Suzuki DF40ASV User manual

1
EN
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ENGLISH
DF40A
DF40ASV
DF50A
DF50AV
DF60A
DF60AV
OWNER’S MANUAL

2
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.......................... 13
BATTERY INSTALLATION .............. 13
USE OF ELECTRICAL
ACCESSORIES..................................... 15
PROPELLER SELECTION AND
INSTALLATION................................... 15
ADJUSTMENT...................................... 16
INDICATOR.......................................... 22
CAUTION SYSTEM............................. 22
DIAGNOSTIC SYSTEM...................... 26
OIL CHANGE REMINDER
SYSTEM................................................. 26
ENGINE STALLING CAUTION
SYSTEM................................................. 27
OPERATION OF TILTING
SYSTEMS............................................... 28
INSPECTION BEFORE BOATING... 32
BREAK-IN ............................................. 33
OPERATION......................................... 34
MOTOR REMOVAL AND
TRANSPORTING................................. 43
TRAILERING........................................ 45
INSPECTION AND
MAINTENANCE................................... 46
FLUSHING THE WATER
PASSAGES............................................. 55
SUBMERGED MOTOR....................... 57
STORAGE PROCEDURE ................... 58
AFTER STORAGE ............................... 59
TROUBLESHOOTING........................ 59
SPECIFICATIONS ............................... 61
INFORMATION REGARDING
EC – DIRECTIVE................................. 62
CHART OF TOTAL OPERATING
HOURS INDICATION
(Remote control model)......................... 62
FLOWCHART OF OIL CHANGE
REMINDER SYSTEM.......................... 64

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.
NOTE:
The fuel tank supplied with this motor is its ded-
icated fuel reservoir and should not be used as
a fuel storage container.
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.

7
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.
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.
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

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.
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
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

10
LOCATION OF PARTS
REMOTE CONTROL MODEL
MONITOR-TACHOMETER
REMOTE CONTROL BOX
Motor cover
Power trim and tilt
(P.T.T.) switch
(Reverse side)
Engine oil drain plug
Clamp bracket
Anode
Gear oil level plug
Water intake hole
Gear oil drain plug
Pilot water hole
Flush plug
Anti-cavitation plate
Trim tab
(Anode)
Flush plug
DF40AT/50AT/60AT
Priming bulb
FUEL TANK
Fuel hose
Air-vent screw
Ignition key
Emergency stop switch
Remote control handle
Warm-up lever
Power trim and tilt
(P.T.T.) switch
Throttle tension adjuster
Lock-out
lever

11
Motor cover
Power trim and tilt
(P.T.T.) switch
(Reverse side)
Engine oil drain plug
Clamp bracket
Anode
Pilot water hole
Flush plug
Anode
(Reverse side)
Anode
Gear oil level plug
Water intake hole
Gear oil drain plug
Anti-cavitation plate
Trim tab
DF40ASVT/50AVT/60AVT

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TILLER HANDLE MODEL
Motor cover
Engine oil drain plug
Clamp bracket
Anode
Gear oil level plug
Anti-cavitation
plate
Gear oil drain plug
Pilot water
hole
Flush plug
Anti-cavitation
plate
Trim tab
(Anode)
Flush plug
Power trim and tilt
(P.T.T.) switch
(Reverse side)
(DF40ATH/50ATH/60ATH)
Throttle
control grip
Troll mode switch
Power trim
and tilt (P.T.T.)
switch
(DF40ATH/50ATH/
60ATH)
Emergency
stop switch
Tachometer/Indicator
Shift lever
Ignition key
DF50AVTH
DF40ATH/QH/50ATH/60ATH
FUEL TANK
Fuel hose
Priming bulb
Air-vent screw
Anode
Water intake
hole
Trim tab
Gear oil
level plug
Water intake
hole
Gear oil
drain plug
Anode
(Reverse side)

13
MOTOR MOUNTING
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.
 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”.
 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
650 Marine Cranking Amps (MCA)/ABYC,
or 512 Cold Cranking Amps (CCA)/SAE
or 160 Reserve Capacity (RC) Minutes/SAE
or 12 Volt, 80 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.

14
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.
Red lead
Hexagon-
nut
Black
lead
Hexagon-
nut
Hexagon-nut
 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.
 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.

15
USE OF ELECTRICAL
ACCESSORIES
The amount of power (DC12V) available for
accessories, however, depends on the operat-
ing condition of the motor. For detailed informa-
tion, please ask 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.
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
DF40A 5000 – 6000
r/min. (min–1)
DF40AS/40ASV
DF50A/50AV
DF60A/60AV
5300 – 6300
r/min. (min–1)

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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 50 – 60 N·m (5.1 – 6.1
kgf-m/37 – 44 lbf-ft).
6. Insert the cotter pin 7and bend it so that it
can’t come off.
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 small (Boat tends to “plow”)
•
Trim angle too large (Boat tends to “porpoise”)
• Proper trim angle
Tilt range
Trim range

17
 WARNING
Trim angle greatly affects steering stability. If
the trim angle is too small, the boat may
“plow” or “bow steer”. If the trim angle is too
large, the boat may “chine walk” from side to
side or “porpoise” up and down. These condi-
tions, which result in loss of steering control,
can cause occupants to be thrown overboard.
Always maintain proper trim angle based on
the combination of your boat, engine, and pro-
peller, as well as operating conditions.
 WARNING
When the motor is tilted beyond the maximum
trim position, the swivel bracket will not have
side support from the clamp bracket and the
tilt system will be unable to cushion the
engine if the lower unit strikes an obstruction.
This could lead to occupant injury.
Do not operate the engine above 1500 r/min or
operate the boat in a planing attitude with the
motor tilted beyond the maximum trim posi-
tion.
NOTICE
If you operate the boat with the motor trimmed
beyond the maximum trim position, the water
intake holes may be above the water line,
causing severe engine damage due to over-
heating.
Never operate the boat with the motor
trimmed beyond the maximum trim position.
DF40A (QH) MODEL
Make a test run in the boat to determine if the
trim down limit position needs to be adjusted.
To adjust the trim angle:
1. Hold the motor in the fully tilted up position.
(Refer to TILT BRACKET section.)
2. Reposition the tilt pins Ain the desired
holes.
3. Lower the motor back down.
To lower the bow, move the pin towards the
boat. To raise the bow, move the pin away from
the boat.
DF40A (T), DF40ASV (T), DF50A (T),
DF50AV (T), DF60A (T), DF60AV (T)
MODEL
Make a test run in the boat to determine if the
trim angle needs to be adjusted. Adjust the trim
angle using the Power Trim and Tilt system.
While operating your boat with the motor
adjusted to the proper trim angle, observe the
position of the needle on the TRIM GAUGE pro-
vided as optional part. When making future trim
angle adjustment, use the TRIM GAUGE as a
guide.
 WARNING
If you operate the motor with the tilt pin
removed, you may not be able to control steer-
ing as expected.
Do not operate the motor with the tilt pin
removed.

18
TRIM TAB ADJUSTMENT
This adjustment is used to compensate for the
possible tendency of your boat to veer slightly
to port or starboard. This tendency could be
due to such things as propeller torque, motor
mounting position, etc.
To adjust the trim tab:
1. Loosen the bolt Athat holds the trim tab in
place.
2. If the boat tends to veer to port, move the
rear end of the trim tab toward the port side.
If the boat tends to veer to starboard, move
the starboard side.
(Optional part)
3. Tighten the bolt that holds the trim tab in
place.
After adjusting the trim tab, check to see if the
boat still tends to veer to one side. If necessary,
readjust the trim tab.
STEERING TENSION ADJUSTMENT
The steering on your outboard motor should be
smooth and not tight. Adjust the steering ten-
sion so that there is only a slight resistance to
steering movement.
DF50AV (TH), DF60A (TH) MODEL
To increase the steering tension, turn the steer-
ing tension bolt Aclockwise. To decrease the
steering tension, turn the steering tension bolt
counterclockwise.
DF40A (TH/QH), DF50A (TH) MODEL
For adjustment, use the steering tension lever
A. To increase the steering tension, move the
lever Ato the left. To decrease the steering
tension, move the lever to the right.

19
THROTTLE TENSION ADJUSTMENT
TILLER HANDLE MODEL
The tension of the throttle control grip can be
adjusted according to your preference. To
increase the tension, turn the throttle tension
adjuster Aclockwise. To decrease the tension,
turn the adjuster counterclockwise.
REMOTE CONTROL MODEL
The tension of the remote control handle can be
adjusted according to your preference. To
increase the tension, turn the throttle tension
adjuster Aclockwise. To decrease the tension,
turn the adjuster counterclockwise.
IDLE SPEED ADJUSTMENT
The idle speed has been factory adjusted
between 750 – 850 r/min in neutral.
NOTE:
If idle speed cannot be set within the specified
range, contact your authorized Suzuki Marine
Dealer.
Increase
Decrease
SETTING OF TILT UPPER LIMIT POSITION
DF40A (ST), DF40ASV (T), DF50AV (T/TH),
DF60A (T/TH), DF60AV (T) MODEL
If the outboard motor contacts the motor well of
the boat during full tilt up operation, the upper
limit setting should be reset.
Perform this set-up after the current position
setting has been canceled, as explained in the
following procedure.
CANCELING THE TILT UPPER POSITION
LIMIT SETTING
1. Turn the ignition key to the “ON” position.
2. Pull out the emergency stop switch lock
plate.
3. Shift the motor into “NEUTRAL”.
“NEUTRAL”
“NEUTRAL”

20
4. Remote control model:
Using the throttle only function of the remote
control box, move the warm-up lever upward
until the caution buzzer sounds one time.
Tiller handle model:
Turn the throttle control grip until the buzzer
sounds one time.
5. Press the “UP” side of the PTT switch for
three seconds and the buzzer will sound
twice briefly indicating the setting has been
canceled.
6. Return the throttle to the fully closed posi-
tion.
SETTING THE TILT UPPER POSITION
LIMIT
7. Press the “UP” side of the PTT switch so
that the optimum full tilt up position for the
boat can be obtained.
8. Remote control model:
Using the throttle only function of the
remote control box, move the warm-up lever
upward until the caution buzzer sounds one
time.
Tiller handle model:
Turn the throttle control grip until the buzzer
sounds one time.
9. Press the “UP” side of PTT switch three
times within three seconds. The buzzer will
sound one time briefly indicating the setting
has been accepted.
10. Return the throttle to the fully closed posi-
tion and install the lock plate on the emer-
gency switch. Operate the full tilt up and full
down operations several times by pressing
the PTT switch and check that the setting of
both the trim lower limit and tilt upper limit
are properly set.
 WARNING
Setting of the tilt upper limit position will not
prevent the outboard motor from tilting fully
up and contacting the motor well if the
motor’s lower unit hits an object at high
speed. Such tilting could damage your motor
and boat and injure the boat occupants.
Keep all occupants away from the motor when
operating at high speed.