2006-2014 Suzuki DF2.5 4-Stroke Outboard Repair Manual

FOUR STROKE

I • , • r, ·. .! '·· - 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 equivalent. • 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 special 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 lubri cant , bond, or sealant is specified, be sure to use the specified type. • When removing the battery, disconnect the negative cable first and then the positive 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 usi ng battery power, disconnect the negative cable from the battery. • Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller diameter. Always tighten from inside to outside diagonally to the specified tightening 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 tightness 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 equivalent 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.

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 1OW-40. If an SAE 1OW-40 motor oil is not available, select an alternative according to the chart at right. ENGINE OIL 'C Tompel'lllure 4j: GENERAL INFORMATION 1-5 I I I I l ' ' I ' ' ' ' I ' ' r I I I I -30 -20 -10 0 10 20 30 40 -22 -4 14 32 50 68 86 104

1-6 GENERALINFORMATION ENGINE BREAK-IN The first 10 hours are. critically important to ensure correct run- ning of either a brand new motor or a motor that has been recon- ditioned or rebuilt. How the motor is operated during this time will have direct bearino on its life soan and lono-term durabilitv. Break-in period: 10 hours WARM-UP REC.OMMENDATION Allow sufficient idling time (more than 5 minutes) for the engine to warm up after cold engine starting. THROTTLE RECOMMENDATION NOTE: Avoid maintaining a constant engine speed for an extended period at any time during the engine break-in by varying the throttle position occasionally. 1. FIRST 2 HOURS For first 15 minutes, operate the engine in-gear at idling speed. During the remaining 1 hour and 45 minutes, operate the engine in-gear at less than 1/2 (half) throttle (3 000 r/min). NOTE: The throttle may be briefly opened beyond the recommended setting to plane the boat, but must be reduced to the recommended setting immediately after planing. 2. NEXT 1 HOUR Operate the engine in-gear at less than 3/4 throttle (4 000 r/min). 3. LAST 7 HOURS Operate the engine in-gear at desired engine speed. However, do not operate continuously at full throttle for more than 5 minutes.

PROPELLERS An outboard motor is designed to develop its rated power within a specified engine speed range. The maximum rated power delivered by the DF2.5 models are shown below. Recommended operating 5 250 - 5 750 r/min range If the standard propeller tails to meet the above requirement, use another pitch propeller to hold the engine speed within the range specified above. Propeller selection chart Code Number Blade x Diameter x Pitch A400 A510 3 X 3 X 188 mm (7-3/8 in) x 188 mm (7-3/8 in) x 115 mm (4-1/2 in) 135 mm (5-3/8 in) I CAUTION I 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. GENERAL INFORMATION 1-7

1·8 GENERAL INFORMATION * SPECIFICATIONS *These specifications are subject to change without notice. Data Item Unit DF2.5 L_ ____ ________ __.r DIMENSIONS & WEIGHT Overall length I mm (in) I 437 (1 7.2): with tiller handle raised (front to back) I Overall width I ! 262 (10.3) (side to side) I mm (in) I Overall height ! s ! mm (in) I 963 (37.9) -- I I - I Weight ' 13.0 (28.7) i s kg (lbs) (without engine oil) j Transom height t I mm I I s (inch type) 435 (15} PERFORMANCE Maximum output ! kW (PS) I 1.8 (2.5) Recommended operating ' j r/min 5 250-5 750 range Idle speed ! rim in I 1 900 :t 1 00 (in·gear: approx. 1 500) I POWER HEAD Engine type I : 4-stroke OHV Number of cylinders i 1 --"J---·--·----- Bore 1 mm (in) ) 48.0 {1.89) Stroke J mm (in) ! 38.0 (1.50) ' Total displacement i (cu. in) I 68 (4.1) I Compression ratio ! : 1 I 9.0 Spark plug I NGK i CR6HSA ! Ignition system I Transistorized ignition Fuel supply system _L Carburetor - Exhaust system J ___ 1, Above prop exhaust Cooling system I Water cooled ·- Lubrication system I Wet sump by trochoid pump Starting system I Manual Choke system I Manual I Throttle control I Twist gnp

GENERAL INFORMATION 1-9 Item Unit Data DF2.5 FUEL & OIL Fuel Suzuki highly recommends that you use alcohol-free unleaded gasoline with a minimum pump octane rating of 87 (A/2 + M/2 method) or 91 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane content may be used. Fuel tank capacity L 1.0 (0.26/0.22) (Built-in tank) (US/Imp. gal) Engine oil API classification SE, SF, SG, SH, SJ Viscosity rating SAE 10W-40 Engine oil amounts L 0.38 (0.40/0.33) (US/Imp. qt) Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil amounts ml 60 (2.0/2.1) (US/Imp. oz) BRACKET Trim angle I Degrees 6-20 Number of tilt pin position 4 Maximum tilt angle I Degrees 74 (from lowest tilt pin position) LOWER UNIT Reversing system Gear Transmission Forward-Neutral Reduction system Bevel gear Gear ratio 13: 28 (2.15) Drive line impact protection Shear pin Propeller Blade x Diam. X Pitch 3 X 188 mm (7-3/8 in) X 115 mm (4-1 /2 in) (A400) 3 X 188 mm (7-3/8 in) X 135 mm (5-3/8 in) (A51 0)

2006-2014 Suzuki DF2.5 4-Stroke Outboard Repair Manual

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