FOUR STROKE

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
,
I •
PROPELLERS ............................................................................................... 1- 7
• r,
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 special tools when instructed.
• Make sure that all parts used in assembly are clean and also lubricated when specified.
• When use of a certain type of lubricant, 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 posit ive cable.
When reconnecting the battery, connect the positive cable first and then the negative cable.
• When performing service to electrical parts, if the service procedures do not require using
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 tight-
en ing 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 Its 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 t ightness 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

j CAUTION j

If leaded gasoline is used, engine damage may result.

Use only unleaded gasoline.
 GENERAL INFORMATION 1-5

ENGINE OIL
Use only oils that are rated SE, SF, SG, SH or SJ under the API I I I I l
(American Petroleum Institute) classification system. ' '
The viscosity rating should be SAE 1OW-40. ENGINE OIL
I
'
If an SAE 1OW-40 motor oil is not available, select an alternative ' ' ' I

according to the chart at right. ' '

I I I I r
'C -30 -20 -10 0 10 20 30 40
Tompel'lllure 4j:
-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 recom-
mended 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.
 GENERAL INFORMATION 1-7

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 3 X 188 mm (7-3/8 in) x 115 mm (4-1/2 in)
A510 3 X 188 mm (7-3/8 in) x 135 mm (5-3/8 in)

ICAUTION 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.
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
(front to back) I
I
mm (in)
I 437 (1 7.2): with tiller handle raised

Overall width
(side to side) I
mm (in) !I 262 (10.3)

Overall height
-- ! s ! mm (in)
- I 963 (37.9)

I
I
Weight '
i
(without engine oil) j
s I kg (lbs) 13.0 (28.7)
t
Transom height mm
s 435 (15}
I
I (inch type) I
PERFORMANCE
Maximum output !' kW (PS) I 1.8 (2.5)
Recommended operating
r/min j 5 250-5 750
range
Idle speed
!
I rim in I 1 900 :t 100 (in·gear: approx. 1 500)

POWER HEAD
I
Engine type : 4-stroke OHV
Number of cylinders i
--"J---·--·-----
1
Bore 1 mm (in) ) 48.0 {1.89)
Stroke J mm (in) !
'
38.0 (1.50)
Total displacement i (cu. in) II 68 (4.1)
Compression ratio ! :1 Ii 9.0
Spark plug I NGK ! 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

Data
Item Unit
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)
1-10 GENERAL INFORMATION

*SERVICE DATA * These service data are subject to change without notice.

Data
Item Unit
DF2.5

POWER HEAD
Recommended operating
r/min 5 250-5 750
range
Idle speed r/min 1 900 ± 100 (in-gear: approx. 1 500)
* Cylinder compression kPa
960- 1 400 (9.6 -14.0, 137 -199)
(kg/cm 2 , psi)
Engine oil API classification SE, SF, SG, SH, SJ
Viscosity rating SAE 10W-40
Engine oil amounts L (US/Imp. qt) 0.38 (0.40/0.33)
Thermostat operating
oc (Of) 48-52 (118- 126)
temperature
*Figures shown are guidelines only, not absolute service limit.

CARBURETOR
Type Walbro LMJ-26
1.0 mark 97J10
Main jet # 70
Pilot jet # 32
Pilot screw Turns open Pre-set
Float height mm 10 ± 2

CYLINDER HEAD/CAMSHAFT

Cylinder head
Limit mm (in) 0.05 (0.002)
distortion
Cam IN, STD mm (in) 28.480-28.680 (1.1213 -1.1291)
height EX Limit mm (in) 28.180 (1.1094)
Rocker
IN
arm shaft
hole - STD mm (in) 4.015- 4.027 (0.1581 - 0.1585)
diameter EX

Rocker
IN
arm shaft
outside STD mm (in) 3.990- 4.005 (0.1571 - 0.1577)
diameter EX
 GENERAL INFORMATION 1-11

Data
Item Unit
DF2.5

VALVENALVE GUIDE
Valve diameter IN mm (in) 20.0 (0.79)
EX mm (in) 18.0 (0.71)
Valve
JN STD mm (in) 0.13 - 0.17 (0.005 - 0.007)
clearance
(Cold engine
EX STD mm (in) 0.13- 0.17 (0.005- 0.007)
condition)
Valve seat angle IN - 45°
EX - 45°
Valve guide STD mm (in) 0.010 - 0.037 (0.0004- 0.0015)
IN
to valve stem Limit mm (in) 0.075 (0.0030)
clearance STD mm (in) 0.025 - 0.052 (0.001 0 - 0.0020)
EX
Limit mm (in) 0.090 (0.0035)
Valve guide
IN,
inside STD mm (in) 4.000- 4.012 (0.1575- 0.1580)
EX
diameter
Valve stem
IN STD mm (in) 3.975- 3.990 (0.1565- 0.1571)
outside
diameter
EX STD mm (in) 3.960- 3.975 (0.1559 - 0.1565)

Valve stem IN,

Limit mm (in) 0.35 (0.014)
deflection EX
Valve stem IN,
Limit mm (in) 0.05 (0.002)
run out EX
Valve head IN,
Limit mm (in) 0.08 (0.003)
radial runout EX
Valve head IN,
Limit mm (in) 0.5 (0.02}
thickness EX
Valve seat IN,
STD mm (in) 0.8- 1.0 (0.03- 0.04)
contact width EX
Valve spring free STD mm (in) 22.42 (0.883)
length Limit mm (in) 21 .52 (0.847}
Valve spring tension STD N (kg, lbs) 36.5-41.9 (3.65- 4.19, 8.05- 9.24) for 15 mm (0.6 in)
Limit N (kg, lbs) 33.3 (3.33, 7.34} for 15 mm (0.6 in)
1·12 GENERAL INFORMATION

Data
Item Unit
DF2.5

CYLINDER/PISTON/PISTON RING
Cylinder distortion Limit mm (in) 0.05 (0.002)
Piston to cylinder STD mm (in) 0.018- 0.033 (0.0007- 0.0013)
clearance Limit mm (in) 0.100 (0.0039)
Cylinder bore STD mm (in) 48.000- 48.015 (1 .8898- 1.8904)
Cylinder measuring
mm (in) 20 (0.8) from cylinder top surface
position
Piston skirt
STD mm (in) 47.975-47.990 (1 .8888- 1.8894)
diameter
Piston measuring position mm (in) 5 (0.2) from piston skirt end
Cylinder bore wear Limit mm (in) 0.100 (0.0039)
Piston ring 1st, STD mm (in) 0.15 - 0.35 (0.006 - 0.014)
end gap 2nd Limit mm (in) 0.50 (0.020)
Piston ring STD mm (in) Approx. 6.1 (0.24)
1st
free end gap Limit mm (in) 4.9 (0.19)
STD mm (in) Approx. 5.7 (0.22)
2nd
Limit mm (in) 4.6 (0.18)
Piston ring to STD mm (in) 0.020- 0.060 (0.0008 - 0.0024)
1st,
groove
2nd Limit mm (in) 0.120 (0.0047)
clearance
Piston ring 1st,
STD mm (in) 1.21 - 1.23 (0.048- 0.049)
groove width 2nd
Oil STD mm (in) 1.51 - 1.53 (0.059- 0.060)
Piston ring 1st,
thickness
STD mm (in) 1.17-1.19 (0.046-0.047)
2nd
Pin clearance in STD mm (in) 0.002 - 0.013 (0.0001 - 0.0005)
piston pin hole Limit mm (in) 0.040 (0.0016)
Piston pin outside STD mm (in) 11.995- 12.000 (0.4722- 0.4724)
diameter Limit mm (in) 11.980 (0.4717)
Piston pin hole STD mm (in) 12.002- 12.008 (0.4725- 0.4728)
diameter Limit mm (in) 12.030 (0.4736)
Pin clearance in STD mm (in) 0.006- 0 .019 (0.0002 - 0.0007)
conrod small end Limit mm (in) 0.050 (0.0020)
 GENERAL INFORMATION 1-13

Data
Item Unit
DF2.5

CRANKSHAFT/CONROD
Conrod small end STD mm (in) 12.006- 12.014 (0.4727 - 0.4730)
inside diameter Limit mm (in) 12.040 (0.4740)
Conrod big end STD mm (in) 0.015- 0.035 (0.0006- 0.0014)
oil clearance Limit mm (in) 0.080 (0.0031)
Conrod big end
STD mm (in) 19.015-19.025 (0.7486-0.7490)
inside diameter
Crank pin out-
STD mm (in) 18.990- 19.000 (0.7476- 0.7480)
side diameter
Crank pin out-
side diameter
difference Limit mm (in) 0.010 (0.0004)
(out-of-round
and taper)
Conrod big end STD mm (in) 0.20-0.70 (0.008 - 0.028)
side clearance Limit mm (in) 1.00 (0.039)
Conrod big end
STD mm (in) 17.50-17.80 (0.689- 0.701)
width
Crank pin width STD mm (in) 18.00-18.20 (0.709- 0.717)
Crankshaft
Limit mm (in) 0.05 (0.002)
run out

ELECTRICAL
Ignition timing Degrees BTDC 30
Ignition coil Primary nat 20 oc 0.5-0.9
resistance Sec-
ondary
kQ at 20 oc 10-16

Spark plug cap resistance kn at 20 oc 4-6

Standard spark Type NGK CR6HSA
plug Gap mm (in) 0.6- 0.7 (0.024- 0.028)

LOWER UNIT
Preliminary gear shim & thrust washer

Pinion gear backup shim mm (in) 2.0 (0.08)

Forward gear backup
mm (in) 0.5 (0.02)
shim
Propeller shaft reverse
mm (in) 1.8 (0.07)
thrust washer
Initial selection-shim adjustment may be required .
1·14 GENERAL INFORMATION

TIGHTENING TORQUE
Tightening torque - Important fasteners
THREAD TIGHTENING TORQUE
ITEM
DIAMETER N·m kg-m lb-ft
Cylinder head cover bolt 5mm 7 0.7 5.0
Cylinder head bolt 6mm 13 1.3 9.5
Crankcase bolt 6mm 11 1.1 8.0
Con rod cap bolt 5mm 7 0.7 5.0
Valve adjusting lock nut 5mm 7 0.7 5.0
Intake pipe bolt 6mm 11 1.1 8.0
Carburetor mounting bolt 6mm 10 1.0 7.0
Flywheel nut 10 mm 45 4.5 32.5
Igniter unit bolt 6mm 10 1.0 7.0
Engine oil drain plug 10mm 10 1.0 7.0
Power unit mounting bolt 6mm 10 1.0 7.0
Tiller handle pivot bolt 8mm 17 1.7 12.5
Lower cover bolt 6mm 8 0.8 6.0
Swivel shaft nut 8mm 10 1.0 7.0
Gearcase bolt 6mm 8 0.8 6.0
Water pump case bolt 6mm 5 0.5 3.5
Propeller shaft bearing housing bolt 6mm 8 0.8 6.0

Tightening torque- General bolt

NOTE:
These value are only applicable when torque for a general bolt is not listed in the "Important fasteners" table.

THREAD TIGHTENING TORQUE

TYPE OF BOLT
DIAMETER N·m kg·m lb-ft
5mm 2-4 0.2-0.4 1.5-3.0
6mm 4-7 0.4-0.7 3.0-5.0
8mm 10-16 1.0-1.6 7.0-11.5
(Conventional or "4" marked bolt) 10mm 22-35 2.2-3.5 16.0-25.5
5mm 2-4 0.2-0.4 1.5-3.0
6mm 6-10 0.6-1.0 4.5-7.0
8mm 15-20 1.5-2.0 11.0- 14.5
(Stainless steel bolt) 10mm 34-41 3.4-4.1 24.5-29.5
5mm 3-6 0.3-0.6 2.0-4.5
6mm 8-12 0.8- 1.2 6.0-8.5
8mm 18-28 1.8-2.8 13.0-20.0
(7 marked or ....' ... marked bolt) 10mm 40-60 4.0-6.0 29.0-43.5
 GENERAL INFORMATION 1-15

SPECIAL TOOLS
1. 2. 3. 4.

09900-20530
09900-20101 (150 mm) 09900-20202 09900-20205 Cylinder gauge set
Vernier calipers Micrometer (25- 50 mm) Micrometer (0- 25 mm) (40-80 mm)
5. 6. 7. 8.

09900-20602 09900-20605 09900-20701 09900-20803

Dial gauge Dial calipers (1 0 - 34 mm) Magnetic stand Thickness gauge
9. 10. 11. 12.

09900-22301
09900-21304 Plastigauge 09900-26006 09913-50121
Steel "V" block set (0.025- 0.076 mm) Engine tachometer Oil seal remover
13. 14. 15. 16.

09915-63311
Compression gauge 09915-64512 09916-10911 09921 -2021 0
adaptor Compression gauge Valve lapper Bearing remover
1·16 GENERAL INFORMATION

17. 18. 19. 20.

09930-301 04 09930-40113 09930·40120 09930-76420

Sliding hammer Flywheel holder Rotor holder attachment Timing light
21. 22. 23. 24.

e @

09950·69512 09950-6971 0
09930-99320 Gearcase oil leakage Gear oil leakage tester 09951-09530
Digital tester tester attachment Gear adjusting gauge
25. 26. 27.

(COOP!\

09952-99310 99954·53008-820* 99954-53883*

Air pump assy Digital voltmeter Gear oil filler

NOTE:
* Marked part No. is in U.S. market DnlJL.
 GENERAL INFORMATION 1·17

MATERIALS REQUIRED
SUZUKI OUTBOARD SUZUKI WATER RESIS- SUZUKI SILICONE SEAL SUZUKI BOND " 12078"
MOTOR GEAR OIL TANTGREASE

*99104-33140
I
99000·22540 99000-25161 99000-31120 99000-31140
(400 ml x 24 pes.) {250 g) (50 g) (100 g)
THREAD LOCK " 1342" 4-STROKE MOTOR OIL

99000-32050 API: SE, SF, SG, SH, SJ

(50 g) SAE: 10W-40

NOTE:
,. Marked part No. is in U.S. market only.
 PERIODIC MAINTENANCE 2·1

PERIODIC MAINTENANCE

CONTENTS
PERIODIC MAINTENANCE SCHEDULE .......................................................2- 2
PERIODIC MAINTENANCE CHART .....................................................2- 2
MAINTENANCE AND TUNE-UP PROCEDURES .....................................•..•.2- 3
ENGINE OIL ...........................................................................................2- 3
GEAR OIL ...............................................................................................2- 5
LUBRICATION .......................................................................................2- 6
SPARK PLUG ........................................................................................2- 7
VALVE CLEARANCE ............................................................................2- 8
IDLE SPEED ...........................................................................................2-11
CARBURETOR ......................................................................................2-12
IGNITION TIMING ..................................................................................2-12
BREATHER HOSE AND FUEL LINE ....................................................2-13
FUEL FILTER .........................................................................................2-13
WATER PUMP .......................................................................................2-13
WATER PUMP IMPELLER ....................................................................2-13
PROPELLER AND PIN ..........................................................................2-14
ANODE ...................................................................................................2-14
BOLTS AND NUTS ................................................................................2-15
CYLINDER COMPRESSION ...........................................................................2-16
2·2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to
the motor operating at peak performance and economy.
Maintenance intervals should be judged number of hours or months, whichever comes first.
NOTE:
More frequent servicing should be performed on outboard motors that are used under severe conditions

PERIODIC MAINTENANCE
Initial 20 hrs. 50 hrs. Every 100 hrs. 200 hr
I
It I or 1 month or 3 months I or 6 months or 12 montll;l
Spark plug I - I
I R
Breather hose and I I I I I I
Fuel line I Replace every 2 years.
Engine oil R - I R R
Gear oil R I R R
Lubrication - I I I I
Anode I I I I
Fuel filter Replace every 400 hours or 2 years. .·.

Ignition timing I - I - - I
Carburetor I I I I
Idle speed I I - - I I
I
Valve clearance - -
Water pump - - I ...

Water pump impeller - - - R

Propeller and Pin I I - I I
Bolts and Nuts ! T ! T I T
1: Inspect and clean, adjust, lubricate or replace, if necessary T: R: Replace
 PERIODIC MAINTENANCE 2·3

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each of the
periodic maintenance requirements.

ENGINE OIL
ENGINE OIL LEVEL CHECK

1. Place the motor in a vertical position.

2. Check the oil level through the oil level inspection window
The oil should be between the upper and lower limits.

If the level is low, add the recommended oil to the upper limit.
Recommended oil:
• 4 stroke motor oil
• API classification SE, SF, SG, SH, SJ
• Viscosity rating SAE 10W-40

Perform the following steps in order to add the oil to the upper
limit
3. Remove the motor cover.
4. Remove the oil filler cap

5. Add the recommended engine oil until the oil level reaches
the upper limit.

Do not overfill, as excessive oil can damage the

engine.
6. Tighten the oil filler cap securely.
2·4 PERIODIC MAINTENANCE

ENGINE OIL CHANGE

Change initially after 20 hours (1 month) and every 100

hours (6 months) thereafter.

NOTE:
Change the engine oil while the engine is warm.

1. Place the motor in a vertical position and remove the motor

cover.
2. Remove the oil filler cap.

3. Place a container under the engine oil drain plug.

4. Remove the engine oil drain plug and the gasket in order to
drain the engine oil.

5. Install the gasket and the engine oil drain plug.

Tighten the plug to the specified torque.
Engine oil drain plug: 10 N·m (1.0 kg-m, 7.0 lb-ft)
I CAUTION I

Do not re-use the removed gasket. Always use a new

gasket.

6. Pour the recommended engine oil to the upper limit.

7. Tighten the oil filler cap securely.
Engine oil amounts: 0.38 L (0.40/0.33 US/Imp. qt)
8. Start the engine. Allow the engine to run for several minutes
at the idle speed. Check for oil leakage.
9. Turn off the engine and wait for approx. two minutes.
Re-check the engine oil level. (See page 2-3.)
 PERIODIC MAINTENANCE 2·5

GEAR OIL
Change initially after 20 hours (1 month) and every 100
hours (6 months) thereafter.

1. Place the outboard motor upright on a level surface.

2. Place a container under the lower unit.

3. Remove the gear oil drain plug CD before the gear oil level
plug (2) and drain the gear oil.

4. Fill with the recommended gear oil through the oil drain hole
until the oil just starts to flow out from the oil level hole.
Gear oil amounts: 60 ml (2.0/2.1 US/Imp. oz)
Recommended oil:
SUZUKI OUTBOARD MOTOR GEAR OIL or SAE #90
HYPOID GEAR OIL
5. Install the oil level plug before removing the oil filler tube
from the drain hole.
6. Install the oil drain plug.
I CAUTION I

Do not re-use the removed gasket. Always use a new

gasket.

NOTE:
To avoid insufficient injection of the gear oil, check the gear oil
level10 minutes after doing the procedure in the step 6. If the oil
level is low, slowly inject the gear oil up to the correct level.
2·6 PERIODIC MAINTENANCE

LUBRICATION
I Inspect every 50 hours (3 months).

Apply the Water Resistant Grease to the following points.

99000-25161: SUZUKI WATER RESISTANT GREASE

Clamp screw

f©--= c o 1

v [_ r

-rf'ijlJ
PmPBIIec •haft
 PERIODIC MAINTENANCE 2-7

SPARK PLUG
• Inspect every 100 hours (6 months).
• Replace every 200 hours (12 months).

Standard spark plug: NGK CR6HSA

:CAUTION!
Only resistor (R) type spark plugs must be used with
th.is engjne. Using a non-resistor spark plug will cause
ignition system malfunctions.

CARBON DEPOSIT
lnspectfor a carbon deposit on the spark plug bases.
If carbon is present, remove carbon with a spark plug cleaning
machine or by carefully using a pointed tool.

SPARK PLUG GAP

Measureforthe plug gap using the thickness gauge.
Adjustto within the $peciflec;l range lf the gap is out of the speci-
fication.
Spark plug gap: - 0.7 mm (0.024- 0.028 in) -= Gap
triiBti 09900-20803: Thickness gauge t
\S:
t
CONDITION OF ELECTRODE/INSULATOR
Check the electrode and insulator condition.
If the electrode is extremely worn or burnt, replace the spark
plug.
If the spark plug has a broken insulator, damaged threads, etc.,
replace the spark plug.

icAUTIONI

Confirm the thread size and reach when replacing the

plug. If the reach is too short, carbon will be deposited
on the threaded portion of the plug hole resulting in
possible engine damage.

Spark plug: 11 N·m (1.1 kg-m, 8.0 lb-ft)

2·8 PERIODIC MAINTENANCE

VALVE CLEARANCE
Inspect initially after 20 hours (1 month) and every 200
hours (12 months) thereafter.

CHECKING
1. Remove the following parts:
• Motor cover (See page 5-2)
• Recoil starter (See page 5-2)
• Spark plug

2. Remove the four bolts CD and the cylinder head

3. Rotate the flywheel clockwise to bring the piston to the Top

Dead Center (TDC) on a compression stroke.
jCAUTIONi

Rotate the crankshaft clockwise to prevent water

, pump impeller damage.

NOTE:
• To confirm whether the piston is at the TOG position on a com-
pression stroke or on a exhaust stroke, rotate the flywheel
within ±15° beyond the TOG position.
- If both rocker arms do not move at all, the piston is at the posi-
tion on a compression stroke.
- If any rocker arm moves, the piston is at the TOG position on
an exhaust stroke. Rotate the flywheel one more turn.
• The valve clearance specification is for COLD engine condi-
tion
 PERIODIC MAINTENANCE 2-9

4. Measure the valve clearance by inserting thickness gauge Valve clearance

between the valve stem end and the rocker arm.
n'foh 09900-20803: Thickness gauge
Valve clearance (cold engine condition):
IN. & EX. 0.13-0.17 mm (0.005- 0.007 in)

If the valve clearance is out of the specification, adjust the clear-

ance.

ADJUSTMENT
5. Loosen the lock nut G) while holding the adjusting screw CZ.
6. Turn the adjusting screw 12) to bring the valve clearance to
within the specification.
tr'fotl 09900-20803: Thickness gauge

7. Tighten the lock nut G) to the specified torque while holding

the adjusting screw 12).
adjusting lock nut: 7 N·m (0.7 kg-m, 5.0 lb-ft)
8. Recheck the valve clearance.
2·10 P.ERIODIC MAINTENANCE

INSTALLATION
Installation is reverse order of removal with the special attention
to the following steps.
• Tighten the four cylinder head cover bolts diagonally to the
specified torque.
Cylinder head cover bolt: 7 N·m (0. 7 kg-m, 5.0 lb-ft)

fCAUTIONI
- '_ _ _ _ .J

Do not re-use the removed gasket. Always use a new

• Make sure that the cylinder head cover gasket is installed cor-
rectly.
 PERIODIC MAINTENANCE 2·11

IDLE SPEED
Inspect initially after 20 hours (1 month) and every 200
hours (12 months) thereafter.

CHECKING
i. Check the link mechanism and the carburetor throttle valves
for smooth operation.

2. Remove the motor cover.

3. Tie a knot in the rope inside of the motor cover, in order to
prevent the rope binding onto the recoil reel when the starter
grip is off.

4. Remove the knot from the grip holder G). Remove the grip
holder and the starter grip C2).
Completely remove the motor cover.

5. Install the starter grip and the holder to the end of the rope.
6. Loosen the knot previously tied in the rope.

7. Attach the tachometer cord to the spark plug high-tension

cord.
lr'&ih 09900-26006: Engine tachometer
8. Start the engine.
9. Warm-up the engine for about 5 minutes.
10. Make sure the engine is in "NEUTRAL" and the throttle is
fully closed.
11. Check the idle speed.
Idle speed (in neutral): 1 800- 2 000 r/min
ADJUSTMENT
If engine idle speed is out of specification, adjust engine speed.
Turn the idle adjustment screw ® clockwise to increase idle
speed or counterclockwise to decrease idle speed.

CARBURETOR
Inspect initially after 20 hours (1 month) and every 100
hours (6 months) thereafter.

Inspect the body, the float chamber, the lever, the linkage, the
connector and the fuel inlet.
If crack or other damage is found, replace.

IGNITION TIMING
I Inspect every 200 hours (12 months).

NOTE:
Before checking the ignition timing, make sure that the idle
speed is adjusted within the specification.

1. Start and warm up the engine.

2. Attach the timing light cord to the spark plug high-tension
cord.
iMOh 09930-76420: Timing light
3. Check the ignition timing while operating the engine at the
idling speed.
Ignition timing: Approx. BTDC 30°
 PERIODIC MAINTENANCE 2·13

BREATHER HOSE AND FUEl liNE

• Inspect initially after 20 hours (1 month) and every
50 hours (3 months) thereafter.
• Replace every 2 years.

If leakage, crack, swelling or other damage is found, replace the

breather hose and/or the fuel line.

FUEl FILTER
J Replace every 400 hours or 2 years.

If water accumulation, sediment, leakage, crack, or other dam-

age is found, replace the fuel cock assy.

WATER PUMP
I· Inspect every 200 hQurs (12 months).
Inspect the pump case, the sleeve and the under panel.
If wear, crack, distortion or corrosion .is found, replace.

WATER PUMP IMPEllER

J Replace every 200 hours (12 months).

If cut, tear, or excessive wear is found, replace the impeller.

2·14 PERIODIC MAINTENANCE

PROPELLER AND PIN

Inspect initially after 20 hours (1 month) and every 100
hours (6 months) thereafter.

• Inspect the propeller for bent, chipped or broken blades.

If damage noticeably affects operation, replace.
• Inspect the shear pin for bent or damage.
• Make sure that the cotter pin is installed securely.

ANODE
[ Inspect every 50 hours (3 months).

If 2/3 of the anode has corroded away, replace the anode.

I Do not paint the anode.

NOTE:
Apply the silicone seal to the anode securing bolts .
.. s;sE4 99000-31120: SUZUKI SILICONE SEAL
 PERIODIC MAINTENANCE 2·15

BOLTS AND NUTS

Inspect initially after 20 hours (1 month) and every 100
hours (6 months) thereafter.

Check that all bolts and nuts listed below are tightened to the
each specified torque.

THREAD TIGHTENING TORQUE

ITEM I DIAMETER N·m kgf-m lb-ft
Cylinder head cover bolt 5mm 7 0.7 5.0
Cylinder head bolt 6mm I 13 1.3 9.5
Flywheel nut 10 mm 45 4.5 32.5
Power unit mounting bolt 6mm 10 I 1.0 7.0
I I
Swivel shaft nut I 8mm I
I
10 I
I 1.0 7.0
Gearcase bolt 6mm 8 0.8 6.0
2·16 PERIODIC MAINTENANCE

CYLINDER COMPRESSION
NOTE:
Figures shown are guidelines only, not absolute service limits.
Cylinder compression:
960-1 400 kPa (9.6 -14.0 kg/cm 2 , 137-199 psi)

Low compression pressure can indicate one or more of the fol-

lowing:
• Excessively worn cylinder wall
• Worn piston or piston rings
• Stuck piston rings
• Poor seating of valves
• Ruptured or otherwise damaged cylinder head gasket

Test procedure
i. Start and warm up the engine, then shut the engine off.
2. Remove the spark plug.
3. Install the compression gauge into the plug hole.
IMOh 09915-64512: Compression gauge
09915-63311: Compression gauge adaptor
4. Disconnect the safety lanyard from the emergency stop
switch.
A WARNING
Disconnect the safety lanyard from the emergency
stop switch prior to cranking the engine.
This will prevent any residual fuel discharged from the
cylinder from being ignited by a spark discharged
from the spark plug cap.

5. Move and hold the throttle control grip in the full-open posi-
tion.
6. While cranking the engine with the recoil starter, note the
maximum compression pressure reading on the gauge.
 IGNITION AND ELECTRICAL 3·1

IGNITION AND ELECTRICAL

CONTENTS
IGNITION SYSTEM ........................................................................................3· 2
OUTLINE .................................................................................................3- 2
IGNITION TROUBLESHOOTING ........................................................... 3- 4
INSPECTION ...........................................................................................3- 5
REMOVAL AND INSTALLATION ...........................................................3- 7
3·2 IGNITION AND ELECTRICAL

IGNITION SYSTEM
OUTUNE
A transistorized ignition system is employed on the DF2.5.
This system consists of flywheel magneto, igniter unit, spark plug and emergency/engine stop switch.

Flywheel magneto

Igniter unit

Spark plug

SPECIFICATiONS
Ignition type '1 Transistorized ignition
Ignition timing I BTDC 30°
 IGNITION AND ELECTRICAL 3-3

OPERATION
The transistorized ignition circuit will be discussed by referring to the diagram below:
When the recoil starter is pulled, the flywheel is turned. An electromotive force generated in the primary
winding (n1) of the ignition coil makes the transistor (TR1) conduct through the resistor (R1) and forms the pri-
mary circuit (indicated by dashed lines).
As the flywheel turns further, the primary current increases, and the terminal voltage of the circuit consisting
of the resistor (R,) and transistor (TR,) increases. This increases the working voltage at the connection of
the series circuit (R2 and R3) connected in parallel to the primary circuit. As the flywheel turns further, the ter-
minal voltage of the resistor (R3) in the resistor circuit (R2 and R3) rises to the level of working voltage of the
transistor (TR2) when the ignition timing approaches, and thus the transistor (TR2) is turned on. As a result,
the base current of (TR1) flowing through the resistor (R1) is by-passed, and the transistor (TR1) is turned off
from the conductive state.
The current flowing through the primary winding (n1) is thus interrupted, and a rapid change occurs in the
magnetic flux across the ignition coil. The result is a high surge voltage in the secondary winding (n2).

TRANSISTOR

EMERGENCY/
ENGINE STOP
SWITCH
 IGNIT10N AND ELECTRICAL

IGNITION TROUBLESHOOTING
Perform the following ignition system tests when the engine is hard to start in order to determine if the cause
is in the ignition or another.

START The cause will not be in the ignition

l system.

l '
Check the spark condition. I
Sparks
Check the ignition timing by using !
the timing light. [Approx. BTDC 30.] i
Not good

No or weak sparks

Check if the spark plug is in good condition. Not good

Replace the spark plug with a new one.
I (See page 2-7.)

OK
Disconnect the emergency/engine stop Sparks Check and/or replace the emergency/
I switch lead wire (Black). engine stop switch. (See page 3-6.)
No or weak sparks
Check the air gap.between the igniter unit
I core and the flywheel. Out of spec.
Adjust the air gap. (See page 3-5.)
i [Air gap: 0.5 mm]
I
Check the igniter unit resistance.
(See page.3-5.) Out of spec.
[Primary: 0.5 -<0.9 Q]
[Secondary: 10 '- 16 kQ]

OK
Check the spark plug cap for any evidence Not good
of the high-tension leak. Replace the spark plug cap.

OK

Check the spark plug cap resistance.

Out of spec.
(See page 3-5.)
[Cap resistance: 4 - 6 kQ]

OK

Replace the igniter unit.

 IGNITION AND ELECTRICAL 3·5

INSPECTION
IGNITER
Measure the resistance in the igniter unit.
I·Mill 09930-99320: Digital tester
Tester range: Q (Resistance)
1. Remove the spark plugcapfrom the high-tension cord.
2. Measure the resistance

Tester probe connection

l
Probe Other probe
Primary coil Terminal Core
Secondary coil High-tension cord Core
Primary coil resistance: 0.5 - 0.9 Q
Secondary coil resistance: 10 - 16 kQ
If the measurement is out of the specification, replace the igniter
unit.
Secondary coil

SPARK PLUG CAP

1R%h 09930-99320: Digital tester
Tester range: Q (Resistance)
Measure the spark plug cap resistance.

Tester probe connection Q

Probe Other probe
Cap end Other cap end
Spark plug cap resistance: 4- 6 kQ
If the measurement is out of the specification, replace the spark
plug cap.

IGNITER TO FlYWHEEL MAGNETO AIR GAP

Measure the air gap of between the flywheel magneto and
igniter unit.
iT'OOtl 09900-20803: Thickness gauge
Air gap: 0.5 mm (0.02 in)
3·6 IGNITION AND ElECTRICAl

EMERGENCY I ENGINE STOP SWITCH 1 . Lock plate

ir'OOtl 09930-99320: Digital tester 2.Button

Tester range: (Continuity)

Inspect the continuity of the emergency/engine stop switch.

Tester probe connection

Probe I Other probe
Black i Black
Emergency/engine stop switch continuity:
Switch condition Continuity
Lock plate IN I No
Lock plate OUT Yes
Lock plate IN & button depressed Yes

If the result is out of the specification, replace the emer-

gency/engine stop switch.
 IGNITION AND ELECTRICAL 3-7

REMOVAL AND INSTALLATION

Nut (1)
Starter pulley (1)
@ 10 N·m (1.0 kg-m, 7.0 lb-ft) @ Flywheel magneto ( 1)

(1
@Key (1)
@Bolt (2)
G) @ Igniter unit ( 1)
({) Spark plug cap (1)

(
4.5kg-m)
32.5 lb-ft
fj; ' ______
;--,-._

NOTE:
Clean the flywheel and crankshaft
mating surfaces with cleaning solvent.

REMOVAL

Prior to removing the electrical parts, disconnect the

spark plug cap from the spark plug.

1. Remove the recoil starter. (See page 5-2.)

2. Disconnect the emergency/engine stop switch lead wire
from the igniter unit.
3. Remove the two bolts securing the igniter unit.

4. Loosen the flywheel nut using the special tools.

NOTE:
Do not remove flywheel nut at this time.
This nut prevents damage to crankshaft when using flywheel
remover tools.
1Ri0h 09930-40113: Flywheel holder
09930-40120: Rotor holder attachment
3·8 IGNITION AND ELECTRICAL

5. Remove the flywheel from the crankshaft using the proper

marketing tool.
6. Remove the key from the crankshaft.

INSTALLATION
Installation is reverse order of removal with the special attention
to the following steps.

Flywheel magneto
.. Clean the flywheel and crankshaft mating surfaces with clean-
ing solvent.
'" Tighten the flywheel nut to the specified torque.
09930-40113: Flywheel holder
09930-40120: Rotor holder attachment
Flywheel nut: 45 N·m (4.5 kg-m, 32.5 lb-ft)

Igniter unit
• Install the igniter unit with an air gap of 0.5 mm between the
both core ends and the flywheel. Check the gaps at the
machining part of the flywheel as shown in the figure.
ir?otl 09900-20803: Thickness gauge
Air gap: 0.5 mm (0.02 in)
" Tighten the two igniter unit bolts to the specified torque.
(!)Igniter unit bolt: 10 N·m (1.0 kg-m, 7.0 lb-ft)
 FUELSYSTEM 4·1

FUEL SYSTEM

, . . . . . . . - - - - - - - - - - - CONTENTS -------,-----....,...-----,
PRECAUTION ON FUEL SYSTEM SERVICE ....................•... ;.................... .4-. 2
GENERAL PRECAUTION...........•.•.•.........................•...••.......•....•...........4- 2
FUEL LINE .......................................................................••.........•................•• 4._ 2
REMOVAL AND INSTALLATION ..........................•...........•....................4- 2
CARBURETORS ......................................•..............................••....................4- 5
REMOVAL AND INSTALLATION .....................................•....•....•...........4- 5
DISASSEMBLY .......................................................•.............•.............•..•4- 7
CLEANING AND INSPECTION ..............................................................4-10
REASSEMBL Y ........................................................................................4-11
FUEL TANK AND FUEL COCK ....................................................................4-13
REMOVAL ...............................................................................................4-13
INSPECTION ...........................................................................................4-14
PRECAUTION ON FUEL SYSTEM SERVICE
GENERAL PRECAUTION

Gasoline is extremely flammable and toxic. Always

observe the following precautions when working
around gasoline or servicing the fuel system.
• Keep the working area well ventilated and away from
open flame (such as gas heater) or sparks.
• Do not smoke or allow anyone else to smoke near
the working areas.
Post a "NO SMOKING" sign.
• Keep a fully charged C02 fire extinguisher and
readily available for use.
• To avoid potential fire hazards, do not allow fuel to
spill on hot engine parts or on operating electrical
components.
• Wipe up fuel spills immediately.

FUEL LINE
REMOVAL AND INSTALLATION
Pay special attention to the following steps when removing or
installing the fuel hoses.
I cAUTION I
• Do not over bend (kink) or twist the hoses when
installing.
• When installing the hose clamps (clips), position the
tabs in order to avoid contact with other parts.
• Be sure that the hoses do not contact the rods,
levers or other components with the engine either
operating or at rest.
• Use extreme care in order not to cut, abrade or
cause any other damage to the hoses.
• Use care in order not to excessively compress
hoses when tightening clamps.

NOTE:
* Check the fuel hose routing. (See page 9-2.)
* Check for fuel leakage.
 FUEL SYSTEM 4·3

2. Remove the recoil starter.

3. Turn the fuel cock lever "OFF" position.
4. Loosen the screw securing the throttle control inner cable.
5. Detach the choke rod (2) from the carburetor.

6. Remove the fuel hose from fuel cock

7. Remove the two bolts@ securing the carburetor.

8.

hose.
If cracks, swelling or other damage is found, replace the
hose.
4·4 FUEL SYSTEM

INSTALLATION
Installation is reverse order of removal with the special attention
to the following steps.
II CAUTION I'
1 Do not re-use the removed gasket. Always use a new
. gasket.
1

• Tighten the carburetor mounting bolts to the specified torque.

mounting bolt: 10 N·m (1.0 kg-m, 7.0 lb-ft)

Throttle control cable installation and adjustment

(See page 4-6.)

CHECK FOR FUEL LEAKAGE

1. Twist the air-vent screw on the fuel tank cap counter-
clockwise to open the vent.

2. Turn the fuel cock lever "ON" position.

3. Check the fuel line for leaks.

 FUEL SYSTEM 4·5

CARBURETORS

Before servicing the fuel system, read and understand

"PRECAUTION ON FUEL SYSTEM SERVICE" in the
previous section.

REMOVAL AND INSTALLATION

REMOVAL
1. Remove the motor cover.
2. Remove the recoil starter.
3. Turn the fuel cock "OFF" position.
4. Loosen the screw securing the throttle control inner cable.

5. Detach the c.hoke rod from the carburetor.

6. Remove the two bolts securing the carburetor.

Remove the carburetor assy and the silencer

7. Remove the fuel hose from the carburetor.

4-6 FUEL SYSTEM

INSTALLATION
Installation is reverse order of removal with the special attention
to the following steps.
,CAUTION!
Do not re-use the removed gasket. Always use a new
gasket.

• Tighten the carburetor mounting bolts to the specified torque.

(!]carburetor mounting bolt: 10 N·m (1.0 kg-m, 7.0 lb-ft)

Throttle control cable installation and adjustment

1. Fully close the throttle control grip.
2. Turn the idle adjusting screw counterclockwise until the
screw do not touch the stopper

3. Insert the throttle control inner cable @ into the linkage hole.
4. While pulling the cable @, tighten the screw @ in order to
secure the cable.
5. Adjust the idle speed. (See page 2-11 and 2-12.)
 FUEL SYSTEM 4·7

DISASSEMBLY

Idle adjusting screw (1)

(2) Screw (4)
--(2) Plate (1)
Main air jet (1)
Pilot air jet(1)
:':'---@ Screw (1)
(J) Pilot jet { 1)
Bolt
®Float chamber (1)
Float pin (1)
Float(1)
Float spring (1)
Needle valve (1)
Main jet(1)
Main nozzle (1)
Gasket (1)
"------@) Screw (1)
®l Spring (1)
@l Carburetor body (1)
® Float chamber gasket ( 1)
Drain screw (1)
@Spring (1)
®Gasket

1. Remove the idle adjusting screw

2. Remove the four screws and plate @.
4·8

3. Remove the main air the air and the screw

4. Remove the

5. Remove the bolt and the chamber

 fUEL SYSTEM 4·9

7. Remove the needle valve @ from the float.

8. Remove the main jet

9. Remove the main nozzle

CLEANING AND INSPECTION
with solvent and compressed air

Do not place any rubber, plastic and

solvent, as severe damage or

Do not use a wire or a small drill bit in order to clean

BODY AND FLOAT CHAMBER

the carburetor body and the float chamber. crack or
replace the body and/or the chamber.
the carburetor body and the float chamber in order to
remove obstructions.

and the nozzle. If crack or other damage is

the and/or the nozzle.
and the nozzle in order to remove obstructions.

NEEDLE VALVE
the needle valve.
or wear is replace the valve.
 FUEl SYSTEM 4·11

is reverse order disassembly with the special

attention to the steps.

MAIN JET NOZZLE

Install the main nozzle to the carburetor body before installing
the

FLOAT
1. float need valve
4·12 FUElSYSTEM

3. Install the float pin spring

NOTE:
After installing float, inspect for smooth movement of float.

CHECKING FLOAT HEIGHT

Measure the float height.
NOTE:
Make sure that float weight is not applied to needle valve.
n'Ohti 09900-20101: Vernier calipers
Float height (til: 10 :t 2 mm

PILOT JET AND AIR JET

Install the pilot jet the pilot air jet (2) and the main air jet@.
 FUELSVSTEM 4·13

FUEL TANK AND FUEL COCK

REMOVAL
1. Remove the motor cover.
2. Remove the recoil starter (See page 5-2.)

3. Turn the fuel cock lever C2> "OFF" position.

4. Remove the fuel hose @ from the fuel cock@.

5. Remove the fuel tank

6. Loosen the screw

Remove the fueLcock from the fuel tank.
4-14 FUEL SYSTEM

INSPECTION
Fuel cock
Check the filte.r:.
If clogged or damaged is found, clean the filter or replace the
fuel cock assy.
Inspect the fuel coc.k. If leakage, deterioration or other damage
is found, replace the fuel cock assy.

Fuel tank
Inspect the fuel tank. If crack, leakage or deterioration is found,
replace the tank.
If water or other contamination is found, drain and clean the
tank.

Tankca:p
Check that the fuel tank vent opens and relieves internal tank
pressure properly.
If vent is suspect, replace the tank cap.

INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
" Place the fuel tank bracket in position.

• Install the fuel and the recoil starter@.

• Check the fuel hose routing. (See page 9-2.)
• Check for fuel leakage.
 RECOIL STARTER 5·1

r------------ CONTENTS---------------,
REMOVAL .................•...................................................................................5- 2
DISASSEMBLY .............................................................................................5- 3
INSPECTION 5
REASSEMBLY ..............................................................................................5- 6
INSTALLATION .............................................................................................5- 7
5·2 . RECO.IL SIAB:tER

REMOVAL
i. Remove the motor cover.

2. Tie a knot in the rope inside of the motor cover to preventthe

rope frorn rewinding onto the recoH reel when the starter grip
is removed .

3. Remove the knot from grip holder G) .

Remove the grip holder G) and the starter grip ell.
Completely remove the motor cover.

4. lnstaiUhe starter gri p and the grip holder to the end of th e

5. Loosen the kn ot previously tied in the rope.

6. Remove the recoil starter assy.

 RECOILSTARTER 5·3

DISASSEMBlY

Because of the coiled tension in the recoil spring,

wear safety glasses and hand protection when wind-
ing or unwinding the component.

(j) Rope (1)

(1)
@ Screw {1)
@ Friction plate (1)
@ Spring (1)
@ Ratchet (1)
([1 Recoil spring (1)
@ Recoil case (l)
® Bolt (1)
(@ Bolt (2)
© Starter grip (1)
@ Grip holder (1)
5-4 RECOiL STARTER

1. Turn the reel CD clockwise in order to release the coiled ten-

sion in the recoil spring.

2. Remove the screw !.2> and the friction plate@.

NOTE:
is a left hand thread.

3. Remove the spring ® and the ratchet@.

4. Slowly remove the reel CD with the recoil :spring from the
recoil case.

5. Remove the recoH spring @ from the reel (D.

NOTE:
Do not remove the recoil spring unless replacement is neces-
sary, Inspect the spring in the assembled position.
 RECOILSJARJER 5-5

6. Remove the the reel

NOTE:
excessive wear, or other is on

springs.
is
recoil case.
or other damage is
the

replace.
REASSEMBLY
is the reverse order disassembly with the special
attention to the steps.

• on the boss in the

toward the center of the reel in a

the Resistant Grease to the recoil spring.

SUZUKI WATER RESISTANT GREASE

" Install rope

.. the and recoil spring to the recoil case align-

the inner end of the with the boss cutaway on the
case.

the ratchet
 5·7

• Install the friction

"Apply THREAD "1342" to threads of screw C2l then
the screw
NOTE:
is a left thread.
THREAD LOCK "1342"

" Rotate the reel 4 turns counterclockwise until

the recoil is tensioned.

INSTALLATION
of removal with the special attention
steps.
• Check to ensure that all removed parts are back in place.
 POWER UNIT 6·1
c '

, , POWER UNIT

POWER UNIT ................................................................................................6- 2

REMOVAL ...............................................................................................6- 2
INSTALLATION.......................................................................................6- 4
CYLINDER HEAD I VALVE I ROCKER ARM ...............................................6- 7
REMOVAL ...............................................................................................6- 7
INSTALLATION.......................................................................................6- 8
DISASSEMBLY .......................................................................................6-1 0
INSPECTION AND SERVICING .............................................................6-11
REASSEMBLY ........................................................................................6-17
CYLINDER I PISTON I CRANKSHAFT I CONROD I CAMSHAFT............... 6-18
DISASSEMBLY .......................................................................................6-18
INSPECTION AND SERVICING .............................................................6-22
REASSEMBL Y ........................................................................................6-31
THERMOSTAT ..............................................................................................6-38
REMOVAL ...............................................................................................6-38
INSPECTION ...........................................................................................6-38
INSTALLA TION....................................................................................... 6-38
OPERATION ..................................................................................................6-39
WATER COOLING SYSTEM ..................................................................6-39
ENGINE LUBRICATION SYSTEM..........................................................6-40
6·2

1.
2.

3.

5. page 3-7

7-1
7. Remove bolts.
8. Detach the

9. Remove then detach the the

cover.

Remove a
Installation is reverse order of removal the attention
to the following steps.
Install the two dowel pins and onto the drive-
housing.

Do not re-use the gasket once removed.

Always use new parts.

2. Apply the Water Resistant Grease to the driveshaft

99000-25161: SUZUKI WATER

3. Apply the Water Resistant to the seal

driveshaft oil seal.
99000-25161: WATER RESISTANT
4. Install the oil seal protector and the bolt
applying the Thread Lock to the bolt.
99000-32050: THREAD "1342"

5. Install the power unit to the lower cover, then tour

bolts to the specified
Lower cover bolt: 8 N·m 6.0
 POWER 6·5

6. cover onto the drive-

7. Silicone to the bolts

t•nr.tan the bolts to the specified

99000-31 20: SUZUKI

bolt: 10 N·m (1.0 7.0

FLYWHEEL MAGNETO
nut to

tT'OOh 09930-40113: holder

09930-40120: Rotor holder attachment
nut: 45 N·m 32.5

.. Install with an air gap of 0.5 mm between the

both core ends and the (See page 3-8.)
09900-20803: Thickness gauge
Air 0.5 mm
6·6 POWER UNIT

FINAL ASSEMBLY CHECK

Perform the following checks in order to ensure proper and safe
operation of the repaired unit.
• All parts removed have been returned to th e origin al posi-
tions .
• Lower unit gear engagement is properly adjusted.
(See page 8-19.)
• Fuel hose routing matchs service manual illustration.
(See page 9-2.)
• Wire routing matchs service manual illustration.
(See page 9-3.)
• No fuel leakage is evident.
• No water leakage is evident during final test running.
 POWER 6-7

I
1. Remove the the intake manifold and the insula-
tor

2. Remove bolts and the head cover

3. lock nuts then remove the

and the rocker arms

5. rods

6.
7. head
 attention

both

99000-31 "12078"

a new head gas-

bolts in
6. the two rods onto cam rocker arms

7. Install the rocker arms and the rocker

8. the valve clearance. 2-8

9.

cover 7 5.0
6·10 UNIT

DISASSEMBLY
the retainer

To remove the
move arrow direction off the valve shaft.

Remove the valve

each valve to their position.

3. the intake vaive and exhaust valve

valve stem seals

stem seal.
 POWERUNIT 6·11

INSPECTION AND SERVICING

NOTE:
If excessive wear, crack, defective or other damage is found on
any component, replace,

CYLINDER HEAD
1. Remove all carbon from the combustion chamber.
NOTE:
• Do not use any sharp edged tool in order to scrape carbon off
the cylinder head or the head components.
• Be careful not to scuff or nick the metal surfaces when decar·
boning.

2. Inspect the cylinder head for crack in the intake and th e

exhaust ports , the combustion chamber and the head sur-
face.

Valve seat
Inspect the valve seats for crack or other damage.

Cylinder head distortion

Using a straightedge and the thickness gauge, measure th e
gasket surface of th e cylinder head at a total of six locations as
shown in the figure.
ir'Mtl 09900-20803: Thickness gauge
Cylinder head d istortion:
Service limit: 0.05 mm (0.002 in)

lf the measurement exceeds the service limit, resurface or

replace the cylinder head.
NOTE:
The cylinder head can be resurfaced, using a surface plate and
a #400grit wet sandpaper.
Move the cylinder head in a figure eight pattern when sanding.
or
 POWER UNIT 6·13

small bore gauge, take the diameter

order to check the
at more than

diameter the micrometer.

a small bore

575- 580
clearance:

the valve

measure

2.
3. "X - measure

service the valve

 the valve stem end face for and wear. If or
the valve stem end may be resurfaced.
of stem has been worn away, the

mm
exceeds the service the valve.

the valve head radial runout.

measurement exceeds the service the valve.

the thickness of the valve head.

IN, & EX, 0.5

exceeds the service replace the valve.
 UNIT 6·15

Valve seat contact

valve seat contact width as follows.
carbon from the valve and seat.
with Prussian Blue

3. the valve into valve guide.

4. Put the on the valve head.

5. the contact area

6. Prussian
blue.
7. valve seat contact

If measurement exceeds valve seat.

NOTE:
Clean head valve compo-
nents.
Fill the intake and the exhaust with solvent order to
check leaks between the valve seat and the valve.
If any leaks occur, the valve seat and the face for burrs
or other could the valve from
VALVE SPRING
Valve spring free length
Measure the valve spring free length.
jr'ClOLi 09900-20101: Vernier
spring free length:
Standard: IN. & EX. 22.42 mm
Service IN. & EX. 21.52 mm
the measurement exceeds the service valve

spring preload
Measure the valve spring preload.
09900-201 01: Vernier
Valve spring preload:
Standard:
IN.&EX. -4.19 8.05- 9.24 lbs)
for15mm
Service
IN. & EX. 33 N

If the measurement exceeds the service replace the valve

 POWER UNIT 6-17

REASSEM
Reassembly is reverse order of disassembly with the special
attention to the following steps.
1. Apply engine oil to the valve stem seals
2. Install the valve stem seals to the valve guide.

3. Apply engine oil to the valve guide bore and valve stem.
4. Install the valve (2) to the valve guide.

5. Install the valve spring@ and the retainer

NOTE:
Reassemble each valve spring to their original position.

6. Push down the retainer with both thumbs to admit the valve
stem into the side hole of the retainer, and let it slide side-
wise into the center hole.

7. Make sure the retainers are properly seated in groove

1. Remove the power unit.
2. Remove the head.

Remove seal

crankcase

Remove the washer

cam rocker cam arm

and shaft
7. Remove the oil shaft camshaft and shaft

8. Remove the two conrod bolts and the conrod cap

9. Remove the the conrad the of the

cylinder bore.

Remove the the block.

11. Remove the circlips the the conrad :@ and

the from the
2. Remove the screw® and the oil pump outer

3. Remove the inner rotor and the outer rotor

14. Remove the four bolts and the thermostat cover

the three screws and the breather ®.

POWER UNIT 6·21
 POWER UNIT

AND SERVICING
NOTE:
If excessive wear, crack, defective or other damage is found on
any replace.

Cam face
the cam face for scratches and wear.

Cam wear
Measure the cam
iRXlt 09900-20202: Micrometer

Standard:
IN. & EX. 28.480- 28.680 mm (1.1213- 1.1291
Service limit: IN. & EX. 28.180 mm (1.1094
the measurement exceeds the service replace the cam-
shaft.

gear for wear or other damage.

it necessary.

the cam rocker arm for wear or other damage.

necessary.
 POWER UNIT 6·23

PISTON

nrc:•t"!nl.a and the thickness gauge, measure the

at a total of six locations as shown

09900-20803: gauge
distortion:
Service limit: 0.05 mm
If the measurement exceeds the service resurface or
the
NOTE:
The a surface and a
#400
when

Water
Inspect the water jackets clog or obstruction.
the water if necessary.

bore
Inspect the scratches, or
which indicate excessive wear.
If the or scratched or
and use a oversize piston.

bore in the
thrust and axial directions at the three positions and
tRiOh set
the
., Difference between the measurements at the three positions

thrust and axial measurements

exceeds the service rebore or

6·24

Piston to clearance
To check the clearance, measure the items.
• bore at 20 mm elevation the gasket surface at a
angle to the crankshaft
" Piston skirt diameter at 5 mm from the skirt end.
09900-20530: Cylinder gauge set
09900-20202: Micrometer
Piston to clearance:
Standard: 0.018-0.033 mm -0.0013

the clearance exceeds the service replace the piston

and/or the or rebore the
Cylinder bore:
Standard: 48.000- 48.015 mm (1.8898 - 1.8904
Piston skirt diameter:
Standard: 47.975 - 47.990 mm (1.8888 - 1.8894

Identification of oversize piston and piston ring

Oversize piston piston are marked as show in the
ures.
Piston

Oversize I.D. mark

0.50 mm 50

1st

1.0. mark

st. 2nd ring

spacer
 POWER UNIT 6·25

to groove clearance
the must be and free
of carbon.
Fit and measure the clear-
ance between the groove using the thickness
gauge.
IT'ooh 09900·20803: Thickness gauge
to clearance:

1st & 2nd 0.020-0.060 mm

Service limit:
1st&2nd 0.120mm
the measurement exceeds the service replace the pis-
ton and/or the
width:
Standard:
st & 2nd 1.21 -1.23 mm -0.049
Oil 1.51 -1.53 mm -0.060
Piston thickness:
Standard:
1st & 2nd 1.17 - 1.19 mm -0.047

Piston end gap

Measure the piston end the in the low-
est of the cylinder bore.
&r'OOh 09900-20803: Thickness gauge
Piston end
Standard:
1st & 2nd 0.15-0.35 mm -0.014
""'""'""'.-·"" limit:
1st & 2nd 0.50 mm
the measurement exceeds the service
tion
 free end gap
the free end gap.

9
8
If the measurement exceeds the service replace the pis-
ton

PISTON /CONROO/
Piston clearance
To check the clearance, measure the items.
outside diameter in the thrust and axial directions.
hole diameter in the thrust and axial
ir'OO'Li 09900-20205: Micrometer
09900-20605: Dial calipers
Pin clearance in piston hole:
Standard: 0.002 - 0.013 mm (0.0001 - 0.0005
Service limit: 0.040 mm (0.0016
Pin clearance conrod small end:
Standard: 0.006-0.019 mm (0.0002- 0.0007
Service limit: 0.050 mm (0.0020
lf the clearance exceeds service the piston, the
and/or the conrod assembly.
outside diameter:
Standard: 11.995- 12.000 mm (0.4722 - 0.4724
Service 11.980 mm
Piston hole diameter:
Standard: 12.002 - 12.008 mm -0.4728
Service limit: 12.030 mm
Conrod end inside
Standard: 12.006 - 12.014 mm -0.4730
 POWER UNIT 6·27

Con rod end side clearance

Measure the clearance with the conrod installed on the crank pin
as shown in the figure.
09900-20803: Thickness gauge
Conrod side clearance:
Standard: 0.20-0.70 mm (0.008- 0.028 in)
Service limit: 1.00 mm (0.039
If the measurement exceeds the service replace the con-
rod assembly crankshaft.
Conrod end
Standard: 17.50-17.80 mm (0.689- 0.701
Crank
Standard: 18.00-18.20 mm (0.709- 7

Crank
Inspect the crank for uneven wear or damage. Measure the
crank outside diameter for out-of-round or taper using the
micrometer.
Out-of-round: A - B
Taper: a- b
1.'00h 09900-20205: Micrometer
Crank pin outside diameter difference
(Out-of-round and Taper):
Service limit: 0.010 mm (0.0004 in)
If the out-of-round or the taper is exceeds the service limit,
replace the crankshaft.
Crank outside diameter:
Standard: 18.990-19.000 mm (0.7476- 0.7480
6-28 UNIT

end oil clearance

the clearance as follows.
the surface of the the conrod cap and the
crank pin.
2. Place a piece the piastigauge on the crank parallel to
the crankshaft, avoiding the oil hole.
09900-22301: Plastigauge

3. Install the conrod and the conrod cap to the crank

4. Install the two conrod bolts and bolts to the spec-
ified two steps.
NOTE:
Do not rotate the conrad with the plastigauge in place.
Conrod bolt:
st step N·m (0.35 kg-m, 2.5
2nd step 7 N·m (0.7 kg-m, 5.0

5. Remove the conrod and the conrod cap from the crank
6. the scale on the plastigauge envelop, measure the
with the widest
Conrod big end clearance:
0.15- 0.035 mm -0.0014
0.080 mm
the measurement exceeds the service limit replace the conrad
and/or crankshaft.
end inside diameter:
1 5-19.025 mm -0.7490

run out
Measure the crankshaft runout as shown in the figure.
09900-20602: Dial
run out:
Service limit: 0.05 mm
the measurement exceeds the service replace the crank-
shaft.
 6·29

in the

noisy,

NOTE:
is found on the oil seals and

removed. use a

Drive the down the as shown in

A:

C: Driveshaft

Crankcase
6·30

the rotor and the rotor plate for

excessive wear or other
it nec::essar
 UNIT 6·31

with the special

"Do
the

the bore and

2. and
insert
3. install

" Make sure that the conrad is installed in the direction shown in
the
• Install the a gap either up or down as
shown the
6·32 POWER UNIT

PISTON RING TO PISTON

ring
1. Apply engine oil to the piston rings.
2. Install the spacer CD then the side rails (ZJ to the piston.

st
oil to the piston rings. "R"
2. the 2nd and the 1st to the piston with the "R"
mark toward the head side.

I
1 1st ring 1 1st ring
differs the 2nd in shape.
the 1st from the 2nd ring by referring to the I
ure.

:2nif
1 I

so that the gaps are staggered at

angles as shown in the figure.
2nd ring
ring upper side rail

result in
6·34 POWER

CONROD CAP
1. Apply engine oil to the crank pin, the connecting rod and the
connecting rod cap

2. Install the conrad cap in the direction as shown in the

3. Apply engine oil to the conrad bolts.

4. the two conrad bolts to the specified in two
steps.
bolt:
1st step 3.5 N·m (0.35
2nd step 7 N·m kg-m, 5.0

1. Apply engine oil to the shaft

2. Install the shaft to the cylinder block.
3. oil to the cam faces, the cam and the

4. While aligning each mark on the camshaft gear and the

crankshaft install the camshaft (2).
6·34 POWER

CONROD CAP
1. Apply engine oil to the crank pin, the connecting rod and the
connecting rod cap

2. Install the conrad cap in the direction as shown in the

3. Apply engine oil to the conrad bolts.

4. the two conrad bolts to the specified in two
steps.
bolt:
1st step 3.5 N·m (0.35
2nd step 7 N·m kg-m, 5.0

1. Apply engine oil to the shaft

2. Install the shaft to the cylinder block.
3. oil to the cam faces, the cam and the

4. While aligning each mark on the camshaft gear and the

crankshaft install the camshaft (2).
 POWER 6·35

CAM ARM
1. Apply engine to the cam rocker arm shaft
2. the washer and the spring @ to the shaft as
shown in the

3. the cam rocker arm the washer and the cam

rocker arm

Be sure the cam rocker arms are positioned as shown the

ure.

PUMP
1. to the inner rotor and the outer rotor.
2. Install the inner rotor and the outer rotor C2J to the crank-
case as shown in the

to the screw
"1
5. Secure the outer with the screw
6·36 POWER

6. shaft

of the cylinder block and the

crankcase.
2. Install the and the to the
block.
3. Install the into the crankshaft.
4. oil to the crank
5. to crankcase the
seal and the driveshaft oil seal.

6. Install the crankcase the block.

7. the crankcase bolts to the specified
the order
Crankcase .1 8.0

BREATHER
and secure with
a screw.
 POWERUNIT 6-.37

2. lnstaH the gasket and breather plate (2) to the cylinder block
and secure with th e three screws.

3. Install the thermostat Q).

4. Apply sealant to both surfaces of thermostat cover gasket

(as shown with hatched lines).
SUZUKI SILICONE SEAL

5. Instal! the gasket and the thermostat cove r @ to the cylinder

block and secure with the four bolts.

CYLINDER HEAD
Install the cylinder head . (See page 6-8 and 6-9.)

POWER UNIT
In stall the power unit (See page 6-4 to 6-6.)
6-38

page 5-2.)
and the thermostat cover
3.

wear or other is clean

as
thread between the thermostat valve/body
a container filled with water.
the container and heat water.
water when the thermostat valve
opens and releases the thread.

Thermometer

Heater

removal attention to

2.

99000-31120:
3. the thermostat cover to the
der block the four bolts
 POWER 6-39

the lower the water tube the lower

. This system cools both the power and the

system must be for corrosion

........................................................ 8-8
........................................................................... 7-6
........................................... 6-38
................. '' ' ... ' .. '.' ..................... 6-11
. ''' .... ' .............. ' ...................................... 6-23

SYSTEM SCHEMATIC
6-40 POWER UNIT

ENGINE LUBRICATION SYSTEM

A camshaft driven trochoid type pump provides engine oil to all power unit components requiring lubrication.

ENGINE OIL LUBRICATION CHART

Crankshaft upper bearing Cylinder head

Cylinder block Valve train

· Connecting rod
·Piston
·Timing gear
· Lower bearing
Oil pump

Lower crankcase (Oil pan)

 MID UNIT 7·1
0' < • •

MID UNIT

, - - - - - - - - - - - - - - CONTENTS--------------,
DRIVESHAFT HOUSING/SWIVEL BRACKET/CLAMP BRACKET ............ .7- 2
DISASSEMBL Y ..................................................................................•.... 7- 2
INSPECTION ...........................................................................................7- 5
REASSEMBLY ........................................................................................ 7- 7
TILLER HANDLE ...........................................................................................l-11
REMOVAL ............................................................................................... l-11
DISASSEMBL Y/REASSEMBLY ............................................................. l-12

' '
"" ,.,_ ,.,_ ,.,_
u ' ' '

? #{ZEEt ?

' ' A
7·2 MID UNIT

DRIVESHAFT·· HOUSING/SWIVEL
BRACKET/CLAMP BRACKET
DISASSEMBLY
Remove the power unit. (See page 6-2.)
Remove th e lower unit. (See page 8-2 .)

Remove the water tube CD with the grommet upside.

Remove the spring pin @ and th e tilt lock wing nut @.

Remove the tilt lock spacer @.

Remove the swivel shaft nut@ and swivel shaft washer(/) .

Remove the port side clamp bracket ® and tilt friction washer
®.
 MID UNIT 7·3

Remove the tilt lock bolt and the thrust block with the lower
thrust mount

Remove the starboard side bracket ®, the tilt friction

washer and the swivel shaft bolt

Remove the two swivel bracket bolts

Remove the side swivel bracket

Take out the steering adjuster plate with the steering adjuster
rubber
7·4 MID UNIT

Remove the stopper bracket@.

Remove the starboard side swivel bracket@).

Take out the steering upper bush ® from the driveshaft housing
 MID UNIT 7-5

If excessive wear, defective or other is found on

any

or

is
clean or
 MID UNIT 7·7

REASSEMBLY
Reassembly is reverse order of disassembly with the special attention to the following steps.

Consisting parts

17€E

\
30

1. Swivel bracket STBD 14. Steering adjuster plate 27. Swivel shaft washer
2. Tilt friction washer 15. Clamp bracket STBD 28. Swivet shaft nut
3. Stopper spring 16. Clamp bracket PORT 29. Lower thrust mount
4. Swivel bracket PORT 17. Clamp handle/screw 30. Thrust block
5. Swivel bracket bolt 18. Clamp plate 31. Driveshaft housing knock pin
6. Steering adjuster spring 19. Clamp handle/screw cap 32 . Driveshaft housing gasket ·
7. Steering adjuster bolt 20. Swivel shaft bolt 33. Driveshaft housing bolt
8. Tilt lock spring 21. Tilt lock spacer 34. Driveshaft housing
9. Tilt lock lever 22. Tilt lock wing nut 35. Reverse thrust stopper
10. Tilt lock lever spacer 23. Tilt lock pin 36. Stopper reverse thrust bolt
11 . Tilt lock lever bolt 24. Tilt lock bolt 37. Water tube
12. Steering upper bushing 25. Stopper shaft 38. Water tube upper grommet
13. Steering adjuster rubbe r 26. Stopper bracket
 the Water

as

"
"
 MID UNIT 7·9

CLAMP BRACKETITHRUST B LOCK

• Apply the Water Resistant Grease to the clamp bracket
through swivel shaft bolt hole.
" Instal l the clamp bracket starboard side G) , the tilt friction
washer@ and the swivel shaft bolt @.
SUZUKI WATER RESISTANT GREASE

.. Install the thrust block® with the lower thrust mount and the
tilt lock bolt@ .

" Install the tilt friction washer ® and the clamp bracket port
side (f).

" Install the tilt friction washer@ and the swivel shaft nut®.
" Tighten the swivel shaft nut to th e specified torque .
shaft nut: 10 N·m (1.0 kg-m, 7.0 lb-ft)
$ Apply the Thread Lock to the swivel shaft nut.
99000-32050: THREAD LOCK "1342"

• install the tilt lock spacer ®land the tilt lock wing nut® .
.. Install the tilt lock pin ® to the tilt lock bolt.
7·10 MID UNIT

reassembly of the mid the Water

Resistant Grease
iilwtRG's] 99000-25161: WATER GREASE
 7-11

the recoil starter.

" carburetor.

cable

.
.
7·12 UNIT

" Remove the

mount and the

" cable
.. Remove the

" Take out the and case

from the
 7·13

.. the handle .

RESISTANT GREASE

"

" spacer
7·14 MID

• Install the handle washers and handle bolt

Lock to the handle bolt.

THREAD LOCK "1342"

. the handle to the specified

Tiller handle bolt: 17 N·m .7 12.5

• Install the
" Install the throttle
" from the

" the choke rod connector the carburetor

" Install choke rod the choke rod connector@.
" that the choke control from the
to
 LOWERUNIT 8·1

-. f.OWER UNIT
. ... ./ '

1 --------·---- CONTENTS---
, REMOVAL AND 0/SASSEMBLY.................................................................. B- 2 '.I

1 INSPECTION ................................................................................................. 8- 6
I
L
REASSEMBLY AND INSTALLATION ............ .............................................. B-10
LOWER UNIT GEARS-SHIMMING AND ADJUSTMENT .............................B-19
________j
I
8·2

2.

3.
rod arm

5.
hous-
 LOWER UNIT 8·3

7. Remove the gear oil drain plug ® before the gear oil level
pl ug (/) and drain the gear oil.

8. Remove the cotter pin® then detach the propeller@.

9. Remove th e shear pi n

10. Pu!i out the shift rod @ .

11. Remove the four bolts© .

12. Remove the pu mp case @.

13. Remove the following parts.

'" Water pump impeller
" Key@
• Pump under panel C:!IJ
8·4 UNIT

i4. Remove the two the

'15. Remove

16. Remove the

17. Pull out the

18.
 UNIT 8·5

19.

SHAFT

2. Push rod out the

Remove clutch

3.
8·6

other is found on

"
 8·7

..
 8·9

remover
hammer

WATER

wear, twist or other is found on

8·10 LOWER UNIT

REASSEMBLY AND INSTALLATION

Reassembly and installation is reverse of removal and disassembly with the special attention to the following
steps.

15 €SJ 5 N·m
3.5 lb-ft)

9
1 Clutch lever knob
2. Clutch lever pin
3. Clutch lever
4. Washer
I1
5. 0-ring
6. Clutch shaft bush
7. Clutch shaft bush No.2
8. Clutch rod arm
/
9. Clutch lever pin
10. Clutch notch spring
11. E-ring €gj t!J 8 N·m
12. Shift rod 0.8 kg-m)
13. 0-ring 26 ( 6.0 lb-ft
14. Water pump case grommet
15. Bolt
16. Water pump case
17. Water pump case seal
18. Water pump case sleeve
19. Water pump impeller
20. Pump case impeller pin
21. Pump case under
22. Pump case panel gasket 27
23. Bolt
28 t!J 10 N·m
24. Protection anode
25. Protection anode bolt 1.0 kg-m)
( 7.0 lb-ft
T
29
26. Driveshalt oil seal
27. Gearcase
28. Drain
29. Drain plug gasket 1.0 kg-m)
( 7.0 lb-ft
T
29
 LOWER UNIT 8·11

46

48

34

©!' 33 oE]fJ

27 38

30. Driveshaft b 37. Push rod 44. Propeller sh

31 D . ush 45. Bolt aft housing
· nveshaft 38. Return sp .
3a p nng
32. E-ring "· Shifter
40. ropelle lr shaft circlip 46. P ropeller shaft .
47. Shear pin housmg oil seal
33. Pinion gear 41 c utch dog
34. Pinion gear b 42 . Propeller shaft 48 . Propeller
35. Forward ackup shim
. Thrust wash 49. Cotter pin
36. Forward ggear backup shim 43 P . er
ear . ropelier shaft houslng . 0-ring
--
 and toler-

NOTE:
The forward has the and the dents at the side of
the bosses.

SUZUKI OUTBOARD MOTOR GEAR

8·14

., Insert rod the shaft

GREASE

., Install the
and
 UNIT 8·15

gasket.

Apply both side sealant

99000-31140: SUZUKI BOND "12078"

.. Install the
" Install the
.. the

SUZUKI BOND "12078" onto the outer-surface of water

sleeve
40: SUZUKI BOND "12078"
water pump sleeve into the water pump case
the boss on the sleeve should be
the case.

.. the water case seal

" the Water Resistant Grease to the
.. Install the
Kl WATER RESISTANT
 PAN
• Install the water pump case
clockwise in order to flex the impeller vanes in the correct
direction.
the water case bolts to the
Water case bolt: 5 N·m 3.5

Install the rod with the stepped section of the shift cam
® toward the propeller shaft.
 LOWER 8·17

the

tester

0: Attachment

sev-
test.

'2.8-

00 kPa .0 '14.2

of 11 0 kPa (1.1
result.

4. the pressure should remain for at

is correct.

shaft.
GREASE

then bend
8·18 LOWER

the Water Resistant Grease to the driveshaft splines.

Install the lower unit
99000-25161 : Kl WATER GREASE
the Silicone Seal to the gearcase retaining bolts \2) and
the bolts to the specified torque.
SEAL
6.0

• Install the shift rod to the clutch rod arm

• Install the
" install the clutch notch spring
.. Shift the clutch lever from neutral and forward to check.

Fill the gearcase with the gear oil. (See page 2-5.)
99000-22540: MOTOR GEAR
 LOWER 8·19

LOWER GEARS-SHI G
ADJ STMENT
If has been rebuilt or has had components
contact and backlash will
order to ensure smooth, reliable opera-

• lnstali the forward gear

II
the forward gear
" Install the gear shim the
gear

i
8·20

rock forward
Gear -0.008
" backlash is the thickness of the
shim must be increased.
" the thickness of shim must

the
.. To assess tooth contact, a coat of Prussian Blue
on the convex surface of the forward
" Install the shaft and the
Do not install the rod.

the propeller shaft the bolts is not

shaft inward and hold

5 - 6 times clockwise.

.. shaft and to check tooth Concave

Convex

Tooth

Tooth bottom
 LOWER UNIT 8·21

tooth contact
the Approx. 1/3 of
order to obtain the tooth width

should be checked when

the thickness of the shim to

EXAMPLE OF INCORRECT
side toe contact: Top side toe contact

shim.
gear shim thickness. f ------.-
TOE
___-/
,
I _ _...---
HEEL \

side toe contact

of the forward and

EXAMPLE OF INCORRECT
Bottom side toe contact
measures:
thickness of the forward gear shim.
shim thickness.
TOE

HEEL
 WIRE ANDHOSEROUTING 9·1

WIRE AND HOSE ROUTING

, . . - - - - - - - - - - - -- CONTENTS-------------.,
HOSE ROUTING ............................................................................................ 9- 2
WIRE ROUTING ............................................................................................ 9- 3
WIRING DIAGRAM ........................................................................................ 9- 4
9·2 WIRE AND HOSE ROUTING

HOSE ROUTING
!CAUTION !
• Do not over-bend {kink) or twist hoses when installing .
.. When installing hose clips, position tab to avoid contact with other parts.
• Check that hoses do not contact rods and levers during either engine operation or standstill.
• Extreme care should be taken not to cut, abrade or cause any other damage on hoses.
• Care should be taken not to cause hoses to be compressed excessively by any clamp when
fitted.

(])
(f)
0
J::.
Q)
:::l
LL

"""0
(,)

(,)

Q)
:::l
LL
 :e-
JJ
m
JJ
Igniter unit
0
c
-1
......
z
G)

::fE
55
m
z
0
Clamp :::t:
0
Ch
m
:::0
0
c::
::::!
z
G)

<D
l>
9·4 WIRE AND HOSE ROUTING

WIR ING DIAGRAM

IGNITER UNIT

l SPARK PLUG

FLYWHEEL
MAGNETO

BJr Wire collor

6: Black
EMERGENCY STOP AND ENGI NE STOP SWITCH
Emergency stop switch: Lock plate IN -7RUN
Lock plate OUT -;.STOP
Engine stop switch: Button pushed-7STOP
 Prepared by

SUZUKI MOTOR CORPORATION

Service Department

May, 2006
Manual No.99500-97100-0 IE
Printed in Japan

148
 TOP

OUTBOARD MOTOR

For 2008 model

SUPPLEMENTARY SERVICE MANUAL

99501-97J00-01E
Printed in Japan TK

K8

DIC563
BOTTOM
 DF2.5 “K8” (’08) MODEL 1

DF2.5 “K8” (2008) MODEL

FOREWORD
This supplementary service manual describes the outline, technical data and servicing proce-
dures for the “K8” (2008) model outboard motor.
Please read and thoroughly familiarize yourself with this information before using it for your ser-
vice activities.

NOTE:
• Use this supplement with the following service manual:
DF2.5 Service Manual (P/no, 99500-97J0 • -01E)
• This Supplementary Service Manual describes the modification for 2008 Model.

CONTENTS
GENERAL INFORMATION .................................................................... 2
SPECIFICATIONS............................................................................ 2
SERVICE DATA ............................................................................... 4
TIGHTENING TORQUE .................................................................. 8
ENGINE SERIAL NUMBER ............................................................ 9
MID UNIT ................................................................................................ 9
SWIVEL BRACKET ........................................................................ 9
TILT LOCK NUT .............................................................................. 9
LOWER UNIT .........................................................................................11
WATER PUMP IMPELLER INSTALLATION ..................................11
PROPELLER SHAFT OIL SEAL PROTECTOR .............................11
2 DF2.5 “K8” (’08) MODEL

GENERAL INFORMATION
* SPECIFICATIONS * These specifications are subject to change without notice.

Data
Item Unit
DF2.5

PRE-FIX 00251F

DIMENSIONS & WEIGHT

Overall length
mm (in) 437 (17.2): with tiller handle raised
(front to back)
Overall width
mm (in) 262 (10.3)
(side to side)
Overall height S mm (in) 963 (37.9)
Weight
S kg (lbs) 13.0 (29)
(without engine oil)
Transom height mm
S 435 (15)
(inch type)

PERFORMANCE
Maximum output kW (PS) 1.8 (2.5)
Recommended operating
r/min 5 250 – 5 750
range
Idle speed r/min 1 900 ± 100 (in-gear: approx. 1 500)

POWER HEAD
Engine type 4-stroke OHV
Number of cylinders 1
Bore mm (in) 48.0 (1.89)
Stroke mm (in) 38.0 (1.50)
Total displacement cm3 (cu. in) 68 (4.1)
Compression ratio :1 9.0
Spark plug NGK CR6HSA
Ignition system Transistorized ignition
Fuel supply system Carburetor
Exhaust system Above prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Manual
Choke system Manual
Throttle control Twist grip
 DF2.5 “K8” (’08) MODEL 3

Data
Item Unit
DF2.5

FUEL & OIL

Fuel Suzuki highly recommends that you use alcohol-free unleaded
gasoline 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.
Fuel tank capacity L
1.0 (0.26/0.22)
(Built-in tank) (US/lmp. gal)
Engine oil • API classification : SE, SF, SG, SH, SJ
or NMMA FC-W classification : SE, SF, SG, SH, SJ
• Viscosity rating : SAE 10W-40 or NMMA FC-W 10W-40
Engine oil amounts L
0.38 (0.40/0.33)
(US/lmp. qt)
Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil)
Gearcase oil amounts ml
60 (2.0/2.1)
(US/lmp. oz)

BRACKET
Trim angle Degrees 6 – 20
Number of tilt pin position 4
Maximum tilt angle 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 × Dia. × Pitch
3 × 188 mm (7-3/8 in) × 135 mm (5-3/8 in) (A510)
4 DF2.5 “K8” (’08) MODEL

* SERVICE DATA * These service data are subject to change without notice.

Data
Item Unit
DF2.5

POWER HEAD
Recommended operating
r/min 5 250 – 5 750
range
Idle speed r/min 1 900 ± 100 (in-gear: approx. 1 500)
* Cylinder compression kPa
960 – 1 400 (9.6 – 14.0, 137 – 199)
(kg/cm2, psi)
Engine oil • API classification : SE, SF, SG, SH, SJ
or NMMA FC-W classification : SE, SF, SG, SH, SJ
• Viscosity rating : SAE 10W-40 or NMMA FC-W 10W-40
Engine oil amounts L (US/lmp. qt) 0.38 (0.40/0.33)
Thermostat operating
°C (°F) 48 – 52 (118 – 126)
temperature
* Figures shown are guidelines only, not absolute service limit.

CARBURETOR
Type Walbro LMJ-26A
I.D mark LMJ-26A
Main jet # 64
Main air jet # 170
Pilot jet # 32
Pilot air jet # 145
Pilot screw Turns open Pre-set (2 ± 1/2)
Float height mm 10 ± 2

CYLINDER HEAD/CAMSHAFT
Cylinder head
Limit mm (in) 0.05 (0.002)
distortion
Cam IN, STD mm (in) 28.480 – 28.680 (1.1213 – 1.1291)
height EX Limit mm (in) 28.180 (1.1094)
Rocker
IN
arm shaft
hole STD mm (in) 4.015 – 4.027 (0.1581 – 0.1585)
diameter EX

Rocker
IN
arm shaft
outside STD mm (in) 3.990 – 4.005 (0.1571 – 0.1577)
diameter EX
 DF2.5 “K8” (’08) MODEL 5

Data
Item Unit
DF2.5

VALVE/VALVE GUIDE
Valve diameter IN mm (in) 20.0 (0.79)
EX mm (in) 18.0 (0.71)
Valve
IN STD mm (in) 0.13 – 0.17 (0.005 – 0.007)
clearance
(Cold engine
EX STD mm (in) 0.13 – 0.17 (0.005 – 0.007)
condition)
Valve seat angle IN — 45°
EX — 45°
Valve guide STD mm (in) 0.010 – 0.037 (0.0004 – 0.0015)
IN
to valve stem Limit mm (in) 0.075 (0.0030)
clearance STD mm (in) 0.025 – 0.052 (0.0010 – 0.0020)
EX
Limit mm (in) 0.090 (0.0035)
Valve guide
IN,
inside STD mm (in) 4.000 – 4.012 (0.1575 – 0.1580)
EX
diameter
Valve stem
IN STD mm (in) 3.975 – 3.990 (0.1565 – 0.1571)
outside
diameter
EX STD mm (in) 3.960 – 3.975 (0.1559 – 0.1565)

Valve stem IN,

Limit mm (in) 0.35 (0.014)
deflection EX
Valve stem IN,
Limit mm (in) 0.05 (0.002)
runout EX
Valve head IN,
Limit mm (in) 0.08 (0.003)
radial runout EX
Valve head IN,
Limit mm (in) 0.5 (0.02)
thickness EX
Valve seat IN,
STD mm (in) 0.8 – 1.0 (0.03 – 0.04)
contact width EX
Valve spring free STD mm (in) 22.42 (0.883)
length Limit mm (in) 21.52 (0.847)
Valve spring tension STD N (kg, lbs) 36.5 – 41.9 (3.65 – 4.19, 8.05 – 9.24) for 15 mm (0.6 in)
Limit N (kg, lbs) 33.3 (3.33, 7.34) for 15 mm (0.6 in)
6 DF2.5 “K8” (’08) MODEL

Data
Item Unit
DF2.5

CYLINDER/PISTON/PISTON RING
Cylinder distortion Limit mm (in) 0.05 (0.002)
Piston to cylinder STD mm (in) 0.018 – 0.033 (0.0007 – 0.0013)
clearance Limit mm (in) 0.100 (0.0039)
Cylinder bore STD mm (in) 48.000 – 48.015 (1.8898 – 1.8904)
Cylinder measuring
mm (in) 20 (0.8) from cylinder top surface
position
Piston skirt
STD mm (in) 47.975 – 47.990 (1.8888 – 1.8894)
diameter
Piston measuring position mm (in) 5 (0.2) from piston skirt end
Cylinder bore wear Limit mm (in) 0.100 (0.0039)
Piston ring 1st, STD mm (in) 0.15 – 0.35 (0.006 – 0.014)
end gap 2nd Limit mm (in) 0.50 (0.020)
Piston ring STD mm (in) Approx. 6.1 (0.24)
1st
free end gap Limit mm (in) 4.9 (0.19)
STD mm (in) Approx. 5.7 (0.22)
2nd
Limit mm (in) 4.6 (0.18)
Piston ring to STD mm (in) 0.020 – 0.060 (0.0008 – 0.0024)
1st,
groove
2nd Limit mm (in) 0.120 (0.0047)
clearance
Piston ring 1st,
STD mm (in) 1.21 – 1.23 (0.048 – 0.049)
groove width 2nd
Oil STD mm (in) 1.51 – 1.53 (0.059 – 0.060)
Piston ring 1st,
STD mm (in) 1.17 – 1.19 (0.046 – 0.047)
thickness 2nd
Pin clearance in STD mm (in) 0.002 – 0.013 (0.0001 – 0.0005)
piston pin hole Limit mm (in) 0.040 (0.0016)
Piston pin outside STD mm (in) 11.995 – 12.000 (0.4722 – 0.4724)
diameter Limit mm (in) 11.980 (0.4717)
Piston pin hole STD mm (in) 12.002 – 12.008 (0.4725 – 0.4728)
diameter Limit mm (in) 12.030 (0.4736)
Pin clearance in STD mm (in) 0.006 – 0.019 (0.0002 – 0.0007)
conrod small end Limit mm (in) 0.050 (0.0020)
 DF2.5 “K8” (’08) MODEL 7

Data
Item Unit
DF2.5

CRANKSHAFT/CONROD
Conrod small end STD mm (in) 12.006 – 12.014 (0.4727 – 0.4730)
inside diameter Limit mm (in) 12.040 (0.4740)
Conrod big end STD mm (in) 0.015 – 0.035 (0.0006 – 0.0014)
oil clearance Limit mm (in) 0.080 (0.0031)
Conrod big end
STD mm (in) 19.015 – 19.025 (0.7486 – 0.7490)
inside diameter
Crank pin out-
STD mm (in) 18.990 – 19.000 (0.7476 – 0.7480)
side diameter
Crank pin out-
side diameter
difference Limit mm (in) 0.010 (0.0004)
(out-of-round
and taper)
Conrod big end STD mm (in) 0.20 – 0.70 (0.008 – 0.028)
side clearance Limit mm (in) 1.00 (0.039)
Conrod big end
STD mm (in) 17.50 – 17.80 (0.689 – 0.701)
width
Crank pin width STD mm (in) 18.00 – 18.20 (0.709 – 0.717)
Crankshaft
Limit mm (in) 0.05 (0.002)
runout

ELECTRICAL
Ignition timing Degrees BTDC 30
Ignition coil Primary Ω at 20 °C 0.5 – 0.9
resistance Sec-
kΩ at 20 °C 10 – 16
ondary
Spark plug cap resistance kΩ at 20 °C 4–6
Standard spark Type NGK CR6HSA
plug Gap mm (in) 0.6 – 0.7 (0.024 – 0.028)

LOWER UNIT
Preliminary gear shim & thrust washer

Pinion gear backup shim mm (in) 2.0 (0.08)

Forward gear backup
mm (in) 0.5 (0.02)
shim
Propeller shaft reverse
mm (in) 1.8 (0.07)
thrust washer
Initial selection-shim adjustment may be required.
8 DF2.5 “K8” (’08) MODEL

TIGHTENING TORQUE
Tightening torque – Important fasteners
THREAD TIGHTENING TORQUE
ITEM
DIAMETER N·m kg-m lb-ft
Cylinder head cover bolt 5 mm 7 0.7 5.0
Cylinder head bolt 6 mm 13 1.3 9.5
Crankcase bolt 6 mm 11 1.1 8.0
Conrod cap bolt 5 mm 7 0.7 5.0
Valve adjusting lock nut 5 mm 7 0.7 5.0
Intake pipe bolt 6 mm 11 1.1 8.0
Carburetor mounting bolt 6 mm 10 1.0 7.0
Flywheel nut 10 mm 45 4.5 32.5
Igniter unit bolt 6 mm 10 1.0 7.0
Engine oil drain plug 10 mm 10 1.0 7.0
Power unit mounting bolt 6 mm 10 1.0 7.0
Tiller handle pivot bolt 8 mm 17 1.7 12.5
Lower cover bolt 6 mm 8 0.8 6.0
Swivel shaft nut 8 mm 10 1.0 7.0
Swivel bracket cover bolt 6 mm 8 0.8 6.01
Gearcase bolt 6 mm 8 0.8 6.0
Water pump case bolt 6 mm 5 0.5 3.5
Propeller shaft bearing housing bolt 6 mm 8 0.8 6.0

Tightening torque – General bolt

NOTE:
These value are only applicable when torque for a general bolt is not listed in the “Important fasteners” table.

THREAD TIGHTENING TORQUE

TYPE OF BOLT
DIAMETER N·m kg-m lb-ft
5 mm 2–4 0.2 – 0.4 1.5 – 3.0
6 mm 4–7 0.4 – 0.7 3.0 – 5.0
8 mm 10 – 16 1.0 – 1.6 7.0 – 11.5
(Conventional or “4” marked bolt) 10 mm 22 – 35 2.2 – 3.5 16.0 – 25.5
5 mm 2–4 0.2 – 0.4 1.5 – 3.0
6 mm 6 – 10 0.6 – 1.0 4.5 – 7.0
8 mm 15 – 20 1.5 – 2.0 11.0 – 14.5
(Stainless steel bolt) 10 mm 34 – 41 3.4 – 4.1 24.5 – 29.5
5 mm 3–6 0.3 – 0.6 2.0 – 4.5
6 mm 8 – 12 0.8 – 1.2 6.0 – 8.5
8 mm 18 – 28 1.8 – 2.8 13.0 – 20.0
(7 marked or marked bolt) 10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5
 DF2.5 “K8” (’08) MODEL 9

ENGINE SERIAL NUMBER

The engine serial number starts from the following six-figure
number located after the model pre-fix.
MODEL PRE-FIX 880001

Serial number

MID UNIT
SWIVEL BRACKET ’08 model parts
The swivel bracket assembly has been changed from right-left
division type to front-rear division type. 2
4
Interchangeability:
The early swivel bracket is interchangeable with late one as an 1
assembly.

1. Swivel bracket 3. Swivel bracket assembly

2. Swivel bracket cover 4. Securing bolt (4 pieces) 3

TILT LOCK NUT 1

The tilt lock bolt tightening nut has been changed from a wing
nut to two (2) hexagon nuts (a hexagon nut plus a self-locking
nut).
In accordance with this change, the spring pin pressed into the
tilt lock bolt has been eliminated. 2

1. Tilt lock bolt 4. Nut (’08 model)

2. Wing nut (’07 model) 5. Nut (’08 model) 4
5
3. Pin (’07 model)
10 DF2.5 “K8” (’08) MODEL

’08 model Consisting parts

13
14
12

12 5 8 N.m
0.8 kg-m 31
4 6.0 lb-ft 32
2 1 10 N.m
33
1.0 kg-m
7.0 lb-ft
20 6 38
3
15 8 7
2

24 9 11
17 10 35
27
18 28
16 10 N.m 36
1.0 kg-m
7.0 lb-ft
22 2 N.m 34
0.2 kg-m 37
21 23 1.5 lb-ft
25
8 N.m
26 0.8 kg-m
6.0 lb-ft
29
18

17
19

30

1. Swivel bracket 14. Steering adjuster plate 27. Swivel shaft washer
2. Tilt friction washer 15. Clamp bracket STBD 28. Swivel shaft nut
3. Stopper spring 16. Clamp bracket PORT 29. Lower thrust mount
4. Swivel bracket cover 17. Clamp handle/screw 30. Thrust block
5. Swivel bracket cover bolt 18. Clamp plate 31. Driveshaft housing dowel pin
6. Steering adjuster spring 19. Clamp handle/screw cap 32. Driveshaft housing gasket
7. Steering adjuster bolt 20. Swivel shaft bolt 33. Driveshaft housing bolt
8. Tilt lock spring 21. Tilt lock spacer 34. Driveshaft housing
9. Tilt lock lever 22. Nut 35. Reverse thrust stopper
10. Tilt lock lever spacer 23. Lock nut 36. Stopper reverse thrust bolt
11. Tilt lock lever bolt 24. Tilt lock bolt 37. Water tube
12. Steering upper bushing 25. Stopper shaft 38. Water tube upper grommet
13. Steering adjuster rubber 26. Stopper bracket
 DF2.5 “K8” (’08) MODEL 11

LOWER UNIT
WATER PUMP IMPELLER INSTALLATION
Before installing the impeller, apply Water Resistant grease to
the inner surface of impeller.
So that the impeller will not stick to the driveshaft.
99000-25160: SUZUKI WATER RESISTANT GREASE

PROPELLER SHAFT OIL SEAL PROTECTOR

A protector has newly been added to protect the propeller shaft Oil seal protector
oil seal.
 Prepared by

Service Department

July, 2007
Manual No.99501-97J00-01E
Printed in Japan

12
 TOP

OUTBOARD MOTOR

For 2008 model

SUPPLEMENTARY SERVICE MANUAL

99501-97J00-01E
Printed in Japan TK

K8

DIC563
BOTTOM
•
•
•
SUZUKI OUTBOARD MOTOR

0
FC1UR STROKE
 DF2.5 (Serial No. 21 0001 and later) 1

DF2.5 (Serial No. 210001 and later)

FOREWORD
This supplementary service manual describes the outline, technical data and servicing proce-
dures which differ from those of the following models.
Please read and thoroughly familiarize yourself with this information before using it for your ser-
vice activities.

•1 Applicable model and effective serial number:

00252F-21 0001 and later

NOTE:
• Use this supplement with the following service manual:
DF2.5 Service Manual (Pino, 99500-97J01-01E)

CONTENTS

GENERAL INFORMA T/ON ................................................................... 2

SPEC/FICA TIONS........................................................................... 2
SERVICE DATA.............................................................................. 4
( PERIODIC MAINTENANCE .................................................................. 10
PERIODIC MAINTENANCE SCHEDULE ...................................... 10
MAINTENANCE AND TUNE-UP PROCEDURES ......................... 11
IGNITION AND ELECTRICAL .............................................................. 12
IGNITION SYSTEM ........................................................................ 12
FUEL SYSTEM (For US market) ......................................................... 13
FUEL PUMP ................................................................................... 13
VACUUM HOSE AND JET ............................................................ 14
FUEL HOSE ROUTING ..................................................(............... 14
LOWER UNIT ........................................................................................ 15
LOWER UNIT COMPONENTS ...................................................... 15
( PROPELLER .................................................................................. 16
PROPELLER SHAFT COMPONENTS .......................................... 17
DR/VESHAFT OIL SEALS .........: .......,........................................... 19
WIRE ROUTING..................................................................................... 20
(
2 DF2.5 (Serial No. 21 0001 and later)

GENERAL INFORMATION
*SPECIFICATIONS *These specifications are subject to change without notice.

Data
Item Unit
DF2.5

PRE-FIX 00252F

DIMENSIONS & WEIGHT

Overall length
mm (in) 437 (17.2): with tiller handle raised
(front to !!Jack)
Overall width
mm (in) 262 (10.3)
(side to side)
Overall height s mm (in) 963 (37.9)
Weight
(without engine oil)
s kg (lbs) 13 (28.7)

Transom height mm
s (inch type)
435 (15)

PERFORMANCE
Maximum output kW (PS) 1.8 (2.5)
Recommended operating
r/min 5 250-5 750
range
Idle speed r/min 1 900 ± 100 (in-gear: approx. 1 500)

POWER HEAD
Engine type 4-stroke OHV
Number of cylinders 1
Bore mm (in) 48.0 (1.89)
Stroke mm (in) 38.0 (1.50)
Total displacement cm 3 (cu. in) 68(4.1)
Compression ratio :1 9.0
Spark plug NGK CR6HSA
Ignition system SUZUKI PEl (Digital CDI)
Fuel supply system Carburetor
Exhaust system · Above prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Manual
Choke system Manual
Throttle control Twist grip
 DF2.5 (Serial No. 21 0001 and later) 3

Data
Item Unit
DF2.5

FUEL & OIL

Fuel Suzuki highly recommends that you use alcohol-free unleaded
gasoline 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.
Fuel tank capacity L
1.0 (0.26/0.22)
(Built-in tank) (US/Imp. gal)
Engine oil • API classification : SG, SH, SJ, SL, SM
or NMMA FC-W classification : SG, SH, SJ, SL, SM
• Viscosity rating : SAE 1OW-40 or NMMA FC-W 1OW-40
Engine oil amounts L
0.38 (0.40/0.33)
(US/Imp. qt)
Gear oil SUZUKI Outboard Motor Gear Oil
(Hypoid gear oil SAE90, API classification GL-5)
Gearcase oil amounts ml
70 (2.4/2.5)
(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
Drive line impact protection Spline drive rubber hub
( Propeller Blade x Dia. X Pitch (ID No.)
3 X 188 mm (7-3/8 in) X 135 mm (5-3/8 in) (A520)

(
4 DF2.5 (Serial No. 21 0001 and later)

* SERVICE DATA .. These service data are subject to change without notice.

Data
Item Unit
DF2.5

POWER HEAD
Recommended operating
r/min 5 250-5 750
range
Idle speed r/min 1 900 ± 100 (in-gear: approx. 1 500)
.. Cylinder compression kPa
• I 960-1 400 (9.6 -14.0, 137 -199)
(kg/cm 2 , psi)
Engine oil • API classification: SG, SH, SJ, SL, SM
or NMMA FC-W classification: SG, SH, SJ, SL, SM
• Viscosity rating : SAE 1OW-40 or NMMA FC-W 1OW-40
Engine oil amounts L (US/Imp. qt) 0.38 (0.40/0.33)
Thermostat operating
.
oc (oF) 48- 52 (118- 126)
temperature
.. Figures shown are guidelines only, not absolute service limit.

CARBURETOR
For all markets except for US market

Type Walbro LMJ-268

I.D mark LMJ-268
Main jet # 62
Main air jet # 140
Pilot jet # 34
Pilot air jet # 135
Pilot screw Turns open Pre-set (1-7/8 ± 1/2)
Float height mm 10 ± 2

For US market

Type Walbro LMJ-48

I.D mark LMJ-48
Main jet # 62
Main air jet # 135
Pilot jet # 34
Pilot air jet # 145
Pilot screw Turns open Pre-set (1-7/8 ± 1/2)
Float height mm 10 ± 2
 DF2.5 (Serial No. 210001 and later) 5

Data
Item Unit
DF2.5

CYLINDER HEAD/CAMSHAFT
Cylinder head
( Limit mm (in) 0.05 (0.002)
distortion
Cam IN, STD mm (in) 28.480-28.680 (1.1213-1.1291)
height EX Limit mm (in) 28.180 (1.1094)
Rocker
IN
arm shaft
( hole
f--- STD mm (in) 4.015- 4.027 (0.1581 - 0.1585)
diameter EX
Rocker
IN
arm shaft
outside - STD. mm (in) 3.990 - 4.005 (0.1571 - 0.1577)
diameter EX

(
6 DF2.5 (Serial No. 21 0001 and later)

Data
Item Unit
DF2.5

VALVENALVE GUIDE
Valve diameter IN mm (in) 20.0 (0.79)
EX mm (in) 18.0 (0.71)
Valve
IN STD mm (in) 0.13- 0.17 (0.005 - 0.007)
clearance
(Cold engine
EX STD mm (in) 0.13- 0.17 (0.005 - 0.007)

Valve seat angle IN - 45°

EX - 45°
Valve guide STD mm (in) 0.010 - 0.037 (0.0004- 0.0015)
IN
to valve stem Limit nim (in) 0.075 (0.0030)
clearance STD mm (in)
. 0.025 - 0.052 (0.001 0- 0.0020)
EX
Limit mm (in) 0.090 (0.0035)
Valve guide
IN,
inside STD mm (in) 4.000-4.012 (0.1575- 0.1580)
EX
diameter
Valve stem
IN STD mm (in) 3.975- 3.990 (0.1565 - 0.1571)
outside
diameter
EX STD mm (in) 3.960-3.975 (0.1559- 0.1565)

Valve stem IN,

Limit mm (in) 0.35 (0.014)
deflection EX
Valve stem IN,
Limit mm (in) 0.05 (0.002)
run out EX
Valve head IN,
Limit mm (in) 0.08 (0.003)
radial runout EX
Valve head IN,
Limit mm (in) 0.5 (0.02)
thickness EX
Valve seat IN,
STD mm (in) 0.8- 1.0 (0.03- 0.04)
contact width EX
Valve spring free STD mm (in) 22.8 (0.90)
length Limit mm (in) 21.9 (0.86)
Valve spring tension STD N (kg, lbs) 36.05- 42.85 (3.61 - 4.29, 8.0- 9.5) for 16.9 mm (0.67 in)
Limit N (kg, lbs) 33.53 (3.35, 7.39) for 16.9 mm (0.67 in)
 DF2.5 (Serial No. 21 0001 and later} 7

Data
Item Unit
DF2.5

CYLINDER/PISTON/PISTON RING
Cylinder distortion Limit mm (in) 0.05 (0.002)
Piston to cylinder STD mm (in) 0.018 - 0.033 (0.0007- 0.0013)
clearance Limit mm (in) 0.100 (0.0039)
Cylinder bore STD mm (in) 48.000-48.015 (1.8898- 1.8904)
Cylinder measuring
mm (in) 20 (0.8) from cylinder top surface
( Piston skirt
STD mm (in) 47.975- 47.990 (1.8888- 1.8894)
diameter
Piston measuring position mm (in) 5 (0.2) from piston skirt end
Cylinder bore wear Limit mm (in) 0.100 (0.0039)
Piston ring 1st, STD mm (in) 0.15- 0.35 (0.006- 0.014)
end gap 2nd Limit mm (in) 0.50 (0.020)
Piston ring STD mm (in) Approx. 6.1 (0.24)
1st
free end gap Limit mm (in) 4.9 (0.19)
STD mm (in) Approx. 5.7 (0.22)
2nd
Limit mm (in) 4.6 (0.18)
Piston ring to STD mm (in) 0.020- 0.060 (0.0008- 0.0024)
1st,
groove
2nd Limit mm (in) 0.120 (0.0047)
clearance
Piston ring 1st,
STD mm (in) 1.21 - 1.23 (0.048- 0.049)
groove width 2nd
Oil STD mm (in) 1.51 - 1.53 (0.059- 0.060)
Piston ring 1st,
STD mm (in) 1.17- 1.19 (0.046- 0.047)
thickness 2nd
Pin clearance in STD mm (in) 0.002- 0.013 (0.0001 - 0.0005)
piston pin hole Limit mm (in) 0.040 (O.OQ16)
Piston pin outside STD mm (in) 11.995- 12.000 (0.4722- 0.4724)
diameter Limit mm (in) 11.980 (0.4717)
Piston pin hole STD mm (in) 12.002- 12.008 (0.4725- 0.4728)
diameter Limit mm (in) 12.030 (0.4736)
Pin clearance in STD mm (in) .0.006- 0.019 (0.0002- 0.0007)
conrod small end Limit mm (in) 0.050 (0.0020)

(
8 DF2.5 (Serial No. 210001 and later)

Data
Item Unit
DF2.5

CRANKSHAFT/CONROD
Conrod small end STD mm (in) 12.006-12.014 (0.4727- 0.4730)
inside diameter Limit mm (in) 12.040 (0.4740)
Conrod big end STD mm (in) 0.020 - 0.040 (0.0008 - 0.0016)
oil clearance Limit mm (in) 0.080 (0.0031)
Conrod big end
STD mm (in) 19.015-19.025 (0.7486- 0.7490)
inside dicimeter
Crank pin out-
STD mm (in) 18.985-18.995 (0.7474- 0.7478)
side diameter
Crank pin out- '

side diameter
difference Limit mm (in) . 0.010 (0.0004)
(out-of-round
and taper)
Conrod big end STD mm (in) 0.20 - 0. 70 (0.008 - 0.028)
side clearance Limit mm (in) 1.00 (0.039)
Conrod big end
STD mm (in) 17.50- 17.80 (0.689 - 0. 701)
width
Crank pin width STD mm (in) 18.00-18.20 (0.709- 0.717)
Crankshaft
Limit mm (in) 0.05 (0.002)
runout

ELECTRICAL
For all markets except for US market
Ignition timing Degrees BTDC 31
Ignition coil Sec-
resistance ondary
k.Q at 20 oc 2.0-2.5

Spark plug cap resistance k.Q at 20 oc 4-6

Standard spark Type NGK CR6HSA
plug Gap mm (in) 0.6- 0.7 (0.024- 0.028)

For US market
Ignition timing Degrees at
BTDC 5 at 2000 - BTDC 31 at 4000
r/min
Ignition coil Sec-
resistance ondary
k.Q at 20 oc 2.0-2.5

Spark plug cap resistance k.Q at 20 oc 4-6

Standard spark Type NGK CR6HSA
plug Gap mm (in) 0.6-0.7 (0.024- 0.028)
 DF2.5 (Serial No. 21 0001 and later) 9

Data
Item Unit
DF2.5

LOWER UNIT
Preliminary gear shim & thrust washer

Pinion gear backup shim mm (in) 2.0 {0.08)

Forward gear backup
mm (in) 0.5 {0.02)
shim
Propeller shaft reverse
mm (in) 1.8 (0.07)
thrust washer
( Initial selection-shim adjustment may be required.

(
10 DF2.5 (Serial No. 21 0001 and later)

PERIODIC MAINTENANCE
Service item has been added, and additional item is "Anodes (internal power head)".

PERIODIC MAINTENANCE SCHEDULE

PERIODIC MAINTENANCE CHART
Initial 20 hrs. Every 50 hrs. Every 100 hrs. Every 200 hrs.
I
lte or 1 month or 3 months or 6 months or 12 months
Spark plug - - I R
BreatherI hose and
I
I I I I
Fuel line (
Engine oil R - R R
Gear oil R - R R
Lubrication - I I I
Anode (external) - I I I
Anodes (internal
- - I I
power head)
Fuel filter Replace every 400 hours or 2 years.
Ignition timing - - - I
Carburetor I - I I
Idle speed I - - I
Valve clearance I - - I
Water pump - - - I
Water pump impeller - - - R
Propeller nut & pin I - I I
Bolts and Nuts T - T T
1: Inspect and clean, adjust, lubricate or replace, if necessary T: Tighten R: Replace
 DF2.5 (Serial No. 21 0001 and later) 11

MAINTENANCE AND TUNE-UP PROCEDURES

GEAR OIL 0 0

OUTLINE Gear oil level

• The position of gear oil level plug has been changed. \iB
==-
plug
• Service procedure is same as previous model.
(

I I
(
PROPELLER/NUT/COTTER PIN
OUTLINE
The propeller has been changed from shear pin type to spline
drive rubber hub type.

Inspect initially after 20 hours (1 month) and every

100 hours (6 months).

• Inspect the propeller for bent, chipped or broken blades.

If damage noticeably affects operation, replace.
• Inspect propeller spli.nes. Replace propeller if splines are
worn, damaged or twisted.
( • Inspect propeller bush for slippage.
Replace if necessary.
• Make sure that the propeller nut is tightened.
• Make sure that the cotter pin is installed securely.

NOTE:
Install the propeller bush stopper to the propeller shaft as its
chamfered side faces to the gear case.

(
12 DF2.5 (Serial No. 210001 and later)

IGNITION AND ELECTRICAL

OUTLINE
The ignition system has been changed from transistorized ignition to digital CDI.
In accordance with this change, the flywheel and'the igniter unit have been changed.

IGNITION SYSTEM
IGNITION TIMING ADVANCE (Late type)
For all markets except for US market
IIgnition advance Approx. 31 o BTDC at 2000-4000 r/min
(

For US market
IIgnition timing advance . 5° BTDC at 2000 r/min- 31 o BTDC at 4000 r/min

INSPECTION
IGNITION SECONDARY COIL RESISTANCE
Measure the secondary coil resistance in the igniter unit.
i.:OOh 09930-99320: Digital tester
Tester range: Q (Resistance)
1. Remove the spark plug cap !rom the high-tension cord.
2. Measure the secondary coil resistance.

Tester probe connection

Probe Other probe
High-tension cord Core

Ignition secondary coil resistance : 2.0- 2.5 kQ

If the measurement is out of the specification, replace the igniter
unit.

IGNITER TO FLYWHEEL MAGNETO AIR GAP

Measure the air gap of between the flywheel magneto and
igniter unit.
i.:OOh 09900-20803: Thickness gauge
Air gap: 0.5 mm (0.02 in)
 DF2.5 (Serial No. 21 0001 and later) 13

FUEL SYSTEM (For US market)

OUTLINE
A fuel pump has been added. This is a diaphragm type and
operated by pulsation inside the intake manifold.

A WARNING
Before servicing the fuel system, read and understand
"PRECAUTION ON FUEL SYSTEM SERVICE" in the
DF2.5 service manual ( P/no., 99500-97J01-01E).

FUEL PUMP
NOTE:
The fuel pump is a non-repairable component.
Do not attempt to disassemble the fuel pump. It must be
replaced as a complete unit if it is defective.
REMOVAL
1. Disconnect the inlet hose G), outlet hose @ and vacuum
hose @ from fuel pump.
2. Remove the two bolts @ securing fuel pump.
3. Remove the fuel pump @ .

INSPECTION
Inspect the fuel pump. If crack or other damage is found, replace
the fuel pump.

INSTALLATION
Installation is reverse order of removal with the special attention
to the following step.
( • Tighten the fuel pump mounting bolts to the specified torque.
Fuel pump mounting bolt: 6 N·m (0.6 kg-m, 4.5 lb-ft)
14 DF2.5 (Serial No. 210001 and later)

VACUUM HOSE AND JET

Inspect the vacuum hose CD.
• If cracks, swelling or other damage is found, .replace the fuel
hose.
• If clogged is found, clean the hose and the jet.

I I

FUEL HOSE ROUTING

VIEW A

VIEWB
 DF2.5 (Serial No. 21 0001 and later) 15

LOWER UNIT
OUTLINE
The lower unit for DF2.5 has been newly designed.
The new one has been made based on 'the early one, but the
contents of change are many as follows.

LOWER UNIT COMPONENTS

I I

14

13

12

11
10

1. Gear case 9. Push rod 17. Propeller shaft bearing housing

2. Oil seal 10. Return spring 18. Bolt
3. Driveshaft 11 . Shifter clutch dog 19. Propeller bush stopper
4. E-ring 12. Propeller shaft 20. Propeller bush
5. Pinion 13. Thrust washer 21. Propeller
6. Pinion backup shim 14. 0-ring 22. Propeller nut
7. Forward gear backup shim 15. Bearing 23. Cotter pin
8. Forward gear 16. Oil seal
16 DF2.5 (Serial No. 210001 and later)

PROPELLER
A WARNING
• When installing or removing the propeller, shift into
"Neutral" and remove the emergency stop switch
lock plate so that the motor cannot be started acci-
dentally.
• To prevent injury from propeller blades, wear gloves
and place a block of wood between the anti-cavita-
tion plate and the propeller blade tips to lock the
in place before attempting to remove or
install propeller nut.

REMOVAL
1. Remove the cotter pin and the propeller nut, then detach the
propeller.

2. Remove the propeller bush stopper.

INSPECTION
• Inspect the propeller for bent, chipped or broken blades.
Replace or repair propeller if in damaged condition .
• Inspect propeller bush splines. Replace or repair propeller if.
splines are worn or damaged.
• Inspect propeller bush for deterioration or slipping.
Replace if necessary.
 DF2.5 (Serial No. 210001 and later) 17

INSTALLATION
• Apply the Water Resistant Grease to the propeller shaft.
•wJRG·a 99000-25350 : Suzuki Water Resi$tant Grease
• Push the cotter pin through the nut and propeller shaft, then
bend the pin securely.

tOWER UNIT
Disassembly and reassembly procedures of the lower unit are
basically the same as previous model except for the following.

PROPELLER SHAFT COMPONENTS

Removal and installation procedures of the propeller shaft com-
ponents are basically the same as previous model.

DISASSEMBLY OF PROPELLER SHAFT COMPONENTS

1. Remove the push rod CD from propeller shaft.
2. Slide the propeller away from bearing housing ®.
Remove the washer @, spring @ and clutch dog shifter @.
18 DF2.5 (Serial No. 21 0001 and later)

INSPECTION
NOTE:
If excessive wear, crack, defective or other damage is found on
any component, replace. ·
• Inspect the push rod. If excessive wear or other damage is
found, replace.
• Inspect the clutch dog shifter. If excessive wear, crack, chip or
other damage is found, replace.
• Inspect the return spring. If excessive wear or other damage
is replace.
(

• Inspect the propeller shaft. If. excessive wear, twist or other

damage is found, replace

REASSEMBLY OF PROPELLER SHAFT COMPONENTS

• Reassemble propeller shaft components with reverse order of
disassembly.
• Apply the Water Resistant Grease to the 0-ring CD and the oil
seals of the bearing housing .
• 99000-25350: SUZUKI WATER RESISTANT GREASE
NOTE:
When installing the propeller shaft/housing assembly to the gear
case, hold the clutch dog shifter the horizontal to prevent clutch
dog shifter dropping out.
 DF2.5 (Serial No. 21 0001 and later) 19

DRIVESHAFT OIL SEALS

INSPECTION
• Visually check the oil seals. If cut, niGk, excessive wear or
other damage is found, replace the oil seals .

• -1

REPLACING DRIVESHAFT OIL SEALS

1. Remove the two oil seals using special tools.
i.ffidt! 09921-20200:Bearing remover
09930-30104: Sliding hammer

ICAUTION I
Do not re-use oil seal once removed.
Always use a new oil seal.

2. Apply the Water Resistant Grease to outer circumference of

the oil seals.
99000-25350: SUZUKI WATER RESISTANT GREASE

3. Drive the two oil seals (one at a time) into the gearcase. Direction of

•
The lipped portion of seal should face towards water pump water pump case

case.

ICAUTION I
When installing oil seals, prevent the oil seal from
closing oil passage.

4. Apply the Water Resistant Grease to the seal lips .

• wiRG's] 99000-25350: SUZUKI WATER RESISTANT

(
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u..
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CD

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-z 0

-
g

-.,...
lgoite• Uolt , Igniter unit - C) I»
::::J

-
D.
iii"
0 CD

Cyliode• Block__/
View A
Spacer
-m
3
...
m

-
"
CD
tn
CD
><

-...
n
CD
"C
.....
0
c
(/)

3
...m
-
"-
CD

Emergency stop and

engine stop switch
 ..----.. ,...-... --... ..---....

-==JJ
m
JJ
0
c:
-z-1
Igniter unit

-
C)
Spacer Clamp
Cyllodec Block__/ " " -
View A "T1
0..,
c
en
3
..,
I»

s
-

c
Fuel pump bracket
(n
en
Emergency stop and
engine stop switch
...
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et
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I
I I

Prepared by

SUZUKI MOTOR CORPORATION

Outboard Motor Engineering Department

March, 2012
Manual No.99501-97J20-01E
Printed in Japan

24
 OUTBOARD MOTOR

SUPPLEMENTARY SERVICE MANUAL

Applicable model and effective serial number:

00252F-410001 and later

Use this supplement with the following service manuals:
DF2.5 Service Manual (P/no., 99500-97J01-01E)
DF2.5 Supplementary Service Manual (P/no., 99501-97J20-01E)

99501-97J30-01E
Printed in Japan TK
 DF2.5 (Serial No. 410001 and later) 1

DF2.5 (Serial No. 410001 and later)

FOREWORD
This supplementary service manual describes the outline, technical data and servicing proce-
dures for the following models.
Please read and thoroughly familiarize yourself with this information before using it for your ser-
vice activities.

Applicable model and effective serial number:

00252F-410001 and later

NOTE:
• Use this supplement with the following service manuals:
DF2.5 Service Manual (P/no, 99500-97J01-01E)
DF2.5 Supplementary Service Manual (P/no, 99501-97J20-01E)

CONTENTS
GENERAL INFORMATION .................................................................... 2
SPECIFICATIONS ........................................................................... 2
SERVICE DATA .............................................................................. 4
PERIODIC MAINTENANCE .................................................................. 10
PERIODIC MAINTENANCE SCHEDULE ...................................... 10
MAINTENANCE AND TUNE-UP PROCEDURES ................................ 11
IGNITION TIMING (For all markets except for US market) ........ 11
THERMOSTAT ............................................................................... 12
IGNITION AND ELECTRICAL .............................................................. 15
CARBURETOR (For all markets except for US market) ................... 16
REASSEMBLY ............................................................................... 16
FUEL TANK AND FUEL COCK
(For all markets except for US market) .............................................. 17
2 DF2.5 (Serial No. 410001 and later)

GENERAL INFORMATION
* SPECIFICATIONS * These specifications are subject to change without notice.

Data
Item Unit
DF2.5

PRE-FIX 00252F

DIMENSIONS & WEIGHT

Overall length
mm (in) 437 (17.2): with tiller handle raised
(front to back)
Overall width
mm (in) 262 (10.3)
(side to side)
Overall height S mm (in) 962 (37.9)
Weight
S kg (lbs) 14 (30.9)
(without engine oil)
Transom height mm
S 435 (15)
(inch type)

PERFORMANCE
Maximum output kW (PS) 1.8 (2.5)
Recommended operating
r/min 5 250 – 5 750
range
Idle speed r/min 1 900 ± 100 (in-gear: approx. 1 500)

POWER HEAD
Engine type 4-stroke OHV
Number of cylinders 1
Bore mm (in) 48.0 (1.89)
Stroke mm (in) 38.0 (1.50)
Total displacement cm3 (cu. in) 68 (4.1)
Compression ratio :1 9.0
Spark plug NGK CR6HSA
Ignition system SUZUKI PEI (Digital CDI)
Fuel supply system Carburetor
Exhaust system Above prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Manual
Choke system Manual
Throttle control Twist grip
 DF2.5 (Serial No. 410001 and later) 3

Data
Item Unit
DF2.5 (P01) DF2.5 (P03)

FUEL & OIL

Fuel Suzuki highly recommends the use alcohol-free unleaded gas-
oline 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.
Fuel tank capacity L
0.9 (0.24/0.20) 1.0 (0.26/0.22)
(Built-in tank) (US/lmp. gal)
Engine oil • API classification : SG, SH, SJ, SL, SM
or NMMA FC-W classification : SG, SH, SJ, SL, SM
• Viscosity rating : SAE 10W-40, 10W-30 or
NMMA FC-W : 10W-40, 10W-30
Engine oil amounts L
0.38 (0.40/0.33)
(US/lmp. qt)
Gear oil SUZUKI Outboard Motor Gear Oil or SAE 90
hypoid gear oil, API classification GL-5.
Gearcase oil amounts ml
70 (2.4/2.5)
(US/lmp. oz)

BRACKET
Trim angle Degrees 6 – 20
Number of tilt pin position 4
Maximum tilt angle Degrees 74 (from lowest tilt pin position)

LOWER UNIT
Reversing system Gear
Transmission Forward-Neutral
Reduction system Bevel gear
Gear ratio 13 : 28 (2.154)
Drive line impact protection Spline drive rubber hub
Propeller Blade × Dia. × Pitch (ID No.)
3 × 188 mm (7-3/8 in) × 135 mm (5-3/8 in) (A520)

NOTE:
P01: Model designated for regions other than USA and Canadian market.
P03: Model designated for USA and Canadian market.
4 DF2.5 (Serial No. 410001 and later)

* SERVICE DATA * These service data are subject to change without notice.

Data
Item Unit
DF2.5

POWER HEAD
Recommended operating
r/min 5 250 – 5 750
range
Idle speed r/min 1 900 ± 100 (in-gear: approx. 1 500)
* Cylinder compression kPa
960 – 1 400 (9.6 – 14.0, 137 – 199)
(kg/cm2, psi)
Engine oil • API classification : SG, SH, SJ, SL, SM
or NMMA FC-W classification : SG, SH, SJ, SL, SM
• Viscosity rating : SAE 10W-40, 10W-30 or
NMMA FC-W : 10W-40, 10W-30
Engine oil amounts L (US/lmp. qt) 0.38 (0.40/0.33)
Thermostat operating
°C (°F) 48 – 52 (118 – 126)
temperature
* Figures shown are guidelines only, not absolute service limit.

CARBURETOR
For all markets except for US market

Type Walbro LMJ-57

I.D mark LMJ-57
Main jet # 62
Main air jet # 160
Pilot jet # 35
Pilot air jet # 95
Pilot screw Turns open Pre-set (2-5/8 ± 3/4)
Float height mm 14.3 ± 2

For US market

Type Walbro LMJ-48

I.D mark LMJ-48A
Main jet # 62
Main air jet # 135
Pilot jet # 34
Pilot air jet # 145
Pilot screw Turns open Pre-set (2-3/4 ± 1/2)
Float height mm 15.4 ± 2
 DF2.5 (Serial No. 410001 and later) 5

Data
Item Unit
DF2.5

CYLINDER HEAD/CAMSHAFT
Cylinder head
Limit mm (in) 0.05 (0.002)
distortion
Cam IN, STD mm (in) 28.480 – 28.680 (1.1213 – 1.1291)
height EX Limit mm (in) 28.180 (1.1094)
Rocker
IN
arm shaft
hole STD mm (in) 4.015 – 4.027 (0.1581 – 0.1585)
diameter EX

Rocker
IN
arm shaft
outside STD mm (in) 3.990 – 4.005 (0.1571 – 0.1577)
diameter EX
6 DF2.5 (Serial No. 410001 and later)

Data
Item Unit
DF2.5

VALVE/VALVE GUIDE
Valve diameter IN mm (in) 20.0 (0.79)
EX mm (in) 18.0 (0.71)
Valve
IN STD mm (in) 0.13 – 0.17 (0.005 – 0.007)
clearance
(Cold engine
EX STD mm (in) 0.13 – 0.17 (0.005 – 0.007)
condition)
Valve seat angle IN — 45°
EX — 45°
Valve guide STD mm (in) 0.010 – 0.037 (0.0004 – 0.0015)
IN
to valve stem Limit mm (in) 0.075 (0.0030)
clearance STD mm (in) 0.025 – 0.052 (0.0010 – 0.0020)
EX
Limit mm (in) 0.090 (0.0035)
Valve guide
IN,
inside STD mm (in) 4.000 – 4.012 (0.1575 – 0.1580)
EX
diameter
Valve stem
IN STD mm (in) 3.975 – 3.990 (0.1565 – 0.1571)
outside
diameter
EX STD mm (in) 3.960 – 3.975 (0.1559 – 0.1565)

Valve stem IN,

Limit mm (in) 0.35 (0.014)
deflection EX
Valve stem IN,
Limit mm (in) 0.05 (0.002)
runout EX
Valve head IN,
Limit mm (in) 0.08 (0.003)
radial runout EX
Valve head IN,
Limit mm (in) 0.5 (0.02)
thickness EX
Valve seat IN,
STD mm (in) 0.8 – 1.0 (0.03 – 0.04)
contact width EX
Valve spring free STD mm (in) 22.8 (0.90)
length Limit mm (in) 21.9 (0.86)
Valve spring tension STD N (kg, lbs) 36.05 – 42.85 (3.61 – 4.29, 8.0 – 9.5) for 16.9 mm (0.67 in)
Limit N (kg, lbs) 33.53 (3.35, 7.39) for 16.9 mm (0.67 in)
 DF2.5 (Serial No. 410001 and later) 7

Data
Item Unit
DF2.5

CYLINDER/PISTON/PISTON RING
Cylinder distortion Limit mm (in) 0.05 (0.002)
Piston to cylinder STD mm (in) 0.018 – 0.033 (0.0007 – 0.0013)
clearance Limit mm (in) 0.100 (0.0039)
Cylinder bore STD mm (in) 48.000 – 48.015 (1.8898 – 1.8904)
Cylinder measuring
mm (in) 20 (0.8) from cylinder top surface
position
Piston skirt
STD mm (in) 47.975 – 47.990 (1.8888 – 1.8894)
diameter
Piston measuring position mm (in) 5 (0.2) from piston skirt end
Cylinder bore wear Limit mm (in) 0.100 (0.0039)
Piston ring 1st, STD mm (in) 0.15 – 0.35 (0.006 – 0.014)
end gap 2nd Limit mm (in) 0.50 (0.020)
Piston ring STD mm (in) Approx. 6.1 (0.24)
1st
free end gap Limit mm (in) 4.9 (0.19)
STD mm (in) Approx. 5.7 (0.22)
2nd
Limit mm (in) 4.6 (0.18)
Piston ring to STD mm (in) 0.020 – 0.060 (0.0008 – 0.0024)
1st,
groove
2nd Limit mm (in) 0.120 (0.0047)
clearance
Piston ring 1st,
STD mm (in) 1.21 – 1.23 (0.048 – 0.049)
groove width 2nd
Oil STD mm (in) 1.51 – 1.53 (0.059 – 0.060)
Piston ring 1st,
STD mm (in) 1.17 – 1.19 (0.046 – 0.047)
thickness 2nd
Pin clearance in STD mm (in) 0.002 – 0.013 (0.0001 – 0.0005)
piston pin hole Limit mm (in) 0.040 (0.0016)
Piston pin outside STD mm (in) 11.995 – 12.000 (0.4722 – 0.4724)
diameter Limit mm (in) 11.980 (0.4717)
Piston pin hole STD mm (in) 12.002 – 12.008 (0.4725 – 0.4728)
diameter Limit mm (in) 12.030 (0.4736)
Pin clearance in STD mm (in) 0.006 – 0.019 (0.0002 – 0.0007)
conrod small end Limit mm (in) 0.050 (0.0020)
8 DF2.5 (Serial No. 410001 and later)

Data
Item Unit
DF2.5

CRANKSHAFT/CONROD
Conrod small end STD mm (in) 12.006 – 12.014 (0.4727 – 0.4730)
inside diameter Limit mm (in) 12.040 (0.4740)
Conrod big end STD mm (in) 0.020 – 0.040 (0.0008 – 0.0016)
oil clearance Limit mm (in) 0.080 (0.0031)
Conrod big end
STD mm (in) 19.015 – 19.025 (0.7486 – 0.7490)
inside diameter
Crank pin out-
STD mm (in) 18.985 – 18.995 (0.7474 – 0.7478)
side diameter
Crank pin out-
side diameter
difference Limit mm (in) 0.010 (0.0004)
(out-of-round
and taper)
Conrod big end STD mm (in) 0.20 – 0.70 (0.008 – 0.028)
side clearance Limit mm (in) 1.00 (0.039)
Conrod big end
STD mm (in) 17.50 – 17.80 (0.689 – 0.701)
width
Crank pin width STD mm (in) 18.00 – 18.20 (0.709 – 0.717)
Crankshaft
Limit mm (in) 0.05 (0.002)
runout

ELECTRICAL
For all markets except for US market
Ignition timing Degrees BTDC 10 at 2000 – BTDC 31 at 4000
Ignition coil Sec-
kΩ at 20 °C 2.0 – 2.5
resistance ondary
Spark plug cap resistance kΩ at 20 °C 4–6
Standard spark Type NGK CR6HSA
plug Gap mm (in) 0.6 – 0.7 (0.024 – 0.028)

For US market
Ignition timing Degrees at
BTDC 5 at 2000 – BTDC 31 at 4000
r/min
Ignition coil Sec-
kΩ at 20 °C 2.0 – 2.5
resistance ondary
Spark plug cap resistance kΩ at 20 °C 4–6
Standard spark Type NGK CR6HSA
plug Gap mm (in) 0.6 – 0.7 (0.024 – 0.028)
 DF2.5 (Serial No. 410001 and later) 9

Data
Item Unit
DF2.5

LOWER UNIT
Preliminary gear shim & thrust washer

Pinion gear backup shim mm (in) 2.0 (0.08)

Forward gear backup
mm (in) 0.5 (0.02)
shim
Propeller shaft reverse
mm (in) 1.8 (0.07)
thrust washer
Initial selection-shim adjustment may be required.
10 DF2.5 (Serial No. 410001 and later)

PERIODIC MAINTENANCE
• The interval of maintenance schedule has been changed as follows.
“Every 50 hrs or 3 months” has not been adopted any longer.
“Every 100 hrs or 6 months” has been changed to “Every 100 hrs or 12 months”.
“Every 300 hrs or 36 months” has been added.
• “Thermostat” has been added to maintenance schedule.

PERIODIC MAINTENANCE SCHEDULE

PERIODIC MAINTENANCE CHART

Interval
Initial 20 hrs. Every 100 hrs. Every 200 hrs. Every 300 hrs.
or 1 month or 12 months or 12 months or 36 months
Item to be serviced
Spark plug – I – –
Breather & Fuel line I I – –
Engine oil R R – –
Gear oil R R – –
Lubrication I I – –
Anodes (external) I I – –
Anodes (internal power
– I – –
head)
Fuel filter – I – –
Ignition timing – – I –
Carburetor I I – –
Idle speed I – I –
Valve clearance I – I –
Water pump – – I –
Water pump impeller – – I R
Propeller pin/nut I I – –
Bolts & Nuts T T – –
Thermostat – I – –
I: Inspect and clean, adjust, lubricate or replace, if necessary T: Tighten R: Replace
 DF2.5 (Serial No. 410001 and later) 11

MAINTENANCE AND TUNE-UP PROCEDURES

IGNITION TIMING
OUTLINE
Ignition timing has been changed.

Inspect every 200 hours (12 months).

NOTE:
Before checking the ignition timing, make sure that the idle
speed is adjusted within the specification.

1. Start and warm up the engine.

2. Attach the timing light cord to the spark plug high-tension
cord.
09930-76311: Timing light
09900-26006: Engine tachometer
3. Check the ignition timing while operating the engine in neu-
tral gear at 2000 r/min.

For all markets except for US market

Ignition timing: Approx. BTDC 10° at 2000 r/min

For US market
Ignition timing: Approx. BTDC 5° at 2000 r/min
12 DF2.5 (Serial No. 410001 and later)

THERMOSTAT
OUTLINE
The thermostat has been added as an service item of periodic maintenance.
The inspection procedure is as follows.

Every 100 hours (12 months).

REMOVAL
For all markets except for US market
See the DF2.5 Service Manual, page 6-38.

For US market
1. Remove the recoil starter assembly. (See the DF2.5 Service
Manual, page 5-2.)
2. Remove the two bolts 1 securing fuel pump 2.
3. Remove the fuel pump 2.

4. Remove the two bolts 3 securing fuel pump bracket 4.

5. Remove the two bolts 6 and the thermostat cover 5.

6. Remove the thermostat 7.

 DF2.5 (Serial No. 410001 and later) 13

INSPECTION
For all markets
If salt deposits, corrosion, wear or other damage is found, clean
or replace the thermostat.

Thermostat operation
Check the thermostat operating temperature as follows.
1. Insert a length of thread between the thermostat valve/body
and suspend the thermostat in a container filled with water.
2. Place the thermometer in the container and heat water.
Observe water temperature when the thermostat valve
opens and releases the thread.
Thermometer
Thermostat operating temperature:
Standard: 48 – 52 °C (118 – 126 °F)
Thermostat
If the thermostat valve does not open as specified above, or Heater
sticks in any position, replace it.

INSTALLATION
Installation is reverse order of removal with the special attention
to the following steps.

For all markets except for US market

See the DF2.5 Service Manual, page 6-38.

For US market
1. Install the thermostat 1.

2. Apply sealant to both surfaces of thermostat cover gasket

(as shown with hatched lines).
93691-80030: SUZUKI SILICONE SEAL (100 g)

Thermostat cover gasket

14 DF2.5 (Serial No. 410001 and later)

3. Install the gasket 2 and the thermostat cover 3 to the cylin-

der block and secure with the two bolts 4.

4. Install the two nuts 6 to the fuel pump bracket 5.

5. Install the fuel pump bracket 5 to the thermostat cover 3

and secure with the two bolts 7.

6. Install the fuel pump 8 to the fuel pump bracket 5.

7. Apply the Thread Lock to fuel pump mounting bolts.
99000-32050: THREAD LOCK “1342”

8. Tighten fuel pump mounting bolts 9 to specified torque.

Fuel pump mounting bolt: 6 N·m (0.6 kg-m, 4.5 lb-ft)
 DF2.5 (Serial No. 410001 and later) 15

IGNITION AND ELECTRICAL

OUTLINE
For all markets except for US market
The advance angle range of ignition timing has been changed
as follows.
Ignition timing: BTDC 10° at 2000 r/min – BTDC 31° at 4000 r/min
In accordance with this change, the igniter unit has been
changed.

NOTE:
Ignition timing for US market has not been changed as follows.
Ignition timing : BTDC 5° at 2000 r/min – BTDC 31° at 4000 r/min

For all markets

The advance angle range of ignition timing has been changed,
two timing marks of 5° and 10° have been added on flywheel
magneto.
5˚
10˚
16 DF2.5 (Serial No. 410001 and later)

CARBURETOR (For all markets except for US market)

OUTLINE
The carburetor setting has been changed.

Type Walbro LMJ-57

I.D mark LMJ-57
Main jet # 62 (no change)
Main air jet # 160
Pilot jet # 35
Pilot air jet # 95
Pilot screw Turns open Pre-set (2-5/8 ± 3/4)
Float height mm 14.3 ± 2

Main air jet

Pilot air jet
Pilot jet
Float
Main jet

REASSEMBLY
CHECKING FLOAT HEIGHT
Measure the float height.

NOTE:
Make sure that float weight is not applied to needle valve.
09900-20101: Vernier calipers
Float height H: 14.3 ± 2 mm
 DF2.5 (Serial No. 410001 and later) 17

FUEL TANK AND FUEL COCK (For all markets except for US market)
OUTLINE
The related parts for fuel tank installation have been changed as follows.
• The fuel tank has been changed in shape.
• In accordance with this change, the fuel tank capacity have been changed.

FUEL TANK COMPONENTS

Fuel tank
Fuel tank bracket
Fuel tank spacer
Fuel tank bracket cushion
18 DF2.5 (Serial No. 410001 and later)

REMOVAL
1. Remove the motor cover.
2. Remove the recoil starter assembly 1. (See the DF2.5 Ser-
vice Manual, page 5-2.)

3. Turn the fuel cock lever 2 “OFF” position and tighten the air
vent screw on the fuel filler cap.

4. Remove the fuel hose 3 from the fuel cock 4 and immedi-
ately plug the fuel hose 3 in order to avoid fuel flow from the
hose.

Wipe up fuel spills immediately.

5. Remove the fuel tank 5.

 DF2.5 (Serial No. 410001 and later) 19

6. Loosen the screw 6.

Remove the fuel cock 4 from the fuel tank 5.
7. Drain all fuel from the tank.

INSPECTION
Fuel cock
Check the filter.
If clogged or damaged is found, clean the filter or replace the
fuel cock assy.
Inspect the fuel cock. If leakage, deterioration or other damage
is found, replace the fuel cock assembly.

Fuel tank
Inspect the fuel tank. If crack, leakage or deterioration is found,
replace the tank.
If water or other contamination is found, drain and clean the
tank.

Tank cap
Check that the fuel tank vent opens and relieves internal tank
pressure properly.
If vent is suspect, replace the tank cap.
20 DF2.5 (Serial No. 410001 and later)

INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
• Place the fuel tank bracket 1 in position.

• Install the fuel tank 2 and the recoil starter 3.

• Check the fuel hose routing. (See the DF2.5 Service Manual,
page 9-2.)
• Check for fuel leakage. (See the DF2.5 Service Manual, page
4-4.)
 Prepared by

Outboard Motor Engineering Department

June, 2013
Manual No.99501-97J30-01E
Printed in Japan

20
 OUTBOARD MOTOR

SUPPLEMENTARY SERVICE MANUAL

Applicable model and effective serial number:

00252F-410001 and later

Use this supplement with the following service manuals:
DF2.5 Service Manual (P/no., 99500-97J01-01E)
DF2.5 Supplementary Service Manual (P/no., 99501-97J20-01E)

99501-97J30-01E
Printed in Japan TK