Suzuki DF25A User manual

1
ENGLISH
DF25A
DF30A
OWNER’S MANUAL
EN
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IMPORTANT
 WARNING/  CAUTION/ NOTICE/ NOTE
Please read this manual and follow its instruc-
tions carefully. To emphasize special informa-
tion, the symbol and the words WARNING,
CAUTION, NOTICE and NOTE have special
meanings. Pay special attention to the mes-
sages highlighted by these signal words.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
This symbol appears in various locations on
your Suzuki product to refer you to important
information in the owner’s manual.
IMPORTANT NOTICE TO
OWNERS
 WARNING
Indicates a potential hazard that could result
in death or serious injury.
 CAUTION
I ndicates a potential hazard that could result
in minor or moderate injury.
NOTICE
Indicates a potential hazard that could result
in damage to the motor or boat.
 WARNING
Failure to take the proper precautions may
increase the risk of death or severe injury to
you and your passengers.
• Prior to first-time use of your outboard
motor, familiarize yourself thoroughly with
the contents of this owner’s manual. Be
aware of all outboard motor features 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 operat-
ing 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 not
attempt to operate at maximum perfor-
mance until you are completely familiar with
all of these characteristics.
• Carry 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 sure you are carrying the equipment
appropriate 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 carbon 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 PFD (Per-
sonal Flotation Device) on board.
• Never operate the boat while under the
influence of alcohol or other drugs.
• Distribute all weight load evenly in the boat.
• Have all scheduled maintenance performed.
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 navigation
rules.
• Pay attention 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 you use only
genuine Suzuki replacement parts/accesso-
ries or their equivalent. Inappropriate or
poor quality replacement parts or accesso-
ries can create unsafe operating conditions.

3
NOTE:
Mounting radio transceiver or navigational
equipment antennae too close to the engine
cowling can cause electrical noise interference.
Suzuki recommends that antennae be mounted
at least one meter (40 inches) away from the
engine cowling.
• Never remove the flywheel cover (except for
when emergency starting).
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.
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
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.

4
TABLE OF CONTENTS
IDENTIFICATION NUMBER
LOCATION.............................................. 5
FUEL AND OIL....................................... 5
LOCATION OF SAFETY LABELS ..... 8
LOCATION OF PARTS....................... 10
MOTOR MOUNTING.......................... 16
BATTERY INSTALLATION .............. 17
USE OF ELECTRICAL
ACCESSORIES..................................... 19
PROPELLER SELECTION AND
INSTALLATION................................... 19
ADJUSTMENT...................................... 20
CAUTION SYSTEM............................. 23
DIAGNOSTIC SYSTEM...................... 26
OIL CHANGE REMINDER
SYSTEM................................................. 27
ENGINE STALLING CAUTION
SYSTEM................................................. 28
OPERATION OF TILTING
SYSTEMS (DF25A/25AR/30A/30AR). 29
OPERATION OF TILTING
SYSTEMS (DF30AQ)............................ 32
OPERATION OF TILTING
SYSTEMS (DF25AT/25ATH/30AT/
30ATH) ................................................... 33
INSPECTION BEFORE BOATING... 35
BREAK-IN ............................................. 37
OPERATION......................................... 38
MOTOR REMOVAL AND
TRANSPORTING................................. 51
TRAILERING........................................ 53
INSPECTION AND
MAINTENANCE................................... 54
FLUSHING THE WATER
PASSAGES............................................. 63
SUBMERGED MOTOR....................... 65
STORAGE PROCEDURE ................... 66
AFTER STORAGE ............................... 67
TROUBLESHOOTING........................ 67
SPECIFICATIONS ............................... 69
INFORMATION REGARDING
EC – DIRECTIVE ................................. 69
FLOWCHART OF OIL CHANGE
REMINDER SYSTEM.......................... 70

5
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.
NOTE:
Oxygenated fuels are fuels which contain oxy-
gen-carrying additives such as alcohol.
NOTICE
Use of leaded gasoline can cause engine dam-
age. Use of improper or poor quality fuel can
affect performance and may damage your
motor and fuel system.
Use only unleaded gasoline. Do not use fuel
having lower than the recommended octane,
or fuel that may be stale or contaminated by
dirt/water etc.
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.
Gasoline/Ethanol Blends
Blends of unleaded gasoline and ethanol (grain
alcohol), also known as “GASOHOL”, are com-
mercially available in some areas. Blends of this
type may be used in your outboard motor if they
are no more than 10% ethanol. Make sure this
gasoline-ethanol blend has octane ratings no
lower than those recommended for gasoline.
Use the recommended gasoline which
conforms to the following labels.
78RB0900*
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.
or

6
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
(Research method).
If engine pinging is experienced, substitute
another brand as there are differences between
brands.
Unleaded gasoline will extend spark plug life.
 WARNING
Gasoline is extremely flammable and toxic. It
can cause a fire and can be hazardous to peo-
ple and pets.
Always take the following precautions when
refueling:
• Never permit anyone other than an adult to
refill the fuel tank.
• If you use a portable fuel tank, always stop
the motor and remove the fuel tank from the
boat to refill it.
• 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.
NOTICE
Gasoline kept in the fuel tank for long periods
of 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 fuel tank supplied with this motor is its ded-
icated fuel reservoir and should not be used as
a fuel storage container.
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 or
10W-30 SUZUKI MARINE 4-CYCLE ENGINE
OIL. If SUZUKI MARINE 4-CYCLE ENGINE
OIL is not available, select a NMMA certified
FC-W oil or good quality 4-cycle motor oil from
the following chart according to the average
temperatures in your area.
NOTE:
In very cold weather (below 5°C (41°F)), use
SAE (or NMMA FC-W) 5W-30 for easier start-
ing and smooth operation.
NOTICE
Use of poor quality engine oil can adversely
affect engine performance and life.
Suzuki recommends that you use Suzuki
Marine 4-Cycle Engine Oil or its equivalent.
–20 –10 0 10 20 30
–4 14 32 50 68 86
40
104
TEMP.
API Classification SAE Viscosity Grade
10W–40
10W–30
˚F
˚C
SG
SH
SJ
SL
SM
SN

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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.

8
LOCATION OF 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.
All models except for EU
WARNING AVERTISSEMENT
8
• Fuel can leak creating a fire hazard if
you lay motor on its side. Drain fuel
completely from vapor separator or
carburetor before laying motor on its side.
• See owner’s manual for details.
• Le carburent risque de fuir et de
présenter un danger d’incendie si le
moteur est placé sur le côté.
Vidanger entièrement le carburant du
séparateur de vapeurs ou du
carburateur avant de procéder.
• Pour plus de détail, voir le manuel
du propriétaire.
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.
WARNING AVERTISSEMENT
8
• To avoid injury, when engine is running,
keep your hands, hair, clothing, etc., away
from engine.
• See owner’s manual for details.
•
Pour éviter toute blessure, quand le moteur
est en marche, éloigner les mains, les
cheveux, les vêtements, etc. du moteur.
• Pour plus de détail, voir le manuel
du propriétaire.
Label symbol meanings
These symbols mean as follows;
: General warning symbol
(Caution or Warning)
: Read owner’s manual carefully
: Remote control lever/gear shift lever
operation-two direction; Forward/
Neutral/Reverse
: Engine start
: Hazard caused by fire
: Hazard caused by laying the
motor on its side
: Hazard caused by rotating parts

9

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LOCATION OF PARTS
TILLER HANDLE MODEL (DF25A/30A)
Throttle control
grip
Clamp screw
Engine oil
drain plug
Pilot water hole
Flush plug
Throttle tension
adjuster
Motor cover
Starter grip
Shift lever
Clamp bracket
Starter button
(Electric starter model)
Fuel connector
Water intake
hole
Trim tab
(Anode)
Anode
Anode
Anode
(Only transom L)
Gear oil level plug
Water intake hole
Tilt pin
Gear oil drain plug
Caution lamp
Combination emergency stop
switch & normal stop button
Steering tension
adjuster
Anode

11
TILLER HANDLE MODEL (DF30AQ)
Throttle control
grip
Clamp screw
Engine oil
drain plug
Pilot water hole
Flush plug
Throttle tension
adjuster
Motor cover
Starter grip
Shift lever
Clamp bracket
Starter button
(Electric starter model)
Fuel connector
Water intake
hole
Trim tab
(Anode)
Anode
Anode
Anode
(Only transom L)
Gear oil level plug
Water intake hole
Gear oil drain plug
Caution lamp
Combination emergency stop
switch & normal stop button
Anode
Steering tension
adjuster

12
TILLER HANDLE MODEL (DF25ATH/30ATH)
Throttle control
grip
Clamp screw
Engine oil
drain plug
Pilot water hole
Flush plug
Throttle tension
adjuster
Motor cover
Starter grip
Shift lever
Clamp bracket
Starter button
Fuel connector
Water intake
hole
Trim tab
(Anode)
Anode Anode
(Only transom L)
Gear oil level plug
Water intake hole
Gear oil drain plug
Caution lamp
Combination emergency stop
switch & normal stop button
Steering tension
adjuster Power trim and tilt (P.T.T.) switch
Anode Anode

13
REMOTE CONTROL MODEL (DF25AR/30AR)
Clamp screw
Anode Engine oil
drain plug
Pilot water hole
Flush plug
Clamp bracket
Water intake
hole
Trim tab
(Anode)
Anode
Anode
Anode
(Only transom L)
Gear oil level plug
Water intake hole
Tilt pin
Gear oil drain plug
Motor cover
Starter grip
Fuel connector Caution lamp

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REMOTE CONTROL MODEL (DF25AT/30AT)
Fuel connector Caution lamp
Clamp screw
Anode
Engine oil
drain plug
Pilot water hole
Flush plug
Clamp bracket
Water intake
hole
Trim tab
(Anode)
Anode
Anode
Anode
(Only transom L)
Gear oil level plug
Water intake hole
Gear oil drain plug
Motor cover
Starter grip
Power trim and
tilt (P.T.T.) switch

15
FUEL TANK
(All models)
Fuel line
Air-vent screw
Priming bulb
REMOTE CONTROL BOX
(DF25AR/25AT/30AR/30AT)
Ignition key
Emergency stop switch
Remote control handle
Warm-up lever
Power trim and tilt
(P.T.T.) switch
(DF25AT/30AT)
Throttle tension adjuster
Lock-out
lever

16
MOTOR MOUNTING
TILLER HANDLE MODEL
Proper transom height is important for good
performance. 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
increase 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.
 WARNING
Overpowering your boat can be hazardous.
Excessive horsepower will have an adverse
effect on hull safety and may cause operating/
handling difficulties. The boat may also sus-
tain stress and hull damage.
Never install an outboard motor with horse-
power exceeding the manufacturer’s recom-
mended maximum horsepower listed 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 transom and secure it
by alternately tightening the clamp screws 1by
hand. Make sure you accurately center the
motor, or the boat will pull to one side during
operation.
Install the bolts 2, washers 3, washers 4and
nuts 5, as illustrated and tighten the bolts
sequentially. Be sure to seal the holes with
sealant to prevent water leakage.
Sealant
Sealant

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After installing the motor, check to make sure
that steering and tilt movement are not
obstructed by any part of the boat. Also make
sure that the battery cable (if provided) doesn’t
interfere with movement of the motor.
REMOTE CONTROL MODEL
Suzuki strongly recommends that you have
your outboard motor, controls and gauges
installed by an authorized Suzuki Marine
Dealer. He has the tools, the facilities and the
know-how.
NOTICE
If you attempt to mount the outboard to the
transom without having mechanical experi-
ence or without being certain where to drill
holes, you can seriously damage the boat.
If you do not have mechanical experience or
are not sure of where to drill holes in the
boat’s transom, you should have your motor
mounted by your authorized Suzuki marine
dealer.
 WARNING
If the motor is not properly secured to the
transom, it can come off.
Be sure to bolt the motor to the transom. The
motor may come off if it is held only by the
clamp screws. Occasionally check the clamp
screws for tightness.
 WARNING
Failure to have your outboard motor and asso-
ciated controls and gauges properly installed
can result in personal injury or damage.
Suzuki strongly recommends that you have
your outboard motor, controls and gauges
installed 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
ELECTRIC STARTER MODEL
650 Marine Cranking Amps (MCA)/ABYC,
or 512 Cold Cranking Amps (CCA)/SAE
or 160 Reserve Capacity (RC) Minutes/SAE
or 12 Volt, 70 AH
NOTE:
• The specifications listed above are the mini-
mum battery rating requirements for starting
the engine.
• Additional electrical loads from the boat will
require larger capacity batteries. Consult
your Suzuki dealer to determine the proper
battery sizing for your boat and engine com-
bination.
• Dual-purpose (Cranking/Deep-cycle) batter-
ies can be used if they meet the minimum
specifications listed above (MCA, CCA, or
RC).
• Do not use a Deep Cycle battery for the main
cranking battery.
• When connecting batteries in parallel, they
must be of the same type, capacity, manufac-
turer, and of similar age. When replacement
is necessary, they should be replaced as a
set. Consult your Suzuki dealer for proper
battery installation information.

18
BATTERY INSTALLATION
Secure the battery in a dry area of the boat,
away from vibration.
NOTE:
• It is recommended that the battery be
installed in an enclosed battery case.
• When connecting batteries, hexagon-nuts
must be used to secure battery leads to bat-
tery posts.
To hook up the battery, first connect the red
lead from the motor to the positive battery ter-
minal, then connect the black lead to the nega-
tive battery terminal.
To remove the battery, first disconnect the black
lead from the negative terminal, then discon-
nect the red lead from the positive terminal.
Suzuki recommends that you install the termi-
nal cap on the positive battery terminal to pre-
vent an accidental short circuit of battery
terminals.
If a terminal cap is required, contact your autho-
rized Suzuki marine dealer.
 WARNING
If you place the battery near the fuel tank, a
spark from the battery may ignite the gaso-
line, causing a fire and/or an explosion.
Do not place the fuel tank in the same com-
partment/area as the battery.
Red lead
Hexagon-
nut
Black
lead
Hexagon-
nut
 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 battery away from
open flames. To avoid creating a spark when
charging the battery, connect the battery
charger cables to the proper terminals before
turning the charger on.
 WARNING
Battery acid is poisonous and corrosive. It
can cause severe injury and can damage
painted surfaces.
Avoid contact with eyes, skin, clothing, and
painted surfaces. If battery acid comes in con-
tact with any of these, flush immediately with
large amounts of water. If acid contacts the
eyes or skin, get immediate medical attention.
NOTICE
The electrical system or its components may
be damaged if proper battery precautions are
not followed.
• Be sure to attach battery leads correctly.
• Do not disconnect battery leads from the
battery while the engine is running.

19
USE OF ELECTRICAL
ACCESSORIES
To use electrical accessories, you must pur-
chase a 70 AH or larger battery, rectifier and
related items. (Recoil starter model only).
The amount of power (DC12V) available for
accessories, however, depends on the operat-
ing condition of the motor. For getting a detailed
information, please inquire of your authorized
Suzuki Marine Dealer.
NOTE:
Use of too much power for electrical accesso-
ries under certain operating conditions can
cause the battery to discharge.
NOTE:
On the models equipped with a receptacle,
detach the charging cord from the receptacle
and fit the cap to prevent water entry when not
using power supply.
NOTICE
If you connect electrical accessories directly
to the power receptacle of the motor, the elec-
trical accessories could be damaged.
Connect lights and electrical accessories for
the boat to the battery. Consult your autho-
rized Suzuki marine dealer for information
about correct wiring.
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.
Excessive engine speed 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 if your propeller is appropri-
ate for use with your boat by using a tachome-
ter to measure engine speed when operating
your boat at full throttle, under minimum load
conditions. If you are using an appropriate pro-
peller, the engine speed will be within the fol-
lowing range:
If the engine speed is not within this range, con-
sult your authorized Suzuki Marine Dealer to
determine which propeller size is best for you.
NOTICE
Installing a propeller with either too much or
too little pitch will cause incorrect maximum
engine speed, which may result in severe
damage to the motor.
Ask your authorized Suzuki marine dealer to
assist you in selecting a suitable propeller for
your boat.
Full throttle
operating
range
DF25A 5000 – 6000
r/min. (min–1)
DF30A 5300 – 6300
r/min. (min–1)

20
PROPELLER INSTALLATION
To install a propeller on your outboard motor,
use the following procedure:
1. Coat the propeller shaft splines 1liberally
with Suzuki water resistant grease to help
prevent corrosion.
2. Place the stopper 2on the shaft.
3. Align the propeller 3with the propeller shaft
splines and slide the propeller onto the shaft.
4. Place the spacer 4and washer 5on the
shaft.
5. Install the propeller nut 6and tighten it with
a torque wrench to 20 – 30 N·m (2.0 – 3.1
kgf-m/15 – 22 lbf-ft).
6. Align the grooves in the propeller nut with
the hole in the shaft, then insert the cotter
pin 7and bend the pin ends over to lock it in
place.
To remove the propeller, reverse the above pro-
cedure.
 WARNING
Failure to take proper precautions when
installing 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 maintain steering stability and good
performance, always maintain the proper trim
angle as shown in the illustration. The appropri-
ate trim angle varies depending on the combi-
nation of the boat, engine, and propeller, as well
as operating conditions.
• Trim angle too large (Boat tends to “porpoise”)
• Trim angle too small (Boat tends to “plow”)
• Proper trim angle