Suzuki DF 25 User manual

FOUR STROKE

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GENERAL INFORMATION 1·1
GENERAL INFORMATION
WARNING/CAUTION/NOTE ....................................... .............................. 1- 2
GENERAL PRECAUTIONS ............
.. ............. .. .............................. .. ............ .. 1- 2
IDENTIFICATION NUMBER LOCATION ......................................
.. ............ .. 1- 4
FUEL
AND OIL ......... .... .. ....... .. ............. .. .... .. ................... .. ............ .. .............. 1- 4
GASOLINE RECOMMENDATION .......................................... .. ............. 1- 4
ENGINE OIL .............................................................
.. ................ ............1· 5
ENGINE BREAK-IN .........................
.. ............ .. ................................ .. ............ 1- 6
WARM-
UP RECOMMENDATION .......................................................... 1- 6
THROTTLE RECOMMENDATION .........................................................1- 6
PROPELLERS .. ........................... .. ................................................. .. ............. 1- 7
SPEC/FICA TIONS ........ .. ................ .. .. .. ......................................................... 1- 8
SERVICE DATA.............................................................................................. 1-10
TIGHTENING TORQUE
.. .................................................................... .. ......... 1-14
SPECIAL TOOLS ............. .. ........................... ... ............................... .. .... .. .. .. ..1-15
MATERIALS REQUIRED ...............
.. ............................................ .. ............... 1-17

1·2 GENERAL INFORMATION
WARNING I CAUTION I NOTE
Please read this manual and follow its instructions ca;efully. To emphasize special information. the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to
the mes·
sages highlighted by these signal words.
A WARNING
Indicates a potential hazard that could result in death or injury.
CAUTION !
Indicates a
potential hazard that could result in motor damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack
of servicing, of the outboard motor. In addition to the
WARNING and CAUTION stated, you must also use good judgement and observe basic mechanical safety
principles.
GENERAL PRECAUTIONS
A WARNING
•
Proper service and repair procedures are important for the safety of the service mechanic
and the safety and reliability of the outboard motor.
• To avoid eye injury, always wear protective goggles when filing metals, working on a grinder,
or doing other work, which could cause flying material particles.
• When 2 or more persons work together, pay attention to the safety of each other.
• When it is necessary to run the outboard motor indoors, make sure that exhaust gas is vented
outdoors.
• When testing an outboard motor in the water and on a boat, ensure that the necessary safety
equipment is on board. Such equipment includes: flotation aids for each person, fire extin-
guisher, distress signals, anchor, paddles, bilge pump, first-aid kit, emergency starter rope,
etc.
• When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated
and that you follow all of the material manufacturer's instructions.
• Never use gasoline as a cleaning solvent.
• To avoid getting burned, do not touch the engine, engine oil or exhaust system during or
shortly after engine operation.
• Oil can be hazardous. Children and pets may be harmed from contact with oil. Keep new and
used
oil away from children and pets. To minimize your exposure to oil, wear a long sleeve
shirt and moisture-proof gloves (such as dishwashing gloves) when changing oil. If oil con-
tacts
your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet
with oil. Recycle or properly dispose of used oil.
1 • After servicing fuel, oil/engine cooling system and exhaust system, check all lines and fit·
tings related to the system for leaks.
• Carefully adhere to the battery handling instructions laid out by the battery supplier.

GENERALINFORMATION 1-3
CAUTION
• If parts replacement Is necessary, replace the parts with Suzuki Genuine Parts or their equiv-
alent .
• When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order and orientation .
• Be sure to use spec ial tools when i nstructed .
• Make sure that all parts used in assembly are clean and also lubricated when specified.
• When use of a certain type of lubr i cant , bond, or sealant is specified, be sure to use the spec -
ified type .
• When removing the battery, disconnect the negative cable first and then the pos it i ve cable.
When reconnecting
the battery , connect the positive cable first and then the negative cable.
• When performing service to electr ical parts, if the service procedures do not require us i ng
battery power, disconnect the negat i ve cable from the battery.
• Tighten cylinder head and case bolts and nuts , beginning with larger diameter and ending
wi th smaller diameter. Always tighten from inside to outside diagonally to the specified tight-
eni ng torque .
• Whenever you remove oil seals , gaskets, packing , 0-rings , locking washers, locking nuts ,
cotter pins, circljps, and certain other parts as specified, always replace them with new. Also,
before. installing these new parts, be sure to remove any left over material from the mating
surfaces.
• Never reuse a circlip . When installing a new circlip, take care not to expand the end gap larger
than required to slip the circllp over the shaft . After Installing a circlip, always ensure that it is
completely seated in I ts groove and securely fitted.
• Use a torque Wrench to tighten fasteners to the specified torque.
Wipe off grease and oil it a threads is smeared with them.
• After reassembly, check parts for ti ghtness and proper operation .
• To protect the environment , do not unlawfully dispose of used motor oil, other fluids, and bat-
teries.
• To protect the Earth's natural resources, properly dispose of used motor and parts.

1·4 GENERALINFORMATION
IDENTIFICATION NUMBER LOCATION
MODEL, PRE-FIX, SERIAL NUMBER
The MODEL, PRE-FIX and SERIAL NUMBER of the motor are
stamped
on a plate attached to the driveshaft housing.
Example
ENGINE SERIAL NUMBER
A second engine senal number plate is pressed into a boss
on
the cylinder block.
FUEL AND OIL
GASOLINE RECOMMENDATION
Suzuki highly recommends that you use alcohol-free unleaded
Qasoline with a minimum pump octane rating of 87 (R/2 + M/2
method) or
91 (Research method). However, blends of
unleaded gasoline and alcohol with eq uivalent octane content
may
be used.
Allowable maximum blend of a single additive (not combination):
5% Methanol, 10% Ethanol, 15% MTBE
jCAUTION j
If leaded gasoline is used, engine damage may result .
Use
only unleaded gasoline .