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
I
D
ES
S
NO
SU
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 )