99500-98L00-01E

99500-98L00-01E
2017

No.814 99500-98L00-01E DF350A Service Manual Cover for PS printing (18mm) 5/1 2017/05/27 DIC619 Pantone 303C Pantone 485 Pantone 294 Black
 IMPORTANT NOTICE

WARNING / CAUTION / NOTICE / NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and
the words ! WARNING , ! CAUTION , NOTICE and NOTE have special meanings.
Pay special attention to the messages highlighted by these signal words.

! WARNING
Indicates a potential hazard that could result in death or serious injury.

! CAUTION
Indicates a potential hazard that could result in minor or moderate injury.

NOTICE
Indicates a potential hazard that could result in damage to the motor or boat.

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 poten-
tial hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the ! WARNING ,
! CAUTION , and NOTICE stated, you must also use good judgment and observe basic mechanical safety prin-

ciples.

! WARNING
This service manual is intended for authorized Suzuki outboard motor dealers and qualified service
technicians only.
Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment
may not be able to properly perform the services described in this manual. Improper repair may result
in injury to the mechanic and may render the engine unsafe for the boat operator and passengers.
 FOREWORD
This manual contains an introductory description of the SUZUKI DF350A Outboard motors and procedures for
inspection, service and overhaul of their main components.
General knowledge information is not included.
Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning this
motor. Read and refer to the other sections in this manual for information regarding proper inspection and service
procedures.
This manual will help you better understand these outboard motors, assisting you in providing your customers
with optimum and quick service.

* This manual has been prepared using the latest information available at the time of publication. Differences
may exist between the content of this manual and the actual outboard motor.
* Illustrations in this manual are used to show the basic principles of operation and work procedures and may
not represent the actual outboard motor in exact detail.
* This manual is intended for use by technicians who already possess the basic knowledge and skills to ser-
vice SUZUKI Outboard motors. Persons without such knowledge and skills should not attempt to service
Suzuki Outboard engines by relying on this manual only and should contact an authorized SUZUKI Out-
board motor dealer.

NOTE:
This manual is compiled with the production model manufactured in May, 2017.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2017

 00
TABLE OF CONTENTS

Precautions............................................................... 00-i
Precautions ............................................................ 00-1 1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Tune-Up..................................... 0B-1
Power Head................................................................. 1-i
2
Precautions .............................................................. 1-1
Engine Control ....................................................... 1A-1
Engine Electrical Devices.......................................1C-1
Power Unit Mechanical ..........................................1D-1 3
Power Unit Lubrication ........................................... 1E-1
Power Unit Cooling System ................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System.......................................................1H-1
Starting System....................................................... 1I-1 4
Charging System.................................................... 1K-1
Mid Unit ....................................................................... 2-i
Precautions .............................................................. 2-1
Housing and Bracket.............................................. 2A-1 5
Power Trim and Tilt ................................................ 2B-1
Lower Unit................................................................... 3-i
Precautions .............................................................. 3-1
Dual PROP Lower Unit ..........................................3D-1 6
Wire / Hose Routing ................................................... 4-i
Precautions .............................................................. 4-1
Wire Routing .......................................................... 4A-1
Fuel / Water Hose Routing..................................... 4B-1 7

10

11

12
 Table of Contents 00- i

Section 00
00

Precautions
CONTENTS

Precautions ...............................................00-1 Precautions........................................................... 00-1

General Precautions ........................................... 00-1
00-1 Precautions:

Precautions
Precautions

Precautions
General Precautions
CENHN1110000001
The WARNING, CAUTION and NOTICE messages below describe some general precautions that you should observe
when servicing the outboard motor. These general precautions apply to many of the service procedures, but they will
not necessarily be repeated for every procedure to which they apply.

! WARNING
Failure to take proper precautions when servicing the outboard motor can cause severe personal
injury.
• To avoid eye injury, always wear protective glasses when filing metals, working on a grinder, or
doing other work, which could cause debris.
• When two 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, ensure that the necessary safety equipment is on
board.
Such equipment includes: flotation aids for each person, fire extinguisher, distress signals, anchor,
paddles, bilge pump, first aid kit, emergency starter rope, etc.
• Whenever handling toxic or flammable materials, wear safety glasses to protect your eyes. Any
toxic or flammable materials getting into your eye may cause inflammation. Also wear moisture-
proof gloves to protect your skin.
• Do not swallow any toxic or flammable materials. Swallowing them could cause diarrhea, nausea or
other health problems. Be especially careful not to allow children and pets to swallow these
materials.
• Keep all toxic or flammable materials out of reach of children and pets.
• 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.
• Avoid contact with new and used oil. Prolonged contact with used oil has been shown to cause skin
cancer in laboratory animals. Brief contact with used oil may irritate the skin. 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 latex gloves) when changing oil. If oil contacts your skin, wash
thoroughly with soap and water. Launder any clothing or rags if wet with oil. Recycle or properly
dispose of used oil.
• Never disconnect any of the fuel lines between the fuel pump and injectors without first releasing
the fuel pressure, or fuel can be sprayed out under pressure.
• After servicing the fuel, lubrication, cooling and/or the exhaust system, check all lines and fittings
related to the system for leaks.
• Carefully adhere to the battery handling instructions laid out by the battery supplier.
 Precautions: 00-2

NOTICE
Failure to take proper precautions when servicing the outboard motor can cause damage to the parts
or the outboard motor.
To prevent the parts or the outboard motor from damage, be sure to take the following precautions:
• 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 where 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 specified
type.
• When removing the battery, disconnect the negative cable first and then the positive cable. When
reconnecting the battery, connect the positive cable first and then the negative cable.
• When performing service to electrical parts, if the service procedures do not require using battery
power, disconnect the negative cable at the battery.
• Do not expose connectors and electrical parts to water, which will cause electrical systems
problems.
• Always be careful not to drop electrical components (ECM, relays, etc.) or handle them in a rough
manner.
• Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, locking nuts, cotter
pins, circlips, and certain other parts as specified, always replace them with new ones. Also, before
installing these new parts, be sure to remove any left over material from the mating surfaces.
• Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than
required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely
seated in its groove and securely fitted.
• Use a torque wrench to tighten fasteners to the torque values when specified.
• Remove grease or oil from screw / bolt threads unless a lubricant is specified.
• After assembly, check parts for tightness and proper operation.

NOTE
• To protect the environment, do not unlawfully dispose of used motor oil, other fluids or batteries.
• To protect the Earth’s natural resources, properly dispose of used motor parts.

Replacement Parts

NOTICE
Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to
performance problems and damage.
Use only genuine SUZUKI replacement parts or their equivalent. Genuine SUZUKI parts are high
quality parts which are designed and built specially for SUZUKI outboard motors.

If parts replacement is necessary, Suzuki strongly recommends that you use genuine Suzuki parts or their equivalent.
They are precision-made to ensure high quality and correct fit.

Precaution for Servicing Exhaust Valves

The exhaust valves are filled with sodium.
Before servicing for exhaust valve, read and understand information of “Precautions for Handling Sodium-filled
Exhaust Valves” in order to reduce personal injury.
Refer to “Precautions for Handling Sodium-filled Exhaust Valves” in Section 1D (Page 1D-1).
00-3 Precautions:
 Table of Contents 0- i

Section 0

General Information
0
CONTENTS

General Information ................................ 0A-1 Scheduled Maintenance ......................................0B-2

General Description .............................................0A-1 Periodic Maintenance Schedule Chart................0B-2
Symbols .............................................................. 0A-1 Lubrication Point .................................................0B-3
Abbreviations ...................................................... 0A-2 Service Instructions .............................................0B-4
Wire Color Symbols ............................................ 0A-3 Engine Oil Level Check.......................................0B-4
Warning, Caution and Information Label Engine Oil Change and Engine Oil Filter
Locations........................................................... 0A-3 Replacement .....................................................0B-5
Outboard Motor Identification Number Gear Oil Change .................................................0B-7
Location ............................................................ 0A-4 Spark Plug Removal and Installation ..................0B-8
Fuel and Oil Recommendations.......................... 0A-4 Spark Plug Inspection .........................................0B-9
Break-In Procedures ........................................... 0A-5 Tappet Clearance (Valve Lash) Inspection
Propeller Selection Guide ................................... 0A-6 and Adjustment .................................................0B-9
Battery Requirement ........................................... 0A-6 Idle Speed Inspection........................................0B-15
Powerhead Direction of Rotation Description ..... 0A-6 Breather Line and Fuel Line Inspection ............0B-16
Specifications.......................................................0A-7 Low Pressure Fuel Filter Inspection..................0B-17
Specifications ...................................................... 0A-7 Low Pressure Fuel Pump Filter Replacement...0B-18
Service Data ....................................................... 0A-9 Water Pump and Water Pump Impeller
Tightening Torque Specifications...................... 0A-14 Inspection........................................................0B-18
Special Tools and Equipment ...........................0A-15 Propeller / Propeller Nut and Cotter Pin
Recommended Service Material ....................... 0A-15 Inspection........................................................0B-19
Special Tool ...................................................... 0A-16 Anode Inspection ..............................................0B-19
Bonding Wire Inspection ...................................0B-20
Maintenance and Tune-Up...................... 0B-1 Battery Inspection .............................................0B-21
Thermostat Inspection.......................................0B-22
Precautions...........................................................0B-1
Bolts and Nuts Inspection .................................0B-22
Precautions for Maintenance .............................. 0B-1
Engine Holder Lubricating.................................0B-22
General Description .............................................0B-1
Oil Pressure Check ...........................................0B-23
Recommended Oil and Lubricants...................... 0B-1
Cylinder Compression Pressure Check ............0B-24
0A-1 General Information:

General Information
General Information

General Description
Symbols
CENHN1110101001
Listed in the table below are the symbols indicating instructions and other important information necessary for proper
servicing.
Please note the definition for each symbol. You will find these symbols used throughout this manual.
Refer back to this table if you are not sure of any symbol(s) meanings.
Symbol Definition
Torque control required.
Data beside it indicates specified torque.
Apply oil.
Use engine oil unless otherwise specified.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1)
Apply SUZUKI Outboard Motor Gear Oil.
Apply SUZUKI Super Grease A.
Apply SUZUKI Moly Paste.
99000-25140
Apply SUZUKI Water Resistant Grease.
Apply SUZUKI Bond 1207B.
Apply SUZUKI Bond 1217G.
Apply SUZUKI Silicone Seal.
Apply SUZUKI Thread Lock 1342.
Apply SUZUKI Thread Lock Super 1333B.
Use special tool.
Do not reuse.
Note on reassembly.
Use peak voltmeter Stevens CD-77.
 General Information: 0A-2

Abbreviations I:
CENHN1110101002 IAT: Intake Air Temperature
Abbreviations used in this service manual are as follows:
IG: Ignition
A:
Ign.: Ignition
ATDC: After Top Dead Center
IN (In.): Intake
AC: Alternating Current
L:
B:
LPS: Lever Position Sensor
BCM: Boat Control Module
M:
BTDC: Before Top Dead Center
MAP: Manifold Absolute Pressure
C:
O:
CKP Sensor: Crankshaft Position sensor
OCV: Oil Control Valve
CMP Sensor: Camshaft Position sensor
P:
D:
PCV: Positive Crankcase Ventilation
DBW: Drive By Wire
PORT: Port
DC: Direct Current
PTT: Power Trim and Tilt
DOHC: Double Over Head Camshaft
S:
E:
SPC System: Suzuki Precision Control System
ECM: Engine Control Module
SPS: Shift Position Sensor
ETV: Electronic Throttle Valve
STBD: Starboard
ESA: Electronic Shift Actuator
SIGP: Start-In-Gear Protection
EX (Ex.): Exhaust
T:
F:
TPS: Throttle Position Sensor
FP: Fuel Pump
V:
G:
VSV: Vacuum Switching Valve
GND: Ground
VVT: Variable Valve Timing
NOTE
On Keyless start system model,
The key operation described in this manual is
as follows:
• “Turn the main switch ON position”
represents that the keyless start system is
turned ON by switch knob operation.
• Conversely, “Turn the main switch OFF
position” represents that the keyless start
system is turned OFF by switch knob
operation.
0A-3 General Information:

Wire Color Symbols

CENHN1110101003
There are two kinds of colored wire used in this product.
One is single colored wire and the other is dual colored (striped) wire.
The single colored wire uses only one color symbol. example: B (Black).
The dual colored wire uses two color symbols. example: Bl/B.
The first symbol represents the base color of the wire and the second symbol represents the color of the stripe.
Example: Bl/B (Blue with Black stripe).
Symbol Wire color Symbol Wire color
B Black Lg Light green
Bl Blue O Orange
Br Brown P Pink
Dg Dark green R Red
G Green V Violet
Gr Gray W White
Lbl Light blue Y Yellow

B (Base Color: Black)

Bl (Base Color: Blue) Bl/B

B (Stripe Color: Black)

IEH511010001-01

Warning, Caution and Information Label Locations

CENHN1110101004
The figure shows main labels among others that are attached to outboard motor.
When servicing outboard motor, refer to WARNING/CAUTION instructions printed on labels.
If any WARNING/CAUTION label is found stained or damage, clean or replace it as necessary.
Do not reuse a label after it has been removed. Always use new label.

WARNING AVERTISSEMENT

• Fuel can leak creating a fire hazard if

you lay motor on its side. Drain fuel
completely from vapor separator or
carburetor before laying motor on its side.
• See owner’s manual for details.

• Le carburent risque de fuir et de

présenter un danger d’incendie si le
moteur est placé sur le côté.
Vidanger entièrement le carburant du
séparateur de vapeurs ou du
carburateur avant de procéder.
• Pour plus de détail, voir le manuel
du propriétaire.

IHN111010003-01

1. Label, engine cover 2. Label S.I.G.P.

 General Information: 0A-4

Outboard Motor Identification Number Location Fuel and Oil Recommendations

CENHN1110101005 CENHN1110101006
Model, Pre-Fix, Serial Number Gasoline
The Model, Pre-fix and Serial number of motor are
stamped on a plate attached to the clamp bracket. NOTICE
Use of leaded gasoline can cause engine
damage.
Use of improper or poor quality fuel can
affect performance and may damage the
motor and fuel system.

Use only unleaded gasoline. Do not use fuel

1 having lower than the recommended octane,
or fuel that may be stale or contaminated by
dirt/water etc.

Suzuki highly recommends that you use alcohol-free

IHN111010004-01
unleaded gasoline with a minimum pump octane rating
1. Identification number plate of 89 (R/2+M/2 method) or 94 (Research method).
However, blends of unleaded gasoline and alcohol with
Example equivalent octane content may be used.
1 Allowable maximum blend of a single additive
10% Ethanol
DF350A
Engine Oil
35001F-XXXXXX NOTICE
Use of a poor quality engine oil can adversely
affect engine performance and life.
2 3
IHN111010005-01
Suzuki recommends that you use Suzuki
Marine 4-Cycle Engine Oil or its equivalent.
1. Model 3. Serial number
2. Pre-fix
Oil quality is a major contributor to your engine’s
performance and life. Always select good quality engine
Engine Serial Number Location oil.
A second engine serial number plate is pressed into a Suzuki recommends the use of SAE 10W-40 or 10W-30
boss on the cylinder block. SUZUKI MARINE 4-CYCLE ENGINE OIL (ECSTAR).
If SUZUKI MARINE 4-CYCLE ENGINE OIL is not
available, select a NMMA certified FC-W oil or good
quality 4-cycle motor oil from the following chart
according to the average temperatures in your area.
1

API Classification SAE Viscosity Grade

SG
XXXXXX SH 10W–40
SJ
SL
10W–30
SM
IHN111010002-01
C –20 –10 0 10 20 30 40
1. Serial number plate TEMP.
F –4 14 32 50 68 86 104
I9J011010003-02

Gear Oil
Suzuki recommends the use of SUZUKI Outboard Motor
Gear Oil. If it is not available, use SAE 90 hypoid gear oil
which is rated GL-5 under the API classification system.
0A-5 General Information:

Break-In Procedures Throttle Recommendation

CENHN1110101007
NOTICE NOTE
Failure to follow the break-in procedures Avoid maintaining a constant engine speed
described below can result in severe engine for an extended period at any time during the
damage. engine break-in period by varying the throttle
position occasionally.
Be sure to follow the engine break-in
procedures described below. First 2 hours
For the first 15 minutes, operate the engine in-gear at
The first 10 hours are critically important to ensure idling speed. During the remaining 1 hour and 45
correct running of either a brand new motor or a motor minutes, operate the engine in-gear at less than 1/2
that has been reconditioned or rebuilt. How the motor is (half) throttle (3 000 r/min).
operated during this time will have direct bearing on its
life span and long-term durability. NOTE

Break-in period The throttle may be briefly opened beyond

10 hours the recommended setting to plane the boat,
but must be reduced to the recommended
Warm-Up Recommendation setting immediately after planning.
NOTICE
Next 1 hour
Running at high speed without sufficient
Operate the engine in-gear at less than 3/4 (three -
warm-up may cause severe engine damage
quarter) throttle (4 000 r/min).
such as piston seizure.
Last 7 hours
Always allow sufficient idling time (5
Operate the engine in-gear at a desired engine speed.
minutes) for the engine to warm-up before
However, do not operate continuously at full throttle for
running at high speed.
more than 5 minutes.
Allow sufficient idling time (more than 5 minutes) for the NOTICE
engine to warm up after cold engine starting.
Running continuously at full throttle for more
than 5 minutes at a time during the last 7
hours of break-in operation may cause
severe engine damage such as seizure.

During the last 7 hours of break-in operation,

do not operate at wide open throttle for more
than 5 minutes at a time.
 General Information: 0A-6

Propeller Selection Guide Battery Requirement

CENHN1110101008 CENHN1110101009
An outboard motor is designed to develop its rated Suzuki recommends a 12 V cranking type lead acid
power within a specified engine speed range. The battery for the DF350A.
maximum rated power delivered by the DF350A model is Minimum battery requirement for starting the engine is
shown below. provided below.
The battery must satisfy one of the specifications
Recommended full throttle speed range described below.
DF350A 5 700 – 6 300 r/min
NOTE
NOTICE • The specifications listed below are the
Installing a propeller with either too much or minimum battery rating requirements for
too little pitch will cause incorrect maximum starting the engine.
engine speed, which may result in severe • If your boat application requires additional
damage to the motor. battery loads, it is recommended that an
auxiliary battery or batteries be installed.
Select a propeller that will allow the engine to • Dual-purpose (Cranking/Deep Cycle)
reach the recommended operating range at batteries can be used if they meet the
full throttle with the maximum boat load. minimum specifications listed below
(MCA, CCA, or RC).
If the standard propeller fails to meet the above
requirement, use another pitch propeller to hold the • Do not use a Deep Cycle battery for the
engine speed within the range specified above. main cranking battery.
• The use of Maintenance-Free, sealed, or
NOTICE Gel-Cell batteries is not recommended
Using the improper combination of front and because they may not be compatible with
rear propellers can cause lower unit damage. Suzuki’s charging system.
• When connecting batteries in parallel, they
Confirm the size of the front and rear must be of the same type, capacity,
propellers when installing them. manufacturer, and of similar age. When
The front and rear propellers must be the replacement is necessary, they should be
same number of blades, diameter and pitch. replaced as a set.
• It is recommended that the battery be
Propeller size chart installed in an enclosed case.
Front propeller • When connecting batteries, hexagon nuts
Blade x Dia. (in.) x Pitch (in.) must be used to secure battery leads to
3 x 15 and 1/2 x 19.5 battery terminals.
3 x 15 and 1/2 x 21
3 x 15 and 1/2 x 22.5 Battery specification
3 x 15 and 1/2 x 24 1 000 Marine Cranking Amps (MCA)/ABYC, or 800
3 x 15 and 1/2 x 25.5 Cold Cranking Amps (CCA)/SAE or 180 Reserve
3 x 15 and 1/2 x 27 Capacity (RC) Minutes/SAE or 12 V 130 AH
3 x 15 and 1/2 x 28.5
Powerhead Direction of Rotation Description
Rear propeller CENHN1110101010
Blade x Dia. (in.) x Pitch (in.) This outboard motor is designed with a L.H. (left hand)
3 x 15 and 1/2 x 19.5 rotation powerhead utilizing an offset crankshaft. This
3 x 15 and 1/2 x 21 design has the advantage of reducing the size of the
3 x 15 and 1/2 x 22.5 motor and keeping the overall motor’s weight closer to
3 x 15 and 1/2 x 24 the boat transom and therefore closer to the boat C/G
3 x 15 and 1/2 x 25.5 (Center of Gravity).
3 x 15 and 1/2 x 27 Rotation of the driveshaft is accomplished through a
3 x 15 and 1/2 x 28.5 crankshaft drive gear and a driveshaft driven gear.
These gears are located beneath the powerhead in the
same oil bath location as the camshaft chain.
As the rotational direction of the driven gear will be
opposite of the drive gear, a left hand rotation
powerhead design was adopted to retain a conventional,
standard rotation (right hand) driveshaft output.
0A-7 General Information:

Specifications
Specifications
CENHN1110107001
NOTE
These specifications are subject to change without notice.

Model Pre-Fix
Data
Item Unit
DF350AT
PRE-FIX 35001F

Dimensions and Weight

Data
Item Unit
DF350AT
Overall length (front to back) mm (in.) 974 (38.3)
Overall width (side to side) mm (in.) 562 (22.1)
X mm (in.) 1 956 (77.0)
Overall height
XX mm (in.) 2 083 (82)
X kg (lbs) 330 (727)
Weight (without engine oil)
XX kg (lbs) 339 (747)
X mm (in. type) 634 (25)
Transom height
XX mm (in. type) 761 (30)

Performance
Data
Item Unit
DF350AT
Maximum output kW (PS) 257.4 (350)
Recommended operating range r/min 5 700 – 6 300
Idle speed r/min 600 ± 50 (in-gear: Approx. 550 – 650)

Powerhead
Data
Item Unit
DF350AT
Engine type 4-stroke DOHC
Number of cylinders V-6
Bore mm (in.) 98 (3.86)
Stroke mm (in.) 97 (3.82)
Total displacement cm3 (cu. in) 4 390 (267.8)
Compression ratio :1 12
Spark plug NGK ILZKR7D8
Ignition system Full-transistorized ignition
Fuel supply system Multi-point sequential electronic fuel injection
Exhaust system Through prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Electric
Throttle control Electronic remote control
 General Information: 0A-8

Fuel and Oil

Data
Item Unit
DF350AT
Suzuki highly recommends the use of alcohol-free
unleaded gasoline with a minimum pump octane rating of
Fuel 89 (R/2+M/2 method) or 94 (Research method). However,
blends of unleaded gasoline and alcohol with equivalent
octane content may be used.
• API classification: SG, SH, SJ, SL, SM or NMMA
certified FC-W oil
Engine oil
• Viscosity rating: SAE 10W-40 or 10W-30,
NMMA FC-W 10W-40 or 10W-30
8.0 (8.5/7.0): Oil change only
Engine oil amounts L (US/Imp. qt)
8.5 (9.0/7.5): Oil filter change
SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear
Gear oil
oil, API classification GL-5.
Gearcase oil capacity L (US/Imp. qt) Approx. 2.7 (2.9/2.4)

Bracket
Data
Item Unit
DF350AT
Trim angle degree 0 – 19 (–4 to 15)
Number of trim position PTT system
Maximum tilt angle degree 71 (–4 to 67)

Lower Unit
Data
Item Unit
DF350AT
Reversing system Gear
Transmission Forward-Neutral-Reverse
Reduction system Bevel gear
Gear ratio 12 : 22 (1.8)
Drive line impact protection Spline drive rubber hub
Front propeller
Blade x Dia. (in.) x Pitch (in.)
3 x 15 and 1/2 x 19.5
3 x 15 and 1/2 x 21
3 x 15 and 1/2 x 22.5
3 x 15 and 1/2 x 24
3 x 15 and 1/2 x 25.5
3 x 15 and 1/2 x 27
3 x 15 and 1/2 x 28.5
Propeller
Rear propeller
Blade x Dia. (in.) x Pitch (in.)
3 x 15 and 1/2 x 19.5
3 x 15 and 1/2 x 21
3 x 15 and 1/2 x 22.5
3 x 15 and 1/2 x 24
3 x 15 and 1/2 x 25.5
3 x 15 and 1/2 x 27
3 x 15 and 1/2 x 28.5

Reduction System
Data
Item
DF350AT
1st reduction gear ratio
32 : 40 (1.25)
(Crankshaft drive gear: Driven gear)
2nd reduction gear ratio (Lower unit gear) 12 : 22 (1.8)
Total reduction gear ratio 2.29 (40/32 x 22/12)
0A-9 General Information:

Service Data
CENHN1110107002
NOTE
These service data are subject to change without notice.

Powerhead
Data
Item Unit
DF350AT
Recommended operating range r/min 5 700 – 6 300
Idle speed r/min 550 – 650 (in-gear: 550 – 650)
kPa
**Cylinder compression pressure 700 – 1 160 (6.8 – 11.4, 97 – 162)
(kgf/cm2, psi.)
**Cylinder compression pressure max. kPa
100 (1.0, 14)
difference between cylinders (kgf/cm2, psi.)
kPa 500 – 700 (5.0 – 7.0, 70 – 100) at 3 000 r/min
**Engine oil pressure
(kgf/cm2, psi.) (at normal operating temp.)
• API classification: SG, SH, SJ, SL, SM
or NMMA certified FC-W oil
Engine oil
• Viscosity rating: SAE 10W-40 or 10W-30,
NMMA FC-W 10W-40 or 10W-30
8.0 (8.5/7.0): Oil change only
Engine oil amounts L (US/Imp. qt)
8.5 (9.0/7.5): Oil filter change
Thermostat operating temperature °C (°F) 53 – 57 (127 – 135)

**Figures shown are guidelines only, not absolute service limits.

Cylinder Head / Camshaft

Data
Item Unit
DF350AT
Cylinder head distortion Limit mm (in.) 0.05 (0.002)
Manifold seating faces distortion Limit mm (in.) 0.10 (0.004)
std. mm (in.) 46.490 – 46.650 (1.8303 – 1.8366)
IN
Limit mm (in.) 46.390 (1.8264)
Cam height
std. mm (in.) 45.410 – 45.570 (1.7878 – 1.7491)
EX
Limit mm (in.) 45.310 (1.7839)
Top, std. mm (in.) 0.043 – 0.085 (0.0017 – 0.0033)
Camshaft journal oil 2nd,
clearance 3rd, Limit mm (in.) 0.120 (0.0047)
4th
Top, std. mm (in.) 26.000 – 26.021 (1.0236 – 1.0244)
Camshaft journal (housing) 2nd,
inside diameter 3rd, Limit mm (in.) —
4th
Top, std. mm (in.) 25.936 – 25.957 (1.0211 – 1.0219)
Camshaft journal outside 2nd,
diameter 3rd, Limit mm (in.) —
4th
Camshaft runout Limit mm (in.) 0.10 (0.004)
Cylinder head bore to tappet std. mm (in.) 0.025 – 0.066 (0.0010 – 0.0026)
clearance Limit mm (in.) 0.150 (0.0059)
Tappet outer diameter std. mm (in.) 33.959 – 33.975 (1.3370 – 1.3376)
Cylinder head tappet bore std. mm (in.) 34.000 – 34.025 (1.3386 – 1.3396)
 General Information: 0A-10

Valve / Valve Guide

Data
Item Unit
DF350AT
IN mm (in.) 37.9 (1.49)
Valve diameter
EX mm (in.) 31.4 (1.2)
Tappet clearance (Valve lash) IN std. mm (in.) 0.23 – 0.27 (0.009 – 0.011)
(Cold engine condition) EX std. mm (in.) 0.33 – 0.37 (0.013 – 0.015)
IN — 30°, 45°, 60°
Valve seat angle
EX — 30°, 45°, 60°
std. mm (in.) 0.020 – 0.047 (0.0008 – 0.0019)
IN
Valve guide to valve stem Limit mm (in.) 0.070 (0.0028)
clearance std. mm (in.) 0.045 – 0.072 (0.0018 – 0.0028)
EX
Limit mm (in.) 0.090 (0.0035)
IN,
Valve guide inside diameter std. mm (in.) 5.500 – 5.512 (0.2165 – 0.2170)
EX
IN,
Valve guide protrusion std. mm (in.) 11.4 – 11.8 (0.45 – 0.46)
EX
IN std. mm (in.) 5.465 – 5.480 (0.2152 – 0.2157)
Valve stem outside diameter
EX std. mm (in.) 5.440 – 5.455 (0.2142 – 0.2148)
IN Limit mm (in.) 0.14 (0.006)
Valve stem deflection
EX Limit mm (in.) 0.18 (0.007)
IN,
Valve stem runout Limit mm (in.) 0.05 (0.002)
EX
IN,
Valve head radial runout Limit mm (in.) 0.08 (0.003)
EX
std. mm (in.) 1.1 (0.04)
IN
Limit mm (in.) 0.7 (0.03)
Valve head thickness
std. mm (in.) 1.1 (0.04)
EX
Limit mm (in.) 0.7 (0.03)
IN std. mm (in.) 1.1 – 1.3 (0.04 – 0.05)
Valve seat contact width
EX std. mm (in.) 1.1 – 1.2 (0.04 – 0.05)
std. mm (in.) 41.25 (1.62)
Valve spring free length
Limit mm (in.) 39.60 (1.56)
std. N (kg, lbs) 147 – 173 (14.7 – 17.3, 32.4 – 38.1) at 32.5 mm (1.28 in.)
Valve spring preload
Limit N (kg, lbs) 136 (13.6, 30.0) at 32.5 mm (1.28 in.)
Valve spring squareness Limit mm (in.) 2.0 (0.08)
0A-11 General Information:

Cylinder / Piston / Piston Ring

Data
Item Unit
DF350AT
Cylinder distortion Limit mm (in.) 0.05 (0.002)
std. mm (in.) 0.045 – 0.065 (0.0018 – 0.0026)
Piston to cylinder clearance
Limit mm (in.) 0.10 (0.0039)
Cylinder bore std. mm (in.) 98.000 – 98.020 (3.8583 – 3.8591)
Cylinder measuring position mm (in.) 50 (2.0) from cylinder top surface
Piston skirt diameter std. mm (in.) 97.945 – 97.965 (3.8561 – 3.8569)
Piston measuring position mm (in.) 12.5 (0.49) from piston skirt end
Cylinder bore wear Limit mm (in.) 0.10 (0.0039)
std. mm (in.) 0.20 – 0.40 (0.008 – 0.016)
1st
Limit mm (in.) 0.70 (0.028)
Piston ring end gap
std. mm (in.) 0.33 – 0.48 (0.013 – 0.019)
2nd
Limit mm (in.) 1.00 (0.039)
std. mm (in.) Approx. 13.6 (0.54)
1st
Limit mm (in.) 10.9 (0.43)
Piston ring free end gap
std. mm (in.) Approx. 13.7 (0.54)
2nd
Limit mm (in.) 10.9 (0.43)
std. mm (in.) 0.030 – 0.070 (0.0012 – 0.0028)
1st
Piston ring to groove Limit mm (in.) 0.12 (0.005)
clearance std. mm (in.) 0.020 – 0.060 (0.0008 – 0.0024)
2nd
Limit mm (in.) 0.10 (0.004)
1st std. mm (in.) 1.22 – 1.25 (0.048 – 0.049)
Piston ring groove width 2nd std. mm (in.) 1.21 – 1.23 (0.048 – 0.048)
Oil std. mm (in.) 2.51 – 2.53 (0.099 – 0.100)
1st std. mm (in.) 1.17 – 1.19 (0.046 – 0.047)
Piston ring thickness
2nd std. mm (in.) 1.17 – 1.19 (0.046 – 0.047)
std. mm (in.) 0.006 – 0.019 (0.0002 – 0.0007)
Pin clearance in piston pin hole
Limit mm (in.) 0.05 (0.0020)
std. mm (in.) 21.995 – 22.000 (0.8659 – 0.8661)
Piston pin outside diameter
Limit mm (in.) 21.980 (0.8654)
std. mm (in.) 22.006 – 22.014 (0.8664 – 0.8667)
Piston pin hole diameter
Limit mm (in.) 22.030 (0.8673)
std. mm (in.) 0.010 – 0.023 (0.0004 – 0.0009)
Pin clearance in conrod small end
Limit mm (in.) 0.050 (0.020)
 General Information: 0A-12

Crankshaft / Conrod
Data
Item Unit
DF350AT
Conrod small end inside diameter std. mm (in.) 22.010 – 22.018 (0.8665 – 0.8669)
std. mm (in.) 0.045 – 0.063 (0.0018 – 0.0025)
Conrod big end oil clearance
Limit mm (in.) 0.080 (0.0031)
Conrod big end inside diameter std. mm (in.) 57.000 – 57.018 (2.2441 – 2.2448)
Crank pin outside diameter std. mm (in.) 53.982 – 54.000 (2.1253 – 2.1260)
Crank pin outside diameter
Limit mm (in.) 0.010 (0.0004)
difference (Out-of-round and taper)
Conrod bearing thickness std. mm (in.) 1.482 – 1.497 (0.0583 – 0.0589)
std. mm (in.) 0.300 – 0.450 (0.0118 – 0.0177)
Conrod big end side clearance
Limit mm (in.) 0.550 (0.0217)
Conrod big end width std. mm (in.) 20.750 – 20.800 (0.8169 – 0.8189)
Crank pin width std. mm (in.) 21.100 – 21.200 (0.8307 – 0.8346)
Crankshaft center journal runout Limit mm (in.) 0.04 (0.002)
std. mm (in.) 0.030 – 0.048 (0.0012 – 0.0020)
Crankshaft journal oil clearance
Limit mm (in.) 0.065 (0.0026)
Crankcase bearing holder inside
std. mm (in.) 78.000 – 78.018 (3.0709 – 3.0716)
diameter
Crankshaft journal outside diameter std. mm (in.) 72.982 – 73.000 (2.8733 – 2.8740)
Crankshaft journal outside diameter
Limit mm (in.) 0.010 (0.0004)
difference (Out-of-round and taper)
Crankshaft bearing thickness std. mm (in.) 2.499 – 2.514 (0.0984 – 0.0990)
std. mm (in.) 0.11 – 0.31 (0.004 – 0.012)
Crankshaft thrust play
Limit mm (in.) 0.35 (0.014)
Crankshaft thrust bearing thickness std. mm (in.) 2.425 – 2.475 (0.0955 – 0.0974)

Electrical
Data
Item Unit
DF350AT
Ignition timing Degree 5° ± 4° ATDC (at 600 r/min) – 9° BTDC (at 6 000 r/min)
Over revolution limiter r/min 6 400
CKP sensor resistance Ω at 20 °C 168 – 252
CMP sensor resistance Ω at 20 °C —
Primary Ω at 20 °C —
Ignition coil resistance
Secondary kΩ at 20 °C —
Battery charge coil resistance Ω at 20 °C 0.16 – 0.32
Battery charge coil output (12 V) Watt 648
Type NGK ILZKR7D8
Standard spark plug
Gap mm (in.) 0.7 – 0.8 (0.028 – 0.031)
Main fuse: 60
Starter motor: 30
Ignition coil, Injector, ECM, F/P, VVT, CMP sensor: 30
PTT switch: 10
Fuse amp. rating A
Throttle valve: 15
Shift actuator: 15
Low pressure fuel pump: 15
Isolator: 40
Recommended battery capacity (12 V) Ah (kC) 130 (468) or larger
Fuel injector resistance Ω at 20 °C 10 – 14
IAT sensor/Cylinder temp. sensor/Ex.
kΩ at 25 °C 1.8 – 2.3
mani. temp. sensor
ECM main relay coil resistance Ω at 20 °C 145 – 190
Starter motor relay coil resistance Ω at 20 °C 145 – 190
PTT motor relay coil resistance Ω at 20 °C 16 – 24
0A-13 General Information:

Starter Motor
Data
Item Unit
DF350AT
Max. continuous time of use Sec. 30
Motor output kW 1.4
std. mm (in.) 12.3 (0.48)
Brush length
Limit mm (in.) 7.0 (0.28)
std. mm (in.) 0.5 (0.02)
Commutator undercut
Limit mm (in.) 0.2 (0.01)
std. mm (in.) 29.4 (1.16)
Commutator outside diameter
Limit mm (in.) 28.4 (1.12)

PTT Motor
Data
Item Unit
DF350AT
std. mm (in.) 9.8 (0.39)
Brush length
Limit mm (in.) 5.5 (0.22)
std. mm (in.) 22.0 (0.87)
Commutator outside diameter
Limit mm (in.) 21.0 (0.83)

Self-Diagnostic Code
Failed item Code Fail-safe system activating
MAP sensor 1 3–4 YES
Cylinder temp. sensor (PORT) 1–4 YES
IAT sensor 2–3 YES
Exhaust manifold temp. sensor 1–6 YES
Cylinder temp. sensor (STBD) 1–5 YES
Trim sensor 3–7 NO
Throttle position sensor 2–1 YES
Shift position sensor 1–2 NO
Rectifier/regulator (Over-charging) 1–1 NO
Fuel injector 4–3 NO
CKP sensor 4–2 NO
CMP sensor 2–4 NO
CMP sensor (VVTPORT) 2–6 YES
CMP sensor (VVTSTBD) 2–5 YES
Air intake system 2–2 YES
MAP sensor 2 (Pressure detect passage) 3–2 NO
Neutral switch 3–3 NO
VVT advance (STBD) 5–1 YES
VVT advance (PORT) 5–2 YES
Oil pressure switch 5–3 NO
Knock sensor 5–4 YES
Oil control valve (STBD) 6–1 NO
Oil control valve (PORT) 6–2 NO
ETV ECM 7–1 YES
ETV Motor 7–2 YES
ETV 7–3 YES
Sub BCM 7–4 YES
DBW system 7–5 NO
ESA ECM 8–1 NO
ESA motor 8–2 NO
ESA 8–3 NO
Keyless system authentication error 9–4 NO
Keyless system communication error 9–5 NO
Keyless system failure 9–6 NO
 General Information: 0A-14

Tightening Torque Specifications

CENHN1110107003
NOTICE
Failure to use the correct fasteners or to properly use fasteners can cause parts or system damage.
• When fasteners are removed, always reinstall them at the locations from which they were removed.
• All fasteners must be replaced with fasteners having the same part number.
If a fastener of the correct part number is not available, a fastener of the same size having equal or
higher strength may be used.

Important Fasteners
Thread Tightening torque
Item
diameter Nm kgf-m lbf-ft
Cylinder head cover bolt 6 mm 11 1.1 8.0
8 mm 23 2.3 16.5
Cylinder head bolt
12 mm 58 Nm (5.8 kgf-m, 42.0 lbf-ft), then plus turn in 90 degrees.
Outside 8 mm 25 2.5 18.0
Crankcase bolt
Inside 11 mm 22 Nm (2.2 kgf-m, 16.0 lbf-ft), then plus turn in 90 degrees.
Crankshaft drive gear bolt 10 mm 48 4.8 34.5
Conrod cap bolt 9 mm 68 6.8 49.0
Camshaft housing bolt 6 mm 12 1.2 8.5
Oil pump bolt 8 mm 23 2.3 16.5
IN. camshaft timing sprocket — 60 6.0 43.5
EX. camshaft timing sprocket — 78 7.8 56.5
OCV bolt 6 mm 11 1.1 8.0
Chain tensioner adjuster bolt 6 mm 11 1.1 8.0
Timing chain guide bolt 8 mm 23 2.3 16.5
Intake manifold bolt/nut 8 mm 30 3.0 22.0
Intake collector bolt/nut 8 mm 23 2.3 16.5
Intake collector cover bolt 8 mm 23 2.3 16.5
Oil pressure switch — 13 1.3 9.5
Fuel delivery pipe nut 8 mm 23 2.3 16.5
Fuel delivery pipe plug/union Upper 14 mm 35 3.5 25.5
bolt Lower 14 mm 35 3.5 25.5
Thermostat cover bolt 6 mm 11 1.1 8.0
Flywheel bolt 12 mm 118 11.8 85.5
Starter motor mounting bolt 8 mm 23 2.3 16.5
Engine oil filter — 14 1.4 10.0
Engine oil drain plug 12 mm 13 1.3 9.5
8 mm 23 2.3 16.5
Power unit mounting bolt
10 mm 50 5.0 36.0
Driveshaft housing bolt 10 mm 50 5.0 36.0
Upper mount nut 14 mm 100 10.0 72.5
Upper mount cover bolt 10 mm 50 5.0 36.0
Lower mount bolt/nut 14 mm 100 10.0 72.5
Clamp bracket shaft nut 7/8-14 UNF 43 4.3 31.0
Water pump case bolt 8 mm 17 1.7 12.5
10 mm 55 5.5 40.0
Gearcase bolt
12 mm 85 8.5 61.5
Propeller shaft bearing housing stopper — 200 20.0 145.0
Reverse drive gear nut — 145 14.5 105.0
Lower driveshaft convex nut — 3 0.3 2.0
Lower driveshaft concave nut — 130 13.0 94.0
Reverse-pinion convex nut — 3 0.3 2.0
Reverse-pinion concave nut — 35 3.5 25.0
Contra-pinion convex nut — 145 14.5 105.0
Contra-pinion concave nut — 85 8.5 62.0
Rear propeller nut 18 mm 55 5.5 40.0
Front propeller nut 44 mm 130 13.0 94.0
0A-15 General Information:

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 kgf-m lbf-ft
5 mm 2–4 0.2 – 0.4 1.5 – 3.0
6 mm 4–7 0.4 – 0.7 3.5 – 5.0
8 mm 10 – 16 1.0 – 1.6 7.0 – 11.5

10 mm 22 – 35 2.2 – 3.5 16.0 – 25.5

I9J011010014-01
(Conventional or “4” marked bolt)
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

10 mm 34 – 41 3.4 – 4.1 24.5 – 29.5

I9J011010015-01
(Stainless steel bolt)
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

10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5

I9J011010016-01
(“7” marked bolt)

Special Tools and Equipment

Recommended Service Material
CENHN1110108001

93691–80030 99000–22B22 99000–25350 99000–31140 99000–32020

SUZUKI Silicone Seal SUZUKI Outboard SUZUKI Water SUZUKI Bond 1207B SUZUKI Thread Lock
(100 g) Motor Gear Oil Resistant Grease EP2 (100 g) Super 1333B (50 g)
(250 g)

99000–32160 99000–22810
SUZUKI Thread Lock PTT Fluid
1342H (50g)
 General Information: 0A-16

Special Tool
CENHN1110108002

09900–20101 09900–20202 09900–20203 09900–20204 09900–20205

Vernier calipers (150 Micrometer (25 – 50 Micrometer (50 – 75 Micrometer (75 – 100 Micrometer (0 – 25
mm) mm) mm) mm) mm)

09900–20605 09900–20606 09900–20607 09900–20701 09900–20803

Dial calipers (10 – 34 Dial gauge Dial gauge Magnetic stand Thickness gauge
mm)

09900–21304 09900–22301 09900–22302 09900–25007 09900–25008

Steel “V” block set Plastigauge (0.025 – Plastigauge (0.051 – Peak volt adapter Multi circuit tester set
0.076 mm) 0.125 mm)

09900–28403 09912–58432 09912–58442 09912–58490 09913–50121

Hydrometer Fuel pressure hose Fuel pressure gauge 3-way joint & hose Oil seal remover

09915–47341 09915–64512 09915–64530 09915–64550 09915–77311

Oil filter wrench Compression gauge Compression gauge Compression gauge Oil pressure gauge
hose hose attachment
0A-17 General Information:

09915–78211 09916–10911 09916–14521 09916–19030 09916–34542

Oil pressure gauge Valve lapper Valve lifter attachment Valve lifter Valve guide reamer
adapter handle

09916–34550 09916–37320 09916–44310 09916–56011 09916–57330

Valve guide reamer (ø Valve guide reamer (ø Valve guide remover Valve guide installer Valve guide installer
5.5 mm) 10.5 mm) attachment

09916–69310 09916–77310 09916–84511 09916–99312 09917–47011

Tappet holder Piston ring Tweezers Flywheel holder Vacuum pump gauge
compressor

09917–49610 09917–98221 09921–29410 09921–29830 09921–29840

Vacuum pump adapter Valve guide stem seal Driveshaft holder Driveshaft nut holder Reverse pinion nut
installer attachment holder

09922–21410 09923–29810 09926–29310 09930–30104 09930–30161

Long socket wrench Propeller nut remover Driveshaft housing Sliding hammer Propeller shaft
remover remover
 General Information: 0A-18

09930–39210 09930–39411 09930–40113 09930–40120 09930–89240

Flywheel remover bolt Flywheel remover Flywheel holder Rotor holder 4-pin connector test
attachment cord

09930–89290 09930–89340 09930–89850 09944–09610 09944–09820

18 pin & 34 pin test 26-pin & 34-pin test 26-pin (B) test cord PTT trim cap tool PTT cylinder cap tool
cord cord

09945–79410 09950–69512 09951–09530 09951–19830 09952–99320

PTT cable extension Gearcase oil leakage Gear adjusting gauge PROP shaft housing Hand air pump
tester stopper remover