Suzuki DF40A Owner'S Manual Download Page 66

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DF40ATH/50ATH/50AVTH/60ATH/60AVTH

UGE

CONNECT

SDS

CONNECT

DIGIT

L GA

UGE

DIA

GRAM

(OPTION)

UGE

CONNECT

SDS

CONNECT

CAP

PTT SWITCH

OLL MODE

SWITCH

SUZUKI

PUSH

TURN

FREE

OFF

GND

RESET

IGNITION

SWITCH

TILLER HANDLE

EMERGENCY

OP SWITCH

LOCK PLA

TE IN R

LOCK PLA

TE OFF ST

CHOMETER/

INDICA

UTION BUZZER

G/Y

G/W

Bl/B

TTER

GNET

CKP SENSOR

TER

BlB

PTT

RELA

TRIM

SENSOR

PTT MO

B/WB

B/W

R R

B B

MAIN

RELA

TER

OTO

RELA

FUSE BO

FUSE

15A

30A

CMP

SENSOR #1

B/W

Y/BlY

B/Bl

B/W

Y/Bl

B/Bl

B/R

IGNITION COIL #1

IGNITION COIL #2

Gr/Y

IGNITION COIL #3

FUEL INJECT

CYLINDER TEMP

SENSOR

Lg/W

B/WB

Lg/W

B/W

OIL PRESSURE SWITCH

RECTIFIER &

REGULA

THR

TTLE & IA

T & MAP

SENSOR

JOINT

CONNECT

OR #2

JOINT

CONNECT

OR #1

JOINT

CONNECT

ENGINE CONTR

OL MODULE

P/B

B/G

R/B

B/G

R/B

W
W

W/R

Y/G

BlB

Y YY

B B B

R R R

, W

B/W

B/Bl

W/R

Lbl

W/R

B/BrB

B/Br

O/BO

O/B

R/WR

R/W

1.0 ± 0.3 kgf/cm

PTT SWITCH

NEUTRAL SWITCH

, R

Lbl

W/R

P P

Lbl

W/R

FUEL PUMP

R/G

W/BW

GrG

W/Bl

R/YR

R/G

W/B

W/Bl

R/Y

B/WB

Br/Y

Lg/BL

B/W

Br/Y

Lg/B

B/W

R/B

B/W

R/B

Y/B

Y/G

B/Bl

Y/B

Y/G

B/Bl

B/G

B/Bl

B/B

B/G

B/Bl

W/Y

B/W

W/Y

B/W

P/W

Lbl/W

bl/

P/W

Lbl/W

B B B

G/W

P/W

Bl/B

Bl/

G/W

P/W

Bl/B

Bl/

G/W

P/W

Bl/B

G/W

P/W

Bl/B

O/Y

B/G

O/Y

B/G

Bl/BB

G/Y

P/WP

G/W

l
L

BrB

Y/B

Bl/RB

B/G

Bl/WB

Bl/B

G/Y

P/W

G/W

Y/B

Bl/R

B/G

Bl/W

G/W

P/W

Bl/B

Bl/

P/W

Bl/B

l/B

G/W

O/Y

B B

B/G

G/W

P/W

Bl/B

P/W

Bl/B

G/W

O/Y

B/G

VVV

P P P

Lbl

G/YG

G/WG

GrG

Bl/BB

l
L

BrB

BlB

W/RW

GrG

BrB

BlB

GrG

BrB

BlB

W/R

Bl/BB

G/WG

GrG

G/YG

Bl/BB

G/WG

GrG

G/YG

Bl/B

G/W

G/Y

l
L

W/RW

l
L

GrG

W/R

GrG

Gr,

Bl/B

G/W

G/Y

BlB

G/Y

G/W

Bl/B

R/G

B/R

O O

Gr/Y

Gr/

B/Br

B/B

B B

P/W

W/Bl

W/B

W/R

O/B

R/W

Lbl/W

l/W

B B

R/Y

R/G

R/B

Bl/W

Bl/

Br/Y

Br/

W/Y

Bl/R

Bl/

B/W

B/G

V V

Lg/W

Bl/B

Bl/

P/B

G/W

O/Y

Y/G

O O

P P

Y/Bl

Y/B

Lg/B

Lbl

Y/B

G/Y

P/W

Y Y

G G

B B

R R

Y Y

B/Bl

B/B

R/B

Bl/W

Br/Y

W/Y

Bl/R

B/W

B/G

Lg/W

Bl/B

P/B

G/W

O/Y

Y/G

Y/Bl

Lg/B

Lbl

Y/B

G/Y

P/W

Y Y Y

B/Bl

B/R

Gr/Y

B/Br

P/W

W/Bl

W/R

O/B

R/W

Lbl/W

R/Y

Y Y Y

R R

B/W B

/W
B/W

W/Y

Lbl

: Black

: Blue

: B

: Green

: Gray

: Light

blue

Lg/B

Light green with Black

WIRE COLOR

B/Br

B/G

: Orange

: Pink

: R

: Violet

: White

: Yellow

Black with Bro

B/Bl

Black with Blue

Black with Green

B/R

B/W

Black with Red

Black with White

Bl/B

Bl/R

Bl/W

Br/Y

Blue with Black

Blue with Red

Blue with White

: Brown

with

Yellow

G/W

G/Y

Gr/Y

Lbl/W

: Green

with

White

: Green

with

Yellow

Gray with Yellow

Light blue with White

Lg/W

O/B

Light green with White

Orange with Black

O/Y

P/B

P/W

R/B

R/G

R/W

R/Y

Orange with Yellow

Pink with Black

Pink with White

Red with Black

Red with Green

Red with White

Red with Yellow

W/B

W/Bl

W/R

W/Y

Y/B

Y/G

White with Black

White with Blue

White with Red

White with Yellow

: Yellow

with

Black

: Yellow

with

Green

Y/Bl

: Yellow

with

Blue

Summary of Contents for DF40A

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

Page 2: ...istics 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 transis...

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: ... SYSTEM 26 OIL CHANGE REMINDER SYSTEM 26 ENGINE STALLING CAUTION SYSTEM 27 OPERATION OF TILTING SYSTEMS 28 INSPECTION BEFORE BOATING 32 BREAK IN 33 OPERATION 34 MOTOR REMOVAL AND TRANSPORTING 43 TRAILERING 45 INSPECTION AND MAINTENANCE 46 FLUSHING THE WATER PASSAGES 55 SUBMERGED MOTOR 57 STORAGE PROCEDURE 58 AFTER STORAGE 59 TROUBLESHOOTING 59 SPECIFICATIONS 61 INFORMATION REGARDING EC DIRECTIVE 6...

Page 5: ...revent 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 Suzuki Marine Dealer can pro vide you advice about water separating fuel fil ter systems and installation Gasoline Ethanol Ble...

Page 6: ...refill the fuel tank If you use a portable fuel tank always stop the motor and remove the fuel tank from the boat to refill it Do not fill the fuel tank all the way to the top or fuel may overflow when it expands due to heating by the sun Be careful not to spill fuel If you do wipe it up immediately Do not smoke and keep away from open flames and sparks NOTE The fuel tank supplied with this motor ...

Page 7: ...es 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 rec...

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

Page 9: ...9 ...

Page 10: ...rgency stop switch Throttle tension adjuster REMOTE CONTROL BOX Fuel hose Priming bulb Air vent screw Motor cover Power trim and tilt P T T switch Reverse side Engine oil drain plug Clamp bracket Anode Gear oil level plug Water intake hole Gear oil drain plug Pilot water hole Flush plug Anti cavitation plate Trim tab Anode Flush plug FUEL TANK DF40AT 50AT 60AT ...

Page 11: ...d tilt P T T switch Reverse side Engine oil drain plug Clamp bracket Anode Pilot water hole Flush plug Anode Reverse side Anode Gear oil level plug Water intake hole Gear oil drain plug Anti cavitation plate Trim tab DF50AVT 60AVT ...

Page 12: ...b Anode Flush plug Power trim and tilt P T T switch Reverse side DF40ATH 50ATH 60ATH Throttle control grip Troll mode switch Power trim and tilt P T T switch DF40ATH 50ATH 60ATH Emergency stop switch Tachometer Indicator Shift lever Ignition key DF50AVTH 60AVTH DF40ATH QH 50ATH 60ATH QH Anode Water intake hole Trim tab Gear oil level plug Water intake hole Gear oil drain plug Anode Reverse side ...

Page 13: ...and the know how to do the job correctly BATTERY INSTALLATION BATTERY REQUIREMENT Choose a 12 Volt cranking type lead acid bat tery that meets the specifications shown below 650 Marine Cranking Amps MCA ABYC or 512 Cold Cranking Amps CCA SAE or 160 Reserve Capacity RC Minutes SAE or 12 Volt 80 AH NOTE The specifications listed above are the mini mum battery rating requirements for starting the eng...

Page 14: ...ry 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 WARNING 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 spark...

Page 15: ...ller loads generally require larger pitch pro pellers larger loads generally require smaller pitch propellers Your authorized Suzuki Marine Dealer will assist you in selecting a suitable pro peller 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 condi...

Page 16: ...G 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 cavitati...

Page 17: ...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 DF40A QH DF60A QH MODEL Make a test run in the boat to determine if the trim down limit position needs to be adjusted To adjust the trim angle 1 Hold the motor in the fully tilted up position Refer to TILT BRACKET section 2 R...

Page 18: ...in place After adjusting the trim tab check to see if the boat still tends to veer to one side If necessary readjust the trim tab STEERING TENSION ADJUSTMENT The steering on your outboard motor should be smooth and not tight Adjust the steering ten sion so that there is only a slight resistance to steering movement DF50AV TH DF60A TH DF60AV TH MODEL To increase the steering tension turn the steer ...

Page 19: ...JUSTMENT The idle speed has been factory adjusted between 750 850 r min in neutral NOTE If idle speed cannot be set within the specified range contact your authorized Suzuki Marine Dealer Increase Decrease SETTING OF TILT UPPER LIMIT POSITION DF40A ST DF50AV T TH DF60A T TH DF60AV T TH MODEL If the outboard motor contacts the motor well of the boat during full tilt up operation the upper limit set...

Page 20: ...l the caution buzzer sounds one time Tiller handle model Turn the throttle control grip until the buzzer sounds one time 9 Press the UP side of PTT switch three times within three seconds The buzzer will sound one time briefly indicating the setting has been accepted 10 Return the throttle to the fully closed posi tion and install the lock plate on the emer gency switch Operate the full tilt up an...

Page 21: ...he tiller handle angle 1 When the stopper is not used the tiller han dle will be the smallest angle If you want to enlarge the angle raise up the tiller handle to install the stopper 2 Select the direction of the stopper 1 to install it on to the tiller handle bracket and tighten the bolt 2 securely 3 Confirm the tiller handle angle after returning down the tiller handle if it is convenient to the...

Page 22: ... the next three seconds the monitor tachometer will indicate the total motor operat ing hours by means of the lamp flashing and needle indicating After this brief check period the monitor tachometer will return to their stand by mode and will only respond to motor conditions requiring a caution alert NOTICE Your outboard motor may become damaged if you rely on the Caution System to alert you to an...

Page 23: ...ki marine dealer Tiller handle model Remote control model REMOTE CONTROL MODEL If this system activates engine speed will auto matically be reduced to approximately 3000 r min with red REV LIMIT lamp lit This system must be reset by moving the throt tle to the idle position for about one second to restore full engine operation OIL PRESSURE CAUTION SYSTEM This system operates when the engine lubric...

Page 24: ... OVERHEAT CAUTION SYSTEM This system is activated when the cylinder wall temperature is too high due to insufficient water cooling If this system activates the red TEMP lamp will light and a buzzer will begin a series of beep In addition when this system is activated at 3000 r min or higher engine speed will automatically be reduced to approximately 3000 r min On the remote control model then the ...

Page 25: ...ing to the above instructions Consult your authorized Suzuki marine dealer if you cannot correct the problem BATTERY VOLTAGE CAUTION SYSTEM This system is activated when the battery volt age deficiency which could impair your motor s performance occurs If this system activates the red CHECK ENGINE lamp will light and buzzer will begin a series of beep This system will be canceled automatically whe...

Page 26: ...horized Suzuki marine dealer for repair of the control system Tiller handle model Remote control model OIL CHANGE REMINDER SYSTEM This system informs the operator of the time for replacing engine oil on the basis of the mainte nance schedule The system is designed to register the total operating hours of the outboard motor and function its operation when the preprogrammed hours have reached Refer ...

Page 27: ...nds that the engine oil be replaced before canceling the system activation 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 ...

Page 28: ... DF40A QH DF60A QH MODEL The Tilt Bracket is provided so you can support the motor in a tilted position for non moving engine support WARNING When you operate the motor with the tilt lock lever in the Release position the tilt lock will not work As a result forces such as from propeller thrust during operation in REVERSE gear rapid deceleration and striking an underwater object can cause the motor...

Page 29: ...ox ice chest or the motor well 4 Move the tilt lock lever 1 to the lock posi tion then pull down the tilt bracket 2 as shown To lower the motor 1 Pull up the tilt bracket 2 then move the tilt lock lever 1 to the release position as shown 2 Lower the motor by pushing the motor cover down 3 Move the tilt lock lever 1 to the lock posi tion WARNING If you do not take proper precautions when tilting up...

Page 30: ...When tilting the motor up position the motor so the tiller handle will not contact such as a tackle box ice chest or the motor well UP DOWN DOWN UP UP DOWN MANUAL TILTING DF40A T TH DF50A T TH DF50AV T TH DF60A T TH DF60AV T TH MODEL 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 m...

Page 31: ...emote Power Trim and Tilt switch will work when the ignition switch is off If some one activates the switch while you are moving the tilt bracket your hand could be injured Keep all persons away from the remote Power Trim and Tilt switch while you are moving the tilt bracket DF50AV 60A 60AV DF40A 50A NOTICE Damage can occur if you use the tilt bracket other than when the boat is moored or is oth e...

Page 32: ...nd motor before beginning a trip can be hazardous Before boating always perform the inspec tions described in this section NOTICE Running the engine with an insufficient amount of oil can cause serious engine dam age Always check the oil level before each trip and add oil if necessary 2 Pull out the oil dipstick 3 and wipe oil off with a clean cloth NOTE If the engine oil is contaminated or discol...

Page 33: ...oil can damage the engine Do not overfill the engine with oil BREAK IN Proper 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 engi...

Page 34: ...te the engine continuously at full throttle for more than 5 minutes at any time NOTICE Running continuously 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 BEFORE ATTEMPTING TO ...

Page 35: ...eration The motor will stop abruptly and the loss of forward motion may unexpect edly throw occupants forward NOTE A spare plastic lock plate is provided for tempo rary use only Remove it from the cord and place it in a safe place on board your boat If you lose or break the emergency stop switch cord lock plate assembly replace it as soon as possible so that you can resume normal use of the emerge...

Page 36: ...atically stop If the motor stops wait about ten seconds for the motor to cool down and try again 5 Warm up the engine for about 5 minutes NOTICE If you hold the ignition key at the START position to start the engine the starter system can be damaged Turn the ignition key to the START position once and release it to start the engine The engine will crank continuously for 4 seconds or until the engi...

Page 37: ...s properly EMERGENCY STARTING If you must get the engine running but are unable to do so because of starter system fail ure or battery discharge you can use the emer gency starting procedure to start the engine 1 Make sure that the motor is in NEUTRAL and the emergency stop switch lock plate is removed WARNING If you touch electrical components when rope starting the engine you can get a severe el...

Page 38: ...e sure to have the starter system repaired as soon as possible You should not continue to use the emergency starting procedure for rou tine engine starting SHIFTING AND SPEED CONTROL WARNING If you attempt to reinstall the ring gear cover or motor cover after starting the engine you can be injured Do not attempt to reinstall the ring gear cover or motor cover after starting the engine WARNING When...

Page 39: ...ndle forward to approximately position A as shown in the illustration To shift into REVERSE squeeze the lock out lever on the control handle and move the con trol handle rearward to approximately position B as shown in the illustration Speed Control To increase speed after you have shifted into gear continue moving the control handle for ward or rearward WARNING Since the same handle is used for s...

Page 40: ...e 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 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 corr...

Page 41: ...p on the monitor gauge will flash indicating that the motor has been set to the troll mode The REV TRL or REV lamp will continue to flash while the motor is in the troll mode Usual scale Trolling mode scale NOTE The troll mode system will not operate if the switch is depressed when the handle shift lever is in the neutral position Adjusting trolling speed When pressing the UP switch one short beep...

Page 42: ...V T TH MODEL To tilt the motor higher than the normal trim angle use the Power Trim and Tilt switch OPERATION IN SALT WATER After operating the motor in salt water you should flush the water passages with clean fresh water as outlined in the FLUSHING THE WATER PASSAGES section If you do not flush the water passages salt can corrode the motor and shorten its life WARNING When the motor is beyond th...

Page 43: ...stand it up in the vertical position so that the cooling system 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 Dealer to do the work for you MOTOR TRANSPORTING When transporting the motor place the motor either vertically or horizontally Vertical transport Attach t...

Page 44: ...DO NOT lay motor on its side without drain 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 th...

Page 45: ... device to support the weight of the motor NOTICE If you use the tilt bracket 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 bracket to hold the motor in the fully tilted up position when trailering the boat Use a tr...

Page 46: ...hat 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 Interval Item to be serviced Initial 20 hrs or 1 month Every 100 hrs or 12 months Every 200 hrs or 12 months Every 300 hrs or 36 months Spark plug I I I Breather Fuel line I I I I Engine o...

Page 47: ...ction and maintenance instructions carefully If you do not have prior mechanical experience do not attempt to per form maintenance on your outboard motor You could be injured or may damage the motor NOTICE The 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 maint...

Page 48: ... standard plug is not suit able for your operating consult your authorized Suzuki Marine Dealer 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 be covered under war...

Page 49: ...rwise it will cause difficulty in starting the engine increase fuel consumption and result in engine troubles Spark plug gap 0 8 0 9 mm 0 031 0 035 in 1 2 3 4 5 6 BREATHER AND FUEL LINE Inspect 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 t...

Page 50: ...y 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 the u...

Page 51: ...AR OIL To check the gear oil level remove the upper oil level plug 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 until the level reaches the bottom edge of the hole Then reinstall and tighten the plug To change the gear oil 1 Make sure the motor is in an upright posi tion Place a drain pan under the lower cas ing 2 ...

Page 52: ...thing or rags that are wet with oil NOTICE If fishing line wraps around the rotating pro peller shaft the propeller shaft oil seal can become damaged and can allow water to enter the gear case causing severe damage If the gear oil has a milky color it is contami nated with water Immediately contact your authorized Suzuki marine dealer for advice Do not operate your outboard until the oil is change...

Page 53: ...tion and replacement of internal anodes attached to the cylinder block cylinder head Bonding wires Bonding wires are used to electrically connect the engine components so they exist in a com mon ground circuit This allows them to be pro tected against electrolysis by the anodes These wires and their terminals should be checked periodically to be sure they have not been damaged NOTICE If anodes are...

Page 54: ...ery s positive terminal and the motor at the same time WARNING Battery posts terminals and related accesso ries contain lead and lead compounds that may be hazardous Wash hands after handling NOTICE If you add diluted sulphuric acid to the battery after it has been initially serviced you will damage the battery NEVER add diluted sulphuric acid to the bat tery after it has been initially serviced F...

Page 55: ...ren and pets away from the area and stay clear of all moving parts NOTICE Severe engine damage can occur in as little 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 To flush the water passages you must obtain a commercially available engine flush device 1 Make sure that the motor is stopped 2 ...

Page 56: ... 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 position 2 Foll...

Page 57: ...e engine through the spark plug holes Coat the engine inner parts with oil by turning the engine over with the emergency starter rope 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...

Page 58: ...n a dry well ventilated area 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 NOTICE Severe engine damage can occur in as little as 15 seconds if the engine is started without supplying water to the cooling system Never start the motor without supplying water to ...

Page 59: ...tart Fuel tank is empty Fuel hose is not properly connected to engine Fuel hose is kinked or pinched Spark plug is fouled Engine idles unstably or stalls Fuel hose is kinked or pinched Spark plug is fouled Engine speed will not increase Engine power is low Engine is overloaded Caution Diagnostic system is activated Propeller is damaged Propeller is not properly matched to loads Engine vibrates exc...

Page 60: ...fuse is blown try to determine the root cause and correct it If the cause is not corrected the fuse may be blown again 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 Always replace a blown fuse with a fuse of the same type and rating NOTICE If a new fus...

Page 61: ...3 57 4 cu in Maximum output 29 4 kW 40PS 36 8 kW 50PS 44 1 kW 60PS Full Throttle Operating Range 5000 6000 r min min 1 5300 6300 r min min 1 Ignition System Full transistor Engine Lubrication Trochoid pump pressure lubrication Engine Oil Capacity 2 7 L 2 9 2 4 US lmp qt Gear Oil Capacity DF40A 50A 60A model 610 cm3 ml 20 6 21 5 US Imp oz DF50AV 60AV model 1050 cm3 ml 35 5 37 0 US Imp oz Spark Plug...

Page 62: ... 1986 CHART OF TOTAL OPERATING HOURS INDICATION REMOTE CONTROL MODEL One flashing is corresponded to 500 hours Regulation Sound pressure level limit 2013 53 EU 72 dB A DF40A 50A 75 dB A DF60A Total operating hours MONITOR TACHOMETER Needle 1 indication REV LIMIT lamp 2 flashing 0h 49h No No 50 h 500 r min No 60 h 600 r min No 540 h 5400 r min No 550 h 500 r min 1 time 560 h 600 r min 1 time 1040 h...

Page 63: ...0 540h 549h 540 550h 559h 100 1 time 50 800h 809h 300 1040h 1049h 540 1050h 1059h 200 2 times 50 1300h 1309h 300 1540h 1549h 540 1550h 1559h 300 3 times 50 1800h 1809h 300 2040h and over remaining at 540 Lapse of Time Tachometer indication First 2 seconds after main switch is turned on 0 Next 2 5 seconds 1st indication Indication of number of time in which the operat ing hours attain to 500 hours ...

Page 64: ...ndication and the indi cated hours of second step indication indicated in units of 10 hours FLOWCHART OF OIL CHANGE REMINDER SYSTEM 1 Lapse of initial 20 hour s 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 Cancella...

Page 65: ...Y B Br Y G B Bl V V V V V V B G B G B Bl B Bl B B B G B Bl B W Y W Y R R B W B W W Y R R R B W B W B W B W P W P W Lbl W Lbl W P W Lbl W B B B G W G W P W P W Bl B Bl B G W G W P W P W Bl B Bl B G W P W Bl B G W P W Bl B O Y O Y B B B G B G O Y B B G EMERGENCY STOP SWITCH LOCK PLATE IN RUN LOCK PLATE OFF STOP Gr Gr Gr Gr Bl Bl Bl Bl Gr Gr Bl Bl W Y W Y B B Bl B Bl B G Y G Y P P G W G W Lbl Lbl P P...

Page 66: ...l R Bl R B G B G Bl W Bl W B B Y Bl B G Y P W G W Lbl P O W Br Y B Bl R B G Bl W B G W G W P W P W Bl B Bl B P W P W Bl B Bl B G W G W O Y O Y B B B G B G G W P W Bl B P W Bl B G W O Y B B G R R R V V V P P P Lbl Lbl Lbl V V G Y G Y G W G W W W Y Y Gr Gr B B P P Bl B Bl B Lbl Lbl O O Br Br G G Bl Bl V B B G G W R W R W W Gr Gr Br Br Bl Bl B G G B B W W W W Gr Gr Br Br Bl Bl G G W R W Gr Br Bl B Bl...

Page 67: ... B Gr Gr W Bl R Y R R B W B W Br Y Br Y Lg B Lg B W W R B W Br Y Lg B W B W B W R B R B B W R B Y B Y B Br Br Y G Y G B Bl B Bl Y B Br Y G B Bl V V V B G B G B Bl B Bl B B B G B Bl B G W G W P W P W Bl B Bl B G W G W P W P W Bl B Bl B G W P W Bl B G W P W Bl B O Y O Y B B B G B G Bl R Bl R B G B G Bl W Bl W B B Bl B Bl B G Y G Y P W P W G W G W O O W W Br Br Y B Y B Bl B G Y P W G W O W Br Y B Bl ...

Page 68: ...Prepared by August 2017 Part No 99011 88L70 054 Printed in Japan COPYRIGHT SUZUKI MOTOR CORPORATION 2017 ...

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