Suzuki DF150, Owner'S Manual

Page 1: ...1 ENGLISH DF150 DF175 OWNER S MANUAL EN ...

Page 2: ...See the INSPECTION BEFORE BOATING section for important items Become thoroughly familiar with all operating and handling characteristics of your boat and motor Practice at low and moderate speeds until you are competent at handling the boat and motor Do no attempt to operate at maxi mum performance until you are com pletely familiar with all of these characteristics Carry boating safety and emerge...

Page 3: ...h apply to new outboard motors The proper adjustment of engine components is necessary for this out board motor to comply with the EPA regula tions Therefore please follow the maintenance instructions closely to ensure emission compli ance Your Suzuki dealer has experienced tech nicians that are trained to provide your outboard motor with the best possible service with the right tools and equipmen...

Page 4: ...njoy boating more and will be a safer boater We recommend that you take a boating safety class Classes explaining required and recommended equipment for small boats and offering training in good seamanship are conducted by the U S Coast Guard Auxiliary the U S Power Squad ron and many Red Cross chapters For infor mation on classes in your area call toll free 1 800 336 BOAT 2628 Your state s depart...

Page 5: ... 21 POWER TRIM AND TILT 21 TILT LIMITER CAM 21 MANUAL TILTING 22 TILT LEVER 22 INSPECTION BEFORE BOATING 23 BREAK IN 25 OPERATION 26 BEFORE ATTEMPTING TO START THE ENGINE 26 STARTING THE ENGINE 27 SHIFTING AND SPEED CONTROL 29 STOPPING THE ENGINE 30 MOORING 31 OPERATION IN SHALLOW WATER 32 OPERATION IN SALT WATER 32 OPERATION IN FREEZING WEATHER 32 MOTOR REMOVAL AND TRANSPORTING 33 MOTOR REMOVAL 3...

Page 6: ...d in your out board motor if the MTBE content is not greater than 15 This oxygenated fuel does not con tain alcohol Gasoline Ethanol Blends Blends of unleaded gasoline and ethanol grain alcohol also known as gasohol may be used in your outboard motor if the ethanol content is not greater than 10 Gasoline Methanol Blends Avoid using blends of unleaded gasoline and methanol wood alcohol whenever pos...

Page 7: ... not covered under the New Outboard Motor Limited Warranty Be careful not to spill fuel containing alcohol while refueling If fuel is spilled wipe it up immediately ENGINE OIL Oil quality is a major contributor to your engine s performance and life Always select good quality engine oil Suzuki recommends the use of SAE 10W 40 SUZUKI MARINE 4 CYCLE ENGINE OIL If SUZUKI MARINE 4 CYCLE ENGINE OIL is n...

Page 8: ... SAFETY LABELS Read and follow all of the labels on your out board motor or fuel tank Make sure you under stand all of the labels Keep the labels on your outboard motor or fuel tank Do not remove them for any reason ...

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Page 10: ...YPE TOP MOUNT TYPE REMOTE CONTROL BOX Option Engine oil drain plug Flush plug Clamp bracket Anode Water intake hole Power trim and tilt P T T switch Pilot water hole Reverse side Anti cavitation plate Trim tab Motor cover Gear oil level plug Air vent hole plug Gear oil drain plug Flush plug No 2 Power trim and tilt P T T switch Remote control handle Free accelerator button Ignition key Emergency s...

Page 11: ...d by your authorized Suzuki marine dealer He has the tools the facilities 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 850 Marine Cranking Amps MCA ABYC or 670 Cold Cranking Amps CCA SAE or 180 Reserve Capacity RC Minutes SAE NOTE The specifications listed above are the ...

Page 12: ...sparks 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 bat tery away from open flames To avoid creating a spark when charging the bat tery connect the battery charger cables to the proper terminals before turning the charger on Do not place the battery near the fuel tank WARNING Ba...

Page 13: ... characteristics The speed of the engine when you operate your boat at full throttle depends on the propeller you use Excessive engine speed can seriously damage the motor while low engine speed at full throttle will adversely affect the performance Your operating load will also affect propeller selec tion Smaller loads generally require larger pitch propellers larger loads generally require small...

Page 14: ...nal 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 cavitation plate ADJUSTMENTS TRIM ANGLE ADJUSTMENT To help maintain steering stability and good performance alway...

Page 15: ...hion the engine if the lower unit strikes an obstruction This could lead to occupant injury Do not operate the engine above 1500 r min or operate the boat in a planing attitude with the motor tilted beyond the maxi mum trim position Trim range Tilt range TRIM TAB ADJUSTMENT This adjustment is used to compensate for the possible tendency of your boat to veer slightly to port or starboard This tende...

Page 16: ... the tension turn the adjuster counterclockwise NOTE Top mount type When adjusting the tension of the remote con trol handle consult your authorized Suzuki Marine Dealer Side mount type IDLE SPEED ADJUSTMENT The idle speed has been factory adjusted between 600 700 r min in neutral NOTE If idle speed cannot be set within the specified range contact your authorized Suzuki Marine Dealer MOTOR COVER F...

Page 17: ...ou to any malfunction that may occur or to give you an indication of the need for maintenance To avoid damage to your outboard motor regularly inspect and maintain it NOTICE Continuing to operate your outboard motor with the Caution System activated can result in severe damage to your out board motor If the Caution System activates while you are operating your outboard motor stop the motor as soon...

Page 18: ...e lubricat ing oil pressure drops below the correct level If this system activates the red OIL lamp will light and a buzzer will begin a series of beep In addition when this system is activated at 1000 r min or higher engine speed will automatically be reduced to approximately 1000 r min with REV LIMIT lamp lit If you continue to run the engine will automati cally stop 3 minutes after beginning of...

Page 19: ... red TEMP lamp will light and the 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 with REV LIMIT lamp lit If you continue to run the engine will automati cally stop 3 minutes after beginning of the above CAUTION system activation NOTE In case that the engine is automatically ...

Page 20: ... and water conditions permitting and inspect the engine according to the above instructions Con sult 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 ...

Page 21: ...l be canceled by pushing the ignition key in NOTICE If the diagnostic system activates while you are operating your outboard motor there is an abnormal condition in one of the sensor signals of the control system Consult your authorized Suzuki marine dealer for repair of the control system OIL CHANGE REMINDER SYSTEM This system informs the operator of the time for replacing engine oil on the basis...

Page 22: ...ng of the system activation is possible regardless of whether or not the engine oil has been replaced Once the system has operated however Suzuki strongly recom mends that 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 syste...

Page 23: ...just the tilt limiter cam to limit maximum tilt position 1 Place the motor in the normal running posi tion 2 Rotate the tilt limiter cam To reduce the amount of tilt move the tab A of cam upward To increase the amount of tilt move the tab A of cam downward 3 To check your adjustment tilt the motor fully up to check for motor contact Adjust further if necessary Return the motor to the normal runnin...

Page 24: ...ecure and that you are able to support the weight of the engine TILT LEVER The Tilt Lever is provided so you can support the motor in a tilted position for non moving engine support To set the Tilt Lever 1 Tilt the motor all the way up by pressing the Power Trim and Tilt UP switch 2 Pull down the Tilt Lever as shown in the illus tration 3 Lower the motor by pressing the Power Trim and Tilt DOWN sw...

Page 25: ...ilt lever when trailering your boat and motor Refer to the TRAILERING sec tion of this manual INSPECTION BEFORE BOATING It is important to make sure that your boat and motor are in good condition and that you are properly prepared for an emergency Always perform the following checks before you begin boating Check that you have enough fuel for the intended run Check the level of engine oil in the s...

Page 26: ...into the engine then remove it again The oil on the dipstick should be between the upper and lower limits shown on the dip stick If the oil level indication is near the lower limit add enough oil to raise the level to the upper limit To fill the engine with oil 1 Remove the oil filler cap 2 Fill with recommended engine oil to the upper level 3 Tighten the oil filler cap securely NOTICE Running the...

Page 27: ...od 10 hours Break in procedure 1 For the initial 2 hours Allow sufficient idling time about 5 minutes for the engine to warm up after cold engine starting After warming up run the engine at idling speed or the lowest in gear speed for about 15 min utes During the remaining 1 hour and 45 minutes if safe boating conditions permit operate the engine in gear at less than 1 2 half throttle 3000 r min N...

Page 28: ...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 sei zure During the last 7 hours of break in opera tion do not operate at wide open throttle for more than 5 minutes at a time OPERATION BEFORE ATTEMPTING TO START THE ENGINE 1 Lower the motor into th...

Page 29: ...e emer gency stop switch works as intended may result in serious injury or death to the operator or passengers Always take the following precautions Make sure that the emergency stop switch cord is fastened securely to the operator s wrist or to an appropriate clothing area belt etc Ensure that no obstructions impede or restrict emergency stop switch opera tion Be careful not to pull the stop swit...

Page 30: ... Cooling water check As soon as the engine starts water should spray out of the pilot water hole 1 indicating that the water pump and cooling system are working properly If you notice that water does not spray out of the pilot water hole stop the engine as soon as possible and consult your authorized Suzuki Marine Dealer NOTICE If you turn the ignition key to START position for more than 5 seconds...

Page 31: ...andle rearward to approximate position B as shown in the illustration A detent or notch is present on all Suzuki con trol boxes to provide a feel for positions A B and neutral Always shift quickly and firmly from neutral to position A or B to prevent abnormal wear on the gear and clutch engagement sur faces NOTICE Severe engine damage may occur if a engine speed is not allowed to return to idle an...

Page 32: ...t to move the con trol handle too far forward or rearward when shifting NEUTRAL 32 32 FORWARD REVERSE Top mount type NEUTRAL FORWARD REVERSE 35 35 STOPPING THE ENGINE NOTE When it is necessary to stop the engine in an emergency pull the emergency stop switch lock plate out of the emergency stop switch by pull ing the emergency stop switch cord To stop the engine 1 Shift into NEUTRAL 2 After operat...

Page 33: ...our boat be sure to remove the key and emergency stop switch lock plate when the boat is unattended WARNING If you leave the motor stopped for a long period of time with the fuel line con nected fuel can leak out Disconnect the fuel line from fuel tank if there is a fuel connector whenever you leave the motor stopped for a long period of time MOORING The motor should be tilted up out of the water ...

Page 34: ...trim position NOTICE If the motor hits bottom serious damage can occur Do not allow the motor to hit bottom If the motor does strike bottom inspect it immediately for damage 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 ...

Page 35: ...g the motor place the motor either vertically or horizontally Vertical transport Attach the clamp bracket to a stand by securing two transom bolts Horizontal transport 1 Drain the engine oil Refer to the ENGINE OIL section 2 Drain the gasoline from the vapor separator as follows 1 Remove the motor cover 1 2 Remove the eight 8 bolts using a 8 mm box wrench then remove the side cover 2 Bolt in the m...

Page 36: ...n NOTICE If you are not careful when resting the outboard on its side and do not take proper precautions such as first draining the engine oil and cooling water com pletely damage can occur Engine oil may enter the cylinder from the sump water may enter the cylinder through the exhaust port or the outer casings may be damaged Always drain the engine oil and cooling water completely before laying t...

Page 37: ...vice to support the weight of the motor NOTICE If you use the tilt up lock arm 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 resulting in damage to the motor and the tilt lock mechanism Never use the tilt up lock arm to hold the motor in the fully tilted up position when trailering the boat Use ...

Page 38: ...EN CERTIFIED UNDER THE PROVISIONS IN THE CLEAN AIR ACT Sec 207 a 2 WARNING Exhaust gas contains carbon monoxide a dangerous gas that is difficult to detect because it is colorless and odorless Breathing 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...

Page 39: ...RNING The safety of you and your passengers depends on how well you maintain your outboard motor Follow all inspection and maintenance instructions carefully If you do not have prior mechanical experience do not attempt to perform maintenance on your outboard motor You could be injured or may damage the motor NOTICE The maintenance intervals in the chart were established for normal usage of your o...

Page 40: ...rd spark plug NGK BKR6E NOTICE Non resistor types of spark plugs will interfere with the function of the elec tronic ignition causing misfiring or causing problems with other electronic boat equipment and accessories Use ONLY resistor type spark plugs in your outboard motor NOTICE Use of improper spark plugs or improp erly tightening spark plugs can cause severe engine damage Do not experiment wit...

Page 41: ...placed Spark plug gap 0 7 0 8 mm 0 028 0 031 in BREATHER AND FUEL LINE Inspect the breather and fuel line for leaks cracks swelling or other damage If the breather and fuel line are damaged in any way they must be replaced Consult your authorized Suzuki Marine dealer if it is necessary to replace them WARNING Fuel leakage can contribute to an explo sion or fire resulting in serious personal injury...

Page 42: ...re 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 upper level Oil capacity 8 0 L 8 5 7 0 US Imp qt En...

Page 43: ...t and water proof gloves when handling oil Wash with soap if oil contacts your skin Launder any clothing or rags that are wet with oil UPPER LIMIT LOWER LIMIT GEAR OIL To check the gear oil level adjust the engine to an upright position 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 u...

Page 44: ...ur it on the ground down a drain or into the water WARNING Gear oil can cause injury to people or pets Repeated prolonged contact with used gear oil may cause skin cancer Even brief contact with used oil may irri tate skin Keep new and used oil away from chil dren and pets Wear a long sleeve shirt and water proof gloves when handling oil Wash with soap if oil contacts your skin Launder any clothin...

Page 45: ...r corrosion by anodes These anodes control electrolysis and help prevent corrosion The anodes will corrode in place of the parts they are protect ing You should periodically inspect each of the anodes and replace them when 2 3 of the metal has corroded away In certain areas of the country the water is unusually harsh on metal Additional anti corro sion measures may be helpful under those con ditio...

Page 46: ... below the MIN level line add DISTILLED WATER ONLY until the battery solution level reaches the MAX level line WARNING Battery acid is poisonous and corrosive and can cause severe injury Avoid contact with eyes skin clothing and painted surfaces If battery acid comes in contact with any of these flush immediately with large amounts of water If acid contacts the eyes or skin get immediate medical a...

Page 47: ...s FLUSHING THE WATER PASSAGES After operation in muddy brackish or salt water you should flush the water passages and motor surface with clean fresh water If you do not flush the water passages salt can corrode the motor and shorten its life Flush the water passages as follows ENGINE RUNNING Vertical position Suzuki recommends that you flush the water passage by using this method To flush the wate...

Page 48: ...n If no water spray is evident stop the motor immediately and consult your dealer NOTICE Severe engine damage can occur in as lit tle 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 4 Allow the engine to run only at idle speed while flushing Readjust the water flow if necessary so that there is...

Page 49: ...ood water flow Flush the engine for about five minutes 4 Turn off the water 5 Remove the hose and connector if used then reinstall the plug into the flushing port 6 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 Follow the ENGINE NOT RUNNING Verti cal position instructions DO N...

Page 50: ...ning tighten the oil drain plug 5 Drain the fuel line and all filters 6 Pour one tablespoon of engine oil in through each spark plug hole Coat the engine inner parts with oil by manually turning the fly wheel several times Don t use the electric starter as this may bend the connecting rods WARNING Gasoline is extremely flammable and toxic It can cause a fire and can be haz ardous to people and pet...

Page 51: ...ed fuel through the engine 6 Stop the engine Then turn off the water and disconnect the flushing attachment 7 Lubricate all other specified parts Refer to the LUBRICATION section Spray entire powerhead with a rust preventative not a penetrating oil product 8 Apply a coat of automotive wax on the external finish of the motor If paint damage is evident apply touch up paint before wax ing 9 Store the...

Page 52: ...contact with battery acid Wear proper protective clothing Safety glasses gloves etc AFTER STORAGE When taking your motor out of storage follow the procedure below to return it to operating condition 1 Thoroughly clean the spark plugs Replace them if necessary 2 Check the gear case oil level and if neces sary add gear oil according to the procedure outlined in the GEAR OIL section 3 Lubricate all m...

Page 53: ...ine 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 Diagnosis system is activated Propeller is damaged Propeller is not properly matched to loads Engine vibrates excessively Engine mounting bolts or clamp screws are loose Foreign ob...

Page 54: ...tor cover 3 Remove the fuse box cover and pull off the fuse NOTE Use the fuse puller at the back of fuse box cover when the fuse is pulled off and installed Fuse box cover 4 Remove the Sub battery cable fuse 5 Inspect the fuse and replace with new fuse if needed Sub battery cable fuse case Normal fuse Main fuse 60A Isolator fuse 30A Blown fuse Normal fuse Blade type fuse Blown fuse ...

Page 55: ...control module Fuel pump fuse 30A 4 IAC CMP VSV VVT fuse 10A a Main fuse 60A b Isolator select fuse 30A c Spare fuse 60A d Spare fuse 30A e Spare fuse 10A f Spare fuse 15A g Sub battery cable fuse 15A SPECIFICATIONS Power rated in accordance with NMMA procedure Item DF150 DF175 Engine Type 4 Stroke Number of Cylinders 4 Bore and Stroke 97 0 97 0 mm 3 81 3 81 in Piston Displacement 2867 cm3 174 9 c...

Page 56: ... When performing cancellation before system activation NOTE This system will activate up to 2100 hour s operation Total operating hours MONITOR TACHOMETER Needle 1 indication REV LIMIT lamp 2 flashing 0h 49h No No 50h 500rpm No 60h 600rpm No 540h 5400rpm No 550h 500rpm 1 time 560h 600rpm 1 time 1040h 5400rpm 1 time 1050h 500rpm 2 times 1540h 5400rpm 2 times 1550h 500rpm 3 times 2030h 5300rpm 3 tim...

Page 57: ...Gray Red Gr G Gray Green Gr Y Gray Yellow Lg B Light green Black Lg R Light green Red Lg W Light green White O B Orange Black O Bl Orange Blue O G Orange Green O W Orange White O Y Orange Yellow P B Pink Black R B Red Black R G Red Green R Y Red Yellow R W Red White V W Violet White W R White Red W Y White Yellow Y B Yellow Black Y Bl Yellow Blue Y G Yellow Green O Bl W B Gr Gr W Bl R Y O Bl W B G...

Page 58: ...n White G Y Green Yellow Gr R Gray Red Gr G Gray Green Gr Y Gray Yellow Lg B Light green Black Lg R Light green Red Lg W Light green White O B Orange Black O Bl Orange Blue O G Orange Green O W Orange White O Y Orange Yellow P B Pink Black R B Red Black R G Red Green R Y Red Yellow R W Red White V W Violet White W R White Red W Y White Yellow Y B Yellow Black Y Bl Yellow Blue Y G Yellow Green O Bl...

Page 59: ...See the INSPECTION BEFORE BOATING section for important items Become thoroughly familiar with all operating and handling characteristics of your boat and motor Practice at low and moderate speeds until you are competent at handling the boat and motor Do no attempt to operate at maxi mum performance until you are com pletely familiar with all of these characteristics Carry boating safety and emerge...