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PROPELLERS

An outboard motor is designed to develop its rated power within a specified engine speed range. The maximum rated power delivered by the Suzuki models are shown in your service manual. If the standard propeller fails to meet the above requirement, use another pitch propeller to hold the engine speed within the range specified in your manual propeller selection chart.
 
Installing a propeller with pitch either too high or too low will cause incorrect maximum engine speed, which may result in severe damage to the motor.

Disassembly of propeller shaft components

1. Slide propeller shaft away from reverse gear housing assembly

Account for reverse gear back-up shim thrust washer

2. Remove horizontal slider and forward gear thrust washer

3. Remove spring

4. Using special tool, push dog pin shifter.

5. Remove clutch dog shifter propeller shaft.

PROPELLER

• Inspect propeller for bent, chipped or broken blades and replace or repair if necessary.

• Inspect propeller bushing splines for wear or other damage and replace if necessary.

• Inspect propeller bushing for deterioration or slipping and replace if necessary.

PROPELLER SHAFT COMPONENTS

• Inspect horizontal slider and connector pin for excessive wear or other damage. Replace if necessary.

• Inspect clutch dog shifter for excessive wear, chip or other damage. Replace if necessary.

• Inspect dog pin for bent or other damage. Replace if necessary.

• Inspect propeller shaft / splines for wear, twist or other damage. Replace if necessary.

PROPELLER SHAFT BEARING HOUSING

• Inspect housing for cracks or other damage. Replace if necessary.

• Inspect propeller shaft bearings and reverse gear bearing for pitting, rough or other damage. Replace if necessary.

• Inspect oil seals and O-ring for cuts, nicks or tears.

Replacing propeller shaft oil seal

1. Remove retaining ring

2. Extract oil seals

1 and washer 2.3 using oil seal remover.

Do not re-use oil seal once removed.

Always use a new oil seal.

3. Apply Water Resistant Grease to inner circumference of housing.

4. Using an oil seal installer, drive two oil seals (one at a time) into housing.

The lipped portion of seal should face towards propeller.

Apply Water Resistant Grease to seal lips.

5. Install washer and retaining ring.

PROPELLER INSTALLATION

1. Install spacer shaft, then slide on propeller

2. Fit spacer specified torque.

1 and propeller stopper 2 onto propeller3.4, washer 5 and nut 6, then tighten nut to

Propeller nut : 55 N.m (5.5 kg-m, 40.0 lb.-ft.)

3. Push cotter pin secure.

PROPELLER SELECTION FOR COUNTER

ROTATION

For counter-rotation model, newly designed stainless steel propellers are available as follows.

Suzuki highly recommend to use the genuine Suzuki counterrotation propeller for the counter rotation model. In case of twin installation, always use on both engines, the same size normal rotation and counter-rotation propellers.

ENGINE CRANKED, BUT NOT START (OR STOPS SHORTLY AFTER STARTING)
UNSTABLE IDLING / TROLLING (OR ENGINE TENDS TO STALL)

• Incorrect by-pass air screw adjustment [NOTE3]
• IAC valve failure [NOTE3]
• IAC passage failure (clogged hose, etc.) [NOTE3]
• Spark plug failure
• Ignition coil failure
• ECM failure
• Wire continuity / connection failure
• Failure of high pressure fuel system components :
• Fuel injector (clog, stuck valve, etc.)
• Fuel pressure regulator (incorrect regulated pressure, etc.)
• Fuel pump (clogged suction filter, leakage in tank, etc.)
• Fuel filter (clog, etc.)
• Hose (clog, kink, leakage, etc.)


FUEL TANK PART DISASSEMBLY / REASSEMBLY

EXPLODED DIAGRAMS

PARTS

Fuel hose assy
Connector
Tank cap
Connector plug
Outlet
Filter
O-ring
Fuel tank
Tank cap
Gasket
Screw
Connector plug
Gasket
Fuel gauge assy
Cover
Gasket
Lens
Gasket
Screw
Float
Push nut
Gasket
Fuel hose assy
Connector
Clip
Connector
Primer bulb
Fuel tank

MID UNIT ASSEMBLY

EXPLODED DIAGRAMS

PARTS

Clutch lever
E-ring
Grease nipple
Clutch shaft arm
Clutch lever link
Clutch shaft
Bushing
Clutch shaft holder
Clutch rod
Guie
Ring
Engine holder
Oil seal
Water return union
T O-ring
Plug
Pin
Upper thrust mount
Upper mount
Upper mount bolt
Mount cover
Washer
Nut
Oil strainer Plug
Oil pan
Water indicator cover
Water indicator tube
Exhaust pipe
Water plug
Water tube
Driveshaft housing
Lower mount cover
Damper
Lower mount
Lower mount bolt
Lower mount bracket
Lower thrust mount
Bushing (type:UL)
Retaining ring
Bonding wire
Screw

LOWER UNIT ASSEMBLY

EXPLODED DIAGRAMS

PARTS

Driveshaft
Wave washer
Driveshaft collar
Shift cam housing
Forward gear
Pinion gear
Pinion nut
Clutch dog shifter
Dog pin
Dog spring
Propeller shaft
Thrust washer
Reverse gear
Shim
Propeller shaft bearing housing
Retaining ring
Stopper
Propeller
Propeller bushing

WIRING DIAGRAMS / HOSE ROUTING

WIRE COLORS

B/Y
: Black
: Brown
: Blue
: Green
: Gray
: Light blue
: Light green
: Orange
: Pink
: Red
: White
: Yellow
: Black with Green tracer
: Black with White tracer
: Black with Yellow tracer
G/Y
G/W
Lg/B
Lg/W
Lg/Y
O/B
O/G
P/B
R/B
R/G
R/W
W/Y
W/R
Y/G
Y/W
: Green with Yellow tracer
: Green with White tracer
: Light green with Black tracer
: Light green with White tracer
: Light green with Yellow tracer
: Orange with Black tracer
: Orange with Green tracer
: Pink with Black tracer
: Red with Green tracer
: Red with Blue tracer
: Red with White tracer
: White with Yellow tracer
: White with Red tracer
: Yellow with Green tracer
: Yellow with Wh

HOSE ROUTING PARTS DIAGRAM

switch "B" terminal
Red lead wire
Main harness
PTT motor relay plate
PTT motor relay cable GND
White lead wire
(To 30A fuse)
Joint connector
To ignition coil and
fuel injector
Main wiring harness
ECM connector
To remo-con connector
PTT motor relay "DOWN"
PTT motor relay "UP"
Sub fuse(30A)
Fuse terminal nut
Fuse terminal bolt
Main fuse terminal
Electric parts holder
Cushion
Electric parts holder
CMP sensor
Ignition coil No.1
Ignition coil No.2
Main harness
Exhaust manifold temp. sensor
When installing sensor, apply water.
Resistant grease to sensor o-ring.
Rectifier & regulator
Clamp
Fix rect & regulator lead wire
Tighten bolt with PTT and temp. sensor lead wire.
and main harness ground lead wire.
ECM main relay
PTT cable Starter relay
PTT motor relay "DOWN"
PTT motor relay "UP"
Battery cable
Sub fuse (30 A) (with spare)
Tighten nut with rect & regulator
Out put white lead and 30 A
fuse white lead wire.
Main fuse (60 A)
Communication connector / Cap
Starter motor bolt
Starter motor
Tighten bolt with starter motor band
Rect & regulator ground lead wire
.


1999-2011 Suzuki Outboard DF40 DF50 Service Manual 40/50 HP
  
1999-2011 Suzuki Outboard Models Covered In this Manual: 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 DF40QH (DF-40-QH, DF40-QH), DF50QH (DF-50-QH, DF50-QH), 1999 DF40T (DF-40-T, DF-40T), 1999 DF50T (DF-50-T, DF-50T), 2000 DF40 Y, 2000 DF50 Y, 2001 DF-40 W K1, 2001 DF-50 W K1, 2002 DF40 K2, 2002 DF50 K2, 2002 DF40 K3, 2003 DF50 K3, 2004 DF40/50 K4, 2005 DF-40/50 K5, 2006 DF-40/50 K6, 2007 DF-40/50 K7, 2008 DF-40/50 K8, 2009 DF-40/50 Models Supplement, 2010 DF 40-50 Supplement, 2011 DF 40-50 Supplement.
 
2000 2003 Suzuki DF25 DF30 Service Manual 25/30 HP 4-Stroke
 
2000 2001 2002 2003 Suzuki Outboard Models Covered in this Service Manual/Repair Manual: 2000 Suzuki Four Stroke DF25 (DF 25) 25HP (25 HP) Engine. 2000 Suzuki Four Stroke DF30 (DF 30) 30HP (30 HP) Engine. 2001 Suzuki Four Stroke DF25 (DF 25) 25HP (25 HP) Engine. 2001 Suzuki Four Stroke DF30 (DF 30) 30HP (30 HP) Engine. 2002 Suzuki Four Stroke DF25 (DF 25)25HP (25 HP) Engine. 2002 Suzuki Four Stroke DF30 (DF 30) 30HP (30 HP) Engine. 2003 Suzuki Four Stroke DF25 (DF 25) 25HP (25 HP) Engine. 2003 Suzuki Four Stroke DF30 (DF 30) 30HP (30 HP) Engine.
 
2001 2009 Suzuki DF 90 100 115 140 HP Service Manual Outboard 4-Stroke
 
2001 2002 2003 2004 2005 2006 2007 2008 2009 Suzuki Outboard Four Stroke Models Covered: DF90 (90HP 90 HP) DF 90 4-Stroke DF100 (100HP 100 HP) DF 100 4-Stroke DF115 (115HP 115 HP) DF 115 4-Stroke DF140 (140HP 140 HP) DF 140 4-Stroke
 
2002-2005 Suzuki Outboard Service Manual DF4/5/6 HP 4 Stroke 
 
This Suzuki 2002 2003 2004 2005 DF 4HP 5HP 6HP Service Manual Covers the following Model Years. 2002 Suzuki Outboard DF4 DF5 DF6 ( 4 HP 5 HP 6 HP) Four Stroke 2003 Suzuki Outboard DF4 DF5 DF6 ( 4 HP 5 HP 6 HP) Four Stroke 2004 Suzuki Outboard DF4 DF5 DF6 ( 4 HP 5 HP 6 HP) Four Stroke 2005 Suzuki Outboard DF4 DF5 DF6 ( 4 HP 5 HP 6 HP) Four Stroke.
 
2003 2007 Suzuki Service Manual DF60 DF70 60/70 HP Outboard 4-Stroke
 
This 2003 2004 2005 2006 2007 Suzuki Outboard 4 Stroke Service Maual Coveres The Followning Models: 2003 Suzuki Outboard 4 Stroke DF60 (DF 60) 60HP (60 HP), 2003 Suzuki Outboard Four Stroke DF70 (DF 70) 70HP (70 HP) Motor, 2004 Suzuki Outboard 4 Stroke DF60 (DF 60) 60HP (60 HP), 2004 Suzuki Outboard Four Stroke DF70 (DF 70) 70HP (70 HP), 2005 Suzuki Outboard 4 Stroke DF60 (DF 60) 60HP (60 HP), 2005 Suzuki Outboard Four Stroke DF70 (DF 70) 70HP (70 HP), 2006 Suzuki Outboard 4 Stroke DF60 (DF 60) 60HP (60 HP), 2006 Suzuki Outboard Four Stroke DF70 (DF 70) 70HP (70 HP), 2007 Suzuki Outboard 4 Stroke DF60 (DF 60) 60HP (60 HP), 2007 Suzuki Outboard Four Stroke DF70 (DF 70) 70HP (70 HP).
 
2003 2011 Suzuki DF9.9 DF15 Service Manual 9.9/15 HP 4-Stroke
 
2003 2004 2005 2006 2007 2008 2009 2010 2011 Suzuki Outboard Models Covered in this Service Manual/Repair Manual: 2003 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2003 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2004 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2004 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2005 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2005 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2006 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2006 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2007 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2007 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2008 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2008 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2009 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2009 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2010 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2010 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP), 2011 Suzuki Four Stroke DF9.9 (DF 9.9) 9.9HP (9.9 HP), 2011 Suzuki Four Stroke DF15 (DF 15) 15HP (15 HP) Engine.
 
2006 2010 Suzuki Service Manual DF150 DF175 150/175 HP 4-Stroke
 
This 2006 2007 2008 2009 2010 Suzuki Outboard 4 Stroke Service Maual Coveres The Followning Models: 2006 Suzuki Outboard 4 Stroke DF150 (DF 150) 150HP (150 HP), 2006 Suzuki Outboard Four Stroke DF175 (DF 175) 175HP (175 HP), 2007 Suzuki Outboard 4 Stroke DF150 (DF 150) 150HP (150 HP), 2007 Suzuki Outboard Four Stroke DF175 (DF 175) 175HP (175 HP), 2008 Suzuki Outboard 4 Stroke DF150 (DF 150) 150HP (150 HP), 2008 Suzuki Outboard Four Stroke DF175 (DF 275) 175HP (175 HP), 2009 Suzuki Outboard 4 Stroke DF150 (DF 150) 150HP (150 HP), 2009 Suzuki Outboard Four Stroke DF175 (DF 175) 175HP (175 HP), 2010 Suzuki Outboard 4 Stroke DF150 (DF 150) 150HP (150 HP), 2010 Suzuki Outboard Four Stroke DF175 (DF 175) 175HP (175 HP).
                             
1988 2003 Suzuki DT Models 2HP Through 225HP Workshop Manual Outboard
 
DT2 (DT-2) 2HP (2 HP) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995 & 1996, DT2.2 (DT-2.2) 2.2HP (2.2 HP)1997, DT4 (DT-4) 4HP (4 HP) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 & 1998, DT5Y (DT-5-Y) 5HP (5 HP) 1998, 1999, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1999, 2000, 2001 & 2002, DT6 ( DT-6) 6HP (6 HP) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 & 1997, DT8 (DT-8) 8HP (8 HP) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 & 1997, DT9.9 ( DT-9.9) 9.9HP (9.9 HP) 1988 thru 1997, DT15 (DT-15) 15HP (15 HP)1988-1989, DT20 (DT-20) 20HP (20 HP) 1988, DT25 (DT-25) 25HP (25 HP) 1990-1991, DT30 (DT-30) 30HP 30 HP 1989-1997, DT35 (DT-35) 35HP (35 HP) 1988-1997, DT40 (DT-40) 40HP (40 HP) 1988-1998, DT55 (DT-55) 55HP (55 HP) 1988-1997, DT65 (DT-65) 65HP (65 HP) 1988-1997, DT75 (DT-75) 75HP (75 HP) 1988-1997, DT85 (DT-85) 85HP (85 HP) 1988-2000, DT90 (DT-90) 90HP (90 HP) 1989-1997, DT100 (DT-100) 100HP (100 HP) 1989-1996 & 1996-2001 EFI, DT140 (DT-140) 140HP (140 HP) 1988-1996 & 1996-2001 EFI, DT150 (150) 150HP (150 HP) 1988-1994 & 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 & 2003 EFI, DT175 175HP (175) 1988-1992, DT200 200 HP (200) 1988-1992 & 1993-2000 EFI, DT225 225H (225) 1990-2003
 
SUPPLEMENT MANUAL- ADDITIONAL SERVICE DATA FOR 1999 & LATER MODELS (1999+ MODELS) INCLUDING CARBURETOR & IGNITION COIL SPECIFICATIONS.
 
1999+ DT4/DT5Y, 1999+ DT5 DT6 & DT8, 1999+ DT25C DT30C (DT25-C, DT30-C), 1999+ DT75 & DT85, 1999+ DT100TC, 1999+ DT115STC & DT140TC EFI (DT115-STC, DT140-TC), 1999+ DT150 / 175 / 200, 1999+ DT225 M


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