Suzuki DF 25 User manual

K6 Printed in Thailand
300 TAKATSUKA, HAMAMATSU, JAPAN
OWNER’S MANUAL
MANUEL DU PROPRIETAIRE
MANUALE DI ISTRUZIONI
BESITZER HANDBUCH
MANUAL DE PROPIETARIO
INSTRUKTIONSBOK
INSTRUKSJONSBOK
OMISTAJAN KÄSIKIRJA
INSTRUCTIEBOEKJE
MANUAL DO PROPRIETÁRIO
BETJENINGSVEJLEDNING
DF2.5
DF2.5
99011-97J00-053
Part No. 99011-97J00-053
December, 2005
Eng. Fre. Ita. Ger. Spa. Swe.
Nor. Fin. Dut. Por. Den. Chi.
TK
*99011-97J00-053*

1
DF2.5
OWNER’S MANUAL
ENGLISH
EN
F
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D
ES
S
NO
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NL
P
DA

2
TABLE OF CONTENTS
WARNING/CAUTION/NOTE ................... 3
IMPORTANT NOTICETOOWNERS .... 3
IDENTIFICATION NUMBER
LOCATION...............................................4
FUEL AND OIL......................................4
LOCATION OF SAFETY LABELS ...6
LOCATION OF PARTS .......................... 7
MOTOR MOUNTING .............................. 8
PROPELLER SELECTION AND
INSTALLATION ....................................... 9
ADJUSTMENT........................................ 10
OPERATION OF TILTING
SYSTEMS ................................................ 12
INSPECTION BEFORE BOATING ...... 14
BREAK-IN ............................................... 15
OPERATION ........................................... 16
MOTOR REMOVAL AND
TRANSPORTING ................................... 21
INSPECTION AND
MAINTENANCE ..................................... 23
FLUSHING THE WATER
PASSAGES.............................................. 29
SUBMERGED MOTOR ......................... 30
STORAGE PROCEDURE ...................... 30
AFTER STORAGE ................................. 31
TROUBLESHOOTING ........................... 32
SPECIFICATIONS .................................. 32
FOREWORD
Thank you for choosing a Suzuki outboard mo-
tor. Please read this manual carefully and re-
view 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
experience safe, enjoyable boating.
All information in this manual is based on the
latest product information available at the time
of publication. Due to improvements or other
changes, there may be discrepancies between
this manual and your outboard motor. Suzuki
reserves the right to make changes at any time
without notice.

3
IMPORTANT
8WARNING/CAUTION/ NOTE
Please read this manual and follow its instruc-
tions carefully. To emphasize special informa-
tion, the symbol 8

and the words WARNING,
CAUTION and NOTE have special meanings.
Pay special attention to the messages high-
lighted by these signal words.
8WARNING
# indicates a potential hazard
that could result in death or injury.
CAUTION
CAUTION indicates a potential hazard that
could result in motor damage.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
IMPORTANT NOTICE TO
OWNERS
8WARNING
You must take precautions to reduce the
chance of accidents and injuries resulting
from the use of your outboard motor and boat.
Some of the important safety precautions you
should take are:
• Before first use of your outboard motor, read
this owner’s manual carefully to become fa-
miliar with the outboard motor’s features,
safety requirements, and maintenance re-
quirements.
• Before each use of your boat, perform a daily
inspection. Specific items to check are listed
in the INSPECTION BEFORE BOATING sec-
tion.
• Never run the outboard motor indoors or in
an enclosed area. Exhaust emissions con-
tain poisonous carbon monoxide fumes
which can cause unconsciousness and may
lead to death.
• Never operate your boat while under the
in
fluence of alcohol or other drugs.
• Practice operating your boat at slow and
moderate speeds until you become thor-
oughly familiar with the operating and han-
dling characteristics of your motor/boat
combination. Do not operate your outboard
motor at maximum performance until you
are thoroughly familiar with these charac-
teristics.
• Be sure that you and your passengers al-
ways wear life jackets on board.
• When loading your boat, distribute weight
evenly between the bow and stern, and the
port and starboard sides.
• Observe periodic maintenance require-
ments–your authorized Suzuki Marine
Dealer is trained and equipped to perform
this service.
• Do not modify your outboard motor. Modi-
fications or removal of original equipment
may make the motor unsafe.
• Learn and obey the navigation rules of the
locality in which you operate your boat.
• Make sure you have the necessary emer-
gency equipment on board such as a flota-
tion device for each passenger, fire extin-
guisher, signaling devices, anchor, paddles,
bilge pump, rope, first-aid kit, tool kit, emer-
gency starter rope, flashlight, extra fuel and
oil, etc.
• Instruct your passengers about emergency
procedures. Make sure they understand the
basics of how to operate the boat, how to
use emergency equipment, and what to do
in case of trouble.
• Do not hold onto the motor cover or any
other parts of your outboard motor while
getting on or off your boat.
• Check the weather forecast before boating
to avoid bad weather.
• Use extreme caution when replacing a part
on your outboard motor or selecting and
installing accessories. Use of inappropri-
ate or poor quality replacement parts or ac-
cessories can create unsafe operating con-
ditions, or result in damage to the motor.
Suzuki strongly recommends that you use
genuine Suzuki replacement parts and ac-
cessories as damage caused by use of
parts and accessories other than genuine
Suzuki replacement parts and accessories
will not be covered under warranty.

4
IDENTIFICATION
NUMBER LOCATION
The model and identification numbers of your
outboard motor are stamped on a plate attached
to the clamp bracket. It is important to know
these numbers when you place a parts order or
if your motor is stolen.
FUEL AND OIL
GASOLINE
Suzuki highly recommends that you use alco-
hol-free unleaded gasoline whenever possible,
with a minimum octane rating of 91 (Research
method). However, blends of unleaded gasoline
and alcohol with equivalent octane content may
be used, provided the guidelines that follow are
met.
CAUTION
If leaded gasoline is used, engine damage
may result. Use only unleaded gasoline.
Gasoline Containing MTBE
Unleaded gasoline containing MTBE (Methyl
Tertiary Butyl Ether) may be used 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, are commer-
cially available in some areas. Gasoline contain-
ing a maximum of 10% ethanol may be used in
your outboard motor without jeopardizing 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 than 5% methanol under any circum-
stances. Fuel system damage or outboard mo-
tor performance problems resulting from the use
of such fuels are not the responsibility of Suzuki
and may not be covered under the New Out-
board Motor Limited Warranty.
Fuel containing 5% or less methanol may be
suitable for use in your outboard motor if they
contain cosolvents and corrosion inhibitors.
Pump Labeling for Gasoline/Alcohol
Blends
In some states, pumps that dispense gasoline/
alcohol blends are required to be labeled for the
type and percentage of alcohol content, and
whether important additives are present. Such
labels may provide enough information for you
to determine if a particular blend of fuel meets
the requirements listed above. In other states,
pumps may not be clearly labeled as to the con-
tent or type of alcohol and additives. If you are
not sure that the fuel you intend to use meets
these requirements, check with the service sta-
tion operator or the fuel suppliers.

5
NOTE:
If you are not satisfied with the operation or fuel
economy of your outboard motor when you are
using gasoline/alcohol blends, you should switch
back to unleaded gasoline containing no alcohol.
Be sure that any gasoline/alcohol blend you use
has octane ratings of at least 91 octane (Re-
search method).
If engine pinging is experienced, substitute an-
other brand as there are differences between
brands.
Unleaded gasoline will extend spark plug life.
CAUTION
Be careful not to spill fuel containing al-
cohol while refueling. Fuels containing al-
cohol can cause paint damage, which is
not covered under warranty.
8WARNING
Gasoline is extremely flammable and toxic.
Always observe the following precautions
when refueling.
• Never permit anyone other than an adult
to refill the fuel tank.
• To refill the fuel tank, always stop the
motor.
• Do not fill the fuel tank all the way to the
top or fuel may overflow when it expands
due to heating by the sun.
• Be careful not to spill fuel. If you do, wipe
it up immediately.
• Do not smoke, and keep away from open
flames and sparks.
• Refuel in a well ventilated area.
• Avoid prolonged contact with skin and
breathing of gasoline vapor.
CAUTION
Always use fresh gasoline. Gasoline kept in
the fuel tank for long periods of time will pro-
duce varnish and gum, which can damage the
engine.
ENGINE OIL
Using a premium quality four stroke motor oil
will increase the service life of your motor. Use
only oils which are rated SE, SF, SG, SH or SJ
under the API classification system. The viscos-
ity rating should be SAE 10W-40. If an SAE 10W-
40 motor oil is not available, select an alterna-
tive according to the chart below.
CAUTION
The choice of engine oil is major factor af-
fecting engine performance and life.
GEAR OIL
Use SUZUKI OUTBOARD MOTOR GEAR OIL,
or an equivalent high quality SAE90 hypoid gear
oil.

6
Keep the labels on your outboard motor or fuel
tank. Do not remove them for any reason.
Read and follow all of the labels on your out-
board motor or fuel tank. Make sure you under-
stand all of the labels.
LOCATION OF SAFETY LABELS

7
LOCATION OF PARTS
Starter grip
Throttle
control grip
Clamp screw
Gear oil level plug
Gear oil drain plug
Anode
Pilot water hole
Combination emergency
stop switch & normal
stop button
Shift lever
Fuel cock lever
Air-vent screw
Choke knob
Oil level inspection window
Steering tension adjuster
Throttle tension
adjuster
Water intake hole

8
MOTOR MOUNTING
8WARNING
Never overpower your boat. Do not install an
outboard motor that exceeds the maximum
horsepower listed on the boat’s “Certification
Plate”. If you are unable to locate the “Certifi-
cation Plate”, consult your authorized Suzuki
Marine Dealer.
Proper transom height is important for good per-
formance. A motor mounted on a transom that
is too high causes the propeller to slip resulting
in wasted power or overheating. A motor
mounted on a transom that is too low will in-
crease drag, causing reduced speed.
Make sure that when the motor is lowered all the
way down, the anti-cavitation plate is located 0 –
25 mm (0 – 1.0 in) below the bottom of the boat.
Center the motor on the transom and secure it by
alternately tightening the clamp bracket screws
by hand. Make sure you accurately center the
motor, or the boat will pull to one side during op-
eration.
After installing the motor, check to make sure
that steering and tilt movement are not ob-
structed by any part of the boat.
CAUTION
• The motor may come off if it is held only
by the clamp screws.Occasionally check
the clamp screws for tightness.
• Run a sturdy rope or cable through the
hole on the clamp bracket and fasten
the ends securely to the boat.
CAUTION
If anti-cavitation plate is above the water sur-
face, this may induce overheating and the
outboard motor will sustain damage.
0 - 25 mm
(0 - 1.0 in)

9
PROPELLER INSTALLATION
8WARNING
• When installing or removing the propel-
ler, be sure to shift into “NEUTRAL” and
disconnect the spark plug wires so the
motor can’t accidentally be started.
• To prevent being cut by the propeller
blades, wear gloves and place a block of
wood between the anti-cavitation plate and
propeller to hold the propeller in place.
To install a propeller on your outboard motor,
use the following procedure:
1. Coat the propeller shaft 1liberally with Suzuki
water resistant grease to help prevent corro-
sion.
2. Install the shear pin 2as illustrated.
3. Slide the propeller 3onto the shaft.
4. Insert the cotter pin 4and bend it so that the
propeller can not come off.
To remove the propeller, reverse the above pro-
cedure.
PROPELLER SELECTION
AND INSTALLATION
PROPELLER SELECTION
It is essential to use a propeller on your out-
board motor that is properly matched to your
boat’s operating characteristics. The speed of
the engine when you operate your boat at full
throttle depends on the propeller you use.
CAUTION
Installing a propeller with pitch either too high
or too low will cause incorrect maximum en-
gine RPM, which may result in severe dam-
age to the motor.
Full throttle
operating range
5250 – 5750
r/min. (min-1 )

10
ADJUSTMENT
TRIM ANGLE ADJUSTMENT
To help maintain steering stability and good per-
formance, always maintain the proper trim angle
as shown in the illustration. The appropriate trim
angle varies depending on the combination of
the boat, engine, and propeller, as well as oper-
ating conditions.
• Trim angle too small (Boat tends to “plow”)
To adjust the trim angle;
1. Hold the motor in the fully tilted up position.
(Refer to the TILT UP LOCK ARM section.)
2. Turn the nut 1counterclockwise.
STEERING TENSION ADJUSTMENT
The steering on your outboard motor should be
smooth and not tight. Adjust the steering tension
so that there is only a slight resistance to steering
movement.
To increase the steering tension, turn the steer-
ing tension adjuster Aclockwise. To decrease
the steering tension, turn the steering tension
adjuster counterclockwise.
• Trim angle too large (Boat tends to “por-
poise”)
• Proper trim angle
3. Pull the spacer 2and tilt pin 3out to the limit
by both side of the swivel bracket.
4. Reposition the tilt pin in the desired holes.
5. Push the spacer 2 and tilt pin 3 buck and
tighten the nut 1.
6. Lower the motor back down.
To lower the bow, move the pin towards the boat.
To raise the bow, move the pin away from the
boat.

11
THROTTLE TENSION ADJUSTMENT
The tension of the throttle control grip can be ad-
justed according to your preference.To increase
the tension, turn the throttle tension adjuster A
clockwise. To decrease the tension, turn the ad-
juster counterclockwise.
IDLE SPEED ADJUSTMENT
The idle speed of your outboard motor has been
set by your dealer. If it is necessary to adjust the
idle speed, use the following procedure:
The part of motor cover on DF2.5 is used as the
holder of recoil starter handle grip, too. Idle speed
adjustment is recommended to be made by the
Suzuki authorized dealer. Even if you need to re-
adjust idle speed by yourselves, make the starter
rope free from the the motor cover by the steps
mentioned below.
1. Slightly remove the motor cover.
2. Tie a knot in the rope inside of the motor cover,
in order to prevent the rope binding onto the
recoil reel when the rope grip is off.
3. Take of the handle grip.
4. Remove rope from the motor cover.
5. Install the handle grip buck to the end of rope.
6. Loosen a knot in the rope.
7. Starter the engine.(Refer to starting the engine
section)
8. Warm up the engine for about 5 minutes.

12
OPERATION OF TILTING
SYSTEMS
TILT UP LOCK ARM
The tilt up lock arm is used to hold the motor in
the fully tilted up position.
FULL TILT UP POSITION
To hold the motor in the fully raised position:
8WARNING
Never place your hands near the mounting
bracket or under the motor when tilting, or
they could be crushed if the motor slips from
your grasp.
1. Shift into “NEUTRAL”.
2. Turn the motor to front, to keep the reverse
thrust stopper Afree.
3. Grab the handle on the back of the motor lower
cover and tilt the motor all the way up until it is
automatically locked in the fully tilted up posi-
tion by the tilt up lock arm 1.
9. Turn the idle adjustment screw Aclockwise
to increase idle speed or counterclockwise
to decrease idle speed.
10. Install buck the grip on the motor cover by the
opposite steps of the above 1 to 6.
NOTE:
If idle speed cannot be set within the specified
range, contact your authorized Suzuki Marine
Dealer.

13
OFF
8WARNING
Be sure to turn the fuel cock lever to right
not to flow fuel from built–in tank before
tilting up the motor, or fuel may leak out.
CAUTION
Never use the throttle grip handle to raise
or lower the motor. The handle may break.
To lower the motor back down, pull the motor
slightly toward you, pull up on the till up lock arm
1and slowly let the motor down.
CAUTION
Never use the throttle grip handle to raise
or lower the motor. The handle may break.

14
Upper limit
Lower limit
INSPECTION BEFORE
BOATING
8WARNING
For the safety of you and your passen-
gers, always perform an inspection as de-
scribed below before you begin boating.
• Make sure that you have enough fuel for
the intended run.
Fuel capacity : 1.0 L (0.26/0.22 US/Imp.gal.)
• Check the level of engine oil in the sump.
CAUTION
Running the engine with insufficient oil
can cause serious engine damage.
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.
2. Check the engine oil level through the oil level
inspection window 1.
The oil should be between the upper and lower
limits.
NOTE:
If the engine oil is contaminated or discolored,
replace with fresh engine oil (Refer to INSPEC-
TION AND MAINTENANCE/Engine oil section).
If the oil level line is seen in the window 1, add
enough oil to rise the level to the upper limit.
To fill the engine oil:
1. Remove the motor cover by unlocking the fas-
tener 2and 3.

15
Upper limit
Lower limit
CAUTION
Do not overfill, as excessive oil can dam-
age the engine.
4. Tighten the oil filler cap securely.
•Visually check the propeller to make sure it
is not damaged.
• Make sure that the motor is securely
mounted to the transom.
• Make sure that the tilt pin is securely in-
stalled in the proper position.
• Make sure the starter rope is free from any
evidence of fraying or wear.
• Make sure you have the boating safty and
emergency equipment on board.
3. Fill the recommended engine oil to the upper
level.
2. Remove the oil filler cap 4.BREAK-IN
Proper operation during this break-in period will
help ensure maximum life and performance from
your engine. The following guidelines will explain
proper break-in procedures.
CAUTION
Failure to follow the break-in procedures de-
scribed below can result in severe engine
damage.
Break-in period: 10 hours
Break-in procedure
1. For the initial 2 hours:
Allow sufficient idling time (about 5 minutes)
for the engine to warm up after cold engine
starting.
CAUTION
High rpm without sufficient warm-up may
cause severe engine damage such as piston
seizure.
After warming up, run the engine at idling speed
or the lowest in-gear speed for about 15 minutes.
During the remaining 1 hour and 45 minutes, if
safe boating conditions permit, operate the en-
gine in gear at less than 1/2 (half) throttle (3000
r/min.).

16
OPERATION
BEFORE ATTEMPTING TO START
THE ENGINE
1. The motor has been lowered into the water.
2. Twist the air–vent screw on the fuel tank cap
counterclockwise to open the vent.
3. Turn the fuel cock lever to left.
NOTE:
When turning the fuel cock lever to left, fuel flow
from the built–in tank.
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 at three-
guarter throttle. Avoid running the engine at
full throttle.
3. Remaining 7 hours:
Safe boating conditions permitting, operate
the engine in gear at desired engine speed.
You may occasionally use full throttle; how-
ever do not operate the engine continuously
at full throttle for more than 5 minutes at any
time.
NOTE:
For the remaining 7 hours of break-in operation,
you may use full throttle however do not oper-
ate the engine continuously at full throttle for
more than 5 minutes at a time or severe engine
damage such as seizure may result.

17
4. Shift the motor into “NEUTRAL”.
5. The lock plate A is in place and the end of the
lanyard is attached to a part of your body.
8WARNING
The operator of your boat should always tie
the end of the emergency stop switch cord
around a part of his or her body before oper-
ating the boat. This way, if the operator is
thrown overboard or an emergency occurs,
the engine can be stopped quickly by pulling
on the cord.
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 emer-
gency stop switch.
STARTINGTHE ENGINE
8WARNING
• Never run the outboard motor indoors
or in an enclosed area. Exhaust emis-
sions contain poisonous carbon mon-
oxide fumes which can cause uncon-
sciousness and may lead to death.
• Before starting the engine, make sure that
you have enough fuel to complete your in-
tended trip.
NOTE:
If the engine fails to start, check the emergency
stop switch lock plate. If the lock plate is not in
position, the engine cannot be started.
1. If the engine is cold:
Pull the choke knob 1fully out. Align the line
mark 2 on the throttle control grip 3with the
position A.
If the engine is warm:
Align the line mark 2 on the throttle control
grip 3with the position A. Do not use the
choke.
NOTE:
You may need to use the choke when restarting
a warm engine. If your engine does not start
quickly when warm, follow the procedure for cold
starting.

18
2. Firmly grasp the starter grip and pull slowly
until resistance is felt. When you feel it en-
gage, pull the rope sharply to start the en-
gine. Do not release the rope when it is pulled
out. Hold the rope and allow it to recoil slowly.
8WARNING
This outboard motor does not have a start-
in-gear protection system. If the shift le-
ver is not in the “NEUTRAL” position, the
boat can start off unexpectedly when the
engine is started, causing personal injury.
CAUTION
Never pull the starter grip while the engine
is running, as the starter system could be
damaged.
3. After starting, use the throttle control grip to
bring the engine to idle.
4. Push the choke knob in.
NOTE:
In cold weather, you may have to leave the choke
knob out for a longer period of time for the en-
gine to warm up.
5. Warm up the engine for about 5 minutes.
Cooling water check
As soon as the engine starts, water should spray
out of the pilot water hole, 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 pos-
sible and consult your authorized Suzuki Marine
Dealer.
CAUTION
Never operate your outboard motor when
there is no water coming out of the pilot
water hole, or severe damage can result.

19
To start the engine when the starter sys-
tem fails:
1. Shift the motor into “NEUTRAL”.
8WARNING
This outboard motor does not have a start-
in-gear protection system. If the shift le-
ver is not in the “NEUTRAL” position, the
boat can start off unexpectedly when the
engine is started, causing personal injury.
2. Remove the motor cover.
3. Remove the bolts securing the recoil starter in
place.
4. Lift off the recoil starter assembly.
5. Tie a knot in one end of the emergency starter
rope located in the tool kit. Tie the other end
around the screw-driver handle in the tool kit.
6. Hook the knotted end of the rope in the pulley
notch and wind the rope around the pulley in a
clockwise direction.
7. Put the emergency stop switch lock plate in
place.
8. After following steps of the normal starting pro-
cedure, pull the emergency starter rope
sharply to start the engine.
8WARNING
• Do not re-install the recoil starter or
motor cover after starting the engine, or
you may be injured.
• When the engine is running, keep your
hands, hair, clothing, etc., away from the
engine.
• Be sure to have the starter system re-
paired as soon as possible. You should
not continue to use the emergency start-
ing procedure for routine engine start-
ing.
EMERGENCY STARTING
If you must get the engine running, but are unable
to do so because of starter system failure, you
can use the emergency starting procedure to start
the engine.
8WARNING
When rope-starting the engine, do not
touch electrical components such as ig-
niter or spark plug lead. Contact with these
items may result in a severe electric shock.