Suzuki DF25 2006 Rigging Manual Download Page 1

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99518-03060-01E

Printed in Japan

2006 RIGGING MANUAL

DF25 -- DF250

2006 RIGGING MANU

DF25 -

- DF250

9 9 5 1 8 - 0 3 0 6 0 - 0 1 E

Summary of Contents for DF25 2006

Page 1: ...2006 RIGGING MANUAL DF25 DF250 9 9 5 1 8 0 3 0 6 0 0 1 E 1 1...

Page 2: ...lication Suzuki reserves the right to make changes at any time without prior notice NOTE This manual may include information on models not designated for your market Therefore before commencing check...

Page 3: ...of contents to easily locate the item and page you need SYMBOL Listed in the table below are the symbols indicating instructions and other important information necessary for proper servicing Please...

Page 4: ...lack of servicing of the outboard motor In addition to the WARNING and CAUTION stated you must always have right judgement and observation based upon the mechanical safety principles TIGHTENING TORQUE...

Page 5: ...1 UNCRATING 1 1 CONTENTS UNCRATING UNCRATING PROCEDURES 1 2 DF200 225 250 1 2 5 5...

Page 6: ...rs Tools for uncrating Wrench 12 mm 14 mm Wrench 17 mm 19 mm Scissors 1 Check damage due to vibration or impact dur ing transportation If there are any abnormal condition found take photograph in the...

Page 7: ...me E by two or more opera tors to remove it 7 Remove styrofoam block F NOTE Use a hook that has a lifting capacity of at least 450 kg 8 Remove the engine cover G 9 Loosen two bolts I on the right and...

Page 8: ...rators one holding the base plate P securely 13 Loosen four bolts O marked with in the illustration and remove the outboard motor from the base plate Make sure to perform this work with two or more op...

Page 9: ...used for removing the engine from its horizontal posi tion in the shipping crate Attempting to lift the motor from its horizontal crated position using the front lift eye creates a chain or sling angl...

Page 10: ...R DIMENSIONS 2 1 CONTENTS MOTOR DIMENSIONS MOTOR DIMENSIONS 2 2 DF4 5 6 2 2 DF9 9 15 2 3 DF25 V2 DF25 30 DF40 50 DF60 70 DF90 115 140 DF150 175 DF200 225 250 2 4 MAJOR DIMENSIONS 2 5 CODE DEFINITION 2...

Page 11: ...ENSIONS MOTOR DIMENSIONS DF4 5 6 Unit mm Tilt 1st position 0 Tilt 2nd position 4 Tilt 3rd position 8 Tilt 4th position 12 Tilt 5th position 16 Shallow 1st position 32 Shallow 2nd position 44 Maximum t...

Page 12: ...MOTOR DIMENSIONS 2 3 DF9 9 15 Unit mm Shallow drive 1st position 27 2nd position 42 315 315 160 163 12 12...

Page 13: ...2 4 MOTOR DIMENSIONS DF25 V2 DF25 30 DF40 50 DF60 70 DF90 115 140 DF150 175 DF200 225 250 Unit mm L3 H4 H 5 L5 L4 L2 L1 A1 A2 H3 H2 H1 W3 W1 A 3 A 4 W2 W4 13 13...

Page 14: ...766 H4 678 3 740 776 824 811 908 1 037 1 041 H5 231 330 325 370 370 353 353 405 L1 495 5 562 619 661 568 568 671 722 L2 H 145 QR T 33 9 137 131 132 132 168 159 R 110 1 Q QE 144 L3 517 5 Q QE 508 QH 7...

Page 15: ...nt on the body when steered to the maximum angle on PORT side H1 Overall height H2 Vertical distance from Transom height datum point to cavitation plate undersurface H3 Vertical distance from datum po...

Page 16: ...CENTERLINE 3 17 SINGLE MOTOR 3 17 SINGLE MOTOR 3 18 DUAL MOTOR 3 19 TRANSOM DRILLING TEMPLATE INSTRUCTIONS 3 20 TRANSOM DRILLING TEMPLATE DIMENSIONS 3 20 DF25 30 DF40 50 BOLT HOLE POSITION 3 21 DF60...

Page 17: ...you are trying to achieve Determine the customer s needs application and use of the perspective rig to make the best overall horsepower recommendation Do not overpower your boat Never install an outbo...

Page 18: ...MOTOR INSTALLATION 3 3 CLAMP BRACKET DIMENSIONS DF4 5 6 Unit mm DF9 9 15 HOLES 2 PLACES HOLES 2 PLACES 18 18...

Page 19: ...3 4 MOTOR INSTALLATION DF25 V2 Unit mm DF25 30 DF40 50 HOLES 4 PLACES HOLES 8 PLACES 19 19...

Page 20: ...MOTOR INSTALLATION 3 5 DF60 70 DF90 115 Unit mm DF140 HOLES 10 PLACES HOLES 2 PLACES HOLES 2 PLACES HOLES 10 PLACES HOLES 2 PLACES HOLES 2 PLACES 20 20...

Page 21: ...3 6 MOTOR INSTALLATION DF150 175 Unit mm DF200 225 250 HOLES 20 PLACES HOLES 20 PLACES 21 21...

Page 22: ...MOTOR INSTALLATION 3 7 MINIMUM SPACE DF25 30 SINGLE MOTOR A Minimum 840 mm D Minimum 230 mm 33 inch 9 inch B Maximum 190 mm E Minimum 230 mm 7 4 inch 9 inch C Maximum 190 mm 7 4 inch A D E B C 22 22...

Page 23: ...DF25 30 DUAL MOTOR A Minimum 1 401 mm E Minimum 181 mm 55 inch 7 1 inch B Minimum 561 mm F Maximum 190 mm 22 inch 7 4 inch C Minimum 230 mm G Maximum 190 mm 9 inch 7 4 inch D Minimum 230 mm 9 inch A...

Page 24: ...MOTOR INSTALLATION 3 9 DF40 50 SINGLE MOTOR A Minimum 838 mm D Minimum 230 mm 33 inch 9 inch B Maximum 189 mm E Minimum 230 mm 7 4 inch 9 inch C Maximum 189 mm 7 4 inch A D E B C 24 24...

Page 25: ...N DF40 50 DUAL MOTOR A Minimum 1 397 mm E Minimum 181 mm 55 inch 7 1 inch B Minimum 559 mm F Maximum 189 mm 22 inch 7 4 inch C Minimum 230 mm G Maximum 189 mm 9 inch 7 4 inch D Minimum 230 mm 9 inch A...

Page 26: ...MOTOR INSTALLATION 3 11 DF60 70 SINGLE MOTOR A Minimum 838 mm D Minimum 200 mm 33 inch 7 9 inch B Maximum 219 mm E Minimum 200 mm 8 6 inch 7 9 inch C Maximum 219 mm 8 6 inch A D E B C 26 26...

Page 27: ...DF60 70 DUAL MOTOR A Minimum 1 397 mm E Minimum 121 mm 55 inch 4 8 inch B Minimum 559 mm F Maximum 219 mm 22 inch 8 6 inch C Minimum 200 mm G Maximum 219 mm 7 9 inch 8 6 inch D Minimum 200 mm 7 9 inch...

Page 28: ...MOTOR INSTALLATION 3 13 DF90 115 140 SINGLE MOTOR A Minimum 838 mm E Minimum 179 mm 33 inch 7 inch B Maximum 240 mm 9 4 inch C Maximum 240 mm 9 4 inch D Minimum 179 mm 7 inch A D E B C 28 28...

Page 29: ...DF140 The counter rotation is recommended to install on port side A Minimum 1 498 mm E Minimum 180 mm 59 inch 7 inch B Minimum 660 mm F Maximum 240 mm 26 inch 9 4 inch C Minimum 179 mm G Maximum 240 m...

Page 30: ...MOTOR INSTALLATION 3 15 DF200 225 250 SINGLE MOTOR A Minimum 940 mm D Minimum 184 mm 37 inch 7 2 inch B Maximum 286 mm E Minimum 184 mm 11 3 inch 7 2 inch C Maximum 286 mm 11 3 inch A D E B C 30 30...

Page 31: ...he counter rotation is recommended to install on port side A Minimum 1 626 mm E Minimum 114 mm 64 inch 4 5 inch B Minimum 686 mm F Maximum 286 mm 27 inch 11 3 inch C Minimum 184 mm G Maximum 286 mm 7...

Page 32: ...d mark B that position on the transom surface 3 Measure the horizontal distance between the two garboard stripes Measure the center 1 2 of the stripe to stripe distance and mark C that position on the...

Page 33: ...MOTOR Checking of vertical line A Check that the right and left spaces divided by vertical line A are equal 1 Check that the length of lines D and D are equal 2 Check that the length of lines E and E...

Page 34: ...line A that has been previously measured for single engine mounting 2 On the horizontal stripe to stripe distance mark C the point at 1 2 of the distance between the engine centers away from and on e...

Page 35: ...DRILLING TEMPLATE DIMENSIONS Unit mm Tool name Part number Applicable model Transom Drilling Template 09914 89510 DF25 30 DF200 225 250 Hole name Model Drill bit diameter B DF25 30 12 5 mm B DF40 50...

Page 36: ...MOTOR INSTALLATION 3 21 DF25 30 DF40 50 BOLT HOLE POSITION Unit mm DF60 70 DF90 115 DF140 BOLT HOLE POSITION DF25 30 DF40 50 Clamp bracket DF60 70 DF90 115 DF140 Clamp bracket...

Page 37: ...3 22 MOTOR INSTALLATION DF150 175 BOLT HOLE POSITION Unit mm DF200 225 250 BOLT HOLE POSITION DF150 175 Clamp bracket DF200 225 250 Clamp bracket...

Page 38: ...Measure the center 1 2 of the chine to chine distance and mark that position on the tran som surface 3 Measure the horizontal distance between the two garboard stripes Measure the center 1 2 of the st...

Page 39: ...holes are fitted to the vertical centerline A 7 Adjust the height and horizontal position of Transom Drilling Template with its wing bolts 8 Tighten the transom clamp arm nut to secure the Transom Dri...

Page 40: ...out of Transom Drilling Tem plate using a tape measure In other words confirm the position of the anti Cavitation Plate 10 Drill the bolt holes into the transom board through the drilling guide hole o...

Page 41: ...sonal injury or cause damage to the engine block Use a hoist which has a minimum lift capacity of at least 450 kg 1 000 lbs when lifting the motor EXAMPLE OF LIFTING DF200 225 250 EXAMPLE OF LIFTING D...

Page 42: ...0 Contained parts Nut D 55 N m 5 5 kgf m 40 0 lb ft NOTE Drill the upper holes center at least 25 mm 1 0 in away from the transom top surface For power trim tilt model drill the lower holes at the pos...

Page 43: ...ial it is necessary to reinforce the tran som board with an attachment plate MOUNTING TO THE TRANSOM DF150 175 DF200 225 250 Contained parts SUZUKI highly recommend to use six mounting bolts for a rig...

Page 44: ...tening torque cannot reach to the specified torque due to weak transom material it is necessary to put the transom board with an reinforcement plate Install the reinforcement plate between the transom...

Page 45: ...2 41153 94500 Color White 41153 94500 Color White 41153 94500 Color White 41153 94500 Color White 41153 94500 Color White 41153 93J00 Color Black 4 4 4 4 4 6 4 4 4 4 4 6 41155 93J00 2 09100 12093 STD...

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