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Suzuki DF300B, Owner'S Manual, Page: 75 / 97

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Suzuki DF300B Owner'S Manual Download Page 75

75

SPARK PLUG

Remove the spark plugs as follows:
1. Remove the motor cover.
2. Remove  the  ignition  coil  bracket  bolts  and

ignition coil brackets 

1

.

3. Remove the bolt securing the ignition coil.
4. Pull out the ignition coil.

NOTE:
Turn  the  ignition  coil 

A

  clockwise  as  shown  in

the figure to remove.
The  installation  is  a  reverse  procedure  of  the
removal.

NOTICE

When  servicing  the  iridium/platinum  spark
plugs, do not touch the center electrode, as it
is easy to damage.

Do  not  touch  the  center  electrode  of  an  irid-
ium spark plug. Avoid cleaning it or adjusting
its electrode gap.

5. Loosen and remove the spark plug using the

box wrench 

2

 and driver 

3

 in the tool bag.

Your  outboard  motor  comes  equipped  with  the
following  “standard”  spark  plug  for  normal
usage.

NGK ILZKR7D8

Standard

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  electronic  boat  equipment  and
accessories.

Use  ONLY  resistor  type  spark  plugs  in  your
outboard motor.

Summary of Contents for DF300B

Page 1: ...1 EN __ __ __ __ __ __ __ __ __ __ __ __ __ ENGLISH DF300B DF325A DF350A 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: ...L CAUTION SYSTEM 39 KEYLESS START SYSTEM CAUTION SYSTEM IF EQUIPPED WITH KEYLESS START SYSTEM 43 DIAGNOSTIC SYSTEM 44 OIL CHANGE REMINDER SYSTEM 45 ENGINE STALLING CAUTION SYSTEM 47 WATER IN FUEL ALERT SYSTEM 47 OPERATION OF TILTING SYSTEMS 48 OPERATION OF MOTOR COVER LEVER 51 INSPECTION BEFORE BOATING 51 BREAK IN 53 OPERATION 54 MOTOR REMOVAL AND TRANSPORTING 70 TRAILERING 72 INSPECTION AND MAINT...

Page 5: ...ting fuel filter assembly between your boat s fuel tank s and outboard motor s Fuel filtration systems of this type will help prevent water that may be present in your 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...

Page 6: ...method If engine pinging is experienced substitute another brand as there are differences between brands Unleaded gasoline will extend spark plug life 8WARNING Gasoline is extremely flammable and toxic It can cause a fire and can be hazardous to peo ple and pets Always take the following precautions when refueling Never permit anyone other than an adult to refill the fuel tank If you use a portabl...

Page 7: ...in your area NOTE In very cold weather below 5 C 41 F use SAE or NMMA FC W 5W 30 for easier start ing and smooth operation GEAR OIL Suzuki recommends the use of SUZUKI OUT BOARD MOTOR GEAR OIL If it is not avail able use SAE 90 hypoid gear oil which is rated GL 5 under the API classification system NOTICE Use of poor quality engine oil can adversely affect engine performance and life Suzuki recomm...

Page 8: ...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 9: ... and tilt P T T switch Tilt limit cam Flush plug Flush plug Anode Front gear oil level plug Water intake hole Gear oil drain plug Auxiliary water supply port Transom XX Auxiliary water supply port Auxiliary water supply port Anti cavitation plate Clamp bracket Rear gear oil level plug Water intake hole Water intake hole ...

Page 10: ...FUNCTION GAUGE Option KEYLESS FOB IF EQUIPPED WITH KEYLESS START SYSTEM REMOTE CONTROL BOX Option Type B Type A Select switch Throttle only switch Emergency stop switch Power trim and tilt P T T switch Remote control handle Throttle only switch Select switch Shift lock button ...

Page 11: ...have your outboard motor controls and gauges installed by your authorized Suzuki marine dealer He has the tools the facilities and the know how to do the job correctly BATTERY INSTALLATION BATTERY REQUIREMENTS Do not use deep cycle batteries and gel cell batteries for starting engines Use a 12 Volt starting type lead acid battery that meets the specifications shown below 1000 Marine Cranking Amps ...

Page 12: ...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 13: ...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 14: ...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 fob Keyless control unit 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 15: ...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 16: ...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 17: ...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 18: ...eed is not within this range con sult your authorized Suzuki Marine Dealer to determine which propeller size is best for you NOTICE Installing a propeller with either too much or too little pitch will cause incorrect maximum engine speed which may result in severe damage to the motor Ask your authorized Suzuki marine dealer to assist you in selecting a suitable propeller for your boat Full throttl...

Page 19: ...ler nut stopper 5 on the shaft NOTE Align section A of the stopper 5 with the punch mark C of the spacer 4 and attach it 5 Install the front propeller nut 6 and tighten it with a torque wrench to 125 135 N m 13 14 kgf m 92 100 lbf ft NOTE Front propeller nut is left hand thread For removing or installing the front propeller nut the Propeller nut remover installer Suzuki genuine part is required Co...

Page 20: ...rd motor use the following procedure 1 Shift to NEUTRAL position 2 Remove the cotter pin 1 from the rear pro peller nut and remove the rear propeller nut 2 3 Remove the washer 3 spacer 4 rear pro peller 5 and rear propeller stopper 6 from the propeller shaft 4 Straighten the locking edges on the front propeller nut stopper 7 from the front pro peller nut and remove the front propeller nut 8 NOTE F...

Page 21: ...s of steering control can cause occupants to be thrown overboard Always maintain proper trim angle based on the combination of your boat engine and pro peller as well as operating conditions 8WARNING When the motor is tilted beyond the maximum trim position the swivel bracket will not have side support from the clamp bracket and the tilt system will be unable to cushion the engine if the lower uni...

Page 22: ...OL 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 adjust the control handle fric tion a...

Page 23: ...re Motor cover METER OPTION MULTI FUNCTION GAUGE This gauge is multifunctional gauge that dis plays the various 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 se...

Page 24: ... 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 25: ...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 26: ...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 27: ...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 28: ...s 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 Auto Trim Diagnosis Display Device List Illumination Menu Ver OFF ON 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 29: ...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 30: ... 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 31: ...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 32: ...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 33: ...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 34: ...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 35: ...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 36: ... 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 37: ...onditions 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 Over Heat Overheat is not displayed on screen Be aware that Over Heat Overheat is dis playe...

Page 38: ... the battery volt age deficiency which could impair your motor s performance occurs If this system activates the Low Battery Volt age and alarm icon are indicated on screen and the buzzer sounds The Low Battery Voltage indication cleares when any of the button is pressed in the gauge However the caution alarm icon is displayed until eliminating the cause This system will be canceled automatically ...

Page 39: ...ly The battery is sound condition If this caution system activates continuously even after you have stopped using engine or boat accessories contact your authorized Suzuki Marine Dealer ELECTRONIC THROTTLE AND SHIFT CONTROL CAUTION SYSTEM CONTROL UNIT COMMUNICATION CAUTION SYSTEM This system is activated in the event of an error in the control system of the electronic throttle and shift systems If...

Page 40: ...is system activates for no apparent rea son there may be a problem with the system Consult your authorized Suzuki marine dealer THROTTLE SYSTEM CAUTION SYSTEM This system is activated in the event of an error of the control system of the electronic throttle If this system activates the Check Throttle System and caution alarm icon are displayed on screen and the buzzer sounds In addition the engine...

Page 41: ... message Check Shift Control is displayed the clutch cannot be shifted to the Forward Neutral or Reverse position The Check Shift Control indication clears when any of the button is pressed in the gauge However the caution alarm icon is displayed until eliminating the cause THROTTLE ONLY SELECT GAUGE COMMUNICATION CAUTION SYSTEM This system activates when there is a commu nication error of the gau...

Page 42: ...he gauge THROTTLE ONLY SELECT TROLL CONDITION CAUTION SYSTEM This system activates when the mode cannot be transferred to the TROLL Mode If this system activates the Check Troll Condi tion is displayed on screen Make sure that the remote control lever has been shifted into forward or reverse and the engine throttle has been fully closed Refer to the Setting the Troll Mode section The Check Troll C...

Page 43: ...ss fob section There is no object interfering with the radio wave between the keyless fob and the key less control unit The keyless fob battery has sufficient capacity The correct keyless fob has been authenti cated by the Keyless Start System If this caution system activates continuously contact your authorized Suzuki Maine Dealer KEYLESS FOB BATTERY CAUTION SYSTEM The caution system is activated...

Page 44: ...ostic system warns of the abnormal condition If this system activates the Check Engine X X and check engine icon are displayed on screen and the buzzer sounds The Check Engine X X is cleared when any of the buttons are pressed in the gauge How ever the check engine icon is displayed until the cause is addressed Also incorporated is a fail safe provision that allows the operation at a restricted sp...

Page 45: ...have reached 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 For the single engine 1 If equipped with Keyless Start System Press and hold the engine switch 1 for more than two seconds to turn on the power If not equipped with Keyless Start System Turn the ignition key to the ON posit...

Page 46: ... Start System Press and hold the engine switch 1 for more than two seconds to turn on the power OFF ON START If not equipped with Keyless Start System Turn the ignition key to the ON position 2 Pull out the emergency stop switch lock plate 2 3 Push the start stop switch 3 three times in 10 seconds A short beep will be heard if the cancellation is successfully finished 4 If equipped with Keyless St...

Page 47: ...er sounds three times WATER IN FUEL ALERT SYSTEM This engine is equipped with an integral fuel fil ter water separator and associated alert sys tem The alert system will activate if water separated from the fuel exceeds a specific volume If this system activates the Water in Fuel and caution alarm icon will display at all the time and a buzzer will sound when the engine is in neutral only The Wate...

Page 48: ...tart System The PTT switch on the remote control lever cannot be activated when the keyless start sys tem is in OFF state If not equipped with Keyless Start System The PTT switch on the remote control lever can not be activated when the ignition key is off NOTE Repeated operation of the power trim and tilt PTT causes the overheating of the PTT motor and the protection circuit may stop the opera ti...

Page 49: ... away from the motor when operating at high speed MANUAL TILTING If you are unable to tilt the motor using the Power Trim and Tilt because of an electrical problem or some other problem you can move the motor manually To tilt the motor up or down turn the manual release valve A two turns counterclockwise move the motor to the desired position then retighten the release screw TILT LOCK LEVER The Ti...

Page 50: ...ICE Damage can occur if you use the tilt lock lever other than when the boat is moored or is oth erwise stationary The tilt lock lever relieves pressure from the 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 8CAUTION The remote Power Trim and Tilt switch will ...

Page 51: ... oil in the sump To check the oil level NOTE To avoid an incorrect assessment of engine oil level check the level only when the engine has cooled 1 Place the motor in a vertical position then remove the motor cover Refer to the OPER ATION OF MOTOR COVER LEVER section 2 Turn the oil dipstick 90 degrees to the left and pull it out and wipe oil off with a clean cloth 8WARNING Failure to inspect your ...

Page 52: ...imit UPPER LIMIT LOWER LIMIT To fill the engine oil 1 Remove the oil filler cap 2 Fill the recommended engine oil to the upper level 3 Insert the oil dipstick and turn it 90 degrees to the right back to its original position as shown in the figure NOTICE If the oil dipstick knob is not correctly posi tioned when installing the motor cover the oil level gauge would be damaged When the motor cover i...

Page 53: ...per operation during this break in period will help ensure maximum life and performance from your engine The following guidelines 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 ...

Page 54: ...uously at full throttle for more than 5 minutes at a time during the last 7 hours of break in operation may cause severe engine damage such as seizure During the last 7 hours of break in operation do not operate at wide open throttle for more than 5 minutes at a time OPERATION ENGINE SWITCH OPTION Use this switch if equipped with Keyless Start System Quickly press the engine switch to start and st...

Page 55: ...nel for sextuple engine STBD For dual engine For triple engine For quadruple engine PORT For quadruple engine STBD For quintuple engine STBD For quintuple engine PORT For sextuple engine PORT For sextuple engine STBD Start Stop Switch This is a switch to start and stop the engine The engine can be started with the remote con trol handle at the neutral position UP DOWN The Power Trim and Tilt is op...

Page 56: ... THROTTLE ONLY mode continue to push the THROTTLE ONLY switch until the buzzer sounds one short beep If the THROTTLE ONLY mode cannot be selected turn off the power and wait for 20 seconds and then turn on the power again Consult your authorized Suzuki marine dealer if the THROTTLE ONLY mode can not be selected Station Select Switch This switch control between driving stations on boats equipped wi...

Page 57: ...ne group and STBD engine group can be controlled by each handle the 1 LEVER LED goes out The 1 LEVER switch is only enabled when the all remote control handle is in the neutral posi tion NOTE When turn on the power 1 lever control mode is automatically canceled By operating this switch with the remote con trol handle in positions other than the neutral the buzzer sounds SELECT 1 LEVER BEFORE ATTEM...

Page 58: ...al operation The motor will stop abruptly and the loss of forward motion may unexpect edly throw occupants 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 keyless fob is in communi cation...

Page 59: ...nk continuously for 4 seconds or until the engine starts OFF ON START To start each engine individually turn the igni tion switch to the ON position Then press the control panel start stop switch to start each engine individually NOTE If equipped with Keyless Start System The communication range is a distance of 1 m 40 in between the keyless fob and the keyless control unit If the Keyless Start Sy...

Page 60: ...ngine check to make sure that there is water coming out of the pilot water hole 8WARNING Operating the boat when the emergency stop switch is not operating properly can be haz ardous Before starting off check to make sure that the emergency stop switch operates properly If equipped with Keyless Start System EMERGENCY START If the keyless fob cannot be used due to a dead keyless fob battery or othe...

Page 61: ...y NOTE If you select yes for Enter Passcode you must complete the entry within 5 minutes After 5 minutes the power turns off If the collation is NG the Enter Passcode screen reappears If you enter the wrong passcode 5 times in a row the keyless start system automatically powers down the keyless start system and does not accept a passcode for 30 seconds To start the engine 5 Make sure the motor is ...

Page 62: ...se 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 1 LEVER SELECT THROTTLE ONLY NOTE When the engine stops the clutch moves to the neutral position irrespective of the posi tion of the remote control lever The clutch cannot be chang...

Page 63: ...the boat to move suddenly resulting in personal injury or property dam age You must be careful not to move the control handle too far forward or rearward when shift ing NEUTRAL 18 18 FORWARD REVERSE STOPPING THE ENGINE NOTE When it is necessary to stop the engine in an emergency pull the emergency stop switch lock plate by pulling the emergency stop switch cord If equipped with Keyless Start Syste...

Page 64: ...topping the engine disconnect the fuel line from the outboard motor if there is a fuel connector 6 Turn the air vent screw on the fuel tank cap clockwise to shut the vent if equipped NOTE To make sure that the emergency stop switch operates properly stop the engine occasionally by pulling out the lock plate while operating the engine at idling speed NOTICE If the Keyless Start System is in ON stat...

Page 65: ...ling speed 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 time to 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 NOTICE If the ignition key is left ON when the engine is not running the batte...

Page 66: ...ng attitude with the engine beyond the maximum trim posi tion NOTICE If the motor hits 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 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 swi...

Page 67: ...ears 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 that cannot operate the troll mode ...

Page 68: ...ng 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 throt...

Page 69: ...he engine speed decreases by 50 r min NOTE Shift operation and throttle control remain oper ational even in troll mode Cancelling the Troll mode The troll mode can be cancelled by shifting the all remote control levers to the neutral position or by increasing the engine speed to 3000 r min or more In both cases two short beeps sound when cancelling the troll mode OPERATION IN SALT WATER After oper...

Page 70: ...ne from the vapor separator as follows 1 Remove the motor cover 2 Tilt the motor fully up 3 Pull the drain hose end 1 out 4 Loosen the vapor separator drain screw 2 and drain the gasoline into a suitable con tainer 5 After draining retighten the vapor separator drain screw 2 6 Tilt down the motor and put the drain hose 1 back 8WARNING Gasoline is extremely flammable and toxic It can cause a fire a...

Page 71: ...in ing fuel Keep the motor away from open flames or sparks Wipe up spilled fuel immediately NOTICE If you are not careful when resting the out board on its side and do not take proper pre cautions such as first draining the engine oil and cooling water completely damage can occur Engine oil may enter the cylinder from the sump water may enter the cylinder through the exhaust port or the outer casi...

Page 72: ...vice 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 motor and the tilt lock mechanism Never use the tilt lock lever to hold the motor in the fully tilted up position when trailering the boat Use a...

Page 73: ... 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 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 ...

Page 74: ... 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 operation in muddy silty sandy acidic o...

Page 75: ...ouch the center electrode as it is easy to damage Do not touch the center electrode of an irid ium spark plug Avoid cleaning it or adjusting its electrode gap 5 Loosen and remove the spark plug using the box wrench 2 and driver 3 in the tool bag Your outboard motor comes equipped with the following standard spark plug for normal usage NGK ILZKR7D8 Standard NOTICE Non resistor types of spark plugs ...

Page 76: ... damage Do not touch the center electrode of an irid ium spark plug Avoid cleaning it or adjusting its electrode gap NOTICE Use of improper spark plugs or improperly tightening spark plugs can cause severe engine damage Do not experiment with other spark plug brands unless you can determine that they are directly equivalent to the specified brand or you may experience engine dam age which will not...

Page 77: ...t the breather and fuel line for leaks cracks swelling or other damage If the breather and fuel line is damaged in any way it must be replaced Consult your authorized Suzuki Marine Dealer if it is necessary to replace them 8 WARNING Fuel leakage can contribute to an explosion or fire resulting in serious personal injury Have your authorized Suzuki Marine Dealer replace the fuel line if there is an...

Page 78: ...ently under this type of use Change your engine oil more frequently 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 t...

Page 79: ...at the oil dipstick knob is positioned as shown in the figure UPPER LIMIT LOWER LIMIT 9 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 Repeated prolonged contact with used engine oil may cause skin cancer Even brief contact with...

Page 80: ...motor is in full trim position 2 Place a drain pan under the lower casing 4 15 3 Remove the gear oil drain plug 3 then remove the rear gear oil level plug 2 4 After the oil has drained completely place the motor in trim up 4 degrees position from horizontal using a digital angle meter 1 5 With the outboard motor in trim up 4 degrees position inject the specified gear oil into the gear oil drain ho...

Page 81: ... nated with water Immediately contact your authorized Suzuki marine dealer for advice Do not operate your outboard until the oil is changed and the cause of the contamination is corrected LOW PRESSURE FUEL FILTER The low pressure fuel filter must be replaced by an authorized Suzuki Marine Dealer periodi cally Replace low pressure fuel filter at every 400 hours 2 years Inspect and clean the fuel fi...

Page 82: ...turning the filter cup counterclockwise 8 Drain the fuel and water in the filter cup into a suitable container 9 Pull out the filter element 5 Inspect the filter element 5 O ring 6 and seal ring 7 for damage If they are damaged replace them 10 Wash the filter element with clean solvent and dry it 11 Reinstall the seal ring and filter element in their original positions 12 Verify that the O ring is...

Page 83: ...operation and long life of each working part of your outboard motor The following chart shows the lubrication points of your motor and the recommended lubricant LOCATION LUBRICANT Shift link Marine grade water resistant grease Propeller shaft Trim ram pad NOTE Before applying grease through the steering bracket grease nipple lock the motor in the fully tilted up position Use a hand operated grease...

Page 84: ...dder angle becomes the largest 6 Inject 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 NOTICE Using a hydraulic or air powered grease gun to service the grease nipple A on the mount oil seal cover may cause damage to the oil seal Do ...

Page 85: ...ransom XX only NOTE Consult your authorized Suzuki Marine Dealer for inspection and replacement of internal anodes attached to the cylinder 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 ...

Page 86: ...NG 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 con tact with any of these 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 whi...

Page 87: ...ter passages you must obtain flushing attachment Suzuki genuine part 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 flush...

Page 88: ... the cooling system 5 Place the remote control handle in the NEUTRAL position with the propeller removed and start the motor As soon as the engine starts water should spray out of the pilot water hole 4 indicating proper water pump operation If no water spray is evident stop the motor immediately and consult your dealer 6 Allow the engine to run only at idle speed while flushing Readjust the water...

Page 89: ...read 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 positi...

Page 90: ...o the engine through the spark plug holes Coat the engine inner parts with oil by manually turning the fly wheel several times 8 WARNING Gasoline is extremely flammable and toxic It can cause a fire and can be hazardous to peo ple and pets Keep flames and sparks away from gasoline Dispose of unwanted fuel properly NOTICE Severe engine damage may occur if you con tinue cranking the engine when you ...

Page 91: ...e external finish of the motor If paint damage is evident apply touch up paint before wax ing 10 Store the motor in an upright position in a dry well ventilated area 8 WARNING When the engine is running there are many moving parts that could cause severe per sonal injury When the engine is running keep your hands hair clothing etc away from the engine BATTERY STORAGE 1 When the outboard motor will...

Page 92: ...y terminal connection is corroded or lost Battery power is lost Starter motor is failed If equipped with Keyless Start System Engine switch or start stop switch is failed If not equipped with Keyless Start System Ignition 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...

Page 93: ...is clogged Fuel is deteriorated Fuel pump is failed Ignition system is failed Electronic throttle system is failed Heavy cargo is on the boat Water is 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 engine switch is oper ated The erro...

Page 94: ...tery 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 8 WARNING If you replace a blown fuse with a fuse having a different amperage rating or with a substi tute such as aluminum foil or a wire extensive electrical system damage and a fire may result Alwa...

Page 95: ...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 A A Spare fuse 15 A B Spare fuse 10 A C Spare fuse 30 A D Sub battery cable fuse 30 A NOTE Spare fuses 0 A and B are provided for the back of fu...

Page 96: ...ttle Operating Range 5300 6300 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 3 2 L 3 4 2 8 US Imp qt Spark Plug NGK ILZKR7D8 Spark Plug Gap Standard 0 7 0 8 mm 0 028 0 031 in Service limit 1 0 mm 0 039 in Valve Clearance Lash IN 0 23 0 27 mm 0 009 0 011 in EX 0 33...

Page 97: ...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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