Suzuki DF250S User manual

99011-93J10-03A
DF250S
Part No. 99011-93J10-03A
September, 2009 Eng. TK
Printed in Japan
Keep with boat at all times.
This owner’s manual contains important
information on safety, operation and
maintenance.
DF250S
83
300 TAKATSUKA, MINAMI, HAMAMATSU, JAPAN
K 10
*99011-93J10-03A*
OWNER’S MANUAL

IMPORTANT
 WARNING/CAUTION/ NOTE
Please read this manual and follow its instruc-
tions carefully. To emphasize special informa-
tion, the symbol and the words WARNING,
CAUTION and NOTE have special meanings.
Pay special attention to the messages high-
lighted by these signal words.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
BREAK-IN INFORMATION
FOR YOUR OUTBOARD MOTOR
The first 10 hours are the most important in the
life of your engine. Proper operation during this
break-in period is essential to help ensure max-
imum life and performance.
Refer to the BREAK-IN section of this manual
for specific break-in recommendations.
IMPORTANT NOTICE TO OWNERS
 WARNING
indicates a potential haz-
ard that could result in death or injury.
CAUTION
CAUTION indicates a potential hazard
that could result in motor damage.
 WARNING
Follow these safety precautions to
decrease your risk of injury:
• Prior to first-time use of your outboard
motor, familiarize yourself thoroughly
with the contents of this owner’s man-
ual. Be aware of all outboard motor fea-
tures and all safety and maintenance
requirements.
• Inspect the boat and motor before each
trip. 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 competent
at handling boat and motor. Do not
attempt to operate at maximum perfor-
mance until you are completely familiar
with all these characteristics.
8 WARNING
• Carry boating safety and emergency
equipment. This important equipment
includes; flotation aids for each person
(plus one throwable buoyant cushion in
any boat 16 feet or longer), fire extin-
guisher, sound signaling device, visual
distress signals, anchor, bilge pump,
bucket, compass, emergency starter
rope, extra fuel and oil, first aid kit, flash-
light, food and water, mirror, paddles,
tool kit, and transistor radio. Be sure
you are carrying the equipment appro-
priate for your trip before launching.
• Never start the engine or let it run
indoors or where there is little or no
ventilation. Exhaust gas contains car-
bon monoxide, a gas that is colorless
and odorless and can cause death or
severe injury.
• Instruct your passengers on how to
operate the boat, how to deal with
emergencies and how to operate safety
and emergency equipment.
• Do not hold onto the motor cover or
any other parts of your outboard motor
while getting on or off your boat.
• Ensure that everyone wears a life jacket
on board.
• Never operate the boat under the influ-
ence of alcohol or other drugs.
• Distribute all weight load evenly in the
boat.
• Have all scheduled maintenance per-
formed. Consult your authorized
Suzuki Marine Dealer as required.
• Do not modify or remove any outboard
motor standard equipment. To do so
may make the motor unsafe to use.
• Learn and obey all applicable naviga-
tion rules.
• Adhere to all weather forecasts. Do not
set out if weather is unsettled.
• Use extreme caution when purchasing
replacement parts or accessories.
Suzuki strongly recommends that only
genuine Suzuki replacement parts/
accessories or their equivalent are
used. Inappropriate or poor quality
replacement parts or accessories can
create unsafe operating conditions.
CAUTION
To prevent noise interference from the
engine electrical systems, Suzuki recom-
mends that radio transceiver or naviga-
tional equipment antennae are mounted
at least one (1) meter (40 inches) away
from the engine cowling.

1
FOREWORD
The proper care and maintenance that your
outboard motor requires is outlined in this man-
ual. By following these instructions explicitly you
will ensure a long trouble-free operating life for
your outboard motor. This outboard motor also
conforms to the U.S Environmental Protection
Agency emission regulations which 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 equipment.
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 production changes
at any time, without notice and without incurring
any obligation to make the same or similar
changes to outboard motor previously built or
sold.
This manual should be considered a per-
manent part of the outboard motor and
should remain with the outboard motor
when resold or otherwise transferred to a
new owner or operator. Please read this
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.
PLEASE PRESERVE NATURE
Protect and preserve your boating waters and
their land access. Never pollute the water or
land with oil, gas, or other harmful products. For
example, make sure you dispose of used gear
oil properly following a gear oil change. Also
remember not to litter. With a little bit of effort,
our boating waters can be enjoyed for many
years to come.
Suzuki Motor Corporation believes in conserva-
tion and protection of Earth’s natural resources.
To that end, we encourage every outboard
motor owner to recycle, trade in, or properly dis-
pose of, as appropriate, used oil and batteries.
TAKE A BOATING SAFETY CLASS
An educated boater will enjoy 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 department of boating and your
Suzuki Marine dealer can supply you with addi-
tional information on boating safety and regula-
tions, or you can call the U.S. Coast Guard
Boating Safety Hotline toll-free at 1-800-368-
5647.
California Proposition 65 Warning
 WARNING
Engine exhaust, some of its constituents,
and certain product components contain
or emit chemicals known to the State of
California to cause cancer and birth
defects or other reproductive harm.

2
TABLE OF CONTENTS
FUEL AND OIL....................................... 3
GASOLINE ............................................ 3
ENGINE OIL .......................................... 4
GEAR OIL ............................................. 4
LOCATION OF SAFETY LABELS ..... 5
LOCATION OF PARTS......................... 7
MOTOR INSTALLATION .................... 8
BATTERY INSTALLATION ................ 8
BATTERY REQUIREMENT .................. 8
BATTERY INSTALLATION .................. 9
SUB BATTERY CABLE...................... 10
USE OF ELECTRICAL
ACCESSORIES................................... 10
PROPELLER SELECTION AND
INSTALLATION................................... 10
PROPELLER SELECTION ................. 10
PROPELLER INSTALLATION ........... 11
ADJUSTMENTS.................................... 11
TRIM ANGLE ADJUSTMENT............. 11
THROTTLE TENSION
ADJUSTMENT .................................... 12
IDLE SPEED ADJUSTMENT.............. 12
MOTOR COVER FASTENING
ADJUSTMENT .................................... 13
CAUTION SYSTEM ............................. 13
INDICATOR CHECK ........................... 13
OVER-REVOLUTION CAUTION
SYSTEM .............................................. 14
OIL PRESSURE CAUTION
SYSTEM .............................................. 14
COOLING WATER CAUTION
SYSTEM .............................................. 15
BATTERY VOLTAGE CAUTION
SYSTEM .............................................. 16
DIAGNOSTIC SYSTEM ...................... 17
OIL CHANGE REMINDER
SYSTEM................................................. 17
SYSTEM ACTIVATION ....................... 17
CANCELLATION ................................ 18
ENGINE STALLING CAUTION
SYSTEM................................................. 18
OPERATION OF TILTING
SYSTEMS............................................... 19
POWER TRIM AND TILT .................... 19
TILT LIMITER CAM............................. 19
MANUAL TILTING .............................. 20
TILT LEVER ........................................ 20
INSPECTION BEFORE
BOATING .............................................. 21
BREAK-IN ............................................. 23
OPERATION ......................................... 24
BEFORE ATTEMPTING TO START
THE ENGINE....................................... 24
STARTING THE ENGINE ................... 25
SHIFTING AND SPEED CONTROL ... 26
STOPPING THE ENGINE ................... 27
MOORING ........................................... 28
OPERATION IN SHALLOW
WATER................................................ 28
OPERATION IN SALT WATER .......... 28
OPERATION IN FREEZING
WEATHER........................................... 28
MOTOR REMOVAL AND
TRANSPORTING ................................. 29
MOTOR REMOVAL ............................ 29
MOTOR TRANSPORTING.................. 29
TRAILERING ....................................... 30
INSPECTION AND
MAINTENANCE................................... 31
MAINTENANCE SCHEDULE ............. 31
SPARK PLUG ..................................... 33
BREATHER AND FUEL LINE ............ 34
ENGINE OIL ........................................ 35
GEAR OIL ........................................... 36
LOW PRESSURE FUEL FILTER........ 37
LUBRICATION .................................... 38
CORROSION PREVENTION .............. 39
BATTERY............................................ 40
ENGINE OIL FILTER .......................... 40
FLUSHING THE WATER
PASSAGES............................................. 41
SUBMERGED MOTOR ....................... 43
STORAGE PROCEDURE ................... 43
MOTOR STORAGE............................. 43
BATTERY STORAGE ......................... 44
AFTER STORAGE ............................... 45
GENERAL INFORMATION............... 45
WARRANTIES .................................... 45
IDENTIFICATION NUMBER
LOCATION .......................................... 45
EMISSION CONTROL
INFORMATION.................................... 46
TROUBLESHOOTING ........................ 46
SPECIFICATIONS ............................... 47
CHART OF TOTAL OPERATING
HOURS INDICATION ......................... 48
FLOWCHART OF OIL CHANGE
REMINDER SYSTEM.......................... 48
WIRING DIAGRAM ............................ 49

3
FUEL AND OIL
GASOLINE
Suzuki highly recommends that you use alco-
hol-free unleaded gasoline whenever possible,
with a minimum pump octane rating of 87
((R+M)/2 method). In some areas, the only
fuels that are available are oxygenated fuels.
Oxygenated fuels which meet the minimum
octane requirement and the requirements
described below may be used in your outboard
motor without jeopardizing the New Outboard
Motor Limited Warranty.
NOTE:
Oxygenated fuels are fuels which contain oxy-
gen-carrying additives such as MTBE or alco-
hol.
Suzuki recommends that you install a water-
separating fuel filter assembly between your
boat’s fuel tank(s) and outboard motor(s). Fuel
filtration systems of this type will help prevent
water that may be present in your boat’s fuel
tank(s) from contaminating your motor’s elec-
tronic fuel injection system. Water contamina-
tion can cause poor engine performance and
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.
CAUTION
• If leaded gasoline is used, engine dam-
age may result. Use only unleaded gas-
oline.
• Do not use fuel of a lower than recom-
mended octane or fuel that may be
stale or contaminated by dirt/water etc.
Such poor quality fuel will affect perfor-
mance and may damage your engine
and fuel system.
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, 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 possible.
DO NOT USE fuels containing more than 5%
methanol under any circumstances. Fuel sys-
tem damage or outboard motor performance
problems resulting from the use of such fuels
are not the responsibility of Suzuki and may not
be covered under the New Outboard Motor Lim-
ited Warranty.
Fuel containing 5% or less methanol may be
suitable for use in your outboard motor if they
contain cosolvents and corrosion inhibitors.
Fuel Pump Labeling
In some states, pumps that dispense oxygen-
ated fuels are required to be labeled for the type
and percentage of oxygenate, 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 oxygenate and additives. If you
are not sure that the fuel you intend to use
meets these requirements, check with the ser-
vice station operator or the fuel suppliers.