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DF200 __
DF225 __
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DF250 __
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OWNER’S MANUAL __
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ENGLISH
1
IMPORTANT • Become thoroughly familiar with all operat-
ing and handling characteristics of your
WARNING/ CAUTION/ NOTICE/ NOTE boat and motor. Practice at low and moder-
Please read this manual and follow its instruc- ate speeds until you are competent at han-
tions carefully. To emphasize special informa- dling the boat and motor. Do not attempt to
tion, the symbol and the words WARNING, operate at maximum performance until you
CAUTION, NOTICE and NOTE have special are completely familiar with all of these
meanings. Pay special attention to the mes- characteristics.
sages highlighted by these signal words. • Carry boating safety and emergency equip-
ment. This important equipment includes;
WARNING flotation aids for each person (plus one
throwable buoyant cushion in any boat 16
Indicates a potential hazard that could result
feet or longer), fire extinguisher, sound sig-
in death or serious injury.
naling device, visual distress signals,
anchor, bilge pump, bucket, compass,
CAUTION emergency starter rope, extra fuel and oil,
Indicates a potential hazard that could result first aid kit, flashlight, food and water, mir-
in minor or moderate injury. ror, paddles, tool kit, and transistor radio.
Be sure you are carrying the equipment
appropriate for your trip before launching.
NOTICE • Never start the engine or let it run indoors
Indicates a potential hazard that could result or where there is little or no ventilation.
in damage to the motor or boat. Exhaust gas contains carbon monoxide, a
gas that is colorless and odorless and can
NOTE: cause death or severe injury.
Indicates special information to make mainte- • Instruct your passengers on how to operate
nance easier or instructions clearer. the boat, how to deal with emergencies, and
how to operate safety and emergency
equipment.
This symbol appears in various locations on • Do not hold onto the motor cover or any
your Suzuki product to refer you to important other parts of your outboard motor while
information in the owner’s manual. getting on or off your boat.
• Ensure that everyone wears a PFD (Per-
sonal Flotation Device) on board.
• Never operate the boat while under the
influence of alcohol or other drugs.
IMPORTANT NOTICE TO • Distribute all weight load evenly in the boat.
OWNERS • Have all scheduled maintenance performed.
Consult your authorized Suzuki marine
dealer as required.
WARNING • Do not modify or remove any outboard
motor standard equipment. To do so may
Failure to take the proper precautions may make the motor unsafe to use.
increase the risk of death or severe injury to • Learn and obey all applicable navigation
you and your passengers. rules.
• Pay attention to all weather forecasts. Do
• Prior to first-time use of your outboard not set out if weather is unsettled.
motor, familiarize yourself thoroughly with • Use extreme caution when purchasing
the contents of this owner’s manual. Be replacement parts or accessories. Suzuki
aware of all outboard motor features and all strongly recommends that you use only
safety and maintenance requirements. genuine Suzuki replacement parts/accesso-
• Inspect the boat and motor before each trip. ries or their equivalent. Inappropriate or
See the INSPECTION BEFORE BOATING poor quality replacement parts or accesso-
section for important items. ries can create unsafe operating conditions.
2
• Never remove the flywheel cover (except for
FOREWORD
when emergency starting).
Thank you for choosing a Suzuki outboard
motor. Please read this manual carefully and
NOTE:
review it from time to time. It contains important
Mounting radio transceiver or navigational
information on safety, operation, and mainte-
equipment antennae too close to the engine
nance. A thorough understanding of the infor-
cowling can cause electrical noise interference.
mation presented in this manual will help you
Suzuki recommends that antennae be mounted
experience safe, enjoyable boating.
at least one meter (40 inches) away from the
engine cowling.
All information in this manual is based on the
latest product information available at the time
This manual should be considered a per- of publication. Due to improvements or other
manent part of the outboard motor and changes, there may be discrepancies between
should remain with the outboard motor this manual and your outboard motor. Suzuki
when resold or otherwise transferred to a reserves the right to make changes at any time
new owner or operator. Please read this without notice.
manual carefully before operating your
new Suzuki and review the manual from
time to time. It contains important infor-
mation on safety, operation, and mainte-
nance.
3
TABLE OF CONTENTS
IDENTIFICATION NUMBER
LOCATION.............................................. 5
FUEL AND OIL....................................... 5
LOCATION OF SAFETY LABELS ..... 8
LOCATION OF PARTS......................... 9
MOTOR MOUNTING.......................... 10
BATTERY INSTALLATION .............. 10
USE OF ELECTRICAL
ACCESSORIES ..................................... 12
PROPELLER SELECTION AND
INSTALLATION................................... 13
ADJUSTMENT...................................... 14
CAUTION SYSTEM ............................. 16
DIAGNOSTIC SYSTEM ...................... 19
OIL CHANGE REMINDER
SYSTEM................................................. 20
ENGINE STALLING CAUTION
SYSTEM................................................. 20
WATER IN FUEL ALERT
SYSTEM................................................. 20
OPERATION OF TILTING
SYSTEMS............................................... 21
INSPECTION BEFORE BOATING ... 23
BREAK-IN ............................................. 25
OPERATION ......................................... 26
MOTOR REMOVAL AND
TRANSPORTING ................................. 31
TRAILERING........................................ 33
INSPECTION AND
MAINTENANCE................................... 34
FLUSHING THE WATER
PASSAGES............................................. 45
SUBMERGED MOTOR ....................... 47
STORAGE PROCEDURE ................... 48
AFTER STORAGE ............................... 49
TROUBLESHOOTING ........................ 49
SPECIFICATIONS ............................... 51
INFORMATION REGARDING
EC – DIRECTIVE ................................. 51
CHART OF TOTAL OPERATING
HOURS INDICATION ......................... 52
FLOWCHART OF OIL CHANGE
REMINDER SYSTEM.......................... 52
4
IDENTIFICATION Suzuki recommends that you install a water-
separating fuel filter assembly between your
NUMBER LOCATION boat’s fuel tank(s) and outboard motor(s). Fuel
filtration systems of this type will help prevent
The model and identification numbers of your water that may be present in your boat’s fuel
outboard motor are stamped on a plate tank(s) from contaminating your motor’s elec-
attached to the clamp bracket. It is important to tronic fuel injection system. Water contamina-
know these numbers when you place a parts tion can cause poor engine performance and
order or if your motor is stolen. 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 ethanol (grain
alcohol), also known as “GASOHOL”, are com-
mercially available in some areas. Blends of this
type may be used in your outboard motor if they
are no more than 10% ethanol. Make sure this
gasoline-ethanol blend has octane ratings no
lower than those recommended for gasoline.
GASOLINE
Suzuki highly recommends that you use alco-
hol-free unleaded gasoline whenever possible, or
with a minimum octane rating of 91 (Research
method). However, blends of unleaded gasoline
and alcohol with equivalent octane content may 78RB0900*
be used, provided the guidelines that follow are
met. Pump Labeling for Gasoline/Alcohol
Blends
In some states, pumps that dispense gasoline/
NOTICE alcohol blends are required to be labeled for the
type and percentage of alcohol content, and
Use of leaded gasoline can cause engine dam- whether important additives are present. Such
age. Use of improper or poor quality fuel can labels may provide enough information for you
affect performance and may damage your to determine if a particular blend of fuel meets
motor and fuel system. the requirements listed above. In other states,
pumps may not be clearly labeled as to the con-
Use only unleaded gasoline. Do not use fuel tent or type of alcohol and additives. If you are
having lower than the recommended octane, not sure that the fuel you intend to use meets
or fuel that may be stale or contaminated by these requirements, check with the service sta-
dirt/water etc. tion operator or the fuel suppliers.
NOTE:
Oxygenated fuels are fuels which contain oxy-
gen-carrying additives such as alcohol.
5
NOTE: ENGINE OIL
If you are not satisfied with the operation or fuel
economy of your outboard motor when you are NOTICE
using gasoline/alcohol blends, you should
switch back to unleaded gasoline containing no Use of poor quality engine oil can adversely
alcohol. affect engine performance and life.
Be sure that any gasoline/alcohol blend you use
has octane ratings of at least 91 octane Suzuki recommends that you use Suzuki
(Research method). Marine 4-Cycle Engine Oil or its equivalent.
If engine pinging is experienced, substitute
another brand as there are differences between
brands. Oil quality is a major contributor to your
Unleaded gasoline will extend spark plug life. engine’s performance and life. Always select
good quality engine oil.
Suzuki recommends the use of SAE 10W-40 or
WARNING 10W-30 SUZUKI MARINE 4-CYCLE ENGINE
OIL. If SUZUKI MARINE 4-CYCLE ENGINE
Gasoline is extremely flammable and toxic. It OIL is not available, select a NMMA certified
can cause a fire and can be hazardous to peo- FC-W oil or good quality 4-cycle motor oil from
ple and pets. the following chart according to the average
temperatures in your area.
Always take the following precautions when
refueling: API Classification SAE Viscosity Grade
• Never permit anyone other than an adult to SG
refill the fuel tank. SH 10W–40
• If you use a portable fuel tank, always stop SJ
SL
the motor and remove the fuel tank from the 10W–30
SM
boat to refill it.
• Do not fill the fuel tank all the way to the top TEMP.
˚C –20 –10 0 10 20 30 40
˚F –4 14 32 50 68 86 104
or fuel may overflow when it expands due to
heating by the sun.
NOTE:
• Be careful not to spill fuel. If you do, wipe it
In very cold weather (below 5°C (41°F)), use
up immediately.
SAE (or NMMA FC-W) 5W-30 for easier start-
• Do not smoke, and keep away from open
ing and smooth operation.
flames and sparks.
NOTICE
NOTICE
6
GEAR OIL
7
LOCATION OF SAFETY LABELS
Read and follow all of the labels on your out- Keep the labels on your outboard motor or fuel
board motor or fuel tank. Make sure you under- tank. Do not remove them for any reason.
stand all of the labels.
8 WARNING AVERTISSEMENT
8
LOCATION OF PARTS
Motor cover
Power trim and tilt
(P.T.T.) switch
Flush plug
MONITOR-TACHOMETER
Clamp bracket
Engine oil drain plug
Anode Anode
Air vent hole plug Anti-cavitation
plate
Gear oil level plug
Trim tab
Priming bulb
FUEL LINE
9
MOTOR MOUNTING BATTERY INSTALLATION
WARNING BATTERY REQUIREMENT
850 Marine Cranking Amps (MCA)/ABYC,
Overpowering your boat can be hazardous. or 670 Cold Cranking Amps (CCA)/SAE
Excessive horsepower will have an adverse or 180 Reserve Capacity (RC) Minutes/SAE
effect on hull safety and may cause operating/ or 12 Volt 100 AH
handling difficulties. The boat may also sus-
tain stress and hull damage. NOTE:
• The specifications listed above are the mini-
Never install an outboard motor with horse- mum battery rating requirements for starting
power exceeding the manufacturer’s recom-
the engine.
mended maximum horsepower listed on the
• Additional electrical loads from the boat will
boat’s “Certification Plate”. Contact your
authorized Suzuki marine dealer if you are require larger capacity batteries. Consult
unable to locate the hull “Certificate Plate”. your Suzuki dealer to determine the proper
battery sizing for your boat and engine com-
bination.
Suzuki strongly recommends that you have
• Dual-purpose (Cranking/Deep-cycle) batter-
your outboard motor, controls and gauges
installed by an authorized Suzuki Marine ies can be used if they meet the minimum
Dealer. He has the tools, the facilities and the specifications listed above (MCA, CCA, or
know-how. RC).
• Do not use a Deep Cycle battery for the main
WARNING cranking battery.
• When connecting batteries in parallel, they
must be of the same type, capacity, manufac-
Failure to have your outboard motor and asso- turer, and of similar age. When replacement
ciated controls and gauges properly installed is necessary, they should be replaced as a
can result in personal injury or damage. set. Consult your Suzuki dealer for proper
battery installation information.
Suzuki strongly recommends that you 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.
10
BATTERY INSTALLATION
WARNING
Secure the battery in a dry area of the boat,
away from vibration.
If you place the battery near the fuel tank, a
NOTE: spark from the battery may ignite the gaso-
• It is recommended that the battery be line, causing a fire and/or an explosion.
installed in an enclosed battery case.
Do not place the fuel tank in the same com-
• When connecting batteries, hexagon-nuts
partment/area as the battery.
must be used to secure battery leads to bat-
tery posts.
WARNING
To hook up the battery, first connect the red
lead from the motor to the positive battery ter- Batteries produce flammable hydrogen gas
minal, then connect the black lead to the nega- and may explode if they are near flames or
tive battery terminal. sparks.
WARNING
NOTICE
To remove the battery, first disconnect the black
lead from the negative terminal, then discon- The electrical system or its components may
nect the red lead from the positive terminal. be damaged if proper battery precautions are
not followed.
Suzuki recommends that you install the termi-
nal cap on the positive battery terminal to pre- • Be sure to attach battery leads correctly.
vent an accidental short circuit of battery • Do not disconnect battery leads from the
terminals. battery while the engine is running.
If a terminal cap is required, contact your autho-
rized Suzuki marine dealer.
11
SUB BATTERY CABLE USE OF ELECTRICAL
The sub battery cable 1 is used to supply volt-
age to the engine control system. In the midst ACCESSORIES
of the cable, a 15A fuse 2 is provided to pro-
tect the control circuit. The amount of power (DC12V) available for
If the sub battery cable is not correctly con- accessories, however, depends on the operat-
nected to the battery, engine cannot be started. ing condition of the motor. For getting a detailed
information, please inquire of your authorized
Suzuki Marine Dealer.
NOTE:
Use of too much power for electrical accesso-
ries under certain operating conditions can
cause the battery to discharge.
12
PROPELLER SELECTION PROPELLER INSTALLATION
AND INSTALLATION WARNING
PROPELLER SELECTION
It is essential to use a propeller on your out- Failure to take proper precautions when
board motor that is properly matched to your installing or removing the propeller can result
boat’s operating characteristics. The speed of in severe personal injury.
the engine when you operate your boat at full
throttle depends on the propeller you use. When installing or removing the propeller:
Excessive engine speed can seriously damage • Always shift into “Neutral” and remove the
the motor, while low engine speed at full throttle emergency stop switch lock plate so that
will adversely affect the performance. Your the motor cannot be started accidentally.
operating load will also affect propeller selec- • Wear gloves to protect hands, and “lock”
tion. Smaller loads generally require larger- the propeller by placing a block of wood
pitch propellers; larger loads generally require between the blades and the anti-cavitation
smaller-pitch propellers. Your authorized Suzuki plate.
Marine Dealer will assist you in selecting a suit-
able propeller for your boat. To install a propeller on your outboard motor,
use the following procedure:
NOTICE
You can determine if your propeller is appropri- 1. Coat the propeller shaft splines 1 liberally
ate for use with your boat by using a tachome- with Suzuki water resistant grease to help
ter to measure engine speed when operating prevent corrosion.
your boat at full throttle, under minimum load 2. Place the stopper 2 on the shaft.
conditions. If you are using an appropriate pro- 3. Align the propeller 3 with the propeller shaft
peller, the engine speed will be within the fol- splines and slide the propeller onto the shaft.
lowing range: 4. Place the spacer 4 and washer 5 on the
shaft.
5000 – 6000 5. Install the propeller nut 6 and tighten it with
DF200 a torque wrench to 50 – 60 N·m (5.0 – 6.0
r/min. (min–1)
Full throttle kg-m/36.0 – 43.5 lb-ft).
5000 – 6000
operating DF225 6. Insert the cotter pin 7 and bend it so that it
r/min. (min–1)
range can’t come off.
5500 – 6100
DF250
r/min. (min–1) To remove the propeller, reverse the above pro-
cedure.
If the engine speed is not within this range, con-
sult your authorized Suzuki Marine Dealer to
determine which propeller size is best for you.
13
ADJUSTMENT WARNING
TRIM ANGLE ADJUSTMENT
Trim angle greatly affects steering stability. If
To help maintain steering stability and good
the trim angle is too small, the boat may
performance, always maintain the proper trim
“plow” or “bow steer”. If the trim angle is too
angle as shown in the illustration. The appropri-
large, the boat may “chine walk” from side to
ate trim angle varies depending on the combi-
side or “porpoise” up and down. These condi-
nation of the boat, engine, and propeller, as well
tions, which result in loss of steering control,
as operating conditions.
can cause occupants to be thrown overboard.
WARNING
• Trim angle too small (Boat tends to “plow”)
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 unit strikes an obstruction.
This could lead to occupant injury.
NOTICE
Tilt range
Trim range
14
Make a test run in the boat to determine if the TRIM TAB ADJUSTMENT
trim angle needs to be adjusted. Adjust the trim This adjustment is used to compensate for the
angle using the Power Trim and Tilt system. If possible tendency of your boat to veer slightly
necessary, you can change the limit of down- to port or starboard. This tendency could be
ward travel that can be achieved using the due to such things as propeller torque, motor
Power Trim and Tilt by moving the tilt pin to mounting position, etc.
another position.
To adjust the trim tab:
While operating your boat with the motor 1. Loosen the bolt A that holds the trim tab in
adjusted to the proper trim angle, observe the place.
position of the needle on the TRIM GAUGE pro-
vided as optional part. When making future trim
angle adjustment, use the TRIM GAUGE as a
guide.
15
THROTTLE TENSION ADJUSTMENT CAUTION SYSTEM
The tension of the remote control handle can be
adjusted according to your preference. To The caution systems are designed to alert you
increase the tension, turn the throttle tension to certain situations which may cause damage
adjuster A clockwise. To decrease the tension, to your outboard motor.
turn the adjuster counterclockwise.
NOTICE
NOTICE
IDLE SPEED ADJUSTMENT
The idle speed has been factory adjusted
Continuing to operate your outboard motor
between 600 – 700 r/min in neutral.
with the Caution System activated can result
in severe damage to your outboard motor.
NOTE:
If idle speed cannot be set within the specified
If the Caution System activates while you are
range, contact your authorized Suzuki Marine
operating your outboard motor, stop the
Dealer.
motor as soon as possible and correct the
problem or consult your authorized Suzuki
marine dealer for assistance.
MOTOR COVER FASTENING
ADJUSTMENT
If you feel motor cover fastening is loose or too
INDICATOR CHECK
Each time the ignition key is turned to the “ON”
tight when locking the levers, adjust as follows:
position, four lamps – the REV LIMIT 1, the
OIL 2, the TEMP 3 and the CHECK ENGINE
1. Loosen the bolts 1, 2 and 3.
4 in the monitor-tachometer will light briefly
2. Adjust the position of brackets 4, 5 and 6.
and the buzzer will also sound for the first two
To increase the fastening, move the brackets
seconds, regardless of the motor conditions.
to the direction A. To decrease the fasten-
ing, move the brackets to the direction B.
For the next three seconds, the monitor-
3. Tighten the bolts.
tachometer will indicate the total motor operat-
ing hours by means of the lamp flashing and
Motor cover
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.
16
NOTICE
NOTE:
OVER-REVOLUTION CAUTION SYSTEM In case that the engine is automatically stopped
This system is activated when engine speed due to the CAUTION system, the engine can be
exceeds maximum recommended speed for started again.
more than 10 seconds. However the CAUTION system will repeatedly
activate until eliminating the cause.
If this system activates, engine speed will
automatically be reduced to approximately
3000 r/min. with red REV LIMIT lamp lit.
17
WARNING NOTE:
In case that the engine is automatically stopped
due to the CAUTION system, the engine can be
If you attempt to remove or reinstall the motor started again.
cover while the engine is running, you may be However the CAUTION system will repeatedly
injured. activate until eliminating the cause.
NOTICE
18
BATTERY VOLTAGE CAUTION SYSTEM DIAGNOSTIC SYSTEM
This system is activated when the battery volt-
age deficiency which could impair your motor’s If abnormal conditions exist in any sensor sig-
performance occurs. nal being input to the control unit, the self-diag-
nostic system warns of the abnormal condition.
If this system activates, the red CHECK
ENGINE lamp will light and buzzer will begin a If this system activates, the red CHECK
series of beep. ENGINE lamp will flash and a buzzer will
sound.
Do not attempt to inspect or service the bat- If the diagnostic system activates while you
tery without first reading the warnings, cau- are operating your outboard motor, there is an
tions, and instructions in the “BATTERY abnormal condition in one of the sensor sig-
INSTALLATION” section of this manual. nals of the control system.
19
OIL CHANGE REMINDER ENGINE STALLING
SYSTEM CAUTION SYSTEM
This system informs the operator of the time for This system informs the operator when the
replacing engine oil on the basis of the mainte- motor stalls while it is operating.
nance schedule. When the engine stalls for any reason, the cau-
The system is designed to register the total tion buzzer sounds three times.
operating hours of the outboard motor and
function its operation when the preprogrammed
hours have reached.
(Refer to the INSPECTION AND MAINTE-
NANCE section and the last page.) WATER IN FUEL ALERT
SYSTEM ACTIVATION SYSTEM
When the total operating hours have reached
the preprogrammed hours, the OIL lamp will This engine is equipped with an integral fuel fil-
flash. If the engine is not running, the buzzer ter/water separator and associated alert sys-
will begin a series of double beeps additionally. tem.
This indication will repeat until you cancel the
system activation. The alert system will activate if water separated
from the fuel exceeds a specific volume.
CANCELLATION
1. Turn the ignition key to the “ON” position. If this system activates, the red REV-LIMIT
2. Pull out the emergency stop switch plate 1. lamp will flash and a buzzer will begin a series
3. Pull up the emergency stop switch knob 2 of double beeps when the engine is in neutral
three times in 10 seconds. A short beep will only.
be heard if the cancellation is successfully
finished.
20
OPERATION OF TILTING TILT LIMITER CAM
If the outboard motor contacts the motor well of
SYSTEMS the boat while tilting, adjust the tilt limiter cam to
limit maximum tilt position.
POWER TRIM AND TILT 1. Place the motor in the normal running posi-
The “Power Trim and Tilt” is operated by press- tion.
ing the switch. To tilt the motor up, press the 2. Rotate the tilt limiter cam:
upper part of the switch. To tilt the motor down, To reduce the amount of tilt, move the tab A
press the lower part of the switch. of cam upward.
To increase the amount of tilt, move the tab
A of cam downward.
UP
DOWN
WARNING
21
MANUAL TILTING 3. Lower the motor by pressing the Power Trim
If you are unable to tilt the motor using the and Tilt “DOWN” switch, until the motor is
“Power Trim and Tilt” because of an electrical supported by the Tilt Bracket.
problem or some other problem, you can move 4. Continue to operate the Power Trim and Tilt
the motor manually. To tilt the motor up or “DOWN” switch until the trim rods are com-
down, turn the manual release valve A two pletely retracted.
turns counterclockwise, move the motor to the
desired position, then retighten the release
screw.
NOTICE
When you tilt the motor manually, ensure that To release the Tilt Lever, tilt the motor all the
your grip and footing are secure and that you way up using the Power Trim and Tilt “UP”
are able to support the weight of the engine. switch, and pull up the Tilt Lever.
CAUTION
TILT BRACKET
The Tilt Bracket is provided so you can support The remote Power Trim and Tilt switch will
the motor in a tilted position for non-moving work when the ignition switch is off. If some-
engine support. one activates the switch while you are moving
To set the Tilt Bracket: the tilt bracket, your hand could be injured.
1. Tilt the motor all the way up by pressing the
Power Trim and Tilt “UP” switch. Keep all persons away from the remote Power
2. Pull down the Tilt Bracket as shown in the Trim and Tilt switch while you are moving the
illustration. tilt bracket.
22
NOTICE INSPECTION BEFORE
BOATING
Damage can occur if you use the tilt bracket
other than when the boat is moored or is oth- WARNING
erwise stationary.
The tilt bracket relieves pressure from the Failure to inspect your boat and motor before
power trim and tilt and should only be used beginning a trip can be hazardous.
when the boat is stationary. Do not use the tilt
bracket when trailering your boat and motor. Before boating, always perform the inspec-
Refer to the TRAILERING section of this man- tions described in this section.
ual.
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:
NOTICE
NOTE:
To avoid an incorrect assessment of engine oil
level, check the level only when the engine has
cooled.
23
2. Pull out the oil dipstick and wipe oil off with a To fill the engine oil:
clean cloth. 1. Remove the oil filler cap.
2. Fill the recommended engine oil to the upper
level.
NOTE:
If the engine oil is contaminated or discolored,
replace with fresh engine oil (Refer to the
INSPECTION AND MAINTENANCE/ENGINE
NOTICE
OIL section).
Running the engine with an excessive amount
3. Insert the dipstick all the way into the engine, of oil can damage the engine.
then remove it again.
Do not overfill the engine with oil.
24
BREAK-IN NOTE:
You may throttle up beyond the recommended
Proper operation during this break-in period will operating range to plane your boat, then imme-
help ensure maximum life and performance diately reduce the throttle to the recommended
from your engine. The following guidelines will operating range.
explain proper break-in procedures.
2. For the next 1 hour:
NOTICE Safe boating conditions permitting, operate
the engine in gear at 4000 r/min. or at three-
quarter throttle. Avoid running the engine at
Failure to follow the break-in procedures full throttle.
described below can result in severe engine 3. Remaining 7 hours:
damage. Safe boating conditions permitting, operate
the engine in gear at desired engine speed.
Be sure to follow the engine break-in proce- You may occasionally use full throttle; how-
dures described below. ever do not operate the engine continuously
at full throttle for more than 5 minutes at any
Break-in period: 10 hours time.
25
OPERATION 4. Make sure that the motor is in “NEUTRAL”.
26
WARNING 1. Squeeze the fuel line priming bulb several
times until you feel resistance.
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 3. Turn the ignition key to the “ON” position.
the emergency stop switch. 4. Turn the ignition key to the “START” position.
WARNING
27
NOTE: NOTICE
The continuous operating time of the starter
motor is set at five seconds.
When this time is exceeded, the starter motor Never operate your outboard motor when
will automatically stop. there is no water coming out of the pilot water
If the motor stops, wait about ten seconds for hole, or severe damage can result.
the motor to cool down and try again.
After starting the engine, check to make sure
NOTICE that there is water coming out of the pilot
water hole.
Always allow the engine to warm up suffi- Severe engine damage may occur if (a) engine
ciently before operating it at high speeds. speed is not allowed to return to idle and boat
speed is not reduced when shifting from
Cooling water check “FORWARD” to “REVERSE” or from
As soon as the engine starts, water should “REVERSE” to “FORWARD”, or (b) care is not
spray out of the pilot water hole 1, indicating taken when operating the boat in reverse.
that the water pump and cooling system are
working properly. If you notice that water does Always allow the engine speed to return to
not spray out of the pilot water hole, stop the idle before shifting. Exercise caution and use
engine as soon as possible and consult your minimal speed when operating the boat in
Suzuki Marine Dealer. reverse. Be sure the handle/shift lever is in the
desired position before accelerating.
NOTICE
28
Shifting STOPPING THE ENGINE
To shift into “FORWARD”, squeeze the lock-out NOTE:
lever on the control handle and move the con- When it is necessary to stop the engine in an
trol handle forward to approximately position A, emergency, pull the emergency stop switch lock
as shown in the illustration. plate out of the emergency stop switch by pull-
ing the emergency stop switch cord.
To shift into “REVERSE”, squeeze the lock-out
lever on the control handle and move the con- To stop the engine:
trol handle rearward to approximately position 1. Shift into “NEUTRAL”.
B, as shown in the illustration. 2. After operating at full throttle, cool off the
engine a few minutes by allowing it to idle or
NEUTRAL troll at low speed.
32˚ 32˚
REVERSE
FORWARD
Speed Control
To increase speed after you have shifted into
gear, continue moving the control handle for- 3. Turn the ignition key to the “OFF” position.
ward or rearward. Always leave the ignition key in the “OFF”
position when the motor is not running, or
the battery can discharge.
WARNING
29
OPERATION IN SHALLOW WATER
WARNING When operating your boat in shallow water, it
may be necessary to tilt the motor higher than
Unauthorized use of your boat could lead to the normal trim angle. When you tilt the motor
an accident or damage to your boat. beyond the normal trim angle, however, you
should only operate the boat at slow speeds.
To prevent unauthorized use of your boat, be After returning to deep water, be sure to lower
sure to remove the key and emergency stop the motor to the normal trim angle.
switch lock plate when the boat is unattended.
WARNING
4. After stopping the engine, disconnect the
fuel line from the outboard motor if there is a When the motor is beyond the maximum trim
fuel connector. position, the swivel bracket will not have side
WARNING support from the clamp bracket and the tilt
system will be unable to cushion the engine if
the lower unit strikes an obstruction. This
If you leave the motor stopped for a long could lead to occupant injury. In addition,
period of time with the fuel line connected, beyond the maximum trim position, the water
fuel can leak out. intake holes may be above the water line,
which can result in severe engine damage
Disconnect the fuel line from fuel tank, if there from overheating.
is a fuel connector, whenever you leave the
motor stopped for a long period of time. Do not operate the engine above 1500 r/min or
operate the boat in a planning attitude with
5. Twist the air-vent screw on the fuel tank cap the engine beyond the maximum trim posi-
clockwise to shut the vent (if equipped). tion.
NOTE: NOTICE
To make sure that the emergency stop switch
operates properly, stop the engine occasionally
by pulling out the lock plate, while operating the If the motor hits bottom, serious damage can
engine at idling speed. occur.
30
OPERATION IN FREEZING WEATHER MOTOR REMOVAL AND
When operating your outboard motor in freez-
ing temperatures, you should keep the lower TRANSPORTING
unit submerged in the water at all times.
When taking motor out of the water, stand it up MOTOR REMOVAL
in a vertical position until the cooling system If it is necessary to remove the outboard motor
drains completely. from your boat, we recommend that you ask
your authorized Suzuki Marine Dealer to do the
NOTICE work for you.
Horizontal transport:
1. Drain the engine oil. Refer to the ENGINE
OIL section.
2. Drain the gasoline from the vapor separator
1 as follows:
(1) Remove the motor cover.
(2) Pull the drain hose end 2 out.
31
(3) Loosen the vapor separator drain screw 3 WARNING
and drain the gasoline into a suitable con-
tainer.
Spilled fuel or fuel vapor can cause a fire and
is hazardous to health.
NOTICE
32
TRAILERING
When trailering your boat with the motor
attached, keep the motor in the normal operat-
ing position unless there is not enough ground
clearance. If you need more ground clearance,
trailer the motor in a tilted position using a tran-
som saver bar or similar device to support the
weight of the motor.
NOTICE
33
INSPECTION AND MAINTENANCE
MAINTENANCE SCHEDULE
It is important to inspect and maintain your out- WARNING
board motor regularly. Follow the chart below.
At each interval, be sure to perform the indi- Exhaust gas contains carbon monoxide, a
cated service. Maintenance intervals should be dangerous gas that is difficult to detect
judged by number of hours or number of because it is colorless and odorless. Breath-
months, whichever comes first. ing carbon monoxide can cause death or
severe injury.
Interval Every 100 hrs. Every 200 hrs. Every 300 hrs.
Initial 20 hrs. or every or every or every
or 1 month 12 months 12 months 36 months
Item to be serviced
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 cylin-
I
der block/cylinder head)
Bonding wire I I
Battery I I
* Engine oil filter R R
I I
Low pressure fuel filter
Replace every 400 hours or every 2 years.
* Low pressure fuel pump
Replace every 1000 hours.
filter
* High pressure fuel filter Replace every 1000 hours.
* Idle speed I I
* Valve clearance (lash) I
* Water pump I
* Water pump impeller I R
* Propeller nut & pin I I
* Bolts & Nuts T T
* Thermostat I
I: Inspect and clean, adjust, lubricate, or replace, if necessary T: Tighten R: Replace
NOTE:
Water-separating fuel filter
Replace the filter element every 12-months (or more frequently if recommended by the filter manu-
facturer).
34
WARNING • Frequent abrupt acceleration and decelera-
tion
Improper maintenance or failure to perform • Frequent shift operation
recommended maintenance can be hazard- Failure to perform maintenance more fre-
ous. Poor maintenance or lack of maintenance quently could result in damage.
increases the chance of an accident or equip-
ment damage. Consult your authorized Suzuki marine dealer
regarding appropriate maintenance intervals
Be sure to have maintenance performed for your usage conditions. When replacing
according to the schedule in the above chart. parts on your outboard motor, Suzuki strongly
Suzuki recommends that only your authorized recommends that you use genuine Suzuki
Suzuki marine dealer or a qualified service parts or their equivalent.
mechanic perform maintenance on those
items in the chart above which are marked
with an asterisk (*). You may perform mainte- TOOL KIT
nance on the unmarked items by referring to A tool kit is provided with your outboard motor.
the instructions in this section if you have Keep the kit on board your boat and make sure
mechanical experience. If you are not sure that all of the items provided remain in the kit.
whether you can successfully complete any of The tool kit contains the following items:
the unmarked maintenance jobs, ask your
authorized Suzuki marine dealer to do the 1 Tool bag
maintenance for you. 2 8 mm Box wrench
3 8 × 10 mm Box wrench
WARNING 4 16 mm Box wrench
5 Combination screw driver
6 Screwdriver handle
The safety of you and your passengers 7 Pliers
depends on how well you maintain your out- 8 Hexagon wrench 8 mm
board motor. 9 Engine oil drain plug gasket (spare)
NOTICE
35
SPARK PLUG
Remove the spark plugs as follows:
NOTICE
1. Remove the bolt securing the ignition coil.
Use of improper spark plugs or improperly
2. Pull out the ignition coil.
tightening spark plugs can cause severe
3. Loosen and remove the spark plug using the
engine damage.
box wrench in the tool bag.
• 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-
ranty. Note that aftermarket cross-reference
charts may not be accurate.
• To install a spark plug; seat it as far as pos-
sible by hand, then use a wrench to tighten
it to either the recommended torque setting
or the specified rotation angle.
Your outboard motor comes equipped with the Tightening torque
following “standard” spark plug for normal 25 – 29 N·m
usage. (2.5 – 2.9 kg-m, 18.0 – 21.0 lb-ft)
Rotation angle
NGK BKR6E Standard
New plug 1/2 – 3/4 of a turn
Re-use plug 1/12 – 1/8 of a turn
NOTICE • Do not overtighten or cross-thread a spark
plug, as this will damage the aluminum
Non-resistor types of spark plugs will inter- threads of the cylinder head.
fere with the function of the electronic igni-
tion, causing misfiring, or causing problems
with other electronic boat equipment and
accessories.
36
To maintain a strong spark, you should clean BREATHER AND FUEL LINE
and adjust the plugs at the intervals shown in Inspect the breather and fuel line for leaks,
the maintenance chart. Remove carbon depos- cracks, swelling, or other damage. If the
its from the spark plugs using a small wire breather and fuel line is damaged in any way, it
brush or spark plug cleaner, and adjust the gap must be replaced. Consult your authorized
according to the following chart: Suzuki Marine Dealer if it is necessary to
replace them.
0.7 – 0.8 mm
Spark plug gap Breather line
(0.028 – 0.031 in.)
Breather line
Fuel line
NOTE:
If the spark plug condition is found as shown in
the illustration above, ensure it is replaced with
new one. Otherwise, it will cause difficulty in
starting the engine, increase fuel consumption,
and result in engine troubles.
WARNING
37
ENGINE OIL 3. Place a drain pan under the engine oil drain
screw.
WARNING
CAUTION
Never perform any ENGINE OIL procedure
with the motor running, as serious injury can The engine oil temperature may be high
occur. enough to burn your fingers when the drain
plug is loosened.
The motor must be shut off before any
ENGINE OIL procedures are performed. Wait until the drain plug is cool enough to
touch with bare hands before removing it.
NOTICE
4. Remove the engine oil drain screw 1 and
Extended trolling can reduce oil life. Your gasket 2, then let the engine oil drain.
engine may be damaged if you do not change
engine oil more frequently under this type of
use.
NOTE:
There are spare gaskets in the tool bag.
38
7. Check the engine oil level. GEAR OIL
To check the gear oil level, remove the gear oil
level plug 1 and look into the hole. The oil level
should be at the bottom edge of the hole. If the
oil level is low, add the specified gear oil until
the level reaches the bottom edge of the hole.
Then, reinstall and tighten the plug.
UPPER LIMIT
LOWER LIMIT
NOTE:
To avoid incorrect measurement of engine oil
level, check oil level only when the engine has
cooled.
NOTE:
Recycle or properly dispose of used engine oil. 3. After the oil has drained completely, inject
Do not throw it in the trash, or pour it on the the specified gear oil into the gear oil drain
ground, down a drain, or into the water. hole 2 until it just starts to come out of the
air vent hole 3. Approximately 1.1 L (1.2/1.0
US/lmp. qt.) of oil will be required.
NOTE:
The oil level plug and the air vent hole plug are
different from the oil drain plug.
The magnet is installed in the drain plug.
Clean the magnet if there is a metal powder on
it.
Do not make a mistake in their positions when
install them.
39
NOTE: LOW PRESSURE FUEL FILTER
To avoid insufficient injection of gear oil, check The low pressure fuel filter must be replaced by
the gear oil level 10 minutes after doing the pro- an authorized Suzuki Marine Dealer periodi-
cedure in the step 4. If the oil level is low, slowly cally.
inject the gear oil into the gear oil level hole 1 Replace low pressure fuel filter at every 400
up to the correct level. hours (2 years).
WARNING WARNING
Gear oil can cause injury to people or pets. Gasoline is extremely flammable and toxic. It
Repeated, prolonged contact with used gear can cause a fire and can be hazardous to peo-
oil may cause skin cancer. Even brief contact ple and pets.
with used oil may irritate skin.
Always take the following precautions when
• Keep new and used oil away from children servicing the fuel filter:
and pets. • Stop the motor before cleaning the fuel fil-
• Wear a long-sleeve shirt and waterproof ter.
gloves when handling oil. • Be careful not to spill fuel. If you do, wipe it
• Wash with soap if oil contacts your skin. up immediately.
• Launder any clothing or rags that are wet • Do not smoke, and keep away from open
with oil. flames and sparks.
NOTE: WARNING
Recycle or properly dispose of used gear oil.
Do not throw it in the trash, or pour it on the Cleaning solvent is toxic and an irritant, and
ground, down a drain, or into the water. can cause injury to people and pets.
NOTICE Keep solvent away from children and pets.
Dispose of solvent properly when you are fin-
If fishing line wraps around the rotating pro- ished.
peller shaft, the propeller shaft oil seal can
become damaged and can allow water to enter Inspect and clean the fuel filter as follows:
the gear case causing severe damage.
1. Turn the engine off and allow it to cool.
If the gear oil has a milky color, it is contami- 2. Make sure that the ignition key is in the OFF
nated with water. Immediately contact your position.
authorized Suzuki marine dealer for advice. 3. Remove the bolts 1 securing the fuel filter
Do not operate your outboard until the oil is cap 2 in place.
changed and the cause of the contamination
is corrected.
40
NOTICE 7. Drain the fuel and water in the filter cup into
a suitable container.
• Be careful not to twist the sensor lead wire If spilled gasoline is just left on painted sur-
when removing the filter cup. face, it may cause a stain or discoloration of
• Disconnect the lead wire connector before the surface coating.
removing the filter cup.
Wipe off any spilled gasoline immediately with
4. Push the connector lock tab “a”, then discon- a soft cloth etc.
nect the water sensor lead wire connector
3. 8. 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.
“a”
NOTE:
If any water exists in the fuel filter cup, remove
the cup and drain the water. Always dispose of
excess fuel safely. For questions, consult your
authorized Suzuki Marine Dealer.
41
LUBRICATION
Proper lubrication is important for the safe,
smooth 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
Swivel bracket
Throttle/Shift linkage
Marine-grade Marine-grade
water resistant water resistant
grease grease
(Grease Gun)
Propeller shaft
NOTE:
Before applying grease through the steering
bracket grease nipple, lock the motor in the fully
tilted up position.
42
Use a hand operated grease gun and follow the ANODES AND BONDING WIRES
steps below when servicing the grease nipple Anodes
A on the mount oil seal cover. The motor is protected from exterior corrosion
by anodes. These pieces of anodes control
1. Turn the engine off and allow it to cool. electrolysis and prevent corrosion. The anodes
2. Inject approximately 10 grams of grease at will corrode in place of the parts they are pro-
initial 20 hours. tecting. You should periodically inspect each of
Inject approximately 5 grams of grease at the anodes and replace them when 2/3 of the
every 100 hours (12 months). metal has corroded away.
NOTICE
NOTE:
Consult your authorized Suzuki Marine Dealer
for inspection and replacement of internal
anodes attached to the cylinder block/cylinder
head.
43
Bonding wires WARNING
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- If you are not careful when checking or servic-
tected against electrolysis by the anodes. ing the battery, you can cause a short circuit,
These wires and their terminals should be which could result in an explosion, fire, or cir-
checked periodically to be sure they have not cuit damage.
been damaged.
Disconnect the negative (black) cable when
checking or servicing the battery. Be careful
not to allow a metal tool or other metal object
to touch the battery’s positive terminal and
the motor at the same time.
WARNING
NOTICE
44
FLUSHING THE WATER NOTICE
PASSAGES
Severe engine damage can occur in as little as
After operation in muddy, brackish, or salt 15 seconds if the engine is started without
water, you should flush the water passages and supplying water to the cooling system.
motor surface with clean, fresh water.
If you do not flush the water passages, salt can Never start the motor without supplying water
corrode the motor and shorten its life. Flush the to the cooling system.
water passages as follows.
1. Make sure that the motor is stopped.
2. Install the flushing attachment 1 so that the
ENGINE RUNNING – Vertical position – water intake holes are covered by the rubber
Suzuki recommends that you flush the water cups on the attachment.
passages by using this method. 3. Connect a garden hose to the flushing
attachment and turn on the water to obtain
To flush the water passages, you must obtain a enough flow so that plenty of excess water is
commercially available engine flush device. flowing out from around the rubber cups on
the attachment.
WARNING
45
ENGINE NOT RUNNING 4. Turn on the water to obtain a good water
– Vertical position – flow. Flush the engine for about five minutes.
1. Make sure that the motor is stopped. 5. Turn off the water.
2. Remove one of the plug A or C from the 6. Remove the hose and connector (if used)
two flushing port. then reinstall the plug into the flushing port.
7. Leave the motor in a vertical position until
the engine is drained completely.
NOTE:
The hose connector (flushing attachment)
matched to the flushing point thread B is
included in the crate parts.
46
SUBMERGED MOTOR 7. Take the motor to your authorized Suzuki
Marine Dealer as soon as possible to be
A motor that has been accidentally submerged overhauled.
in water must be overhauled as soon as possi-
ble to prevent corrosion. In the event that your NOTICE
motor is accidentally submerged, take the fol-
lowing steps:
If the fuel supply is contaminated with water,
1. Get the motor out of the water as soon as
engine damage may occur.
possible.
2. Wash it thoroughly with fresh water to com-
If the boat’s fuel tank filler and vent were sub-
pletely remove all salt, mud, and seaweed.
merged, inspect the fuel supply to make sure
3. Remove the spark plugs. Drain the water
it is not contaminated with water.
from the cylinders through the spark plug
holes by manually turning the flywheel sev-
eral times.
4. Check if any water is evident in the engine
oil. If water is seen, remove the oil drain plug
and drain the oil. After draining, tighten the
oil drain plug.
5. Drain the fuel line.
WARNING
NOTICE
47
STORAGE PROCEDURE BATTERY STORAGE
1. When the outboard motor will not be used
for a month or longer, remove the battery
MOTOR STORAGE and store it in a cool, dark place. Completely
When storing your motor for a long period of
recharge the battery before reusing it.
time (for example, at the end of the boating sea-
2. If the battery will be stored for a long period
son), it is recommended that you take your
of time, check the specific gravity of the bat-
motor to your authorized Suzuki Marine Dealer.
tery solution at least once a month and
However, if you choose to prepare the motor for
recharge the battery when low.
storage yourself, follow the procedure outlined
below:
1. Change the gear oil as outlined in the GEAR WARNING
OIL section.
2. Change the engine oil as outlined in the Failure to take proper precautions when
ENGINE OIL section. charging the battery can be hazardous. Bat-
3. Fill a fuel stabilizer to the fuel tank according teries produce explosive vapors that can
to the instructions on the stabilizer can. ignite. Battery acid is poisonous and corro-
4. Flush the water passages in the motor thor- sive, and can cause severe injury.
oughly. Refer to the FLUSHING THE
WATER PASSAGES (Engine running) sec- • Do not smoke and keep battery away from
tion. open flames and sparks.
5. Readjust the water flow, run the engine at • To avoid creating a spark when charging
about 1500 r/min in neutral for five minutes the battery, connect the battery charger
to distribute the stabilized fuel through the cables to the proper terminals before turn-
engine. ing the charger on.
6. Stop the engine. Then turn off the water and • Handle the battery with extreme care and
disconnect the flushing attachment. avoid skin contact with battery acid.
7. Lubricate all other specified parts. Refer to • Wear proper protective clothing (Safety
the LUBRICATION section. glasses, gloves, etc.)
8. Apply a coat of automotive wax on the exter-
nal finish of the motor. If paint damage is evi-
dent, apply touch up paint before waxing.
9. Store the motor in an upright position in a
dry, well-ventilated area.
WARNING
NOTICE
48
AFTER STORAGE TROUBLESHOOTING
When taking your motor out of storage, follow This troubleshooting guide is provided to help
the procedure below to return it to operating you find the cause of common complaints.
condition:
1. Thoroughly clean the spark plugs. Replace NOTICE
them if necessary.
2. Check the gear-case oil level and if neces-
sary, add gear oil according to the procedure Failure to troubleshoot a problem correctly
outlined in the GEAR OIL section. can damage your outboard motor. Improper
3. Lubricate all moving parts according to the repairs or adjustments may damage the out-
LUBRICATION section. board motor instead or fixing it. Such damage
4. Check the engine oil level. may not be covered under warranty.
5. Clean the motor and wax the painted sur-
faces. If you are not sure about the proper action to
6. Recharge the battery before installing it. correct a problem, consult your Suzuki marine
dealer.
Engine overheats:
• Cooling water intake(s) are blocked.
• Engine is overloaded.
• Propeller is not properly matched to loads.
49
FUSE 5. Inspect the fuse and replace with new fuse if
1. Turn the ignition key to the “off” position. needed.
2. Remove the motor cover and electric parts
holder cover.
Main fuse (60A)
Electric parts
holder cover
Spare fuse
Main fuse
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
4. Remove the sub battery cable fuse. blown again.
NOTICE
50
SPECIFICATIONS
Item DF200 DF225 DF250
Engine Type 4 Stroke
Number of Cylinders 6
Bore and Stroke 95.0 × 85.0 mm
(3.74 × 3.35 in.)
Piston Displacement 3 614 cm3
(220.5 cu. in.)
Maximum output 147.1 kW (200PS) 165.5 kW (225PS) 183.9 kW (250PS)
Full Throttle Operating Range 5 000 – 6 000 5 500 – 6 100
r/min. (min–1) 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.)
Fuel Type Alcohol-free unleaded gasoline
Minimum Fuel Octane Rating 91 (Research method)
51
CHART OF TOTAL OPERATING HOURS INDICATION
Total MONITOR-TACHOMETER
operating Needle 1 REV-LIMIT
hours indication lamp 2 flashing *
0 h- (49 h) 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- 5400 r/min 1 time
1050 h- 500 r/min 2 times
: : :
: : :
1540 h- 5400 r/min 2 times
1550 h- 500 r/min 3 times
: : :
: : :
2030 h- 5300 r/min 3 times
2040 h or over 5400 r/min 3 times
*: One flashing is corresponded to 500 hours.
Indication Cancellation
(*2) (*4)
Indication Cancellation
(*3) (*4)
Indication Cancellation
(*3) (*4)
52
PTT SWITCH
UP DN WIRE COLOR
DF200T/Z
P
Bl : Blue Lg/B : Light green / Black
Lbl
W/R
Br : Brown Lg/R : Light green / Red
Dg : Dark Green Lg/W : Light green / White
IAT SENSOR G : Green O/B : Orange / Black
P
LOW PRESSURE FUEL PUMP
Lbl
Gr : Gray O/Bl : Orange / Blue
Lg/B ALTERNATOR Lbl : Light blue
W/R
B/W B B/Y O/Y : Orange / Yellow
FP R Gr
CYLINDER TEMP SENSOR Lg : Light green P/B : Pink / Black
O : Orange P/Bl : Pink / Blue
B Lg/W HIGH PRESSURE FUEL PUMP
B B/W P : Pink P/W : Pink / White
DIGITAL GAUGE DIAGRAM R : Red
CKP SENSOR B B/R R/B : Red / Black
EXH MANI TEMP SENSOR #2 FP Bl Gr (OPTION)
W : White R/G : Red / Green
B G/R
B B/W B/G B/W Y : Yellow R/Y : Red / Yellow
R/B R/B FUSE 15A STARTER
M ISC B/Bl : Black / Blue R/W : Red / White
R/G MOTOR MODIFICATION OF WIRING , .
W/B B/Br : Black / Brown V/W : Violet / White
THROTTLE POSITION SENSOR Gr RELAY
Gr
W/Bl B/G : Black / Green W/B : White / Black
R/Y
Br/Y COMMUNICATION B/R : Black / Red W/Bl : White / Blue
R GAUGE CONNECTOR 2 CAP
B/W CONNECTOR
RECTIFIER & B/W : Black / White W/G : White / Green
V/W B EXH MANI TEMP Bl/B B/Y : Black / Yellow
MAP SENSOR B/W B REGULATOR STARTER MOTOR CAP P/W W/R : White / Red
SENSOR #1 G/W
FUSE 60A Bl/B : Blue / Black W/Y : White / Yellow
R
W
W
Dg
R
Y/G
R M Bl/R : Blue / Red Y/B : Yellow / Black
B/W B/W
Y/Bl CMP SENSOR #1 COMMUNICATION Bl/Y : Blue / Yellow Y/Bl : Yellow / Blue
Gr
W
O/Y
CONNECTOR GAUGE CONNECTOR 1 Bl/W : Blue / White Y/G : Yellow / Green
R
B
Gr
W/R
B
B
B
Br/Y : Brown / Yellow Y/R : Yellow / Red
B W
O/B FUEL G/R : Green / Red
Gr R R
FUEL INJECTOR #2 INJECTOR #1 B Bl/B G/W : Green / White
RECTIFIER & O/Y P/W
B/Br Gr G/W G/Y : Green / Yellow
Gr REGULATOR Y
WIRING DIAGRAM
R/W FUEL
Gr FUSE 30A
FUEL INJECTOR #4 INJECTOR #3
Lg
Gr OIL PRESSURE
O/Bl FUEL
Gr SWITCH
FUEL INJECTOR #6 INJECTOR #5 JOINT
HI
W
Bl
Gr
Dg
Y/R Bl Option parts
Gr LO CONNECTOR
P/B
IGNITION COIL #1
Y/G
W/R
Gr
O Gr
IGNITION COIL #2 B
Gr
W
Bl
Bl
Gr
Dg
B IGNITION COIL #3 ECM
Gr
P/B
Y/G
W/R
Gr/Y ENGINE CONTROL MODULE MAIN
B
IGNITION COIL #4 RELAY
Gr
JOINT
Lg/R IGNITION COIL #5 CONNECTOR
B Gr
W/G
B B
IGNITION COIL #6
B
Y
B
R
W
Bl
Bl
Lg
Y/B
P/B
G/Y
B/R
O/Y
O/B
R/G
G/R
P/W
Bl/Y
B/W
Y/Bl
P/Bl
Bl/R
O/Bl
Gr/Y
W/Bl
Lg/B
Gr
METER
Bl/Y
W
W
Gr
R/G
B
B
O
O
P/B ILLUMINATION
Br
Gr
Dg
R/Y
Y/R
B/Y
R/B
B
V/W
R/W
W/B
W/G
G/W
Bl/B
B/Bl
R/Bl
Br/Y
B/Br
Lg/R
Bl/W
Lg/W
B
W
W/R Gr SWITCH
B
R/G
B
B
Gr Gr
R/G
METER
B B
R/G
R/G
B
B
R/G
W/Y W/Y Gr Gr
R/G
B B TRIM METER
B B
R/G R/G
B B
MONITOR Gr Gr
G/Y G/Y TACHO- B B
Bl/B Bl/B
P P METER Y Y
G/W G/W
FUSE 10A
PTT SWITCH
UP DN
NEUTRAL SWITCH REMOTE CONTROL BOX
R/Bl
N ON (SIDE)
B
R F, R OFF
Lbl Lbl
Bl
P P
IG
G
OFF
START
WATER
FREE
PUSH
IGNITION
IN FUEL B GND SWITCH
GAUGE CONNECTOR 2 SWITCH G STOP
GAUGE
Bl
W BATT
B
CONNECTOR 1
G
Gr IG
G/Y G/Y Br Br
Bl/B Bl/B Bl/B Bl/B Br Br Br START
P/W P/W P/W P
G/W G/W G/W G/W
W/Y W/Y Lbl Lbl O BUZZER
RESET EMERGENCY
B B W/R
Lbl Lbl P P TURN PUSH STOP SWITCH
P P
O O O O LOCK PLATE IN RUN
W W W W Gr Gr BZ
Br Br Br Br Bl Bl
Y/B Y W/R W/R LOCK PLATE OFF STOP
Bl/R G G G
B/Bl Gr Gr Gr G B
Bl/W Bl/W Bl/W Bl B B
B B B B
B Gr Gr B/W R
Lbl
Bl
Lbl
W/Y
Y/G
Y
B
R
B
Br
SHIFT
Lbl
W/Y
POSITION
B
Lbl
SENSOR Br
Y/G
M
R B/W Br Lbl P B NEUTRAL BATTERY
JOINT SWITCH
TILT LIMIT PTT MOTOR TRIM SENDER
SWITCH
CONNECTOR N ON
F, R OFF
PTT SWITCH
WIRE COLOR
UP DN
DF225T/Z
Lbl
W/R
Br : Brown Lg/R : Light green / Red
Dg : Dark Green Lg/W : Light green / White
G : Green O/B : Orange / Black
IAT SENSOR Gr : Gray O/Bl : Orange / Blue
P
LOW PRESSURE FUEL PUMP
Lbl
Lbl : Light blue O/Y : Orange / Yellow
Lg/B ALTERNATOR
W/R
B/W B B/Y Lg : Light green P/B : Pink / Black
FP R Gr
CYLINDER TEMP SENSOR O : Orange P/Bl : Pink / Blue
B Lg/W HIGH PRESSURE FUEL PUMP P : Pink P/W : Pink / White
B B/W
R : Red R/B : Red / Black
DIGITAL GAUGE DIAGRAM
CKP SENSOR B B/R W : White R/G : Red / Green
EXH MANI TEMP SENSOR #2 FP Bl Gr (OPTION)
B
Y : Yellow R/Y : Red / Yellow
G/R
B B/W B/G B/W B/Bl : Black / Blue R/W : Red / White
R/B R/B FUSE 15A STARTER
M ISC B/Br : Black / Brown V/W : Violet / White
R/G MOTOR MODIFICATION OF WIRING , .
W/B B/G : Black / Green W/B : White / Black
THROTTLE POSITION SENSOR Gr RELAY
Gr
W/Bl B/R : Black / Red W/Bl : White / Blue
R/Y
Br/Y COMMUNICATION B/W : Black / White
R GAUGE CONNECTOR 2 CAP W/G : White / Green
B/W CONNECTOR
RECTIFIER & B/Y : Black / Yellow W/R : White / Red
V/W B EXH MANI TEMP Bl/B
MAP SENSOR B/W B REGULATOR STARTER MOTOR CAP P/W Bl/B : Blue / Black W/Y : White / Yellow
SENSOR #1 G/W
FUSE 60A Bl/R : Blue / Red Y/B : Yellow / Black
R
W
W
Dg
R
Y/G
R M Bl/Y : Blue / Yellow Y/Bl : Yellow / Blue
B/W B/W
Y/Bl CMP SENSOR #1 COMMUNICATION Bl/W : Blue / White
Gr Y/G : Yellow / Green
W
O/Y
VACUUM SWITCHING VALVE CONNECTOR GAUGE CONNECTOR 1 Br/Y : Brown / Yellow Y/R : Yellow / Red
R
B
Gr
W/R
B
B
B G/R : Green / Red
Gr/R B W
Gr O/B FUEL G/W : Green / White
Gr R R
FUEL INJECTOR #2 INJECTOR #1 B Bl/B G/Y : Green / Yellow
RECTIFIER & O/Y P/W
B/Br Gr G/W
Gr REGULATOR Y
R/W FUEL
Gr FUSE 30A
FUEL INJECTOR #4 INJECTOR #3
Lg
Gr OIL PRESSURE
O/Bl FUEL
Gr SWITCH
FUEL INJECTOR #6 INJECTOR #5 JOINT Option parts
HI
W
Bl
Gr
Dg
Y/R Bl
Gr LO CONNECTOR
P/B
IGNITION COIL #1
Y/G
W/R
Gr
O Gr
IGNITION COIL #2 B
Gr
W
Bl
Bl
Gr
Dg
B IGNITION COIL #3 ECM
Gr
P/B
Y/G
W/R
Gr/Y ENGINE CONTROL MODULE MAIN
B
IGNITION COIL #4 RELAY
Gr
JOINT
Lg/R IGNITION COIL #5 CONNECTOR
B Gr
W/G
B B
IGNITION COIL #6
B
R
W
Bl
Bl
Lg
Y/B
P/B
G/Y
B/R
O/Y
O/B
R/G
G/R
P/W
Bl/Y
B/W
Y/Bl
P/Bl
Bl/R
O/Bl
Gr/Y
Gr/R
W/Bl
Lg/B
Gr
METER
Bl/Y
W
W
Gr
R/G
B
B
O
O
P/B
ILLUMINATION
Br
Gr
Dg
R/Y
Y/R
B/Y
R/B
B
V/W
R/W
W/B
W/G
G/W
Bl/B
B/Bl
R/Bl
Br/Y
B/Br
Lg/R
Bl/W
Lg/W
B
W
W/R Gr SWITCH
B
R/G
B
B
Gr Gr
R/G
METER
B B
R/G
R/G
B
B
R/G
W/Y W/Y Gr Gr
R/G
B B TRIM METER
B B
R/G R/G
B B
MONITOR Gr Gr
G/Y G/Y TACHO- B B
Bl/B Bl/B
P P METER Y Y
G/W G/W
FUSE 10A
PTT SWITCH
UP DN
NEUTRAL SWITCH REMOTE CONTROL BOX
R/Bl
N ON (SIDE)
B
R F, R OFF
Lbl Lbl
Bl
P P
IG
G
OFF
START
FREE
PUSH
WATER IGNITION
IN FUEL B GND SWITCH
GAUGE CONNECTOR 2
SWITCH G STOP
GAUGE
Bl
W BATT
B
CONNECTOR 1
G
Gr IG
G/Y G/Y Br Br
Bl/B Bl/B Bl/B Bl/B Br Br Br START
P/W P/W P/W P
G/W G/W G/W G/W
W/Y W/Y Lbl Lbl O BUZZER
RESET EMERGENCY
B B W/R
Lbl Lbl P P TURN PUSH STOP SWITCH
P P
O O O O LOCK PLATE IN RUN
W W W W Gr Gr BZ
Br Br Br Br Bl Bl
Y/B Y W/R W/R LOCK PLATE OFF STOP
Bl/R G G G
B/Bl Gr Gr Gr G B
Bl/W Bl/W Bl/W Bl B B
B B B B
B Gr Gr B/W R
Lbl
Bl
Lbl
W/Y
Y/G
Y
B
R
B
Br
SHIFT
Lbl
W/Y
POSITION
B
Lbl
SENSOR Br
Y/G
M
R B/W Br Lbl P B NEUTRAL BATTERY
JOINT SWITCH
TILT LIMIT PTT MOTOR TRIM SENDER
SWITCH
CONNECTOR N ON
F, R OFF
IAT SENSOR PTT SWITCH
UP DN
WIRE COLOR
Lg/B
B/W B : Black G/R : Green / Red
DF250T/Z
P
G/W : Green / White
Lbl
W/R
B Lg/W
Br : Brown G/Y : Green / Yellow
B B/W
Dg : Dark Green Gr/R : Gray / Red
EXH MANI TEMP SENSOR #2 G : Green Gr/Y : Gray / Yellow
P
LOW PRESSURE FUEL PUMP Gr : Gray
Lbl
B G/R
Lg/B : Light green / Black
B B/W Lbl : Light blue Lg/R : Light green / Red
ALTERNATOR
W/R
B B/Y
FP R Gr Lg : Light green Lg/W : Light green / White
CMP SENSOR #1
B/W O : Orange O/B : Orange / Black
Y/Bl
Gr HIGH PRESSURE FUEL PUMP P : Pink O/Bl : Orange / Blue
DIGITAL GAUGE DIAGRAM R : Red O/G : Orange / Green
CKP SENSOR B B/R
CMP SENSOR #2 FP Bl Gr (OPTION) W : White O/Y : Orange / Yellow
B/W Y : Yellow P/B : Pink / Black
O/G B/G B/W
Gr R/B R/B FUSE 15A STARTER
M ISC B/Bl : Black / Blue P/Bl : Pink / Blue
R/G MOTOR MODIFICATION OF WIRING , . B/Br : Black / Brown
W/B P/W : Pink / White
THROTTLE POSITION SENSOR Gr RELAY
Gr B/G : Black / Green R/B : Red / Black
W/Bl
R/Y B/O : Black / Orange
Br/Y COMMUNICATION R/G : Red / Green
R GAUGE CONNECTOR 2 CAP
B/W CONNECTOR B/R : Black / Red R/Y : Red / Yellow
RECTIFIER &
V/W B EXH MANI TEMP Bl/B B/W : Black / White R/W : Red / White
MAP SENSOR B/W B REGULATOR STARTER MOTOR CAP P/W
SENSOR #1 G/W B/Y : Black / Yellow V/W : Violet / White
FUSE 60A
R
W
W
Dg
R Bl/B : Blue / Black W/B : White / Black
Y/G
R M
B/W B/W
B/O CMP SENSOR #3 COMMUNICATION Bl/R : Blue / Red W/Bl : White / Blue
Gr
W
O/Y
VACUUM SWITCHING VALVE CONNECTOR GAUGE CONNECTOR 1 Bl/Y : Blue / Yellow W/G : White / Green
R
B
Gr
W/R
B
B
Bl/W: Blue / White W/R : White / Red
Gr/R B
B W Br/R : Brown / Red W/Y : White / Yellow
Gr O/B FUEL
Gr R R Br/W: Brown / White Y/B : Yellow / Black
FUEL INJECTOR #2 INJECTOR #1 B Bl/B
RECTIFIER & O/Y P/W Br/Y : Brown / Yellow Y/Bl : Yellow / Blue
B/Br Gr G/W
Gr REGULATOR Y
R/W FUEL Y/G : Yellow / Green
Gr FUSE 30A
FUEL INJECTOR #4 INJECTOR #3 Y/R : Yellow / Red
Lg
Gr OIL PRESSURE
O/Bl FUEL
Gr SWITCH
FUEL INJECTOR #6 INJECTOR #5 JOINT
HI
W
Bl
Gr
Dg
Y/R Bl
Gr LO CONNECTOR
P/B
IGNITION COIL #1
Y/G
W/R
Gr Option parts
O Gr
IGNITION COIL #2 B
Gr
W
Bl
Bl
Gr
Dg
B IGNITION COIL #3 ECM
Gr
P/B
Y/G
W/R
Gr/Y ENGINE CONTROL MODULE MAIN
B
IGNITION COIL #4 RELAY
Gr
JOINT
Lg/R IGNITION COIL #5 CONNECTOR
B Gr
W/G
B B
IGNITION COIL #6
B
R
W
Bl
Bl
Lg
Y/B
P/B
G/Y
B/R
O/Y
O/B
R/G
B/O
G/R
O/G
P/W
Bl/Y
B/W
P/Bl
Bl/R
O/Bl
Gr/Y
Gr/R
W/Bl
Lg/B
Br/W
OCV SOLENOID #1 METER
Gr
Bl/Y
W
W
Gr R/G
B
B
O
O
ILLUMINATION
P/B
Br
Gr
Dg
Gr
R/Y
Y/R
B/Y
R/B
B
V/W
R/W
W/B
Y/Bl
W/G
G/W
Bl/B
B/Bl
R/Bl
Br/Y
B/Br
Br/R
Lg/R
Bl/W
Lg/W
Br/W B
W
W/R
Gr SWITCH
B
OCV SOLENOID #2 R/G
B
B
Gr
Br/R
Gr Gr
R/G
METER
B B
R/G
R/G
B
B
R/G
W/Y W/Y Gr Gr
R/G
B B TRIM METER
B B
R/G R/G
B B
MONITOR Gr Gr
G/Y G/Y TACHO- B B
Bl/B Bl/B
P P METER Y Y
G/W G/W
FUSE 10A
PTT SWITCH
UP DN
NEUTRAL SWITCH REMOTE CONTROL BOX
R/Bl
N ON (SIDE)
B
R F, R OFF
Lbl Lbl
Bl
P P
IG
G
OFF
WATER
START
FREE
PUSH
IGNITION
IN FUEL B GND SWITCH
GAUGE CONNECTOR 2 SWITCH G STOP
GAUGE
Bl
W BATT
B
CONNECTOR 1
G
Gr IG
G/Y G/Y Br Br
Bl/B Bl/B Bl/B Bl/B Br Br Br START
P/W P/W P/W P
G/W G/W G/W G/W
W/Y W/Y Lbl Lbl O BUZZER
RESET EMERGENCY
B B W/R
Lbl Lbl P P TURN PUSH STOP SWITCH
P P
O O O O LOCK PLATE IN RUN
W W W W Gr Gr
Br Br Br Br Bl Bl BZ
Y/B Y W/R W/R LOCK PLATE OFF STOP
Bl/R G G G
B/Bl Gr Gr Gr G B
Bl/W Bl/W Bl/W Bl B B
B B B B
B Gr Gr B/W R
Lbl
Bl
Lbl
W/Y
Y/G
Y
B
R
B
Br
SHIFT
Lbl
W/Y
POSITION
B
Lbl
SENSOR Br
Y/G
M
R B/W Br Lbl P B NEUTRAL BATTERY
JOINT SWITCH
TILT LIMIT PTT MOTOR TRIM SENDER
SWITCH
CONNECTOR N ON
F, R OFF
If you cannot find your local language in this owner’s manual please contact your Suzuki Marine dealer.
English
Si vous ne trouvez pas la langue que vous cherchez dans ce manuel du propriétaire, contactez vote
concessionnaire marine Suzuki local. French
Se il presente manuale non include la vostra lingua, entrare in contatto con un rivenditore di prodotti
marini Suzuki. Italian
Wenn Sie Ihre Landessprache in dieser Bedienungsanleitung nicht finden können, setzen Sie sich bitte
mit Ihrem Suzuki-Marine-Händler in Verbindung. German
Si no puede encontrar su idioma local en este manual del propietario, póngase en contacto con su pro-
veedor Suzuki Marine. Spanish
Kontakta din återförsäljare av Suzukis marinprodukter, om du inte hittar ditt lokala språk i denna bruks-
anvisning. Swedish
Hvis du ikke finner ditt språk i denne bruksanvisningen ber vi deg vennligst om å kontakte din Suzuki
Marine forhandler. Norwegian
Jos omaa kieltäsi ei löydy näistä käyttöohjeista, pyydämme ottamaan yhteyttä Suzuki Marine -jälleen-
myyjään. Finnish
Als uw taal in deze gebruikshandleiding niet te vinden is, neemt u dan alstublieft contact op met uw
Suzuki Marine dealer. Dutch
Prepared by
Se você não puder encontrar o seu idioma neste manual do proprietário, entre em contato com o seu
revendedor marítimo Suzuki. Portuguese
Kontakt venligst din Suzuki Marine forhandler, hvis du ikke kan finde dit sprog i denne vejledning.
Danish
Pokud v tomto návodu na použití, nenaleznete Váš mateřský jazyk, obraťte se prosím, na Vašeho
obchodního zástupce Suzuki Marine. Czech
W przypadku, gdy niniejsza instrukcja obsługi użytkownika nie zawiera tekstu w Państwa języku,
uprzejmie prosimy skontaktować się z dealerem Suzuki Marine. Polish
August, 2018
Kui te ei leia sellest kasutusjuhendist oma kohalikku keelt, pöörduge palun kohaliku Suzuki Marine
edasimüüja poole. Estonian
Part No. 99011-93JG0-054
Ако в този наръчник на потребителя не откривате Вашият език, моля обърнете се към
Printed in Japan
регионалният дилър на Suzuki Marine. Bulgarian
Jeigu šioje naudotojo instrukcijoje negalite surasti informacijos reikiama kalba, prašome kreiptis į © COPYRIGHT SUZUKI MOTOR CORPORATION 2018
„Suzuki Marine“ bendrovės atstovą. Lithuanian
V prípade, že sa v tejto príručke majiteľa nenachádza jazyková verzia Vašej krajiny, skontaktujte sa s
Vaším distribútorom Suzuki Marine. Slovak
Dacă nu puteţi găsi limba dumneavoastră în acest manual, vă rugăm să contactaţi distribuitorul Suzuki
Marine. Rumanian
Ja Jūs neatrodat savu vietējo valodu šajā lietotāja rokasgrāmatā, lūdzu kontaktējaties ar savu Suzuki
Marine pārstāvi. Latvian
Amennyiben e kézikönyvben az Ön országában beszélt nyelv szerinti útmutató nem elérhető, kérjük
lépjen kapcsolatba a Suzuki Marine helyi kereskedelmi képviselőjével. Hungarian
Εάν δεν μπορείτε να βρείτε την τοπική σας γλώσσα σε αυτό το εγχειρίδιο ιδιοκτήτη παρακαλούμε να έλθετε σε
επαφή με την αντιπροσωπία της Suzuki Marine. Greek
Ako ne možete pronaći Vaš jezik u ovom priručniku, molimo kontaktirajte Vašeg lokalnog predstavnika
programa Suzuki Marine. Hrvatski