accident Do not use a right hand rotation propeller with a counter rotation lower unit or a left hand rotation propeller with a regular rotation lower unit To identify the lower unit rotation type 1 Remove the motor cover 2 Co...

Page 24: ...you in selecting a suit able propeller for your boat Right hand propeller 3 16 R Left hand propeller 3 16 L You can determine if your propeller is appropri ate for use with your boat by using a tachome ter to measure engine speed when operating your boat at full throttle under minimum load conditions If you are using an appropriate pro peller the engine speed will be within the fol lowing range If...

Page 25: ...l 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 always ...

Page 26: ...hion 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 attitude with the motor tilted beyond the maxi mum trim position Trim range Tilt range TRIM TAB ADJUSTMENT This adjustment is used to compensate for the possible tendency of your boat to veer slightly to port or starboard This tende...

Page 27: ...handle detent force can be adjusted to suit operator s preference The control handle friction adjust ment will change the overall effort to move the control handle This will help prevent undesired movement of the control handle in rough water conditions Consult your authorized Suzuki marine dealer to adjust the control handle fric tion and detent force IDLE SPEED ADJUSTMENT The idle speed has been...

Page 28: ...n through digital communication with the engine Information displayed are engine speed shift position fuel level fuel consumption etc NOTE There is information that cannot be displayed depending on the model and equipment NOTE Consult your authorized Suzuki marine dealer for setting up the multi function gauge NOTE For details the proper handling of the multi function gauge refer to OPERATION INST...

Page 29: ... holding the SET button can change the illumination for the gauge screen to that for the daytime or nighttime Day Night P M P M SCREEN SELECTION The multi function gauge can select the display screen from the following choices Engine Speed Ground Speed Fuel Information Fuel Information All Items Display Screen Full Item To select the display screen Press the SET button and select the desired displ...

Page 30: ...play Screen The speed 1 fuel level 2 sub information 3 and time 4 are displayed The sub information display can be switched by pressing the or buttons This screen can be selected between digital and analog display Refer to the MENU INFORMATION SELECTION section Digital Analog Digital Analog 3 Fuel Information Display Screen This screen indicates the remaining fuel lev els of each tank installed al...

Page 31: ...ayed press the or button to switch the sub Information display in the following sequence NOTE Press and hold either the or button to reset the trip time trip distance average fuel consumption and total fuel consumption in the sub information simultaneously All other items are also reset simultaneously in addition to the displayed item Total operating hours Trip time Trip distance Battery voltage C...

Page 32: ...ater temperature and battery voltage are displayed 5 Instantaneous fuel flow This screen indicates the instantaneous fuel flow of each outboard motor 6 Total Instantaneous fuel flow This screen indicates the total instantaneous fuel flow of all outboard motors installed 7 Instantaneous fuel economy This screen indicates the total instantaneous fuel economy of all outboard motors installed 8 Averag...

Page 33: ...le the menu screen is displayed press the MENU button to return to the previous screen The MENU has four items of Illumination Diagnosis Display and Initial Setting Press the or button to select a menu item 1 Illumination Press the or button to select Illu mination and then press the SET button to display the Illumination selection menu Brightness The screen brightness can be adjusted in 10 steps ...

Page 34: ...on Next select ON synchronous or OFF asynchronous using the or button and then press the SET button Sync ON OFF Day Night P M P M 2 Diagnosis Press the or button to select Diagno sis and then press the SET button to display the Diagnosis selection menu Current Code Press the or button to select Current Code and then press the SET button to dis play the diagnostic code and or caution mes sage that ...

Page 35: ...g indication and indication OFF Select the display item using the or button Then press the SET button to select Analog1 Analog2 Digital or OFF As the Fuel screen displays only in digital mode the available selection is either ON or OFF Log Create Data Data Output When the indication is set to OFF the display screen for that item is skipped and the next screen is displayed Refer to the SCREEN SELEC...

Page 36: ...Unit Setting for the following units Distance set the unit for distance Press the SET button to select the unit Revise initial setting Yes No Speed Scale LOW HIGH L G US G IMP Quantity Econ D Q Q D I 100km Quantity set the unit for fuel quantity Press the SET button to select the unit Speed Scale setting for the speed scale The setting of Speed Scale is reflected only on the analog screen display ...

Page 37: ...te the input position and adjust the time difference using the or button Press the or button briefly to change the time in 15 minute increment Press and hold the button to change the time continuously by 15 minutes NOTE If the Timezone is not displayed confirm the connection of the GPS receiver If a GPS receiver is not installed the screen displays Position Setting for the gauge and engine positio...

Page 38: ...d 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 damage to your outboard motor regularly inspect and maintain it NOTICE Continuing to operate your outboard motor with the C...

Page 39: ...horized Suzuki marine dealer NOTICE If the Caution System is not working properly you may not be alerted to a con dition that can cause damage to your out board motor If the buzzer does not sound when the main switch is turned to the ON posi tion the buzzer may be broken or a fail ure may exist in the system circuit Consult your authorized Suzuki marine dealer OVER REVOLUTION CAUTION SYSTEM This s...

Page 40: ...tors like over trimming or ventilation there may be a problem with the Over Revolution Caution System Consult your authorized Suzuki marine dealer if the Over Revolution Caution System activates for no apparent reason The Low Oil Pressure indication clears when any of the button is pressed in the gauge How ever the caution alarm icon is displayed until eliminating the cause If this system activate...

Page 41: ... wind conditions permitting stop the engine tilt it out of the water and remove any debris like seaweed plastic bags or sand that may have blocked the water intakes Lower the engine into the water being sure that water intakes are immersed and restart it Check A that water discharges from the pilot hole and B that Overheat is not displayed on screen Be aware that Overheat is displayed on screen ag...

Page 42: ...pt to inspect or service the battery without first reading the warn ings cautions and instructions in the BATTERY INSTALLATION section of this manual NOTE A marginal battery may have enough power to start your engine yet may still cause this caution system to activate whenever engine or boat accessory use places a high current demand on the battery If equipped with Keyless Start System If a messag...

Page 43: ...until eliminating the cause For single engine Control panel For dual triple or quadruple engine 2ND STATION CAUTION SYSTEM This system is activated in the event of an error in the control system of the 2nd station If this system activates the Check 2nd Station and caution alarm icon are displayed on screen and the buzzer sounds In addition the red lamp 1 on the control panel lights up If this syst...

Page 44: ...em Consult your authorized Suzuki marine dealer NOTICE If this system activates for no apparent reason there may be a problem with the system Consult your authorized Suzuki marine dealer SHIFT CONTROL CAUTION SYSTEM This system is activated in the event of an error of the control system of the electronic shift If this system activates the Check Shift Con trol and caution alarm icon are displayed o...

Page 45: ...aler NOTICE If this system activates for no apparent reason there may be a problem with the system Consult your authorized Suzuki marine dealer STATION SETTING TROLL MODE CAUTION SYSTEM This system is activated when the TROLL mode operation is started on the gauge screen of the cockpit where the TROLL Mode operation is not available If this system activates the Check Station Set ting is displayed ...

Page 46: ...ki Maine Dealer KEYLESS START SYSTEM CAUTION SYSTEM IF EQUIPPED WITH KEYLESS START SYSTEM KEY FOB CAUTION SYSTEM The caution system is activated when key fob identification error If this system activates the Check Remote Key and caution alarm icon are indicated on the screen The Check Remote Key is cleared when any of the buttons are pressed on the gauge How ever the caution alarm icon is displaye...

Page 47: ...ection KEYLESS CONTROL UNIT CAUTION SYSTEM This system is activated when the 12 volt bat tery voltage to the keyless control unit drops to a point which could impair the keyless control unit performance If this system activates the Keyless Unit Bat tery Low and caution alarm icon are indicated on the screen The Keyless Unit Battery Low is cleared when any of the buttons are pressed on the gauge Ho...

Page 48: ...at allows the operation at a restricted speed even under such a failure condition NOTE If equipped with Keyless Start System This diagnostic code is designed to appear while the Keyless Start System is in ON state If not equipped with Keyless Start System This diagnostic code is designed to appear while the main switch is turned on The buzzer sound with diagnostic system activating will be cancele...

Page 49: ...d the preprogrammed hours the Change Oil is displayed on screen and the buzzer sounds This indication will repeat until you cancel the system activation CANCELLATION 1 If equipped with Keyless Start System Turn the Keyless Start System to ON state by turn the main switch to the position and then release it The main switch auto matically returns to the position If not equipped with Keyless Start Sy...

Page 50: ...tion Even if the engine oil has been replaced with the system not operating it is still necessary to perform the cancellation ENGINE STALLING CAUTION SYSTEM This system informs the operator when the motor stalls while it is operating When the engine stalls for any reason the cau tion buzzer sounds three times WATER IN FUEL ALERT SYSTEM This engine is equipped with an integral fuel fil ter water se...

Page 51: ...ERATION OF TILTING SYSTEMS POWER TRIM AND TILT The Power 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 If equipped with Keyless Start System WARNING The power trim and tilt PTT switch on the side cover can be accidentally acti vated when the Keyless Start System is in OFF state res...

Page 52: ...off result ing in injury Keep all persons away from the outboard motor to help prevent accidental activa tion of the PTT system 3 To check your adjustment tilt the motor fully up to check for motor contact Adjust further if necessary Return the motor to the normal running posi tion for each adjustment and repeat your check after each adjustment MANUAL TILTING If you are unable to tilt the motor us...

Page 53: ...and that you are able to support the weight of the engine 4 Continue to operate the Power Trim and Tilt DOWN switch until the trim rods are com pletely retracted To release the Tilt Lever tilt the motor all the way up using the Power Trim and Tilt UP switch and pull up the Tilt Lever If equipped with Keyless Start System NOTICE If you do not retract the trim rams com pletely when mooring they may ...

Page 54: ...or Refer to the TRAILERING 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...

Page 55: ...into the engine then remove it again The oil on the dipstick should be between the upper and lower limits shown on the dip stick 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 securely NOTICE Running the...

Page 56: ...elines will explain proper break in procedures Break in period 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...

Page 57: ...es at a time OPERATION MAIN SWITCH OPTION If equipped with Keyless Start System Turn the Keyless Start System to ON or OFF state by as follows 1 Make sure that the key fob is within the com munication range of the keyless control unit 2 Turn the main switch to the position and then release it The main switch automati cally returns to the position When the Keyless Start System has been turned to ON...

Page 58: ...ontrol panel at the driving station selected comes on and the SELECT LED at the driving station not selected goes out This switch is enabled only when the remote control handle at the 1st and 2nd driving sta tions are at the neutral position NOTE If equipped with Keyless Start System When the Keyless Start System has been turned to ON state by operating the main switch the 1st driving station is a...

Page 59: ...ther than neutral the THROTTLE ONLY LED blinks and a buzzer sounds at the same time NOTE When selecting the THROTTLE ONLY mode continue to push the THROTTLE ONLY switch until the buzzer sounds one short beep If equipped with Keyless Start System If the THROTTLE ONLY mode cannot be selected operate the main switch to turn the Keyless Start System to OFF state and wait for 20 seconds and then turn i...

Page 60: ...ne is at the neutral position and the engine speed is kept at idling When unlinking is selected the CENTER CTRL LED goes out Only when all the remote control handles are at the neutral position this switch is enabled NOTE If equipped with Keyless Start System When the Keyless Start System has been turned to ON state by operating the main switch link is automatically selected If not equipped with K...

Page 61: ...hat the motor fuel hose and the hose from the boat s fuel tank are securely attached and clamped 3 Make sure the motor is in NEUTRAL 4 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 ...

Page 62: ...will stop abruptly and the loss of forward motion may unexpectedly throw occu pants forward STARTING THE ENGINE NOTE If the emergency stop switch lock plate is not in position the starter motor cannot operate 1 Squeeze the fuel line priming bulb several times until you feel resistance 2 If equipped with Keyless Start System 1 Confirm that the key fob is in communication ON mode Refer to the Switch...

Page 63: ...econds continuously until the engine starts NOTE The continuous operating time of the starter motor is set at five seconds When this time is exceeded the starter motor will automatically stop If the motor stops wait about ten seconds for the motor to cool down and try again NOTICE If you hold in the START STOP switch to start the engine the starter system can be damaged Push the START STOP switch ...

Page 64: ...open throttle immediately after starting the engine without allowing the engine 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 when there is no water coming out of the pilot water hole or severe damage can result After starting the engine check to make sure that there is water coming ...

Page 65: ... OFF locked state can be released by using the emergency key and entering the 4 digit passcode 1 Turn the main switch 1 to the right about 15 and pull it out 2 Insert the emergency key 2 into the key cyl inder 15 3 Make sure lock plate 3 is in position 4 Turn the emergency key to position and then release it to the position The buzzer emits one 1 long sound and five 5 short sounds 5 Pull out the e...

Page 66: ...The main switch automati cally returns to the position 2 The buzzer starts emitting short sounds When the buzzer sounds for the same num ber of times as the 1st digit of the passcode immediately turn the emergency key to the position and release it to the posi tion To enter 0 in the passcode turn the switch after the buzzer sounds 10 times 3 After an 11th long sound repeat steps 1 and 2 to enter t...

Page 67: ...hen sounds three 3 times to notify that the input operation has been can celled To enter the passcode again after the input operation has been cancelled repeat the pro cedure from Step 2 The passcode input can be interrupted by installing the lock plate on the emergency stop switch Buzzer sound When entering the 1st digit When entering the 2nd digit When entering the 3rd digit When entering the 4t...

Page 68: ...n the emergency key to the position and then release it to the position to turn the Keyless Start System to OFF state And then pull out the emergency key from the key cylinder NOTE The passcode authentication state is main tained for 15 seconds after turning the emer gency key to the position In this state the engine can be started by turning the emer gency key to the left and pressing the START S...

Page 69: ...s not taken when 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 Shifting NOTE Type B remote control box The type B remote control box has a lock mech anism to help prevent accidental moving from neutra...

Page 70: ...handle past the detent and engage the throttle This can cause the boat 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 rearward when shifting 4 Turn the Keyless Start System to OFF locked status by one of the following meth ods Make sure that the key fob is within the communication range of the keyless con tro...

Page 71: ...your boat be sure to remove the key and emergency stop switch lock plate when the boat is unattended WARNING If you leave the motor stopped for a long period of time with the fuel line con nected fuel can leak out Disconnect the fuel line from fuel tank if there is a fuel connector whenever you leave the motor stopped for a long period of time If not equipped with Keyless Start System To stop the ...

Page 72: ...boat is unattended WARNING If you leave the motor stopped for a long period of time with the fuel line con nected fuel can leak out Disconnect the fuel line from fuel tank if there is a fuel connector whenever you leave the motor stopped for a long period of time MOORING The motor should be tilted up out of the water when you moor the boat in shallow water or if the motor will not be used for some...

Page 73: ...ious damage can occur Do not allow the motor to hit bottom If the motor does strike bottom inspect it immediately for damage OPERATING THE TROLL MODE MULTI FUNCTION GAUGE Switching to TROLL Mode Press and hold the MENU button during cruis ing operation at Trolling Speed minimum speed and this will switch the operation to TROLL Mode For the Trolling Speed the desired engine speed can be set and mai...

Page 74: ...s on the screen of the Multi Function Gauge s that did not be oper ated to get into the troll mode This icon appears on the screen of the Multi Function Gauge s that cannot operate the troll mode Example of the troll mode display on the Multi Function Gauge that can operate the troll mode Example of the troll mode display on the Multi Function Gauge that cannot operate the troll mode ...

Page 75: ...ressing the button at the upper limit of trolling speed of all engines the engine speed will not change and three long beeps will sound For the multiple engines If the button is operated when one engine has reached the adjustment limit of trolling speed while any other engine has not one short beep sounds and the rpm of engine which has not reached the adjustment limit changes Shift operation and ...

Page 76: ... engine speed increases by 50 r min When pressing the DN switch one short beep sounds and the engine speed decreases by 50 r min NOTE When pressing the DN switch at the lower limit of trolling speed of all engines the engine speed will not change and three long beeps will sound When pressing the UP switch at the upper limit of trolling speed of all engines the engine speed will not change and thre...

Page 77: ...er in freezing temperatures keep the lower unit submerged in the water at all times When the motor is stored out of the water in freezing temperatures stand it up in the vertical position so that the cooling sys tem drains completely MOTOR REMOVAL AND TRANSPORTING MOTOR REMOVAL If it is necessary to remove the outboard motor from your boat we recommend that you ask your authorized Suzuki Marine De...

Page 78: ...3 After draining retighten the drain screw 1 and install the motor cover 3 Rest the motor on a case protector with the port side downwards as shown NOTICE If spilled gasoline is just left on painted surface it may cause a stain or discolora tion of the surface coating Wipe off any spilled gasoline immediately with a soft cloth etc WARNING Spilled fuel or fuel vapor can cause a fire and is hazardou...

Page 79: ...ngine Never let the lower unit sit higher than the power head when transporting or storing your outboard TRAILERING When trailering your boat with the motor attached keep the motor in the normal operat ing position unless there is not enough ground clearance If you need more ground clearance trailer the motor in a tilted position using a tran som saver bar or similar device to support the weight o...

Page 80: ...HE 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 month Every 100 hrs or every 12...

Page 81: ...ntenance intervals in the chart are designed for normal usage of your outboard motor If your outboard motor is used under severe conditions as outlined below you may need to perform mainte nance more often than indicated in the chart Frequent full throttle operation TOOL KIT A tool kit is provided with your outboard motor Keep the kit on board your boat and make sure that all of the items provided...

Page 82: ... Use ONLY resistor type spark plugs in your outboard motor Your authorized Suzuki Marine Dealer can determine if the standard spark plug is suitable for your type of motor usage by inspecting the color of the plug s porcelain 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 immediatel...

Page 83: ...recommended torque setting or the specified rotation angle Tightening torque 15 19 N m 1 5 1 9 kgf m 11 14 lbf 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 maintenan...

Page 84: ...y they must be replaced Consult your authorized Suzuki Marine dealer if it is necessary to replace them Breather line Fuel line Fuel line WARNING Fuel leakage can contribute to an explo sion or fire resulting in serious personal injury Have your authorized Suzuki marine dealer replace the fuel line if there is any evidence of leaking cracking or swelling ...

Page 85: ...equently if your engine is used for extended trolling 3 Place a drain pan under the engine oil drain screw 4 Remove the engine oil drain screw 1 and gasket 2 then let the engine oil drain 5 After draining secure the engine oil drain screw with a new gasket NOTE There are spare gaskets in the tool bag 6 Fill with recommended engine oil to the upper level Oil capacity 8 0 L 8 5 7 0 US Imp qt Engine ...

Page 86: ...irt and water proof gloves when handling oil Wash with soap if oil contacts your skin Launder any clothing or rags that are wet with oil UPPER LIMIT LOWER LIMIT GEAR OIL To check the gear oil level adjust the engine to an upright position remove the gear oil level plug 1 and look into the hole The oil level should be at the bottom edge of the hole If the oil level is low add the specified gear oil...

Page 87: ... 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 your skin Launder any clothing or rags that are wet with oil LOW PRESSURE FUEL FILTER The low pressure fuel filter must be replaced by an authorized Suzuki Marine Dealer periodi cally Replace low pressure fuel ...

Page 88: ...the resonator 2 in place 4 Remove the resonator 2 5 Push the connector lock tab a then discon nect the water sensor lead wire connector 3 6 Place a rag under the filter before removal to catch any spilled fuel 7 Separate the filter cup 4 from the cap 5 by turning the filter cup counterclockwise NOTICE Improperly loosening the filter cup can cause sensor lead wire damage Be careful not to twist the...

Page 89: ...t the engine and check that there are no leaks around the fuel filter NOTE If any water exists in the fuel filter cup remove the cup and drain the water Always dispose of excess fuel safely For questions consult your authorized Suzuki marine dealer NOTICE If spilled gasoline is just left on painted surface it may cause a stain or discolora tion of the surface coating Wipe off any spilled gasoline ...

Page 90: ...ct approximately 10 grams of grease at initial 20 hours Inject approximately 5 grams of grease at every 100 hours 12 months NOTE If grease will not inject into the fitting consult your Authorized Suzuki Marine Dealer Your authorized Suzuki Marine Dealer may also have additional recommendations due to regional climate or operating conditions Please consult him for advice NOTICE Using a hydraulic or...

Page 91: ...ro sion measures may be helpful under those con ditions Consult your authorized Suzuki Marine Dealer for details NOTE Consult your authorized Suzuki Marine Dealer for inspection and replacement of internal anodes attached to the powerhead NOTICE If anodes are not properly maintained underwater aluminum surfaces such as the lower unit will suffer galvanic corro sion damage Periodically inspect anod...

Page 92: ...s below the MIN level line add DIS TILLED WATER ONLY until the battery solution level 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 acid comes in contact with any of these flush immediately with large amounts of water If acid contacts the eyes or skin get immediate medical...

Page 93: ... the water passages salt can corrode the motor and shorten its life Flush the water passages as follows ENGINE RUNNING Vertical position Suzuki recommends that you flush the water passage by using this method To flush the water passages you must obtain a commercially available engine flush device WARNING Exhaust gas contains carbon monoxide a dangerous gas that is difficult to detect because it is...

Page 94: ...water pump operation If no water spray is evident stop the motor immediately and consult your dealer NOTICE Severe engine damage can occur in as lit tle as 15 seconds if the engine is started without supplying water to the cooling system Never start the motor without supplying water to the cooling system 5 Allow the engine to run only at idle speed while flushing Readjust the water flow if necessa...

Page 95: ...nt thread B is included in the crate parts 4 Turn on the water to obtain a good water flow Flush the engine for about five minutes 5 Turn off the water 6 Remove the hose and connector if used then reinstall the plug into the flushing port 7 Leave the motor in a vertical position until the engine is drained completely ENGINE NOT RUNNING Full tilt up position 1 Raise the engine to the full tilt up p...

Page 96: ...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 97: ... parts Refer to the LUBRICATION section Spray entire powerhead with a rust preventative not a penetrating oil product 8 Wash the exterior of the engine with fresh water After washing the water remaining on the engine should be wiped off with dry clothes High pressure washer should be used only for washing exterior And the nozzle of the high pressure washer should be well away from the engine 9 App...

Page 98: ...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 Replace them if necessary 2 Check the gear case oil level and if neces sary add gear oil according to the procedure outlined in the GEAR OIL section 3 Lubricate all m...

Page 99: ... Starter motor is failed Main switch or start stop switch is failed Electric wiring connection is loose Engine will not start hard to start Fuel tank is empty Fuel is deteriorated Engine starting procedure is not correct Fuel tank air vent is not opened Fuel hose is not properly connected to engine Fuel hose is kinked or pinched Fuel filter is clogged Fuel pump is failed Fuel tank filter is clogge...

Page 100: ...stem is failed Electronic throttle system is failed Heavy cargo is on the boat Water has entered into the boat Bottom of boat is not clean or damaged Engine vibrates excessively Propeller is damaged Engine mounting bolts or clamp screws are loose The Keyless Start System does not turn ON even when the main switch is oper ated The error sound five short buzzer beeps is NOT heard If equipped with Ke...

Page 101: ... NOTE Use the fuse puller at the back of fuse box cover when the fuse is pulled off and installed Fuse box cover Fuse puller 4 Remove the Sub battery cable fuse 5 Inspect the fuse and replace with new fuse if needed NOTE If a fuse is blown try to determine the root cause and correct it If the cause is not corrected the fuse may be blown again Sub battery cable fuse case Normal fuse Main fuse 60A I...

Page 102: ...stallation you may have a major electri cal system problem Consult your SUZUKI marine dealer Fuse box cover 1 Starter motor relay fuse 30 A 2 Ignition coil Injector Engine control module Fuel pump fuse 30 A 3 Throttle valve fuse 15 A 4 Shift actuator fuse 15 A 5 PTT switch fuse 10 A 6 Main fuse 60 A 7 Isolator select fuse 30 A 8 Spare fuse 60 A 9 Spare fuse 30 A 0 Spare fuse 15 A A Spare fuse 10 A...

Page 103: ... in Piston Displacement 2867 cm3 174 9 cu in Maximum output 110 3 kW 150PS 128 7 kW 175PS 147 0 kW 200PS Full Throttle Operating Range 5000 6000 r min min 1 5500 6100 r min min 1 Idle speed in Neutral 600 700 r min min 1 Ignition System Full transistor Engine Lubrication Trochoid pump pressure lubrication Engine Oil Capacity 8 0 L 8 5 7 0 US Imp qt Spark Plug NGK LKR6E Spark Plug Gap 0 8 0 9 mm 0 ...

Page 104: ...Y G Br R Bl Br Y P W B W OIL PRESSURE SWITCH Bl FUEL PUMP H SELECT TERMINAL M MAP SENSOR THROTTLE SENSOR THROTTLE MOTOR M R Y W Bl W B W B R O Y R Gr B B Bl JOINT CONNECTOR 2 STARTER RELAY FUSE FUSE BOX MAIN RELAY 15A 10A 30A 30A 15A 60A 30A G B R B W R W W O R R R R R R W W W W Y Gr Gr Br CKP SENSOR STATER MOTOR CMP SENSOR 1 CMP SENSOR 2 CYLINDER TEMP SENSOR O2 SENSOR IAT SENSOR THROTTLE RELAY SH...

Page 105: ...Lg W G P B W B Y 120 DUMMY SELECT 120 W B Lg R B Bl Br G Gr Lbl Lg O P R V W Y B Br B Lg B R B W Bl B Bl R Bl W Bl Y Br B Br R Br W Br Y G B G Bl G W Gr G Gr R Gr Y Lbl W Black Blue Brown Green Gray Light blue Light green Orange Pink Red Violet White Yellow Black with Brown tracer Black with Light green tracer B G Black with Green tracer Black with Red tracer Black with White tracer Blue with Blac...

Page 106: ...t green with White tracer Orange with Black tracer Orange with Green tracer Orange with Yellow tracer Pink with Black tracer Pink with Blue tracer Pink with Yellow tracer P W Pink with White tracer Red with Black tracer Red with Blue tracer Red with White tracer Red with Yellow tracer Violet with White tracer White with Black tracer White with Blue tracer W G White with Green tracer White with Red...

Page 107: ...Prepared by June 2019 Part No 99011 96LD0 03B Printed in Japan COPYRIGHT SUZUKI MOTOR CORPORATION 2019 ...

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