Suzuki DF250AP Owner'S Manual Download Page 7

Page: 7 / 92

LOCATION OF SAFETY LABELS

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

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

WARNING AVERTISSEMENT

Label symbol meanings
These symbols mean as follows;

: General warning symbol

(Caution or Warning)

: Read owner

’

s manual carefully

: Remote control lever/gear shift lever

operation-two direction; Forward/

Neutral/Reverse

: Engine start

: Hazard caused by fire

: Hazard caused by laying the

motor on its side

• Fuel can leak creating a fire hazard if

you lay motor on its side. Drain fuel
completely from vapor separator or
carburetor before laying motor on its side.

• See owner’s manual for details.

• Le carburent risque de fuir et de

présenter  un  danger  d’incendie  si  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.

Summary of Contents for DF250AP

Page 1: ...1 EN __ __ __ __ __ __ __ __ __ __ __ __ __ ENGLISH DF250AP DF300AP OWNER S MANUAL ...

Page 2: ...cs Carry boating safety and emergency equip ment This important equipment includes flotation aids for each person plus one throwable buoyant cushion in any boat 16 feet or longer fire extinguisher sound sig naling device visual distress signals anchor bilge pump bucket compass emergency starter rope extra fuel and oil first aid kit flashlight food and water mir ror paddles tool kit and transistor ...

Page 3: ...rating your new Suzuki and review the manual from time to time It contains important infor mation on safety operation and mainte nance FOREWORD Thank you for choosing a Suzuki outboard motor Please read this manual carefully and review it from time to time It contains important information on safety operation and mainte nance A thorough understanding of the infor mation presented in this manual wi...

Page 4: ...SHIFT CONTROL CAUTION SYSTEM 39 KEYLESS START SYSTEM CAUTION SYSTEM IF EQUIPPED WITH KEYLESS START SYSTEM 42 DIAGNOSTIC SYSTEM 44 OIL CHANGE REMINDER SYSTEM 44 ENGINE STALLING CAUTION SYSTEM 47 WATER IN FUEL ALERT SYSTEM 47 OPERATION OF TILTING SYSTEMS 47 INSPECTION BEFORE BOATING 50 BREAK IN 52 OPERATION 53 MOTOR REMOVAL AND TRANSPORTING 68 TRAILERING 70 INSPECTION AND MAINTENANCE 71 FLUSHING THE...

Page 5: ... boat s fuel tank s from contaminating your motor s elec tronic fuel injection system Water contamina tion can cause poor engine performance and can also cause damage to the electronic fuel injection system components Your Authorized Suzuki Marine Dealer can pro vide you advice about water separating fuel fil ter systems and installation Gasoline Ethanol Blends Blends of unleaded gasoline and etha...

Page 6: ...oduce varnish and gum which can damage the engine Always use fresh gasoline NOTICE Fuels containing alcohol can cause paint damage which is not covered under the New Outboard Motor Limited Warranty Be careful not to spill 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 selec...

Page 7: ...rol lever gear shift lever operation two direction Forward Neutral Reverse Engine start Hazard caused by fire Hazard caused by laying the motor on its side Fuel can leak creating a fire hazard if you lay motor on its side Drain fuel completely from vapor separator or carburetor before laying motor on its side See owner s manual for details Le carburent risque de fuir et de présenter un danger d in...

Page 8: ...se side Power trim and tilt P T T switch Water intake hole FUEL LINE Priming bulb REMOTE CONTROL BOX Option Type B Type A MULTI FUNCTION GAUGE Option Gear oil drain plug KEYLESS FOB IF EQUIPPED WITH KEYLESS START SYSTEM SELECT THROTTLE ONLY SELECT THROTTLE ONLY Select switch Emergency stop switch Power trim and tilt P T T switch Remote control handle Throttle only switch Select switch Shift lock b...

Page 9: ...ki marine dealer He has the tools the facilities and the know how to do the job correctly 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 specification from the factory To change the rotation from regular rotation to counter the rotation select connector locat...

Page 10: ...hown below 1000 Marine Cranking Amps MCA ABYC or 800 Cold Cranking Amps CCA SAE or 180 Reserve Capacity RC Minutes SAE or 12 Volt 130 AH NOTE The specifications listed above are the mini mum battery rating requirements for starting the engine When connecting batteries in parallel they must be of the same type capacity manufac turer and of similar age When replacement is necessary they should be re...

Page 11: ...ery near the fuel tank a spark from the battery may ignite the gaso line causing a fire and or an explosion Do not place the fuel tank in the same com partment area as the battery 8WARNING Batteries produce flammable hydrogen gas and may explode if they are near flames or sparks Never smoke or cause sparks when working near the battery Keep the battery away from open flames To avoid creating a spa...

Page 12: ...ndard to option dual battery charging system will be effective Be sure to check if the optional 40 A fuse in OPT position is blown when the second battery for accessories will not be charged Please ask your authorized Suzuki Marine Dealer for installation of the isolator lead assembly USE OF ELECTRICAL ACCESSORIES The amount of power DC12V available for accessories however depends on the operat in...

Page 13: ...e keyless control unit uses radio communication to check if the keyless fob ID is registered in the Keyless Start System If the keyless fob ID is not registered the sys tem prevents the engine from starting using the keyless fob Keyless control unit Keyless fob KEYLESS FOB Two 2 keyless fobs are supplied with the Key less Start System NOTE The keyless fob falls under the category of restricted ele...

Page 14: ...equipment etc or receive medical treatment with the keyless fob in your pocket etc NOTE Do NOT erase or tamper with the confor mance certification mark A maximum of six 6 keyless fobs can be registered in one keyless control unit The battery life of the keyless fob is about two 2 years which can vary depending on use The keyless fob is always in transmission mode in order to communicate with the k...

Page 15: ...nk batteries might have been swallowed or placed inside any part of the body seek immediate medical attention Keep new and used batteries away from children If the battery compartment cannot be closed securely stop using this product and keep it away from children IIf the keyless fob battery runs low Keyless FOB Battery Low appears on the gauge which indicates the battery should be replaced 8CAUTI...

Page 16: ...per formance deteriorates which can cause the keyless fob to malfunction Be careful not to damage the O ring when removing it 3 Insert a flat blade screwdriver into the slot at the mark on the cover to remove the bat tery 4 Replace the battery so its terminal faces the cover side as shown in the illustration Lithium disc type battery CR2025 or equiva lent Confirm that the O ring is placed in posit...

Page 17: ...n lower unit or a left hand rotation propeller on a regular rotation lower unit the boat could go in the opposite direc tion expected which could lead to an acci dent 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 Confirm the rotati...

Page 18: ... 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 when operating your boat at full throttle under minimum load conditions If you are using an app...

Page 19: ... Failure to take proper precautions when installing or removing the propeller can result in severe personal 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 cavitatio...

Page 20: ...gine above 1500 r min or operate the boat in a planing attitude with the motor tilted beyond the maximum trim posi tion NOTICE If you operate the boat with the motor trimmed beyond the maximum trim position the water intake holes may be above the water line causing severe engine damage due to over heating Never operate the boat with the motor trimmed beyond the maximum trim position Make a test ru...

Page 21: ... necessary readjust the trim tab CONTROL HANDLE ADJUSTMENT The control handle friction and control 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...

Page 22: ... information 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 OPE...

Page 23: ... 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 display screen Every time the SET button is pressed the dis play screen switches in the following sequence NOTE Screens that had been set to OFF in the dis play setting...

Page 24: ...play Screen This screen indicates the remaining fuel lev els of each tank installed along with sub information The sub information display can be switched by pressing the or buttons This screen indicates only in digital mode Digital Analog Digital Analog 4 All Items Display Screen This screen displays all the general indica tion items for this gauge This screen can be selected between digital anal...

Page 25: ...ly in addition to the displayed item Total operating hours Trip time Trip distance Battery voltage Cooling water temperature Instantaneous fuel flow Instantaneous fuel economy Average fuel economy Total fuel used Latitude Longitude Total Instantaneous fuel flow 1 Total Operating Hours The total operating hours from brand new engine are displayed 2 Trip Time This screen indicates the trip time sinc...

Page 26: ...aneous fuel economy of all outboard motors installed 8 Average fuel economy This screen indicates the total average fuel economy of all outboard motors installed FLOW TOTAL 9 Total fuel used This screen indicates the total fuel used of all outboard motors installed 10 Latitude Longitude The latitude and longitude of current boat position are displayed NOTE If the Latitude Longitude are not display...

Page 27: ...ss can be adjusted in 10 steps Press the or button to select Bright ness and press the SET button Next adjust the brightness using the or button and then press the SET button Diagnosis Display Device List Initial Setting Ver 1 170 1 210 46828 Day or Night Sync ON OFF Day Night Day or Night Press the or button to select Day or Night Next select Day or Night using the SET button Sync The Brightness ...

Page 28: ...n gauge screen The PTT switch operations take priority even when the Auto Trim mode is set ON If the PTT switch is operated when the Auto Trim mode is set ON the Auto Trim mode is interrupted and the A flashes on the dis play Auto Trim mode engages again when the engine speed is reduced to 1500 r min or below or the outboard motor is set in the full trim down position 3 Diagnosis Press the or butt...

Page 29: ... using the or button Then press the SET button to select A1 A2 D 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 SELECTION section NOTE It is not possible to set all the display items to OF...

Page 30: ...de You can also change the passcode 1 If you have the keyless fob Confirm the keyless fob is within the com munication range of the Keyless Start System Confirm that the keyless fob is in commu nication ON mode Refer to Switching the communication mode of the keyless fob section Press the or button to select Keyless and then press the SET button to display the Keyless selection menu Passcode The p...

Page 31: ...een Initial Setting contains eight 8 menus Select the Initial Setting menu using the or button and then press the SET button to display the setting screen Language Sets the display language Use the or button to select the display language and press the SET button Revise initial setting Yes No Unit Time Position Component Setting Initial Setting Language The confirmation message appears To change t...

Page 32: ...00km Time Setting for the time indication Clock setting for display non display of the clock Press the SET button to select ON or OFF 12h or 24h select 12 hour or 24 hour display Press the SET button to select 12h or 24h Timezone set the time zone This gauge can be set the time by entering the time difference from the standard time Green wich time After the time difference is entered it is not req...

Page 33: ...ange of Tank Keyless Setting Setting for Keyless Consult your authorized Suzuki marine dealer for setting change of Keyless Setting Demo Mode Setting Setting for Demo Mode Consult your authorized Suzuki marine dealer for setting change of Demo Mode Setting ALARM Alarms alert the user of an operating condition that requires action If an alarm occurs the gauge screen will display the caution message...

Page 34: ...perly you may not be alerted to a condition that can cause damage to your outboard motor If the buzzer does not sound when the Key less Start System has been turned to ON state by operating the engine switch the buzzer may be broken or a failure may exist in the system circuit Consult your authorized Suzuki marine dealer If not equipped with Keyless Start System Each time the ignition key is turne...

Page 35: ... recommended maximum throttle and you are sure that the propeller pitch is suffi cient and there are no factors like over trim ming 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 acti vates for no apparent reason The Low Oil Pressure indication clears when any of the button is pressed ...

Page 36: ...ctivates for no apparent rea son there may be a problem with the system Consult your authorized Suzuki marine dealer OVERHEAT CAUTION SYSTEM This system is activated when the cylinder wall temperature is too high due to insufficient water cooling NOTE The overheat caution system will not detect high combustion chamber temperature caused by for example an oil system malfunction poor quality fuel or...

Page 37: ... or incorrect spark plugs NOTE If the engine is operated beyond the maximum trim position the water intake holes may be above the water line In this situation the over heat caution system may activate NOTICE Operating the engine with the Overheat Cau tion System activated can result in severe engine damage If the Overheat Caution System activates stop the engine as soon as possible wind and water ...

Page 38: ...mpt to inspect or service the bat tery without first reading the warnings cau tions 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 mess...

Page 39: ...n there may be a problem with the system Consult your authorized Suzuki marine dealer 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 If this system is activated the engine cannot be controlled any more from the 2n...

Page 40: ...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 on screen and the buzzer sounds If this system is activated the engine speed or shift cannot be controlled by operating the remote control lever but the engine can be operated at the idle speed By shifting the remote control lever to the neu ...

Page 41: ...stem 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 on screen Identify the cockpit where the SELECT LED 1 on the remote control box is turned ON a...

Page 42: ...LESS START SYSTEM CAUTION SYSTEM IF EQUIPPED WITH KEYLESS START SYSTEM KEYLESS FOB CAUTION SYSTEM The caution system is activated when keyless fob identification error If this system activates the Check Keyless FOB and caution alarm icon are indicated on the screen The Check Keyless FOB is cleared when any of the buttons are pressed on the gauge How ever the caution alarm icon is displayed until t...

Page 43: ...LACEMENT section 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 th...

Page 44: ...ed to appear while the ignition key is turned on The buzzer sound with diagnostic system activating will be canceled by pushing the ignition key in NOTICE If the diagnostic system activates while you are operating your outboard motor there is an abnormal condition in one of the sensor sig nals of the control system Consult your authorized Suzuki marine dealer for repair of the control system OIL C...

Page 45: ...t beep will be heard if the cancellation is success fully finished OFF ON START 4 If equipped with Keyless Start System Press and hold the engine switch 1 for more than two seconds to turn off the power NOTE The power can also be turned off by pressing the lock button on the keyless fob If not equipped with Keyless Start System Turn the ignition key to the OFF position 5 Set the plate 2 in the ori...

Page 46: ...power can also be turned off by pressing the lock button on the keyless fob OFF ON START If not equipped with Keyless Start System Turn the ignition key to the OFF position 5 Set the plate 2 in the original position NOTE Canceling of the system activation is possible regardless of whether or not the engine oil has been replaced Once the system has operated however Suzuki strongly recom mends that ...

Page 47: ... the eliminating the cause If this system activates stop the engine imme diately if wind and water conditions are safe to do so and check the fuel filter water separator for water Or consult your authorized Suzuki marine dealer For inspection and cleaning of the fuel filter refer to the LOW PRESSURE FUEL FILTER in the INSPECTION AND MAINTENANCE sec tion OPERATION OF TILTING SYSTEMS POWER TRIM AND ...

Page 48: ...Keep all persons away from the outboard motor to help prevent accidental activation of the PTT system TILT LIMITER CAM If the outboard motor contacts the motor well of the boat while tilting adjust the tilt limiter cam to limit maximum tilt position 1 Place the motor in the normal running posi tion 2 Rotate the tilt limiter cam To reduce the amount of tilt move the tab A of cam upward To increase ...

Page 49: ...ry heavy When you tilt it man ually you could injure your back or slip and fall causing 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 4 Continue to operate the Power Trim and Tilt DOWN switch until the trim rods are com pletely retracted To release the Tilt Lock Lever tilt the motor all the way up usin...

Page 50: ...power trim and tilt and should only be used when the boat is stationary Do not use the tilt lock lever when trailering your boat and motor Refer to the TRAILERING section 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...

Page 51: ...ap securely Check the battery solution level The level should be kept between the MAX and the MIN level lines at all times If the level drops below the MIN level line refer to MAINTENANCE section Make sure that the battery leads are securely connected to the battery termi nals Visually check the propeller to make sure it is not damaged Make sure that the motor is securely mounted to the transom Ch...

Page 52: ...up may cause severe engine damage such as piston seizure Always allow sufficient idling time 5 minutes for the engine to warm up before running at high speed NOTE You may throttle up beyond the recommended operating range to plane your boat then imme diately reduce the throttle to the recommended operating range 2 For the next 1 hour Safe boating conditions permitting operate the engine in gear at...

Page 53: ... the START posi tion automatically starts all engines OFF ON START CONTROL PANEL OPTION NOTE On a boat equipped with quadruple engines use control panel for quadruple engine PORT and control panel for quadruple engine STBD On a boat equipped with quintuple engines use control panel for quintuple engine PORT and control panel for quintuple engine STBD On a boat equipped with sextuple engines use co...

Page 54: ...tral thereby allowing operation the throttle without changing the shift position When the shift posi tion is hold in neutral the THROTTLE ONLY LED comes on and when the switch is released the THROTTLE ONLY LED goes out The throttle only switch is only enabled when the remote control handle is in the neutral posi tion NOTE If this switch is operated with the remote control handle in a position othe...

Page 55: ... con trol handle in positions other than the neutral the SELECT LED blinks and the buzzer sounds at the same time THROTTLE ONLY NOTE When pushing the SELECT switch to select station continue to push SELECT switch until the buzzer sounds one short beep If failed to switch from the 2nd station to the 1st station turn off the power and wait for 20 seconds and then turn on the power again Consult your...

Page 56: ...ord and lock plate should be replaced as soon as possible 8WARNING Failure to properly attach the emergency stop switch cord or to take proper precautions to help ensure that the emergency stop switch works as intended may result in serious injury or death to the operator or passengers Always take the following precautions Make sure that the emergency stop switch cord is fastened securely to the o...

Page 57: ...e can cause death or severe injury Never start the engine or let it run indoors or where there is little or no ventilation 3 To start each engine individually press and hold the engine switch for at least 2 seconds to set Keyless Start System to ON state buzzer sounds once Then press the con trol panel start stop switch to start each engine individually If not equipped with Keyless Start System Tu...

Page 58: ...and check the oil level OFF ON START 4 Warm up the engine for about 5 minutes 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 Suzuki Marine Dealer NOTICE Oper...

Page 59: ...de entry screen Selecting NO turns the system off 3 Enter a 6 digit passcode Use the or buttons to select a num ber for each digit Press the SET button to move to the next digit Press the MENU button to return to the previous digit 4 If the entered digits matches the 6 digit passcode pressing the SET button will dis play the normal screen appears and starts the engines The system returns to the sc...

Page 60: ...e engines the center engine port center engine and port engine are started with port shift lever 1 to link the center engine with the two engines on port side and the two engines on star board side are started with shift lever 2 On a boat equipped with sextuple engines the three engines on port side are started with shift lever 1 and the three engines on starboard side are started with shift lever...

Page 61: ... the control handle forward to approximate position A as shown in the illustration To shift into REVERSE move the control han dle rearward to approximate position B as shown in the illustration SELECT THROTTLE ONLY Type B Shift lock button A detent or notch is present on all Suzuki con trol boxes to provide a feel for positions A B and neutral Always shift quickly and firmly from neutral to positi...

Page 62: ...to OFF locked status by one of the following meth ods Make sure that the keyless fob is within the communication range of the keyless control unit Press and hold the engine switch for at least 3 seconds to set Keyless Start Sys tem to OFF state The buzzer is triggered for one short beep NOTE While engines are running press and hold the engine switch for at least 2 seconds to shut off all engines a...

Page 63: ...d to an accident or damage to your boat To prevent unauthorized use of your boat be sure to remove the key and emergency stop switch lock plate when the boat is unattended 8WARNING If you leave the motor stopped for a long period of time with the fuel line connected 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 lon...

Page 64: ... pro tect it from damage by underwater obstacles at low tide or corrosion from salt water Refer to the TILT LOCK LEVER section for details on how to tilt up the motor OPERATION IN SHALLOW WATER When operating your boat in shallow water it may be necessary to tilt the motor higher than the normal trim angle When you tilt the motor beyond the normal trim angle however you should only operate the boa...

Page 65: ...s bottom serious damage can occur Do not allow the motor to hit bottom If the motor does strike bottom inspect it immedi ately for damage 3 When YES is selected When YES is selected and the SET button is pressed one beep sounds to show that it is now in TROLL Mode At the same time the screen will change and display the specific TROLL Mode screen and is displayed on the gauge screen When the gauge ...

Page 66: ...l not switch to TROLL Mode For the multiple engines If the throttle of all engines are fully closed and one of engines is in gear it shifts to the troll mode when the MENU button is pressed In gear idle speed of all engines is con trolled at the same time When No is selected When No is selected and the SET button is pressed the display will return to the original gauge screen Adjusting Trolling Sp...

Page 67: ... For the Trolling Speed the desired engine speed can be set and maintained within the range from 650 r min to 1200 r min using the UP button or DN switch NOTE Please contact your authorized Suzuki Marine Dealer for more information Troll mode switch TROLL MODE Setting the Troll Mode 1 Shift into forward or reverse gear and make sure that the throttle is fully closed in geari dle speed 2 Press the ...

Page 68: ... motor out of the water stand it up in a vertical position until the cooling system drains completely NOTICE If you leave your outboard motor out of the water in freezing temperatures with water still in the cooling system the water can freeze and expand causing severe damage to the motor When your outboard is in the water in freezing temperatures keep the lower unit submerged in the water at all ...

Page 69: ... shown 8WARNING Spilled fuel or fuel vapor can cause a fire and is hazardous to health Always take the following precautions Drain the fuel from the fuel line and fuel vapor separator before transporting the boat outboard motor and before removing the motor from the boat DO NOT lay motor on its side without drain ing fuel Keep the motor away from open flames or sparks Wipe up spilled fuel immediat...

Page 70: ...ot 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 of the motor NOTICE If you use the tilt lock lever to hold the motor in the fully tilted up position when trailering the boat towing motion or poor road surfaces may cause unexpected tilt lock release result ing in damage to the moto...

Page 71: ...oxide 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 months Every 200 hrs or every 12 months Every 300 hrs or every 36 months Spark plug I Breather Fuel line I I Engine oil R R Gear oil R R Lubrication I I Anodes external I I Anodes internal cyl...

Page 72: ...e maintenance 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 maintenance more often than indicated in the chart Frequent full throttle operation Prolonged continuous operation at the maximum speed Prolonged continuous operation at idling speed or trolling speed Frequent ope...

Page 73: ... equipped with the following standard spark plug for normal usage NGK BKR6E Standard A normally operating spark plug is very light brown in color If the standard plug is not suit able for your operating consult your authorized Suzuki Marine Dealer NOTICE Non resistor types of spark plugs will inter fere with the function of the electronic igni tion causing misfiring or causing problems with other ...

Page 74: ...t 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 aluminum threads of the cylinder head To maintain a strong spark you should clean and adjust the plugs at the intervals shown in the maintenance chart Remove carbon depos its from the spark plugs using a small wire brush or spark plug cleaner and adjust...

Page 75: ...E OIL Engine oil change The engine 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 3 Place a drain pan under the engine oil drain screw 8 WARNING Never perform any ENGINE OIL procedure with the motor running as serious injury can o...

Page 76: ...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 of properly dispose of used engine oil Do not throw it in the trash pour it on the ground down a drain or into the water 8 WARNING Engine oil can cause injury to people or pets Repe...

Page 77: ...hten 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 into the water 8 ...

Page 78: ...ways take the following precautions when servicing the fuel filter Stop the motor before cleaning the fuel fil ter Be careful not to spill fuel If you do wipe it up immediately Do not smoke and keep away from open flames and sparks 8 WARNING Cleaning solvent is toxic and an irritant and can cause injury to people and pets Keep solvent away from children and pets Dispose of solvent properly when yo...

Page 79: ...wire connec tor 3 NOTICE If spilled gasoline is just left on painted sur face it may cause a stain or discoloration of the surface coating Wipe off any spilled gasoline immediately with a soft cloth etc 13 Reinstall the fuel filter with the attaching bolts 14 Restart 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 a...

Page 80: ...at every 100 hours 12 months NOTE If it is difficult to inject the grease in correct vol ume consult your Authorized Suzuki Marine Dealer ANODES AND BONDING WIRES Anodes The motor is protected from exterior corrosion by anodes These pieces of anodes control electrolysis and prevent corrosion The anodes will corrode in place of the parts they are pro tecting You should periodically inspect each of ...

Page 81: ...er block cylinder head NOTICE If anodes are not properly maintained under water aluminum surfaces such as the lower unit will suffer galvanic corrosion damage Periodically inspect anodes to make sure they have not become detached Do not paint anodes as this will render them ineffective Periodically clean anodes with a wire brush to remove any coating which might decrease their protective ability F...

Page 82: ...hese flush immediately with large amounts of water If acid contacts the eyes or skin get immediate medical attention 8 WARNING If you are not careful when checking or servic ing the battery you can cause a short circuit which could result in an explosion fire or cir cuit damage Disconnect the negative black cable when checking or servicing the battery Be careful not to allow a metal tool or other ...

Page 83: ...r passages you must obtain a commercially available engine flush device 8 WARNING Exhaust gas contains carbon monoxide a dangerous gas that is difficult to detect because it is colorless and odorless Breath ing 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 8 WARNING Failure to take proper precautions when fl...

Page 84: ...g system Never start the motor without supplying water to the cooling system 5 Place the remote control lever in the NEU TRAL position with the propeller removed start the motor and allow it to run at idle 6 Readjust the water flow if necessary so that there is still plenty of excess water flow ing out from around the rubber cups 7 Allow the water to continue circulating for a few minutes 8 Stop t...

Page 85: ...o prevent corrosion In the event that your motor is accidentally submerged take the fol lowing steps 1 Get the motor out of the water as soon as possible 2 Wash it thoroughly with fresh water to com pletely remove all salt mud and seaweed 3 Remove the spark plugs Drain the water from the cylinders through the spark plug holes by manually turning the flywheel sev eral times 4 Check if any water is ...

Page 86: ...s in the motor thor oughly Refer to the FLUSHING THE WATER PASSAGES Engine running sec tion 5 Readjust the water flow run the engine at about 1500 r min in neutral for five minutes to distribute the stabilized 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 8 Wash the ext...

Page 87: ...e Battery acid is poisonous and corro sive and can cause severe injury Do not smoke and keep battery away from open flames and sparks To avoid creating a spark when charging the battery connect the battery charger cables to the proper terminals before turn ing the charger on Handle the battery with extreme care and avoid skin contact with battery acid Wear proper protective clothing Safety glasses...

Page 88: ...on to correct a problem consult your Suzuki marine dealer Engine idles unstably or stalls Spark plug is fouled Fuel hose is kinked or pinched Fuel hose is not properly connected to engine Fuel is deteriorated Fuel filter is clogged Fuel pump is failed Ignition system is fouled Incorrect engine oil is used Thermostat is failed Electric wiring connection is loose Caution system is activated Caution ...

Page 89: ...ting range Keyless fob battery is dead Keyless fob is in OFF mode The keyless fob is not authenticated Communication failure due to strong radio wave or noise Electric wiring connection failure between the keyless control unit and outboard motor Authentication error between the keyless control unit and outboard motor Abnormality exists in the electronic control system of the engine The Keyless Sta...

Page 90: ... Normal fuse Main fuse 60 A Isolator fuse 40 A Blown fuse Normal fuse Blade type fuse Blown fuse 1 Starter motor relay fuse 30 A 2 Ignition coil Injector Engine control module High pressure fuel pump fuse 30 A 3 Throttle valve fuse 15 A 4 Shift actuator fuse 15 A 5 PTT switch fuse 10 A 6 Low pressure fuel pump fuse 15 A 7 Main fuse 60 A 8 Isolator select fuse 40 A 9 Spare fuse 60 A 0 Spare fuse 30...

Page 91: ... kW 300PS Full Throttle Operating Range 5500 6100 r min min 1 5700 6300 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 Gear Oil Capacity 1 1 L 1 2 1 0 US Imp qt Spark Plug NGK BKR6E Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in Valve Clearance Lash IN 0 23 0 27 mm 0 009 0 011 in EX 0 33 0 37 mm 0 013 0 015 in...

Page 92: ...operation 2 Lapse of 80 hour s operation 3 Lapse of 100 hour s operation 4 When performing cancellation before system activation Action Starting operation Cancellation Indication 1 4 Cancellation Indication Cancellation Indication Cancellation Indication Repeat 2 4 3 4 3 4 ...

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Suzuki DF250AP, Owner'S Manual

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