Suzuki DF4 User manual

99500-91J00-01E

This manual contains an introductory description on
SUZUKI Outboard motor DF4/5 and procedures for
the inspection, service and overhaul of its main com-
ponents.
General knowledge information is not included.
Please read the GENERAL INFORMATION sec-
tion to familiarize yourself with basic information
concerning this motor. Read and refer to the other
sections in this manual for information regard-
ing proper inspection and service procedures.
This manual will help you better understand this out-
board motor so that you may provide your custom-
ers with optimum and quick service.
GENERAL INFORMATION
PERIODIC MAINTENANCE
IGNITION AND ELECTRICAL
FUEL SYSTEM
RECOIL STARTER
POWER UNIT
MID UNIT
LOWER UNIT
WIRE / HOSE ROUTING
Marine & Power Products Division
GROUP INDEX
!
Apprentice mechanics or do-it-yourself me-
chanics that don’t have the proper tools and
equipment may not be able to properly per-
form the services described in this manual.
Improper repair may result in injury to the
mechanic and may render the engine unsafe
for the boat operator and passengers.
FOREWORD
1
2
3
4
5
6
7
8
9
• This manual has been prepared using the lat-
est information available at the time of publi-
cation.
If a modification has been made since then,
differences may exist between the content of
this manual and the actual outboard motor.
• Illustrations in this manual are used to show
the basic principles of operation and work pro-
cedures and may not represent the actual out-
board motor in exact detail.
•Thismanualisintendedforusebytechnicians
who already possess the basic knowledge and
skills to service SUZUKI outboard motors.
Persons without such knowledge and skills
should not attempt to service an outboard en-
gine by relying on this manual only.
Instead, please contact your nearby autho-
rized SUZUKI outboard motor dealer.
COPYRIGHT SUZUKI MOTOR CORPORATION 2001
NOTE:
This manual is compiled based on 2002 (K2) model.

HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE
LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed on the previous page
in a GROUP INDEX. Select the section needed
for reference.
3. Holding the manual as shown at the right will al-
low you to find the first page of the section easily.
4. The first page of each section lists a table of con-
tents to easily locate the item and page you need.
COMPONENT PARTS AND IMPORTANT ITEM ILLUSTRATIONS
Under the name of each system or unit, an exploded view is provided with work instructions and other
service information such as the tightening torque, lubrication and locking agent points.
Example :
NOTE:
Clean the flywheel and crankshaft
mating surfaces with cleaning solvent.
1Nut (1)
2Key (1)
3Flywheel (1)
4CDI & coil unit (1)
5Spark plug cap (1)
6Bolt (2)

SYMBOL
Listed in the table below are the symbols indicating instructions and other important information neces-
sary for proper servicing. Please note the definition for each symbol. You will find these symbols used
throughout this manual. Refer back to this table if you are not sure of any symbol(s) meanings.
Apply THREAD LOCK “1342”.
Apply THREAD LOCK SUPER
“1333B”.
Measure in DC voltage range.
Measure in resistance range.
Measure in continuity test range.
Use peak voltmeter
“Stevens CD-77”.
Use special tool.
To r q u e c o n t r o l r e q u i r e d .
Data beside it indicates specified
torque.
Apply oil. Use engine oil unless
otherwise specified.
Apply SUZUKI OUTBOARD
MOTOR GEAR OIL.
Apply SUZUKI SUPER GREASE “A”.
Apply SUZUKI WATER
RESISTANT GREASE.
Apply SUZUKI BOND “1104”.
Apply SUZUKI BOND “1207B”.
Apply SUZUKI SILICONE SEAL.
SYMBOL DEFINITION SYMBOL DEFINITION
"
#
$
%
&
'
(
)
*
+
,
-
.
/
0

GENERAL INFORMATION 1-1
GENERAL INFORMATION
1
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- 4
ENGINE BREAK-IN ________________________________________ 1- 5
PROPELLERS ____________________________________________ 1- 6
SPECIFICATIONS _________________________________________ 1- 7
SERVICE DATA ___________________________________________ 1- 9
TIGHTENING TORQUE _____________________________________ 1-15
SPECIAL TOOLS __________________________________________ 1-17
MATERIALS REQUIRED ____________________________________ 1-19
CONTENTS

1-2 GENERAL INFORMATION
WARNING / CAUTION / NOTE
Please read this manual and follow its instructions carefully. 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.
!
Indicates a potential hazard that could result in death or injury.
"
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 obser ve basic mechanical safety
principles.
GENERAL PRECAUTIONS
•Properserviceandrepairproceduresareimportantforthesafetyoftheservicemechanic
and the safety and reliability of the outboard motor.
•Toavoideyeinjury,alwayswearprotectivegoggleswhenfilingmetals,workingonagrinder,
or doing other work, which could cause flying material particles.
•When2ormorepersonsworktogether,payattentiontothesafetyofeachother.
• 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
extinguisher, distress signals, anchor, paddles, bilge pump, first-aid kit, emergency starter
rope, etc.
•Whenworkingwithtoxicorflammablematerials,makesurethattheareayouworkiniswell-
ventilated and that you follow all of the material manufacturer’s instructions.
•Neverusegasolineasacleaningsolvent.
• To avoid getting burned, do not touch the engine, engine oil or exhaust system during or
shortly after engine operation.
•Oilcanbehazardous.Childrenandpetsmaybeharmedfromcontactwithoil.Keepnewand
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.
•Afterservicingfuel,oil/enginecoolingsystemandexhaustsystem,checkalllinesandfit-
tings related to the system for leaks.
•Carefullyadheretothebatteryhandlinginstructionslaidoutbythebatterysupplier.
!

GENERAL INFORMATION 1-3
•Ifpartsreplacementisnecessary,replacethepartswithSuzukiGenuinePartsortheirequiva-
lent.
•Whenremovingpartsthataretobereused,keepthemarrangedinanorderlymannersothat
they may be reinstalled in the proper order and orientation.
•Besuretousespecialtoolswheninstructed.
•Makesurethatallpartsusedinassemblyarecleanandalsolubricatedwhenspecified.
• When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the
specified type.
•Whenremovingthebattery,disconnectthenegativecablefirstandthenthepositivecable.
When reconnecting the battery, connect the positive cable first and then the negative cable.
•Whenperformingservicetoelectricalparts,iftheserviceproceduresdonotrequireusing
battery power, disconnect the negative cable at the battery.
•Tightencylinderheadandcaseboltsandnuts,beginningwithlargerdiameterandending
with smaller diameter. Always tighten from inside to outside diagonally to the specified tight-
ening torque.
• Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, locking nuts,
cotter pins, circlips, 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 circlip over the shaft. After installing a circlip, always ensure
that it is completely seated in its groove and securely fitted.
•Useatorquewrenchtotightenfastenerstothetorquevalueswhenspecified.
Remove grease or oil from screw / bolt threads unless a lubricant is specified.
•Afterassembly,checkpartsfortightnessandoperation.
• To protect the environment, do not unlawfully dispose of used motor oil, other fluids, and
batteries.
•ToprotecttheEarth’snaturalresources,properlydisposeofusedmotorparts.
"

1-4 GENERAL INFORMATION
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 clamp bracket.
Example
FUEL AND OIL
GASOLINE RECOMMENDATION
Suzuki highly recommends that you use alcohol - free un-
leaded gasoline with a minimum pump octane rating of 87
(R+M / 2 method) or 91 (Research method). However, blends
of unleaded gasoline and alcohol with equivalent octane con-
tent may be used.
Allowable maximum blend of a single additive (not combina-
tion) :
5% Methanol, 10% Ethanol, 15% MTBE
"
If leaded gasoline is used, engine damage may re-
sult. Use only unleaded gasoline.
ENGINE OIL
Use only oils that are rated SE, SF, SG, SH, or SJ under the
API (American Petroleum Institute) classification system.
The viscosity rating should be SAE 10W-40.
If an SAE 10W-40 motor oil is not available, select an alterna-
tive according to the chart at right.
ENGINE SERIAL NUMBER
A second engine serial number plate is pressed into a boss
on the sylinder block.
THAI SUZUKI MOTOR CO.,LTD.
MADE IN THAILAND FABRIQUE AU THAILANDE