Suzuki DF4A, Owner'S Manual

Page 1: ...1 ENGLISH DF4A DF5A DF6A OWNER S MANUAL EN __ __ __ __ __ __ __ __ __ __ __ __ https www boat manuals com ...

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

Page 3: ...ew 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 will help you e...

Page 4: ... OVER REVOLUTION LIMITING SYSTEM 15 OPERATION OF TILTING SYSTEMS 16 INSPECTION BEFORE BOATING 19 BREAK IN 21 OPERATION 22 MOTOR REMOVAL AND TRANSPORTING 32 TRAILERING 34 INSPECTION AND MAINTENANCE 35 FLUSHING THE WATER PASSAGES 43 SUBMERGED MOTOR 45 STORAGE PROCEDURE 46 AFTER STORAGE 47 TROUBLESHOOTING 47 SPECIFICATIONS 48 INFORMATION REGARDING EC DIRECTIVE 48 https www boat manuals com ...

Page 5: ... gasoline and ethanol grain alcohol also known as gasohol are commer cially available in some areas Gasoline con taining a maximum of 10 ethanol may be used in your outboard motor without jeopardiz ing the New Outboard Motor Limited Warranty Gasoline Methanol Blends Blends of unleaded gasoline and methanol wood alcohol are also commercially available in some areas DO NOT USE fuels containing more ...

Page 6: ...f time will produce varnish and gum which can damage the engine Always use fresh gasoline NOTICE Fuels containing alcohol can cause paint damage which is not covered under the New Outboard Motor Limited Warranty Be careful not to spill fuel containing alcohol while refueling If fuel is spilled wipe it up immediately NOTE The separate fuel tank optional part is its ded icated fuel reservoir and sho...

Page 7: ...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 https www boat manuals com ...

Page 8: ...anual for details Le carburent risque de fuir et de présenter un danger d incendie si le moteur est incliné avec la vis de purge d air desserrée ou placée sur le côté Serrer la vis de l évent d air avant de basculer ou de déplacer le moteur Vidanger entièrement le carburant du séparateur de vapeurs ou du carburateur avant de procéder Pour plus de détail voir le manuel du propriétaire To avoid inju...

Page 9: ...rd Neutral Reverse Engine start Hazard caused by fire Hazard caused by laying the motor on its side Hazard caused by rotating parts Hazard caused by fuel leak WARNING AVERTISSEMENT Secure both mounting bolts and clamps to avoid motor drop See owner s manual Fixer les deux boulons de montage et des brides pour éviter la chute du moteur Voir le manuel du propriétaire https www boat manuals com ...

Page 10: ... Motor cover Starter grip Throttle tension adjuster Throttle control grip Shift lever Choke knob Tilt pin Gear oil drain plug Gear oil level plug Tilt up lock arm Water intake hole Fuel cock lever Flush plug Pilot water hole Combination emergency stop switch normal stop button Fuel connector Only for DF5A DF6A Fuel connector cap Air vent screw Fuel line Priming bulb https www boat manuals com ...

Page 11: ...on the boat s Certification Plate Contact your authorized Suzuki marine dealer if you are unable to locate the hull Certificate Plate NOTICE Operating your outboard motor with the anti cavitation plate above water can cause over heating and severe damage to your outboard motor Do not operate your outboard motor with the anti cavitation plate above water 0 25 mm 0 1 0 in Center the motor on the tra...

Page 12: ...ed can seriously damage the motor while low engine speed at full throttle will adversely affect performance Your operat ing load will also affect propeller selection Smaller 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 i...

Page 13: ...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 cavitation plate ADJUSTMENT TRIM ANGLE ADJUSTMENT To help mai...

Page 14: ...n proper trim angle based on the combination of your boat engine and pro peller as well as operating conditions WARNING If you operate the motor with the tilt pin removed you may not be able to control steer ing as expected Do not operate the motor with the tilt pin removed STEERING TENSION ADJUSTMENT The steering on your outboard motor should be smooth and not tight Adjust the steering ten sion s...

Page 15: ...em which activates when engine speed exceeds 6000 r min Over revolution can result from cavitation when turning hard a propeller with a slipping bush or worn down blades or a trim setting that is too high If the over revolution limiting system activates the motor will exhibit a rough running condition and you must immediately reduce engine speed to within the recommended operating range If the sys...

Page 16: ...al injury When using the shallow water position pro ceed with caution and only at very low speeds TILT UP LOCK ARM The tilt up lock arm is used to hold the motor in the fully tilted up position and shallow water position FULL TILT UP POSITION To hold the motor in the fully raised position 1 Shift into NEUTRAL 2 Turn the fuel cock lever to the right off posi tion and tighten the air vent screw on t...

Page 17: ...nect the fuel line whenever you leave the motor tilted up for a long period of time To lower the motor back down pull the motor slightly toward you pull up on the tilt up lock arm 1 and slowly let the motor down Alternative power source NOTICE If you use the throttle grip handle to raise or lower the motor the handle may break Never use the throttle grip handle to raise or lower the motor NOTICE I...

Page 18: ...n the shallow water position is used 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 to lift out of the water resulting in per sonal injury When using the shallow water position pro ceed with caution and only at very low speeds WARNING If you do not take proper pre...

Page 19: ...ove the upper limit A Fuel tank Fuel tank filter Mesh part on the bottom of filter Check the level of engine oil in the sump To check the engine oil level NOTE To avoid an incorrect assessment of engine oil level check the level only when the engine has cooled 1 Place the motor in a vertical position and remove the motor cover 1 by unlocking the lever 2 and 3 2 Remove the oil filler cap dipstick 4...

Page 20: ...filler cap dipstick 4 and wipe oil off with a clean cloth 2 Fill the recommended engine oil to the upper level To check the upper oil level touch the filler cap threads onto the filler cap edge as shown Do not screw the filler cap Upper limit Lower limit Upper limit Lower limit 3 Tighten the oil filler cap securely Visually check the propeller to make sure it is not damaged Make sure that the moto...

Page 21: ...evere engine damage such as piston seizure Always allow sufficient idling time 5 minutes for the engine to warm up before running at high speed NOTE You may throttle up beyond the recommended operating range to plane your boat then imme diately reduce the throttle to the recommended operating range 2 For the next 1 hour Safe boating conditions permitting operate the engine in gear at 4000 r min or...

Page 22: ...sed Install the fuel connector cap 1 to fuel con nector NOTE When using the built in fuel tank disconnect the fuel line of the separate fuel tank from the fuel connector on the engine side If not the fuel from the built in tank may not flow correctly 5 Make sure that the motor is in NEUTRAL 6 The lock plate is in place and the end of the emergency stop switch cord is attached to a part of your bod...

Page 23: ... 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 operation Be careful not to pull the stop switch cord or knock out the lock plate during normal operation The motor will stop abruptly and the loss of forward motion may unexpect edly throw occupants forward Using SEPARATE FUEL TANK For DF5A DF...

Page 24: ...ion 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 emergency stop switch 7 Squeeze the fuel line priming bulb several tim...

Page 25: ...it run indoors or where there is little or no ventilation 2 Firmly grasp the starter grip 3 and pull slowly until resistance is felt When you feel it engage pull the rope sharply to start the engine Do not release the rope when it is pulled out Hold the rope and allow it to recoil slowly 3 After starting use the throttle control grip 2 to bring the engine to idle 4 Push the choke knob in NOTE In c...

Page 26: ...ARTING If you must get the engine running but are unable to do so because of starter system fail ure you can use the emergency starting proce dure to start the engine To start the engine when the starter sys tem fails 1 Pull out the emergency stop switch lock plate 2 Shift the motor into NEUTRAL WARNING If you touch electrical components when rope starting the engine you can get a severe elec tric...

Page 27: ...move the motor cover 6 Loosen the lock nut 1 take off the NSI cable from the recoil starter NEUTRAL 7 Separate the end of cable from the recoil starter 8 Put the NSI cable inside of the side cover 9 Remove the bolts securing the fuel tank in place 10 Remove a washer 2 from fuel tank https www boat manuals com ...

Page 28: ...e clamp 4 with recoil starter secur ing bolt Bind the throttle cables to the clamp 4 14 Remove the air vent duct 5 15 Remove the cushion 6 16 Remove the bolts securing the cooling fan 7 in place 17 Put the fuel tank in place by aligning the position of fuel cock 8 with that of fuel cock lever 9 https www boat manuals com ...

Page 29: ...following steps of the normal starting procedure pull the emergency starter rope sharply to start the engine NOTE Be 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 WARNING If you attempt to reinstall the recoil starter assembly or motor cover after starting the engine you can be injured Do no...

Page 30: ...OTICE If you shift gears when the engine is not run ning the shifting mechanism can be dam aged Avoid shifting gears when the engine is not running FORWARD REVERSE Speed Control After shifting control the engine speed by twist ing the throttle control grip 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...

Page 31: ... in shallow water use the shallow water position to tilt the motor slightly from the normal trim angle When using the shallow water position however you should only operate the motor at slow speeds Refer to the SHALLOW WATER POSITION section 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 WAT...

Page 32: ... the vertical position so that the cooling system drains completely MOTOR REMOVAL AND TRANSPORTING MOTOR REMOVAL 1 Make sure that the engine has stopped com pletely 2 Turn the fuel cock lever to right 3 Tighten the built in fuel tank cap and its air vent screw 4 Remove the fuel hose from the motor if pro vided NOTE When the fuel hose is disconnected from the fuel connector fix a connector plug cap...

Page 33: ...ower cover MOTOR TRANSPORTING When transporting the motor place the motor either vertically or horizontally Vertical transport Incline the handle backward and attach the motor to the carrier by securing the clamp bracket with two clamp screws Never use display stand for transportation of the motor Horizontal transport Incline the tiller handle backward and rest the motor on a case protector with t...

Page 34: ...the lower unit of your outboard sit higher than the power head during transport ing or storing water may trickle into the power head causing damage to the engine Never let the lower unit sit higher than the power head when transporting or storing your outboard INCORRECT TRAILERING When trailering your boat with the motor attached keep the motor in the normal operat ing position unless there is not...

Page 35: ...less 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 oil R R R R Gear oil R R R R Lubrication I I I I Anodes I I ...

Page 36: ...tenance 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 maintenance more of...

Page 37: ...ugs 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 ranty Note that aftermarket cross reference charts may not be accurate To install a spark plug seat it as far as pos sible by ...

Page 38: ...Otherwise 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 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 to replac...

Page 39: ...engine oil more frequently under this type of use Change your engine oil more frequently if your engine is used for extended trolling 3 Fully steer the motor to the starboard side 4 Place a drain pan under the engine oil drain plug 5 Remove the engine oil drain plug and gas ket then let the engine oil drain 6 After draining secure the engine oil drain plug with a new gasket CAUTION The engine oil ...

Page 40: ...limit GEAR 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 ca...

Page 41: ...d used oil away from children and pets Wear a long sleeve shirt and waterproof gloves when handling oil Wash with soap if oil contacts your skin Launder any clothing 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 mil...

Page 42: ...rolysis and prevent corrosion The anodes will corrode in place of the parts they are pro tecting You should periodically inspect each of the anodes and replace them when 2 3 of the metal has corroded away NOTE Consult your authorized Suzuki Marine Dealer for inspection and replacement of internal anodes attached to the cylinder block cylinder head NOTICE If anodes are not properly maintained under...

Page 43: ...the water passages by using this method WARNING Exhaust gas contains carbon monoxide a dangerous gas that is difficult to detect because it is colorless and odorless Breath ing carbon monoxide can cause death or severe injury Never start the engine or let it run indoors or where there is little or no ventilation WARNING Failure to take proper precautions when flush ing the water passages can be ha...

Page 44: ...rnal finish of the motor ENGINE NOT RUNNING Vertical position To flush the water passages you must obtain an optional flushing attachment from your authorized Suzuki Marine Dealer 1 Remove the flush plug and install the flush ing attachment 1 2 Connect a garden hose to the flushing attachment 3 Turn on the water to obtain a good water flow Flush the engine for about five minutes 4 Turn off the wat...

Page 45: ...spark plug holes and carburetors Coat the engine inner parts with oil by turning the engine over with the emergency starter rope or recoil starter 7 Take the motor to your authorized Suzuki Marine Dealer as soon as possible to be overhauled 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 Dispos...

Page 46: ...el through the engine 6 Stop the engine Then turn off the water 7 Turn the fuel cock lever to right 8 Disconnect the fuel line of the separate fuel tank from the fuel connector on the engine side if provided Install the fuel connector cap to fuel con nector 9 Lubricate all other specified parts Refer to the LUBRICATION section 10 Apply a coat of automotive wax on the external finish of the motor I...

Page 47: ...connected to engine For DF5A DF6A Fuel hose is kinked or pinched Spark plug is fouled Engine idles unstably or stalls Choke knob is not pushed in securely Fuel hose is kinked or pinched Spark plug is fouled Engine speed will not increase Engine power is low Engine is overloaded Propeller is damaged Propeller is not properly matched to loads Engine vibrates excessively Engine mounting bolts or clam...

Page 48: ...e 4000 5000 r min min 1 4500 5500 r min min 1 4750 5750 r min min 1 Ignition System Digital CDI Engine Lubrication Trochoid pump lubrication Engine Oil Capacity 0 7 L 0 74 0 62 US lmp qt Gear Oil Capacity 190 cm3 ml 6 4 6 7 US Imp oz Build in Fuel Tank Capacity 1 0 L 0 26 0 22 US Imp gal Spark Plug NGK CPR6EA 9 Spark Plug Gap 0 8 0 9 mm 0 031 0 035 in Valve Lash IN 0 13 0 17 mm 0 005 0 007 in EX 0...

Page 49: ...WIRING DIAGRAM IGNITER UNIT B B https www boat manuals com ...

Page 50: ...Prepared by January 2016 Part No 99011 97L00 055 Printed in Thailand COPYRIGHT SUZUKI MOTOR CORPORATION 2016 https www boat manuals com ...