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ENGLISH

DF9.9BDF15ADF20A

OWNER’S MANUAL

EN________________________

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IMPORTANT

WARNING/ CAUTION/ NOTICE/ NOTEPlease read this manual and follow its instruc-tions carefully. To emphasize special informa-tion, the symbol and the words WARNING,CAUTION, NOTICE and NOTE have specialmeanings. Pay special attention to the mes-sages highlighted by these signal words.

NOTE:Indicates special information to make mainte-nance easier or instructions clearer.

This symbol appears in various locations onyour Suzuki product to refer you to importantinformation in the owner’s manual.

IMPORTANT NOTICE TO OWNERS

WARNINGIndicates a potential hazard that could resultin death or serious injury.

CAUTIONIndicates a potential hazard that could resultin minor or moderate injury.

NOTICEIndicates a potential hazard that could resultin damage to the motor or boat.

WARNING

Failure to take the proper precautions mayincrease the risk of death or severe injury toyou and your passengers.

• Prior to first-time use of your outboardmotor, familiarize yourself thoroughly withthe contents of this owner’s manual. Beaware of all outboard motor features and allsafety and maintenance requirements.

• Inspect the boat and motor before each trip.See the INSPECTION BEFORE BOATINGsection for important items.

• Become thoroughly familiar with all operat-ing and handling characteristics of your-boat and motor. Practice at low andmoderate speeds until you are competent athandling the boat and motor. Do notattempt to operate at maximum perfor-mance until you are completely familiar withall of these characteristics.

• Carry boating safety and emergency equip-ment. This important equipment includes;flotation aids for each person (plus onethrowable buoyant cushion in any boat 16feet or longer), fire extinguisher, sound sig-naling device, visual distress signals,anchor, bilge pump, bucket, compass,emergency starter rope, extra fuel and oil,first aid kit, flashlight, food and water, mir-ror, paddles, tool kit, and transistor radio.Be sure you are carrying the equipmentappropriate for your trip before launching.

• Never start the engine or let it run indoorsor where there is little or no ventilation.Exhaust gas contains carbon monoxide, agas that is colorless and odorless and cancause death or severe injury.

• Instruct your passengers on how to operatethe boat, how to deal with emergencies, andhow to operate safety and emergencyequipment.

• Do not hold onto the motor cover or anyother parts of your outboard motor whilegetting on or off your boat.

• Ensure that everyone wears a PFD (Per-sonal Flotation Device) on board.

• Never operate the boat while under theinfluence of alcohol or other drugs.

• Distribute all weight load evenly in the boat.• Have all scheduled maintenance performed.

Consult your authorized Suzuki marinedealer as required.

• Do not modify or remove any outboardmotor standard equipment. To do so maymake the motor unsafe to use.

• Learn and obey all applicable navigationrules.

• Pay attention to all weather forecasts. Donot set out if weather is unsettled.

• Use extreme caution when purchasingreplacement parts or accessories. Suzukistrongly recommends that you use onlygenuine Suzuki replacement parts/accesso-ries or their equivalent. Inappropriate orpoor quality replacement parts or accesso-ries can create unsafe operating conditions.

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NOTE:Mounting radio transceiver or navigationalequipment antennae too close to the enginecowling can cause electrical noise interference.Suzuki recommends that antennae be mountedat least one meter (40 inches) away from theengine cowling.

• Never remove the flywheel cover (except forwhen emergency starting).

This manual should be considered a per-manent part of the outboard motor andshould remain with the outboard motorwhen resold or otherwise transferred to anew owner or operator. Please read thismanual carefully before operating yournew Suzuki and review the manual fromtime to time. It contains important infor-mation on safety, operation, and mainte-nance.

FOREWORD

Thank you for choosing a Suzuki outboardmotor. Please read this manual carefully andreview it from time to time. It contains importantinformation on safety, operation, and mainte-nance. A thorough understanding of the infor-mation presented in this manual will help youexperience safe, enjoyable boating.

All information in this manual is based on thelatest product information available at the timeof publication. Due to improvements or otherchanges, there may be discrepancies betweenthis manual and your outboard motor. Suzukireserves the right to make changes at any timewithout notice.

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TABLE OF CONTENTS

IDENTIFICATION NUMBERLOCATION.............................................. 5FUEL AND OIL....................................... 5LOCATION OF SAFETY LABELS ..... 8LOCATION OF PARTS....................... 10MOTOR MOUNTING.......................... 15BATTERY INSTALLATION .............. 16USE OF ELECTRICALACCESSORIES ..................................... 18BATTERY CHARGE CUTOUTSYSTEM (DF9.9BE/15AE/20AE)........... 18PROPELLER SELECTION ANDINSTALLATION................................... 19ADJUSTMENT...................................... 20CAUTION SYSTEM............................. 22DIAGNOSTIC SYSTEM ...................... 25OIL CHANGE REMINDERSYSTEM................................................. 25OPERATION OF TILTINGSYSTEMS (DF9.9B/9.9BR/15A/15AR/20A/20AR) ............................................... 26OPERATION OF TILTINGSYSTEMS (DF9.9BT/9.9BTH/15ATH/20AT/20ATH) ........................................... 29INSPECTION BEFORE BOATING ... 31BREAK-IN ............................................. 32OPERATION ......................................... 33MOTOR REMOVAL ANDTRANSPORTING ................................. 46TRAILERING........................................ 48INSPECTION ANDMAINTENANCE................................... 49FLUSHING THE WATERPASSAGES............................................. 58SUBMERGED MOTOR....................... 60STORAGE PROCEDURE ................... 61AFTER STORAGE ............................... 62TROUBLESHOOTING........................ 62SPECIFICATIONS ............................... 64INFORMATION REGARDINGEC – DIRECTIVE ................................. 64FLOWCHART OF OIL CHANGEREMINDER SYSTEM.......................... 65

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IDENTIFICATION NUMBER LOCATIONThe model and identification numbers of youroutboard motor are stamped on a plateattached to the clamp bracket. It is important toknow these numbers when you place a partsorder or if your motor is stolen.

FUEL AND OILGASOLINESuzuki highly recommends that you use alco-hol-free unleaded gasoline whenever possible,with a minimum octane rating of 91 (Researchmethod). However, blends of unleaded gasolineand alcohol with equivalent octane content maybe used, provided the guidelines that follow aremet.

NOTE:Oxygenated fuels are fuels which contain oxy-gen-carrying additives such as alcohol.

NOTICE

Use of leaded gasoline can cause engine dam-age. Use of improper or poor quality fuel canaffect performance and may damage yourmotor and fuel system.

Use only unleaded gasoline. Do not use fuelhaving lower than the recommended octane,or fuel that may be stale or contaminated bydirt/water etc.

Suzuki recommends that you install a water-separating fuel filter assembly between yourboat’s fuel tank(s) and outboard motor(s). Fuelfiltration systems of this type will help preventwater that may be present in your boat’s fueltank(s) from contaminating your motor’s elec-tronic fuel injection system. Water contamina-tion can cause poor engine performance andcan also cause damage to the electronic fuelinjection system components.Your Authorized Suzuki Marine Dealer can pro-vide you advice about water-separating fuel fil-ter systems and installation.

Gasoline/Ethanol BlendsBlends of unleaded gasoline and ethanol (grainalcohol), also known as “GASOHOL”, are com-mercially available in some areas. Blends of thistype may be used in your outboard motor if theyare no more than 10% ethanol. Make sure thisgasoline-ethanol blend has octane ratings nolower than those recommended for gasoline.

Use the recommended gasoline whichconforms to the following labels.

78RB0900*

Pump Labeling for Gasoline/Alcohol BlendsIn some states, pumps that dispense gasoline/alcohol blends are required to be labeled for thetype and percentage of alcohol content, andwhether important additives are present. Suchlabels may provide enough information for youto determine if a particular blend of fuel meetsthe requirements listed above. In other states,pumps may not be clearly labeled as to the con-tent or type of alcohol and additives. If you arenot sure that the fuel you intend to use meetsthese requirements, check with the service sta-tion operator or the fuel suppliers.

or

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NOTE:If you are not satisfied with the operation or fueleconomy of your outboard motor when you areusing gasoline/alcohol blends, you shouldswitch back to unleaded gasoline containing noalcohol.Be sure that any gasoline/alcohol blend you usehas octane ratings of at least 91 octane(Research method).If engine pinging is experienced, substituteanother brand as there are differences betweenbrands.Unleaded gasoline will extend spark plug life.

WARNING

Gasoline is extremely flammable and toxic. Itcan cause a fire and can be hazardous to peo-ple and pets.

Always take the following precautions whenrefueling:• Never permit anyone other than an adult to

refill the fuel tank.• If you use a portable fuel tank, always stop

the motor and remove the fuel tank from theboat to refill it.

• Do not fill the fuel tank all the way to the topor fuel may overflow when it expands due toheating by the sun.

• Be careful not to spill fuel. If you do, wipe itup immediately.

• Do not smoke, and keep away from openflames and sparks.

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

NOTICE

Gasoline kept in the fuel tank for long periodsof time will produce varnish and gum, whichcan damage the engine.

Always use fresh gasoline.

NOTICE

Fuels containing alcohol can cause paintdamage, which is not covered under the NewOutboard Motor Limited Warranty.

Be careful not to spill fuel containing alcoholwhile refueling. If fuel is spilled, wipe it upimmediately.

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ENGINE OIL

Oil quality is a major contributor to yourengine’s performance and life. Always selectgood quality engine oil.Suzuki recommends the use of SAE 10W-40 or10W-30 SUZUKI MARINE 4-CYCLE ENGINEOIL. If SUZUKI MARINE 4-CYCLE ENGINEOIL is not available, select a NMMA certifiedFC-W oil or good quality 4-cycle motor oil fromthe following chart according to the averagetemperatures in your area.

NOTE:In very cold weather (below 5°C (41°F)), useSAE (or NMMA FC-W) 5W-30 for easier start-ing and smooth operation.

GEAR OIL

Suzuki recommends the use of SUZUKI OUT-BOARD MOTOR GEAR OIL. If it is not avail-able, use SAE 90 hypoid gear oil which is ratedGL-5 under the API classification system.

NOTICE

Use of poor quality engine oil can adverselyaffect engine performance and life.

Suzuki recommends that you use SuzukiMarine 4-Cycle Engine Oil or its equivalent.

–20 –10 0 10 20 30

–4 14 32 50 68 86

40

104TEMP.

API Classification SAE Viscosity Grade

10W–40

10W–30

˚F

˚C

SGSHSJSLSM

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LOCATION OF SAFETY LABELSRead and follow all of the labels on your out-board motor or fuel tank. Make sure you under-stand all of the labels.

Keep the labels on your outboard motor or fueltank. Do not remove them for any reason.

WARNING AVERTISSEMENT�

• Fuel can leak creating a fire hazard if you lay motor on its side. Drain fuelcompletely from vapor separator orcarburetor 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 lemoteur est placé sur le côté.Vidanger entièrement le carburant duséparateur de vapeurs ou du carburateur avant de procéder.

• Pour plus de détail, voir le manueldu propriétaire.

WARNING AVERTISSEMENTSecure both mounting bolts andclamps to avoid motor drop. See owner’s manual. Fixer les deux boulons de montageet des brides pour éviter la chute dumoteur. Voir le manuel du propriétaire.

Label symbol meaningsThese symbols mean as follows;

: General warning symbol (Caution or Warning)

: Read owner’s manual carefully

: Remote control lever/gear shift lever operation-two direction; Forward/ Neutral/Reverse

: Engine start

: Hazard caused by fire

: Hazard caused by laying the motor on its side

: Hazard caused by rotating parts

WARNING AVERTISSEMENT�• To avoid injury, when engine is running,

keep your hands, hair, clothing, etc., awayfrom engine.

• See owner’s manual for details. • Pour éviter toute blessure, quand le moteur

est en marche, éloigner les mains, lescheveux, les vêtements, etc. du moteur.

• Pour plus de détail, voir le manuel du propriétaire.

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LOCATION OF PARTSTILLER HANDLE MODEL (DF9.9B/15A/20A)

Motor cover

Starter grip

Shift lever

Throttle control grip

Clamp screw

Clamp bracket

Tilt pin

Gear oil level plug

Gear oil drain plug

Anode

Engine oil drain plug(Reverse side)

Pilot water hole

Flush plug

Water intake hole

Fuel connector

Caution lamp

Combination emergencystop switch & normalstop buttonTilt lock lever

Starter button(Electric starter model)

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TILLER HANDLE MODEL (DF9.9BTH/15ATH/20ATH)

Starter button

Motor cover

Starter grip

Shift lever

Throttle control grip

Clamp screw

Clamp bracket

Tilt pin

Anode

Anode(only transom L)

Gear oil level plug

Gear oil drain plug

Anode


Pilot water hole

Water intake hole

Fuel connector

Caution lamp

Combination emergencystop switch & normalstop button

Flush plug

PT switch

PT switch

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REMOTE CONTROL MODEL (DF9.9BR/15AR/20AR)

Motor cover

Starter grip

Clamp screw

Clamp bracket

Tilt pin

Gear oil level plug

Gear oil drain plug

Anode


Pilot water hole

Water intake hole

Fuel connector

Caution lamp

Tilt lock lever

Flush plug

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REMOTE CONTROL MODEL (DF9.9BT/20AT)

Motor cover

Starter grip

Clamp screw

Clamp bracket

Tilt pin

Gear oil level plug

Gear oil drain plug

Anode


Pilot water hole

PT switch(Reverse side)

Water intake hole

Fuel connector

Caution lamp

Flush plug

Anode

Anode(only transom L)

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Air-vent screw

Fuel hose

Priming bulb

FUEL TANK

Remote control handle

Warm-up leverLock-out lever Ignition key

Emergency stop switch

Throttle tension adjuster

REMOTE CONTROL BOX

Power tilt (P.T.) switch(DF9.9BT/20AT)

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MOTOR MOUNTING

TILLER HANDLE MODELProper transom height is important for goodperformance. A motor mounted on a transomthat is too high causes the propeller to slipresulting in wasted power or overheating. Amotor mounted on a transom that is too low willincrease drag, causing reduced speed.Make sure that when the motor is lowered allthe way down, the anti-cavitation plate islocated 0 – 25 mm (0 – 1.0 in) below the bottomof the boat.

WARNING

Overpowering your boat can be hazardous.Excessive horsepower will have an adverseeffect on hull safety and may cause operating/handling difficulties. The boat may also sus-tain stress and hull damage.

Never install an outboard motor with horse-power exceeding the manufacturer’s recom-mended maximum horsepower listed on theboat’s “Certification Plate”. Contact yourauthorized Suzuki marine dealer if you areunable to locate the hull “Certificate Plate”.

NOTICE

Operating your outboard motor with the anti-cavitation plate above water can cause over-heating and severe damage to your outboardmotor.

Do not operate your outboard motor with theanti-cavitation plate above water.

0 – 25 mm(0 – 1.0 in.)

Center the motor on the transom and secure itby alternately tightening the clamp bracketscrews by hand. Make sure you accurately cen-ter the motor, or the boat will pull to one sideduring operation.

Install 8 mm bolts, washers, lock washers andnuts, as illustrated and tighten the bolts sequen-tially. Be sure to seal the holes with sealant toprevent water leakage.

After installing the motor, check to make surethat steering and tilt movement are notobstructed by any part of the boat. Also makesure that the battery cable (if provided) doesn’tinterfere with movement of the motor.

NOTICE

If you attempt to mount the outboard to thetransom without having mechanical experi-ence or without being certain where to drillholes, you can seriously damage the boat.

If you do not have mechanical experience orare not sure of where to drill holes in theboat’s transom, you should have your motormounted by your authorized Suzuki marinedealer.

Sealant

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REMOTE CONTROL MODELSuzuki strongly recommends that you haveyour outboard motor, controls and gaugesinstalled by an authorized Suzuki MarineDealer. He has the tools, the facilities and theknow-how.

WARNING

If the motor is not properly secured to thetransom, it can come off.

Be sure to bolt the motor to the transom. Themotor may come off if it is held only by theclamp screws. Occasionally check the clampscrews for tightness.

WARNING

Failure to have your outboard motor and asso-ciated controls and gauges properly installedcan result in personal injury or damage.

Suzuki strongly recommends that you haveyour outboard motor, controls and gaugesinstalled by your authorized Suzuki marinedealer. He has the tools, the facilities, and theknow-how to do the job correctly.

BATTERY INSTALLATION

BATTERY REQUIREMENTELECTRIC STARTER MODEL

450 Marine Cranking Amps (MCA)/ABYC,or 330 Cold Cranking Amps (CCA)/SAEor 70 Reserve Capacity (RC) Minutes/SAEor 12 Volt, 35 AH

NOTE:• The specifications listed above are the mini-

mum battery rating requirements for startingthe engine.

• Additional electrical loads from the boat willrequire larger capacity batteries. Consultyour Suzuki dealer to determine the properbattery sizing for your boat and engine com-bination.

• Dual-purpose (Cranking/Deep-cycle) batter-ies can be used if they meet the minimumspecifications listed above (MCA, CCA, orRC).

• Do not use a Deep Cycle battery for the maincranking battery.

• When connecting batteries in parallel, theymust be of the same type, capacity, manufac-turer, and of similar age. When replacementis necessary, they should be replaced as aset. Consult your Suzuki dealer for properbattery installation information.

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BATTERY INSTALLATIONSecure the battery in a dry area of the boat,away from vibration.

NOTE:• It is recommended that the battery be

installed in an enclosed battery case.• When connecting batteries, hexagon-nuts

must be used to secure battery leads to bat-tery posts.

To hook up the battery, first connect the redlead from the motor to the positive battery ter-minal, then connect the black lead to the nega-tive battery terminal.

To remove the battery, first disconnect the blacklead from the negative terminal, then discon-nect the red lead from the positive terminal.

Suzuki recommends that you install the termi-nal cap on the positive battery terminal to pre-vent an accidental short circuit of batteryterminals.If a terminal cap is required, contact your autho-rized Suzuki marine dealer.

WARNING

If you place the battery near the fuel tank, aspark from the battery may ignite the gaso-line, causing a fire and/or an explosion.

Do not place the fuel tank in the same com-partment/area as the battery.

Red lead

Hexagon-nut

Black lead

Hexagon-nut

WARNING

Batteries produce flammable hydrogen gasand may explode if they are near flames orsparks.

Never smoke or cause sparks when workingnear the battery. Keep the battery away fromopen flames. To avoid creating a spark whencharging the battery, connect the batterycharger cables to the proper terminals beforeturning the charger on.

WARNING

Battery acid is poisonous and corrosive. Itcan cause severe injury and can damagepainted surfaces.

Avoid contact with eyes, skin, clothing, andpainted surfaces. If battery acid comes in con-tact with any of these, flush immediately withlarge amounts of water. If acid contacts theeyes or skin, get immediate medical attention.

NOTICE

The electrical system or its components maybe damaged if proper battery precautions arenot followed.

• Be sure to attach battery leads correctly.• Do not disconnect battery leads from the

battery while the engine is running.

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USE OF ELECTRICAL ACCESSORIES

To use electrical accessories, you must pur-chase a 35 AH or larger battery, rectifier andrelated items. (Recoil starter model only).

The amount of power (DC12V) available foraccessories, however, depends on the operat-ing condition of the motor. For getting a detailedinformation, please inquire of your authorizedSuzuki Marine Dealer.

NOTE:Use of too much power for electrical accesso-ries under certain operating conditions cancause the battery to discharge.

NOTE:On the models equipped with a receptacle,detach the charging cord from the receptacleand fit the cap to prevent water entry when notusing power supply.

NOTICE

If you connect electrical accessories directlyto the power receptacle of the motor, the elec-trical accessories could be damaged.

Connect lights and electrical accessories forthe boat to the battery. Consult your autho-rized Suzuki marine dealer for informationabout correct wiring.

BATTERY CHARGE CUTOUT SYSTEM(DF9.9BE/15AE/20AE)

This system activates when the battery voltagedrops to less than 6 volts while the engine isrunning.The battery charging circuit is open while thesystem is activated.All the charging current from the rectifier/regula-tor is then used to power the engine controlsystem.

NOTE:• Charging current will not flow from the recti-

fier/regulator to the battery while this systemis activated.

• When the system is activated the startermotor will not operate because the batteryvoltage is too low.Check the battery condition and re-chargethe battery if necessary.

WARNING

Failure to take proper precautions wheninspecting or servicing the battery can be haz-ardous.

Do not attempt to inspect or service the bat-tery without first reading the warnings, cau-tions, and instructions in the “BATTERYINSTALLATION” section of this manual.

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PROPELLER SELECTION AND INSTALLATION

PROPELLER SELECTIONIt is essential to use a propeller on your out-board motor that is properly matched to yourboat’s operating characteristics. The speed ofthe engine when you operate your boat at fullthrottle depends on the propeller you use.Excessive engine speed can seriously damagethe motor, while low engine speed at full throttlewill adversely affect performance. Your operat-ing load will also affect propeller selection.Smaller loads generally require larger-pitch pro-pellers; larger loads generally require smaller-pitch propellers. Your authorized Suzuki MarineDealer will assist you in selecting a suitable pro-peller for your boat.

You can determine if your propeller is appropri-ate for use with your boat by using a tachome-ter to measure engine speed when operatingyour boat at full throttle, under minimum loadconditions. If you are using an appropriate pro-peller, the engine speed will be within the fol-lowing range:

If the engine speed is not within this range, con-sult your authorized Suzuki Marine Dealer todetermine which propeller size is best for you.

NOTICE

Installing a propeller with either too much ortoo little pitch will cause incorrect maximumengine speed, which may result in severedamage to the motor.

Ask your authorized Suzuki marine dealer toassist you in selecting a suitable propeller foryour boat.

Full throttle operating range

DF9.9B4700 – 5700r/min. (min–1)

DF15A5000 – 6000r/min. (min–1)

DF20A5300 – 6300r/min. (min–1)

PROPELLER INSTALLATION

To install a propeller on your outboard motor,use the following procedure:

1. Coat the propeller shaft splines 1 liberallywith Suzuki water resistant grease to helpprevent corrosion.

2. Place the stopper 2 on the shaft.3. Align the propeller 3 with the propeller shaft

splines and slide the propeller onto the shaft.4. Place the washer 4 on the shaft.5. Install the propeller nut 5 and tighten it with

a torque wrench to 16 – 20 N·m (1.6 – 2.0kg-m/12 – 14 lb-ft).

6. Insert the cotter pin 6 and bend it so that itcan’t come off.

To remove the propeller, reverse the above pro-cedure.

WARNING

Failure to take proper precautions wheninstalling or removing the propeller can resultin severe personal injury.

When installing or removing the propeller:• Always shift into “Neutral” and remove the

emergency stop switch lock plate so thatthe motor cannot be started accidentally.

• Wear gloves to protect hands, and “lock”the propeller by placing a block of woodbetween the blades and the anti-cavitationplate.

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ADJUSTMENT

TRIM ANGLE ADJUSTMENTTo help maintain steering stability and goodperformance, always maintain the proper trimangle as shown in the illustration. The appropri-ate trim angle varies depending on the combi-nation of the boat, engine, and propeller, as wellas operating conditions.

• Trim angle too large (Boat tends to “porpoise”)

• Trim angle too small (Boat tends to “plow”)

• Proper trim angle

DF9.9B/9.9BR/15A/15AR/20A/20AR MODELMake a test run in the boat to determine if thetrim angle needs to be adjusted.

To adjust the trim angle:1. Hold the motor in the fully tilted up position.

(Refer to TILT UP LOCK ARM section.)2. Reposition the tilt pin A in the desired holes.

3. Lower the motor back down.

To lower the bow, move the pin towards theboat. To raise the bow, move the pin away fromthe boat.

DF9.9BT/9.9BTH/15ATH/20AT/20ATH MODELMake a test run in the boat to determine if thetrim angle needs to be adjusted.To adjust the trim angle:

1. Lock the motor in the fully tilted up position.(Refer to TILT UP LOCK KNOB section.)

2. Loosen the bolts B securing tilt pin A.Reposition the tilt pin A in the desired holes,then tighten the bolts securely.

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3. Lower the motor back down.

To lower the bow, move the pin towards theboat. To raise the bow, move the pin away fromthe boat.

WARNING

Trim angle greatly affects steering stability. Ifthe trim angle is too small, the boat may“plow” or “bow steer”. If the trim angle is toolarge, the boat may “chine walk” from side toside or “porpoise” up and down. These condi-tions, which result in loss of steering control,can cause occupants to be thrown overboard.

Always maintain proper trim angle based onthe combination of your boat, engine, and pro-peller, as well as operating conditions.

WARNING

If you operate the motor with the tilt pinremoved, you may not be able to control steer-ing as expected.

Do not operate the motor with the tilt pinremoved.

STEERING TENSION ADJUSTMENTThe steering on your outboard motor should besmooth and not tight. Adjust the steering ten-sion so that there is only a slight resistance tosteering movement.

REMOTE CONTROL MODELTo increase the steering tension, turn the steer-ing tension bolt A clockwise. To decrease thesteering tension, turn the steering tension boltcounterclockwise.

TILLER HANDLE MODELTo increase the steering tension, turn the steer-ing tension bolt A clockwise. To decrease thesteering tension, turn the steering tension boltcounterclockwise.For auxiliary adjustment, use the steering ten-sion lever B. To increase the steering tension,move the lever B to the left. To decrease thesteering tension, move the lever to the right.

NOTE:• To adjust initial steering friction, use the

steering tension bolt A with the steering ten-sion lever B positioned right fully.

• Do not apply a grease to the area C.

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THROTTLE TENSION ADJUSTMENTTILLER HANDLE MODELThe tension of the throttle control grip can beadjusted according to your preference. Toincrease the tension, turn the throttle tensionadjuster A clockwise. To decrease the tension,turn the adjuster counterclockwise.

REMOTE CONTROL MODELThe tension of the remote control handle can beadjusted according to your preference. Toincrease the tension, turn the throttle tensionadjuster A clockwise. To decrease the tension,turn the adjuster counterclockwise.

IDLE SPEED ADJUSTMENTThe idle speed has been factory adjustedbetween 800 – 900 r/min. in neutral.

NOTE:If idle speed cannot be set within the specifiedrange, contact your authorized Suzuki MarineDealer.

CAUTION SYSTEM

The caution systems are designed to alert youto certain situations which may cause damageto your outboard motor.

Caution lamp check

TILLER HANDLE MODELEach time the starter system is operated, thecaution lamp will light briefly for the first twoseconds, regardless of the motor condition.

NOTICE

Your outboard motor may become damaged ifyou rely on the Caution System to alert you toany malfunction that may occur or to give youan indication of the need for maintenance.

To avoid damage to your outboard motor, reg-ularly inspect and maintain it.

NOTICE

Continuing to operate your outboard motorwith the Caution System activated can resultin severe damage to your outboard motor.

If the Caution System activates while you areoperating your outboard motor, stop themotor as soon as possible and correct theproblem or consult your authorized Suzukimarine dealer for assistance.

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REMOTE CONTROL MODELEach time the ignition key is turned to the “ON”position, the caution lamp will light briefly for thefirst two seconds and the buzzer in the remotecontrol box will also sound.

NOTE:On remote control model:The caution buzzer sounds when ignition switchis turned ON. Then it stops sounding whenengine starts and the oil pressure switch turnsOFF by reaching engine oil pressure at 29.4kPa (0.30 kg/cm2, 4 psi).

NOTICE

If the Caution System is not working properly,you may not be alerted to a condition thatcould cause damage to your outboard motor.

If the caution lamp does not come on brieflyonce the starter system is operated, the cau-tion lamp may be broken or a failure may existin the system circuit. Consult your authorizedSuzuki marine dealer.

NOTICE

If the Caution System is not working properly,you may not be alerted to a condition that cancause damage to your outboard motor.

If the caution lamp does not come on or thebuzzer does not sound when the ignition keyis turned on, the caution lamp or buzzer maybe broken or a failure may exist in the systemcircuit. Consult your authorized Suzukimarine dealer.

NOTICE

Continuing to operate your outboard motorwith the Oil pressure Caution System acti-vated can result in severe damage to your out-board motor.

If the Oil Pressure Caution System activates,stop the engine as soon as possible and addoil if necessary. If the oil level is correct, con-sult your authorized Suzuki marine dealer.

OVER-REVOLUTION CAUTION SYSTEMThis system is activated when engine speedexceeds the maximum recommended speed formore than 10 seconds.

If this system activates, engine speed willautomatically be reduced to approximately3000 r/min. with the caution lamp lit.

This system must be reset by moving the throt-tle to the idle position for about one second torestore full engine operation.

OIL PRESSURE CAUTION SYSTEMThis system operates when the engine lubricat-ing oil pressure drops below the correct pres-sure.

If this system activates, the caution lamp willlight. On the remote control model, the buzzerin the remote control box will simultaneouslybegin a series of beeps. When this system isactivated at 2000 r/min. or higher, engine speedwill automatically be reduced to approximately2000 r/min.

If you continue to run, the engine will automati-cally stop 3 minutes after beginning of theabove CAUTION system activation.

NOTE:In case that the engine is automatically stoppeddue to the CAUTION system, the engine can bestarted again.However the CAUTION system will repeatedlyactivate until eliminating the cause.

NOTICE

If the Over-Revolution Caution System acti-vates at recommended maximum throttle andyou are sure that the propeller pitch is suffi-cient and there are no factors like “over-trim-ming” or “ventilation”, there may be aproblem with the Over-Revolution CautionSystem.

Consult your authorized Suzuki marine dealerif the Over-Revolution Caution System acti-vates for no apparent reason.

24

If this system activates, stop the engine imme-diately, if wind and water conditions make it safeto do so.

Check the oil level and add oil if necessary. Ifthe oil level is correct, consult your authorizedSuzuki Marine Dealer.

OVERHEAT CAUTION SYSTEMThis system is activated when the cylinder walltemperature is too high due to insufficient watercooling.

If this system activates, the caution lamp willlight. On the remote control model, the buzzerin the remote control box will simultaneouslybegin a series of beeps. When this system isactivated at 3000 r/min. or higher, engine speedwill automatically be reduced to approximately3000 r/min.

WARNING

If you attempt to remove or reinstall the motorcover while the engine is running, you may beinjured.

To check the oil level, stop the engine andthen remove the motor cover.

NOTICE

Your engine may become severely damaged Ifyou rely on the Oil Pressure Caution Systemto indicate the need to add engine oil.

Check the engine oil level periodically and addoil as necessary.

NOTICE

Operating the engine with the Oil PressureCaution System activated can result in severeengine damage.

If the Oil Pressure Caution System activates,stop the engine as soon as possible and addengine oil, if necessary, or otherwise correctthe problem.

If you continue to run, the engine will automati-cally stop 3 minutes after beginning of theabove CAUTION system activation.

NOTE:In case that the engine is automatically stoppeddue to the CAUTION system, the engine can bestarted again.However the CAUTION system will repeatedlyactivate until eliminating the cause.

If the overheat caution system activates whenoperating, reduce engine speed immediatelyand check to see if water is being dischargedfrom the pilot water hole. If no water is seen, fol-low the procedures outlined below.

Water and wind conditions permitting, stop themotor, tilt it out of the water and remove anydebris like seaweed, plastic bags or sand thatmay have blocked the water intakes.Lower the motor into the water, being sure thatwater intakes are immersed, and restart it.

Check (A) that water discharges from the pilothole and (B) that the caution lamp is no longerlit.Be aware that the caution lamp may light againif engine temperature rises abnormally. If eitherof the above situations arises, your authorizedSuzuki Marine Dealer must be consulted assoon as possible.

NOTICE

Operating the engine with the overheat cau-tion system activated can result in severeengine damage.

If the overheat caution system activates, stopthe engine as soon as possible, wind andwater conditions permitting, and inspect theengine according to the above instructions.Consult your authorized Suzuki marine dealerif you cannot correct the problem.

25

DIAGNOSTIC SYSTEM

If abnormal conditions exist in any sensor sig-nal being input to the control unit, the self-diag-nostic system warns of the abnormal condition.

TILLER HANDLE MODELIf this system activates, the caution lamp willflash.

Also incorporated is a fail-safe provision thatallows the operation at a restricted speed evenunder such a failure condition.

The failed system can be identified by the modeof the caution lamp flashing.The diagnostic code is designed to appearwhen the engine is running.

REMOTE CONTROL MODELIf this system activates, the caution lamp willflash and a buzzer will sound.

Also incorporated is a fail-safe provision thatallows the operation at a restricted speed evenunder such a failure condition.

The failed system can be identified by the modeof the caution lamp flashing and buzzer sound-ing.This diagnostic code is designed to appearwhile the ignition key is turned on.The buzzer sound with diagnostic system acti-vating will be stopped after approx. thirty sec-onds.

NOTICE

If the diagnostic system activates while youare operating your outboard motor, there is anabnormal condition in one of the sensor sig-nals of the control system.

Consult your authorized Suzuki marine dealerfor repair of the control system.

OIL CHANGE REMINDER SYSTEM

This system informs the operator of the time forreplacing engine oil on the basis of the mainte-nance schedule.The system is designed to register the totaloperating hours of the outboard motor andfunction its operation when the preprogrammedhours have reached.(Refer to the INSPECTION AND MAINTE-NANCE section and the last page.)

SYSTEM ACTIVATIONTILLER HANDLE MODELWhen the total operating hours have reachedthe preprogrammed hours, the caution lamp willflash while the engine is running. This indicationwill repeat until you cancel the system activa-tion.

REMOTE CONTROL MODELWhen the total operating hours have reachedthe preprogrammed hours, the caution lamp willflash. This indication will repeat until you cancelthe system activation.

CANCELLATIONTILLER HANDLE MODEL1. Start the motor.

Make sure that the motor is in “NEUTRAL”and the throttle grip is fully closed.

NOTE:The engine stops when the engine stop buttonis kept to push more than 0.5 seconds.

26

2. Push the engine stop button 1 three timeswithin three seconds so that the engineshould not stall.The caution lamp is no longer lit when thereminder cancellation is successful.

3. Stop the engine.

CANCELLATIONREMOTE CONTROL MODEL1. Shift into “NEUTRAL”.2. Turn the ignition key to the “ON” position.3. Pull out the emergency stop switch plate 1.4. Pull up the emergency stop switch knob 2

three times within 4 seconds. The cautionlamp is no longer lit when the reminder can-cellation is successful.

5. Turn the ignition key to the “OFF” position.6. Set the plate 1 in the original position.

NOTE:• Canceling of the system activation is possible

regardless of whether or not the engine oilhas been replaced. Once the system hasoperated, however, Suzuki strongly recom-mends that the engine oil be replaced beforecanceling the system activation.

• Even if the engine oil has been replaced withthe system not operating, it is still necessaryto perform the cancellation.

OPERATION OF TILTING SYSTEMS (DF9.9B/9.9BR/15A/15AR/20A/20AR)

TILT LOCK LEVERThe tilt lock lever A has two positions.

“Lock” PositionUse this position whenever you operate themotor in “REVERSE” gear and whenever youoperate the motor in deep water where you donot expect to encounter underwater objects.Placing the tilt lock lever in the “lock” positionprevents the motor from lifting out of the waterdue to forces such as propeller thrust duringoperation in “REVERSE” gear or rapid deceler-ation.

“Release” PositionUse this position whenever you operate themotor in “FORWARD” gear in shallow water.Placing the tilt lock lever in the “release” posi-tion allows the motor to tilt up if you strike anunderwater object, reducing the chance of dam-age to the motor. Refer to the OPERATION INSHALLOW WATER section for details on shal-low water operation.

NOTICE

If you strike an underwater object with the tiltlock lever in the “LOCK” position, your out-board motor or boat may be damaged.

When operating the motor in an area whereyou may encounter underwater objects, movethe tilt lock lever to the “RELEASE” positionand operate the motor only at very lowspeeds.

Lock

27

TILT UP LOCK ARMThe tilt up lock arm is used to hold the motor inthe fully tilted up position. To hold the motor inthe fully raised position:

WARNING

When you operate the motor with the tilt locklever in the “Release” position, the tilt lockwill not work. As a result, forces such as frompropeller thrust during operation in“REVERSE” gear, rapid deceleration, andstriking an underwater object can cause themotor to lift out of the water, resulting in per-sonal injury.

When using the “Release” position, proceedwith caution and only at very low speed.

WARNING

If you place your hands near the mountingbracket or under the motor when tilting it,your hands can be crushed if the motor slipsfrom your grasp.

Never place your hands near the mountingbracket or under the motor when tilting it.

Release

1. Shift into “NEUTRAL”.2. Move the tilt lock lever 1 to the “release”

position.

3. Grab the handle on the back of the motorcover and tilt the motor all the way up until itis automatically locked in the fully tilted upposition by the tilt up lock arm 2.

To lower the motor back down:1. Move the tilt lock lever 1 to the lock position.

NOTICE

If you use the throttle grip handle to raise orlower the motor, the handle may break.

Never use the throttle grip handle to raise orlower the motor.

28

2. Pull the motor slightly towards you andslowly let the motor down.

WARNING

If you do not take proper precautions whentilting up the motor, fuel may leak out.

Disconnect the fuel line whenever you leavethe motor tilted up for a long period of time.

NOTICE

If you use the tilt up lock arm to hold themotor in the fully tilted position for trailering,the tilt up lock arm could release resulting indamage to the motor.

When trailering your boat, never use the tilt uplock arm to hold the motor in the fully tiltedposition.

SHALLOW WATER POSITIONTo set the shallow water position:1. Shift into “NEUTRAL”.2. Move the tilt lock lever 1 to the release posi-

tion.

3. Slowly tilt the motor up until you hear it makea “click” sound.

4. Slowly lower the motor. It will stop in a posi-tion that is slightly tilted up from the normaltrim angle.

NOTE:There are two shallow water positions. Usewhichever one is appropriate, depending on thedepth of the water.

29

To lower the motor back down:1. Move the tilt lock lever 1 to the lock position.

2. Pull the motor slightly towards you andslowly let the motor down.

WARNING

When the shallow water position is used, thetilt lock will not work. As a result, forces suchas from propeller thrust during operation in“REVERSE” gear, rapid deceleration, andstriking an underwater object can cause themotor to lift out of the water, resulting in per-sonal injury.

When using the shallow water position, pro-ceed with caution and only at very lowspeeds.

OPERATION OF TILTING SYSTEMS(DF9.9BT/9.9BTH/15ATH/20AT/20ATH)

POWER TILTThe “Power Tilt” is operated by pressing theswitch. To tilt the motor up, press the upper(right) part of the switch. To tilt the motor down,press the lower (left) part of the switch.

WARNING

The power tilt (PT) switch can be accidentallyactivated when the ignition key is off, result-ing in injury.

Keep all persons away from the outboardmotor to help prevent accidental activation ofthe PT system.

UPDOWN

UP

DOWN

DOWN

UP

30

MANUAL TILTINGIf you are unable to tilt the motor using the“Power Tilt” because of an electrical problem orsome other problem, you can move the motormanually. To tilt the motor up or down, turn themanual release screw A two turns counter-clockwise, move the motor to the desired posi-tion, then retighten the release screw.

TILT UP LOCK KNOBThe tilt up lock knob is provided so you can sup-port the motor in a tilted position for non-movingengine support.

To set the tilt up lock knob:1. Tilt the motor all the way up using the power

tilt.2. Push in the tilt up lock knob 1 to hold the

motor in the fully raised position.

CAUTION

The motor is very heavy. When you tilt it man-ually, you could injure your back or slip andfall causing injury.

When you tilt the motor manually, ensure thatyour grip and footing are secure and that youare able to support the weight of the engine.

3. Lower the motor using the power tilt, until themotor is supported by the tilt up lock knob.

To release the knob, tilt the motor all the way upusing the power tilt, and pull out the tilt up lockknob.

WARNING

If you do not take proper precautions whentilting up the motor, fuel may leak out.


CAUTION

The remote Power Tilt switch will work whenthe ignition switch is off. If someone activatesthe switch while you are moving the tilt uplock knob, your hand could be injured.

Keep all persons away from the remote PowerTilt switch while you are moving the tilt uplock knob.

NOTICE

Damage can occur if you use the tilt up lockknob other than when the boat is moored or isotherwise stationary.

The tilt up lock knob relieves pressure fromthe power tilt and should only be used whenthe boat is stationary. Do not use the tilt uplock knob when trailering your boat andmotor. Refer to the TRAILERING section ofthis manual.

31

INSPECTION BEFORE BOATING

It is important to make sure that your boat andmotor are in good condition and that you areproperly prepared for an emergency.Always perform the following checks before youbegin boating:

• Make sure that you have enough fuel forthe intended run.

• Check the level of engine oil in the sump.

To check the oil level:

NOTE:To avoid an incorrect assessment of engine oillevel, check the level only when the engine hascooled.

1. Place the motor in a vertical position, andremove the motor cover by unlocking thelever.

WARNING

Failure to inspect your boat and motor beforebeginning a trip can be hazardous.

Before boating, always perform the inspec-tions described in this section.

NOTICE

Running the engine with an insufficientamount of oil can cause serious engine dam-age.

Always check the oil level before each trip andadd oil if necessary.

2. Pull out the oil dipstick 1 and wipe oil offwith a clean cloth.

NOTE:If the engine oil is contaminated or discolored,replace with fresh engine oil (Refer to Inspec-tion and maintenance/engine oil section).

3. Insert the dipstick all the way into the engine,then remove it again.

The oil on the dipstick should be between theupper and lower limits shown on the stick.If the oil level indication is near the lower limit,add enough oil to raise the level to the upperlimit.

UPPER LIMIT

LOWER LIMIT

32

To fill the engine oil:1. Remove the oil filler cap.2. Fill the recommended engine oil to the upper

level.

3. Tighten the oil filler cap securely.

• Check the battery solution level.The level should be kept between the MAXand the MIN level lines at all times. If thelevel drops below the MIN level line, referto MAINTENANCE section.

• Make sure that the battery leads aresecurely connected to the battery termi-nals.

• Visually check the propeller to make sureit is not damaged.

• Make sure that the motor is securelymounted to the transom.

• Make sure that the tilt pin is securelyinstalled in the proper position.

• Make sure the starter rope is free from anyevidence of fraying or wear.

• Make sure you have the boating safetyand emergency equipment on board.

• Make sure that the emergency stop switchoperates properly.

• Make sure the obstacle is not attached towater intake hole.

NOTICE

Running the engine with an excessive amountof oil can damage the engine.

Do not overfill the engine with oil.

BREAK-IN

Proper operation during this break-in period willhelp ensure maximum life and performancefrom your engine. The following guidelines willexplain proper break-in procedures.

Break-in period: 10 hours

Break-in procedure1. For the initial 2 hours:

Allow sufficient idling time (about 5 minutes)for the engine to warm up after cold enginestarting.

After warming up, run the engine at idlingspeed or the lowest in-gear speed for about15 minutes.During the remaining 1 hour and 45 minutes,if safe boating conditions permit, operate theengine in gear at less than 1/2 (half) throttle(3000 r/min.).

NOTICE

Failure to follow the break-in proceduresdescribed below can result in severe enginedamage.

Be sure to follow the engine break-in proce-dures described below.

NOTICE

Running at high speed without sufficientwarm-up may cause severe engine damagesuch as piston seizure.

Always allow sufficient idling time (5 minutes)for the engine to warm-up before running athigh speed.

33

NOTE:You may throttle up beyond the recommendedoperating range to plane your boat, then imme-diately reduce the throttle to the recommendedoperating range.

2. For the next 1 hour:Safe boating conditions permitting, operatethe engine in gear at 4000 r/min. or at three-quarter throttle. Avoid running the engine atfull throttle.

3. Remaining 7 hours:Safe boating conditions permitting, operatethe engine in gear at desired engine speed.You may occasionally use full throttle; how-ever do not operate the engine continuouslyat full throttle for more than 5 minutes at anytime.

NOTICE

Running continuously at full throttle for morethan 5 minutes at a time during the last 7hours of break-in operation may cause severeengine damage such as seizure.

During the last 7 hours of break-in operation,do not operate at wide open throttle for morethan 5 minutes at a time.

OPERATION

BEFORE ATTEMPTING TO START THE ENGINE1. The motor has been lowered into the water.2. The fuel hose is securely connected to the

fuel tank and the motor.

3. Twist the air-vent screw 1 on the fuel tankcap counterclockwise to open the vent.

NOTICE

If spilled gasoline is just left on painted sur-face, it may cause a stain or discoloration ofthe surface coating.

Wipe off any spilled gasoline immediately witha soft cloth etc.

34

4. Set the tilt lock lever 2 to the “Lock” posi-tion. (DF9.9B/9.9BR/15A/15AR/20A/20AR)

5. Make sure that the motor is in “NEUTRAL”.

6. The lock plate is in place and the end of theemergency stop switch cord is attached to apart of your body.

NOTICE

When the motor is in gear, the recoil startercannot be operated and attempting to use itcan damage the recoil starter.

Make sure that the motor is in “NEUTRAL”before pulling the recoil starter rope.

NOTE:A spare plastic lock plate is provided for tempo-rary use only. Remove it from the cord andplace it in a safe place on board your boat. Ifyou lose or break the emergency stop switchcord/lock plate assembly, replace it as soon aspossible so that you can resume normal use ofthe emergency stop switch.

WARNING

Failure to properly attach the emergency stopswitch cord or to take proper precautions tohelp ensure that the emergency stop switchworks as intended may result in serious injuryor death to the operator or passengers.

Always take the following precautions:• Make sure that the emergency stop switch

cord is fastened securely to the operator’swrist or to an appropriate clothing area (beltetc.).

• Ensure that no obstructions impede orrestrict emergency stop switch operation.

• Be careful not to pull the stop switch cordor knock out the lock plate during normaloperation. The motor will stop abruptly, andthe loss of forward motion may unexpect-edly throw occupants forward.

35

STARTING THE ENGINE

NOTE:• If the engine fails to start, check the emer-

gency stop switch lock plate. If the lock plateis not in position, the engine cannot bestarted.

• The starter motor can operate even with thelock plate not in position; however, the enginecannot be started.

NOTE:Perform the following prior to starting if yourmotor is brand-new or there is no fuel in the fueltank:Fill the fuel tank with fresh gasoline.Squeeze the fuel line priming bulb several timesuntil you feel resistance.Pull the starter grip sharply several times oroperate the starter motor to fill the fuel line withfuel, then follow the normal starting proceduresteps.

WARNING

Exhaust gas contains carbon monoxide, adangerous gas that is difficult to detectbecause it is colorless and odorless. Breath-ing carbon monoxide can cause death orsevere injury.

Never start the engine or let it run indoors orwhere there is little or no ventilation.

TILLER HANDLE MODEL1. Squeeze the fuel line priming bulb several

times until you feel resistance.

2. Make sure that the throttle control grip is inthe fully closed position.

36

3. a) Recoil starter modelFirmly grasp the starter grip 1 and pullslowly until resistance is felt. When youfeel it engage, pull the rope sharply tostart the engine. Do not release the ropewhen it is pulled out. Hold the rope andallow it to recoil slowly.

WARNING

If the battery cables are not connected to abattery and they contact each other while theengine is running, it could cause electricalsystem damage and could present a fire haz-ard.

If you are not using a battery with an electricstarter models, you must insulate the terminalends of the battery cables so that they will nottouch each other.

NOTICE

If you pull the starter grip while the engine isrunning, the starter system can be damaged.

Never pull the starter grip while the engine isrunning.

b) Electric starter modelPush the starter button 2.

NOTE:If the engine fails to start after 5 seconds, wait10 seconds and try again.

NOTICE

If you push the starter button for more than 5seconds, the starter system could be dam-aged.

Never push the starter button for more than 5seconds.

NOTICE

If you push the starter button while the engineis running, the starter system could be dam-aged.

Never push the starter button while the engineis running.

NOTICE

If the Caution System is not working properly,you may not be alerted to a condition thatcould cause damage to your outboard motor.

If the caution lamp does not come on brieflyonce the starter system is operated, the cau-tion lamp may be broken or a failure may existin the system circuit. Consult your authorizedSuzuki marine dealer.

37

4. Warm up the engine for about 5 minutes.

REMOTE CONTROL MODEL1. Squeeze the fuel line priming bulb several

times until you feel resistance.

2. Make sure that the warm-up lever is in thefully closed position.

NOTICE

Continuing to operate your outboard motorwith the Caution System activated couldresult in severe damage to your outboardmotor.

If the caution lamp remains lit after startingthe engine, check the engine oil level and addoil if necessary. If the oil level is correct, con-sult your authorized Suzuki marine dealer.

NOTICE

Operating the engine at high RPM or “wideopen throttle” immediately after starting theengine without allowing the engine to warmup may cause engine failure.

Always allow the engine to warm up suffi-ciently before operating it at high speeds.

3. Turn the ignition key to the “ON” position.4. Turn the ignition key to the “START” position.

NOTE:If the engine fails to start after 5 seconds, wait10 seconds and try again.

NOTICE

If you turn the ignition key to the “START”position for more than 5 seconds, the startersystem could be damaged.

Never turn the ignition key to the “START”position for more than 5 seconds.

NOTICE

If you turn the ignition key to the “START”position while the engine is running, thestarter system could be damaged.

Never turn the ignition key to the “START”position while the engine is running.

NOTICE

If the Caution System is not working properly,you may not be alerted to a condition that cancause damage to your outboard motor.

If the caution lamp does not come on or thebuzzer does not sound when the ignition keyis turned on, the caution lamp or buzzer maybe broken or a failure may exist in the systemcircuit. Consult your authorized Suzukimarine dealer.

38

5. Warm up the engine for about 5 minutes.

Cooling water checkAs soon as the engine starts, water shouldspray out of the pilot water hole 1, indicatingthat the water pump and cooling system areworking properly. If you notice that water doesnot spray out of the pilot water hole, stop theengine as soon as possible and consult yourauthorized Suzuki Marine Dealer.

NOTICE

Continuing to operate your outboard motorwith the Caution System activated couldresult in severe damage to your outboardmotor.

If the caution lamp remains lit after startingthe engine, check the engine oil level and addoil if necessary. If the oil level is correct, con-sult your authorized Suzuki marine dealer.

NOTICE

Operating the engine at high RPM or “wideopen throttle” immediately after starting theengine without allowing the engine to warmup may cause engine failure.

Always allow the engine to warm up suffi-ciently before operating it at high speeds.

EMERGENCY STARTING

NOTE:The electric starter models are equipped with arecoil starter as the back-up system for emer-gency starting. Therefore, an additional emer-gency starter rope is not provided.

If you must get the engine running, but areunable to do so because of recoil starter sys-tem failure, you can use the emergency startingprocedure to start the engine.

NOTICE

Never operate your outboard motor whenthere is no water coming out of the pilot waterhole, or severe damage can result.

After starting the engine, check to make surethat there is water coming out of the pilotwater hole.

WARNING

Operating the boat when the emergency stopswitch is not operating properly can be haz-ardous.

Before starting off, check to make sure thatthe emergency stop switch operates properly.

WARNING

If you touch electrical components when rope-starting the engine, you can get a severe elec-trical shock.

When rope-starting the engine, be careful notto touch electrical components such as igni-tion coils or spark plug leads.

39

To start the engine when the recoil starter fails:1. Shift the motor into “NEUTRAL”.

2. Remove the motor cover by turning the locklever in the direction of the arrow and liftingthe cover off.

WARNING

When you use the emergency starting proce-dure, the start-in-gear protection system willnot work. If the shift lever is not in the “NEU-TRAL” position, the boat can start off unex-pectedly when the engine is started, throwingoccupants or causing an accident.

Make sure that the shift lever is in the “NEU-TRAL” position before attempting to start themotor using the emergency starting proce-dure.

3. Remove the NSI cable 1 from the recoilstarter.

4. Pull the breather hose 2 out from hoseclamp on the recoil starter.

5. Disconnect the evaporation hose 3 from thevapor separator.

40

6. Remove the four bolts securing the recoilstarter assembly in place.

7. Lift the recoil starter assembly and roll theport side. Reconnect the evaporation hose3 to the vapor separator.

8. Secure the recoil starter assembly with thesuitable rope as shown.

9. Disconnect the breather hose 2 fromsilencer case, and then insert the hose intothe silencer case as shown.

NOTE:Make sure that the breather hose and othercables do not touch to the flywheel and the tim-ing belt.

10. Tie a knot in one end of the emergencystarter rope located in the tool kit. Tie theother end around the screw-driver handle inthe tool kit.

11. Hook the knotted end of the rope in the pul-ley notch and wind the rope around the pul-ley in a clockwise direction.

12. Put the emergency stop switch lock plate inplace.

13. Remote control model:Turn the ignition key to the “ON” position.

14. After following steps of the normal startingprocedure, pull the emergency starter ropesharply to start the engine.

41

NOTE:Be sure to have the starter system repaired assoon as possible. You should not continue touse the emergency starting procedure for rou-tine engine starting.

WARNING

If you attempt to reinstall the recoil starterassembly or motor cover after starting theengine you can be injured.

Do not attempt to reinstall the recoil starterassembly or motor cover after starting theengine.

WARNING

When the engine is running, there are manymoving parts that could cause severe per-sonal injury.

When the engine is running, keep your hands,hair, clothing, etc., away from the engine.

SHIFTING AND SPEED CONTROL

TILLER HANDLE MODELShiftingTo shift the motor into “FORWARD”, set thethrottle control grip to the idle position and pullthe shift lever towards you firmly.

To shift into “REVERSE”, put the tilt lock leverinto the “lock” position, set the throttle to the idleposition, and push the shift lever away from youfirmly.

NOTICE

Severe engine damage may occur if (a) enginespeed is not allowed to return to idle and boatspeed is not reduced when shifting from“FORWARD” to “REVERSE” or from“REVERSE” to “FORWARD”, or (b) care is nottaken when operating the boat in reverse.

Always allow the engine speed to return toidle before shifting. Exercise caution and useminimal speed when operating the boat inreverse. Be sure the handle/shift lever is in thedesired position before accelerating.

NOTICE

If you shift gears when the engine is not run-ning, the shifting mechanism can be dam-aged.

Avoid shifting gears when the engine is notrunning.

FORWARDREVERSE

42

Speed ControlAfter shifting, control the engine speed by twist-ing the throttle control grip.

REMOTE CONTROL MODELShiftingTo shift into “FORWARD”, squeeze the lockoutlever on the control handle and move the con-trol handle forward to approximately position A,as shown in the illustration.

To shift into “REVERSE”, squeeze the lockoutlever on the control handle and move the con-trol handle rearward to approximately positionB, as shown in the illustration.

SLOWER

FASTER

NEUTRAL

32˚ 32˚

FORWARDREVERSE

Speed ControlTo increase speed after you have shifted intogear, continue moving the control handle for-ward or rearward.

STOPPING THE ENGINENOTE:When it is necessary to stop the engine in anemergency, pull the emergency stop switch lockplate out of the emergency stop switch by pull-ing the emergency stop switch cord.

TILLER HANDLE MODELTo stop the engine:1. Turn the throttle control grip to the idle posi-

tion.2. Shift into “NEUTRAL”.3. After operating at full throttle, cool off the

engine a few minutes by allowing it to idle ortroll at low speed.

4. Push and hold in the stop button A until theengine stops.

5. After stopping the engine, disconnect thefuel connector from outboard motor.

WARNING

Since the same handle is used for shifting andspeed control it is possible to move the han-dle past the detent and engage the throttle.This can cause the boat to move suddenlyresulting in personal injury or property dam-age.

You must be careful not to move the controlhandle too far forward or rearward when shift-ing.

43

6. Turn the air-vent screw on the fuel tank capclockwise to shut the vent.

REMOTE CONTROL MODELTo stop the engine:1. Shift into “NEUTRAL”.2. After operating at full throttle, cool off the

engine a few minutes by allowing it to idle ortroll at low speed.

3. Turn the ignition key to the “OFF” position.Always leave the ignition key in the “OFF”position when the motor is not running, orbattery can discharge.

WARNING

If you leave the motor stopped for a longperiod of time with the fuel line connected,fuel can leak out.

Disconnect the fuel line, whenever you leavethe motor stopped for a long period of time.

NOTICE



OFFON

START

4. After stopping the engine, disconnect thefuel connector from outboard motor.

5. Turn the air-vent screw on the fuel tank capclockwise to shut the vent.

NOTE:To make sure that the emergency stop switchoperates properly, stop the engine occasionallyby pulling out the lock plate, while operating theengine at idling speed.

MOORINGThe motor should be tilted up out of the waterwhen you moor the boat in shallow water or ifthe motor will not be used for some time, to pro-tect it from damage by underwater obstacles atlow tide or corrosion from salt water.Refer to the TILT UP LOCK ARM section(DF9.9B/9.9BR/15A/15AR/20A/20AR) or TILTUP LOCK KNOB section (DF9.9BT/9.9BTH/15ATH/20AT/20ATH) for details on how to tilt upthe motor.

WARNING

If you leave the motor stopped for a longperiod of time with the fuel line connected,fuel can leak out.

Disconnect the fuel line, whenever you leavethe motor stopped for a long period of time.

NOTICE



WARNING

Unauthorized use of your boat could lead toan accident or damage to your boat.

To prevent unauthorized use of your boat, besure to remove the key and emergency stopswitch lock plate when the boat is unattended.

44

WARNING

If you leave the motor tilted up for a longperiod of time with the fuel line connected,fuel can leak out.


NOTICE

Improperly securing your boat may causedamage to your boat or motor, or other prop-erty damage.

Do not allow your motor to rub against quaywalls, piers or other boats when the boat istied up.

OPERATION IN SHALLOW WATER(DF9.9B/9.9BR/15A/15AR/20A/20AR)When operating your outboard motor in shallowwater, use the shallow water position to tilt themotor slightly from the normal trim angle. Whenusing the shallow water position, however, youshould only operate the motor at slow speeds.Refer to the SHALLOW WATER POSITIONsection.

WARNING

When the shallow water position is used, thetilt lock will not work. As a result, forces suchas from propeller thrust during operation in“REVERSE” gear, rapid deceleration, andstriking an underwater object can cause themotor to lift out of the water, resulting in per-sonal injury.

When using the shallow water position, pro-ceed with caution and only at very lowspeeds.

NOTICE

If you do not take proper precautions whenoperating your boat in shallow water, youroutboard motor or boat could be damaged.

• When you operate your motor in shallowwater using the shallow water position,make sure that the water intake holesremain in the water at all times and thatwater is always spraying out of the waterdischarge hole.

• Do not allow your motor to hit bottom, par-ticularly when operating in “REVERSE”gear, or serious damage can result. Whenthe motor hits bottom while operating in“REVERSE” gear, the shock acts directly onthe transom, and both the motor and theboat could be damaged.

45

OPERATION IN SHALLOW WATER(DF9.9BT/9.9BTH/15ATH/20AT/20ATH)When operating your boat in shallow water, itmay be necessary to tilt the motor higher thanthe normal trim angle. When you tilt the motorbeyond the normal trim angle, however, youshould only operate the boat at slow speeds.After returning to deep water, be sure to lowerthe motor to the normal trim angle.

To tilt the motor higher than the normal trimangle, use the Power Tilt switch. Refer toPOWER TILT section.

OPERATION IN SALT WATERAfter operating the motor in salt water, youshould flush the water passages with clean,fresh water as outlined in the FLUSHING THEWATER PASSAGES section. If you do not flushthe water passages, salt can corrode the motorand shorten its life.

WARNING

When the motor is beyond the maximum trimposition, the swivel bracket will not have sidesupport from the clamp bracket and the tiltsystem will be unable to cushion the engine ifthe lower unit strikes an obstruction. Thiscould lead to occupant injury. In addition,beyond the maximum trim position, the waterintake holes may be above the water line,which can result in severe engine damagefrom overheating.

Do not operate the engine above 1500 r/minor operate the boat in a planing attitude withthe engine beyond the maximum trim posi-tion.

NOTICE

If the motor hits bottom, serious damage canoccur.

Do not allow the motor to hit bottom. If themotor does strike bottom, inspect it immedi-ately for damage.

OPERATION IN FREEZING WEATHERWhen operating your outboard motor in freez-ing temperatures, you should keep the lowerunit submerged in the water at all times.When taking motor out of the water, stand it upin a vertical position until the cooling systemdrains completely.

OPERATION OF OUTBOARD MOTOR AS AUXILIARY PROPULSIONIf the outboard motor is used for auxiliary pro-pulsion, stop the motor and tilt the outboardmotor out of the water when using the mainmotor.Tilt the outboard out of water. Refer to the TILTUP LOCK ARM section (DF9.9B/9.9BR/15A/15AR/20A/20AR) or TILT UP LOCK KNOB sec-tion (DF9.9BT/9.9BTH/15ATH/20AT/20ATH).

NOTICE

If you leave your outboard motor out of thewater in freezing temperatures with water stillin the cooling system, the water can freezeand expand, causing severe damage to themotor.

When your outboard is in the water in freezingtemperatures, keep the lower unit submergedin the water at all times. When the motor isstored out of the water in freezing tempera-tures stand it up in the vertical position sothat the cooling system drains completely.

NOTICE

If your outboard motor is used for auxiliarypropulsion and it is left in the down positionwhen the main engine is powering the boat,the outboard motor or boat could be dam-aged.

Make sure that the motor is tilted out of thewater and locked whenever it is not beingused.

46

MOTOR REMOVAL AND TRANSPORTING

MOTOR REMOVALTILLER HANDLE MODEL1. Make sure that the engine has stopped com-

pletely.2. Remove the fuel hose from the motor.3. Remove the motor cover.4. Drain the gasoline from the engine fuel line

as follows:(1)Pull out the drain hose end 1 from steering

tension adjuster. (On the remote controlmodel, pull out the drain hose end from drainhose holder.)

(2)Tilt the motor fully down.(3)Loosen the drain screw 2 and drain the

gasoline from fuel vapor separator 3 into asuitable container.

(4)Tighten the drain screw 2.(5)Tilt the motor fully up.(6)Loosen the drain screw 2 again and drain

the remaining gasoline into a suitable con-tainer.

(7)After draining completely, retighten drainscrew 2.

(8)Tilt down the motor and put the drain hose1 back.

5. Install the motor cover.6. Remove the mounting bolts.7. Loosen the clamp screws.8. Lift the motor off the transom.9. Stand the motor vertically and drain the

water from the lower unit.10. To carry, hold the motor by gripping the

steering bracket and engine side cover.

WARNING


Use a proper, safe container to store any gas-oline drained from the outboard motor. Keepgasoline away from sparks, flames, people,and pets.

NOTICE



47

REMOTE CONTROL MODELIf it is necessary to remove the outboard motorfrom your boat, we recommend that you askyour authorized Suzuki Marine Dealer to do thework for you.

MOTOR TRANSPORTINGWhen transporting the motor, place the motoreither vertically or horizontally.

Vertical transport:Attach the motor to the carrier by securingclamp bracket with two clamp screws.Never use display stand for transportation of themotor.

Horizontal transport:1. Drain the gasoline from the engine fuel line.

Refer to the MOTOR REMOVAL section.2. Raise the tiller handle and rest the motor on

a case protector with the port side down-wards as shown.

WARNING

Spilled fuel or fuel vapor can cause a fire andis hazardous to health.

Always take the following precautions:• Drain the fuel from the fuel line and fuel

vapor separator before transporting theboat/outboard motor and before removingthe motor from the boat.

• DO NOT lay motor on its side without drain-ing fuel.

• Keep the motor away from open flames orsparks.

• Wipe up spilled fuel immediately.

NOTICE

If you do not take proper precautions whentransporting your outboard, it can be dam-aged.

• Do not rest the engine in any of the posi-tions shown below, as water and oil mayenter the cylinder through the exhaust portor the outer casings may be damaged.

• Do not place the engine on its side beforethe cooling water has drained from it com-pletely, as water may enter the cylinderthrough the exhaust port and cause prob-lems.

INCORRECT

48

NOTICE

If you let the lower unit of your outboard sithigher than the power head during transport-ing or storing, water may trickle into thepower head, causing damage to the engine.

Never let the lower unit sit higher than thepower head when transporting or storing youroutboard.

TRAILERING

When trailering your boat with the motorattached, keep the motor in the normal operat-ing position unless there is not enough groundclearance. If you need more ground clearance,trailer the motor in a tilted position using a tran-som saver bar or similar device to support theweight of the motor.

NOTICE

If you use the tilt up lock arm/knob to hold themotor in the fully tilted up position whentrailering the boat, towing motion or poor roadsurfaces may cause unexpected tilt lockrelease, resulting in damage to the motor andthe tilt lock mechanism.

Never use the tilt up lock arm/knob to hold themotor in the fully tilted up position whentrailering the boat. Use a transom saver bar orsimilar device to support the weight of themotor.

49

INSPECTION AND MAINTENANCE

MAINTENANCE SCHEDULEIt is important to inspect and maintain your out-board motor regularly. Follow the chart below.At each interval, be sure to perform the indi-cated service. Maintenance intervals should bejudged by number of hours or number ofmonths, whichever comes first.

I: Inspect and clean, adjust, lubricate, or replace, if necessary T: Tighten R: Replace

NOTE:Water-separating fuel filterReplace the filter element every 12-months (or more frequently if recommended by the filter manu-facturer).

WARNING



Interval

Item to be serviced

Initial 20 hrs.or 1 month

Every 100 hrs.or every

12 months


12 months


36 months

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 cylin-der block/cylinder head)

I

Bonding wires I I

Battery I I

* Engine oil filter R R

* Low pressure fuel filterI I

Replace every 400 hours or every 2 years.

* Timing beltI

Replace every 4 years.

* Idle speed I I

* Valve clearance (lash) I I

* Water pump I

* Water pump impeller I R

* Propeller nut & pin I I

* Bolts & Nuts T T

* Thermostat I

50

WARNING

Improper maintenance or failure to performrecommended maintenance can be hazard-ous. Poor maintenance or lack of maintenanceincreases the chance of an accident or equip-ment damage.

Be sure to have maintenance performedaccording to the schedule in the above chart.Suzuki recommends that only your authorizedSuzuki marine dealer or a qualified servicemechanic perform maintenance on thoseitems in the chart above which are markedwith an asterisk (*). You may perform mainte-nance on the unmarked items by referring tothe instructions in this section if you havemechanical experience. If you are not surewhether you can successfully complete any ofthe unmarked maintenance jobs, ask yourauthorized Suzuki marine dealer to do themaintenance for you.

WARNING

The safety of you and your passengersdepends on how well you maintain your out-board motor.

Follow all inspection and maintenanceinstructions carefully. If you do not have priormechanical experience, do not attempt to per-form maintenance on your outboard motor.You could be injured or may damage themotor.

NOTICE

The maintenance intervals in the chart aredesigned for normal usage of your outboardmotor. If your outboard motor is used undersevere conditions as outlined below, you mayneed to perform maintenance more often thanindicated in the chart.• Frequent full throttle operation• Prolonged continuous operation at the

maximum speed• Prolonged continuous operation at idling

speed or trolling speed• Frequent operation in muddy, silty, sandy,

acidic or shallow water• Operation without appropriate warmup

TOOL KITA tool kit is provided with your outboard motor.Keep the kit on board your boat and make surethat all of the items provided remain in the kit.The tool kit contains the following items:

1 Tool bag2 8 mm Box wrench3 10 × 12 mm Box wrench4 16 mm Box wrench5 Combination screw driver6 Screwdriver handle7 Pliers8 Hexagon wrench 8 mm9 Emergency starter rope

• Frequent abrupt acceleration and decelera-tion

• Frequent shift operationFailure to perform maintenance more fre-quently could result in damage.

Consult your authorized Suzuki marine dealerregarding appropriate maintenance intervalsfor your usage conditions. When replacingparts on your outboard motor, Suzuki stronglyrecommends that you use genuine Suzukiparts or their equivalent.

NOTE:An emergency starter rope is not pro-vided with the electric starter models.

51

SPARK PLUGYour outboard motor comes equipped with thefollowing “standard” spark plug for normalusage.

A normally operating spark plug is very light-brown in color. If the standard plug is not suit-able for your operating, consult your authorizedSuzuki outboard motor dealer.

NGK MR6K-9 Standard

NOTICE

Non-resistor types of spark plugs will inter-fere with the function of the electronic igni-tion, causing misfiring, or causing problemswith other electronic boat equipment andaccessories.

Use ONLY resistor type spark plugs in youroutboard motor.

NOTICE

Use of improper spark plugs or improperlytightening spark plugs can cause severeengine damage.

• Do not experiment with other spark plugbrands unless you can determine that theyare directly equivalent to the specifiedbrand, or you may experience engine dam-age which will not be covered under war-ranty. Note that aftermarket cross-referencecharts may not be accurate.

• To install a spark plug; seat it as far as pos-sible by hand, then use a wrench to tightenit to either the recommended torque settingor the specified rotation angle.

Tightening torque

10 – 12 N·m (1.0 – 1.2 kg-m, 7.0 – 8.5 lb-ft)

Rotation angle

New plug 1/2 – 3/4 of a turn

Re-use plug 1/12 – 1/8 of a turn

• Do not overtighten or cross-thread a sparkplug, as this will damage the aluminumthreads of the cylinder head.

52

To maintain a strong spark, you should cleanand adjust the plugs at the intervals shown inthe maintenance chart. Remove carbon depos-its from the spark plugs using a small wirebrush or spark plug cleaner, and adjust the gapaccording to the following chart:

1. Excessive wear 2. Breakage 3. Melting4. Erosion 5. Yellow deposits 6. Oxidation

NOTE:If the spark plug condition is found as shown inthe illustration above, ensure it is replaced withnew one. Otherwise, it will cause difficulty instarting the engine, increase fuel consumption,and result in engine troubles.

Spark plug gap0.8 – 0.9 mm

(0.031 – 0.035 in.)

BREATHER AND FUEL LINEInspect the breather and fuel line for leaks,cracks, swelling, or other damage. If thebreather and fuel line is damaged in any way, itmust be replaced. Consult your authorizedSuzuki Marine Dealer if it is necessary toreplace them.

WARNING

Fuel leakage can contribute to an explosion orfire, resulting in serious personal injury.

Have your authorized Suzuki Marine Dealerreplace the fuel line if there is any evidence ofleaking, cracking or swelling.

Fuel line

Fuel line

Breather line

53

ENGINE OIL

Engine oil changeThe oil should be changed when engine iswarm so that the oil will drain thoroughly fromthe engine.

To change the engine oil:1. Place the motor in a vertical position and

remove the motor cover.2. Remove the oil filler cap 1.

WARNING

Never perform any ENGINE OIL procedurewith the motor running, as serious injury canoccur.

The motor must be shut off before anyENGINE OIL procedures are performed.

NOTICE

Extended trolling can reduce oil life. Yourengine may be damaged if you do not changeengine oil more frequently under this type ofuse.

Change your engine oil more frequently ifyour engine is used for extended trolling.

3. Place a drain pan under the engine oil drainplug.

4. Remove the engine oil drain screw 2 andgasket 3, then let the engine oil drain.

5. After draining, secure the engine oil drainplug with a new gasket.

6. Fill with recommended engine oil to theupper level.

Oil capacity: 1.0 L

CAUTION

The engine oil temperature may be highenough to burn your fingers when the drainplug is loosened.

Wait until the drain plug is cool enough totouch with bare hands before removing it.

NOTICE

A previously-used gasket may leak, resultingin engine damage.

Do not re-use gaskets. Be sure to always usenew gaskets.

54

7. Check the engine oil level.

NOTE:To avoid incorrect measurement of engine oillevel, check oil level only when the engine hascooled.

8. Reinstall the oil filler cap.

NOTE:Recycle of properly dispose of used engine oil.Do not throw it in the trash, or pour it on theground, down a drain, or into the water.

WARNING

Engine oil can cause injury to people or pets.Repeated, prolonged contact with usedengine oil may cause skin cancer. Even briefcontact with used oil may irritate skin.

• Keep new and used oil away from childrenand pets.

• Wear a long-sleeve shirt and waterproofgloves when handling oil.

• Wash with soap if oil contacts your skin.• Launder any clothing or rags that are wet

with oil.

UPPER LIMIT

LOWER LIMIT

GEAR OILTo check the gear oil level, remove the upper oillevel plug and look into the hole. The oil levelshould be at the bottom edge of the hole. If theoil level is low, add the specified gear oil untilthe level reaches the bottom edge of the hole.Then, reinstall and tighten the plug.

To change the gear oil:1. Make sure the motor is in an upright posi-

tion. Place a drain pan under the lower cas-ing.

2. Remove the gear oil drain plug 1, thenremove the gear oil level plug 2.

3. After the oil has drained completely, injectthe specified gear oil into the lower drainhole until it just starts to come out of theupper hole. Approximately 0.25 L (0.3/0.2US/lmp. qt.) of oil will be required.

4. Reinstall and tighten the gear oil level plug2, then quickly reinstall and tighten the gearoil drain plug 1.

NOTE:To avoid insufficient injection of gear oil, checkthe gear oil level 10 minutes after doing the pro-cedure in the step 4. If the oil level is low, slowlyinject the gear oil up to the correct level.

55

NOTE:Recycle or properly dispose of used gear oil.Do not throw it in the trash, or pour it on theground, down a drain, or into the water.

LUBRICATIONProper lubrication is important for the safe,smooth operation and long life of each workingpart of your outboard motor. The following chartshows the lubrication points of your motor andthe recommended lubricant:

WARNING

Gear oil can cause injury to people or pets.Repeated, prolonged contact with used gearoil may cause skin cancer. Even brief contactwith used oil may irritate skin.

• Keep new and used oil away from childrenand pets.

• Wear a long-sleeve shirt and waterproofgloves when handling oil.

• Wash with soap if oil contacts your skin.• Launder any clothing or rags that are wet

with oil.

NOTICE

If fishing line wraps around the rotating pro-peller shaft, the propeller shaft oil seal canbecome damaged and can allow water to enterthe gear case causing severe damage.

If the gear oil has a milky color, it is contami-nated with water. Immediately contact yourauthorized Suzuki marine dealer for advice.Do not operate your outboard until the oil ischanged and the cause of the contaminationis corrected.

LOCATION LUBRICANT

Throttle linkage

Marine-grade water resistant grease

Throttle cable

Clamp screw

Propeller shaft

56

NOTE:Before applying grease through the steeringbracket grease nipple, lock the motor in the fullytilted up position.

Swivel bracketMarine-grade water resistant grease(Grease Gun)

Steering bracket

ANODESThe motor is protected from exterior corrosionby anodes. These pieces of anodes controlelectrolysis and prevent corrosion. The anodeswill corrode in place of the parts they are pro-tecting. You should periodically inspect each ofthe anodes and replace them when 2/3 of themetal has corroded away.

NOTE:Consult your authorized Suzuki Marine Dealerfor inspection and replacement of internalanodes attached to the cylinder block/cylinderhead.

NOTICE

If anodes are not properly maintained, under-water aluminum surfaces (such as the lowerunit) will suffer galvanic corrosion damage.

• Periodically inspect anodes to make surethey have not become detached.

• Do not paint anodes, as this will renderthem ineffective.

• Periodically clean anodes with a wire brushto remove any coating which mightdecrease their protective ability.

DF9.9BT/9.9BTH/15ATH/20AT/20ATH

57

BONDING WIRES (DF9.9BT/9.9BTH/15ATH/20AT/20ATH)Bonding wires are used to electrically connectthe engine components so they exist in a com-mon ground circuit. This allows them to be pro-tected against electrolysis by the anodes.These wires and their terminals should bechecked periodically to be sure they have notbeen damaged.

BATTERYThe battery solution level must be kept betweenthe MAX and the MIN level lines at all times. Ifthe level drops below the MIN level line, addDISTILLED WATER ONLY until the batterysolution level reaches the MAX level line.

WARNING

Battery acid is poisonous and corrosive, andcan cause severe injury.

Avoid contact with eyes, skin, clothing, andpainted surfaces. If battery acid comes in con-tact with any of these, flush immediately withlarge amounts of water. If acid contacts theeyes or skin, get immediate medical attention.

WARNING

If you are not careful when checking or servic-ing the battery, you can cause a short circuit,which could result in an explosion, fire, or cir-cuit damage.

Disconnect the negative (black) cable whenchecking or servicing the battery. Be carefulnot to allow a metal tool or other metal objectto touch the battery’s positive terminal andthe motor at the same time.

WARNING

Battery posts, terminals, and related accesso-ries contain lead and lead compounds thatmay be hazardous.

Wash hands after handling.

NOTICE

If you add diluted sulphuric acid to the batteryafter it has been initially serviced, you willdamage the battery.

NEVER add diluted sulphuric acid to the bat-tery after it has been initially serviced. Followthe battery manufacturer’s instructions forspecific maintenance procedures.

58

ENGINE OIL FILTERThe engine oil filter must be changed by anauthorized Suzuki Marine Dealer periodically.Replace engine oil filter with a new one at initial20 hours (1 month).Replace engine oil filter with a new one at every200 hours (12 months).

FUEL FILTERThe fuel filter must be inspected by authorizedSuzuki Marine Dealer periodically.

Low pressure fuel filterInspect low pressure fuel filter at initial 20 hours(1 month).Inspect low pressure fuel filter at every 100hours (12 months).Replace low pressure fuel filter with a new oneat every 400 hours (2 years).

TIMING BELTThe timing belt must be changed by authorizedSuzuki Marine Dealer periodically.Inspect timing belt at every 200 hours (12months).Replace timing belt with a new one at every 4years.

FLUSHING THE WATER PASSAGES

After operation in muddy, brackish, or saltwater, you should flush the water passages andmotor surface with clean, fresh water.If you do not flush the water passages, salt cancorrode the motor and shorten its life. Flush thewater passages as follows.

ENGINE RUNNING – Vertical position –Suzuki recommends that you flush the waterpassages using this method.

To flush the water passages, you must obtain acommercially available engine flush device.

WARNING



WARNING

Failure to take proper precautions when flush-ing the water passages can be hazardous.

When flushing the water passages, alwaystake the following precautions:• Make sure that the engine remains in NEU-

TRAL. If shifted into gear, the propellershaft will turn and could cause severe per-sonal injury.

• Make sure the motor is properly clamped toa secure stand or boat, and remain in atten-dance until flushing is completed.

• Keep children and pets away from the area,and stay clear of all moving parts.

59

1. Make sure that the motor is stopped.2. Install the flushing attachment 1 so that the

water intake holes are covered by the rubbercups on the attachment.

3. Connect a garden hose to the flushingattachment and turn on the water to obtainenough flow so that plenty of excess water isflowing out from around the rubber cups onthe attachment.

4. Shift the motor into “NEUTRAL” and removethe propeller. Start the motor and allow it torun at idle.

5. Readjust the water flow, if necessary, so thatthere is still plenty of excess water flowingout from around the rubber cups.

6. Allow the water to continue circulating for afew minutes.

7. Stop the motor, then turn off the water.8. Remove the flushing attachment.9. Clean the motor surface and apply a coat of

automotive wax on the external finish of themotor.

NOTICE

Severe engine damage can occur in as little as15 seconds if the engine is started withoutsupplying water to the cooling system.

Never start the motor without supplying waterto the cooling system.

ENGINE NOT RUNNING – Vertical position –1. Make sure that the motor is stopped.2. Remove the plug A from the flushing port.

3. Install garden hose by using a hose connec-tor matched to flushing port thread B.Thread B: 0.75 – 11.5 NHR (American stan-dard hose coupling threads for garden hoseapplications.)

NOTE:The hose connector (flushing attachment)matched to the flushing point thread B isincluded in the crate parts.

4. Turn on the water to obtain a good waterflow.Flush the engine for about five minutes.

5. Turn off the water.6. Remove the hose and connector (if used)

then reinstall the plug into the flushing port.7. Leave the motor in a vertical position until

the engine is drained completely.

60

ENGINE NOT RUNNING– Full tilt up position –1. Raise the engine to the full tilt up position.2. Follow the “ENGINE NOT RUNNING – Verti-

cal position” instructions.DO NOT RUN ENGINE IN THE FULL TILTUP POSITION.

3. Lower the motor a vertical position until theengine is drained completely.

SUBMERGED MOTOR

A motor that has been accidentally submergedin water must be overhauled as soon as possi-ble to prevent corrosion. In the event that yourmotor is accidentally submerged, take the fol-lowing steps:1. Get the motor out of the water as soon as

possible.2. Wash it thoroughly with fresh water to com-

pletely remove all salt, mud, and seaweed.3. Remove the spark plugs. Drain the water

from the cylinders through the spark plugholes by manually turning the flywheel sev-eral times.

4. Check if any water is evident in the engineoil. If water is seen, remove the oil drain plugand drain the oil. After draining, tighten theoil drain plug.

5. Drain the fuel line and all filters.

6. Pour engine oil into the engine through thespark plug holes. Turn the engine over byoperating the recoil starter so that oil coatsthe surfaces of the engine’s inner parts.

WARNING


Keep flames and sparks away from gasoline.Dispose of unwanted fuel properly.

NOTICE

Severe engine damage may occur if you con-tinue cranking the engine when you encounterfriction or resistance.

If you encounter friction or resistance whilecranking the engine, stop at once and do notattempt to start the engine until you find andcorrect the problem.

61

7. Take the motor to your authorized SuzukiMarine Dealer as soon as possible to beoverhauled.

NOTICE

If the fuel supply is contaminated with water,engine damage may occur.

If the boat’s fuel tank filler and vent were sub-merged, inspect the fuel supply to make sureit is not contaminated with water.

STORAGE PROCEDURE

MOTOR STORAGEWhen storing your motor for a long period oftime (for example, at the end of the boating sea-son), it is recommended that you take yourmotor to your authorized Suzuki Marine Dealer.However, if you choose to prepare the motor forstorage yourself, follow the procedure outlinedbelow:

1. Change the gear oil as outlined in the GEAROIL section.

2. Change the engine oil as outlined in theENGINE OIL section.

3. Fill a fuel stabilizer to the fuel tank accordingto the instructions on the stabilizer can.

4. Flush the water passages in the motor thor-oughly. Refer to the FLUSHING THEWATER PASSAGES section.

5. Readjust the water flow, run the engine atabout 1500 r/min. in neutral for five minutesto distribute the stabilized fuel through theengine.

6. Stop the engine. Then turn off the water anddisconnect the flushing attachment.

7. Lubricate all other specified parts. Refer tothe LUBRICATION section.

8. Apply a coat of automotive wax on theexternal finish of the motor. If paint damageis evident, apply touch up paint before wax-ing.

9. Store the motor in an upright position in adry, well-ventilated area.

WARNING

When the engine is running, there are manymoving parts that could cause severe per-sonal injury.

When the engine is running, keep your hands,hair, clothing, etc., away from the engine.

NOTICE

Severe engine damage can occur in as little as15 seconds if the engine is started withoutsupplying water to the cooling system.

Never start the motor without supplying waterto the cooling system.

62

BATTERY STORAGEELECTRIC STARTER MODEL1. When the outboard motor will not be used

for a month or longer, remove the batteryand store it in a cool, dark place. Completelyrecharge the battery before reusing it.

2. If the battery will be stored for a long periodof time, check the specific gravity of the bat-tery solution at least once a month andrecharge the battery when low.

NOTICE



WARNING

Failure to take proper precautions whencharging the battery can be hazardous. Bat-teries produce explosive vapors that canignite. Battery acid is poisonous and corro-sive, and can cause severe injury.

• Do not smoke and keep battery away fromopen flames and sparks.

• To avoid creating a spark when chargingthe battery, connect the battery chargercables to the proper terminals before turn-ing the charger on.

• Handle the battery with extreme care andavoid skin contact with battery acid.

• Wear proper protective clothing (Safetyglasses, gloves, etc.)

AFTER STORAGE

When taking your motor out of storage, followthe procedure below to return it to operatingcondition:1. Thoroughly clean the spark plugs. Replace

them if necessary.2. Check the gear-case oil level and if neces-

sary, add gear oil according to the procedureoutlined in the GEAR OIL section.

3. Lubricate all moving parts according to theLUBRICATION section.

4. Check the engine oil level.5. Clean the motor and wax the painted sur-

faces.6. Recharge the battery before installing it.

TROUBLESHOOTING

This troubleshooting guide is provided to helpyou find the cause of common complaints.

Recoil starter/starter motor will not oper-ate:• Shift lever is not in NEUTRAL.• Fuse is blown out. (Electric start model).

Engine will not start (hard to start):• Emergency stop switch lock plate is not in

position.• Fuel tank is empty.• Fuel hose is not properly connected to

engine.• Fuel hose is kinked or pinched.• Spark plug is fouled.

NOTICE

Failure to troubleshoot a problem correctlycan damage your outboard motor. Improperrepairs or adjustments may damage the out-board motor instead or fixing it. Such damagemay not be covered under warranty.

If you are not sure about the proper action tocorrect a problem, consult your Suzuki marinedealer.

63

Engine idles unstably or stalls:• Fuel hose is kinked or pinched.• Spark plug is fouled.

Engine speed will not increase (Engine power is low):• Engine is overloaded.• Caution/Diagnosis system is activated.• Propeller is damaged.• Propeller is not properly matched to loads.

Engine vibrates excessively:• Engine mounting bolts or clamp screws are

loose.• Foreign object (seaweed etc.) is tangled on

propeller.• Propeller is damaged.

Engine overheats:• Cooling water intake(s) are blocked.• Engine is overloaded.• Propeller is not properly matched to loads.

FUSE1. Remove the motor cover.2. Remove the fuse case cover and pull off

fuse.

1 Main fuse: 30A (white fuse case)2 ECM fuse: 10A (yellow fuse case)

Fuse case cover

3. Inspect the fuse and replace with the newfuse if needed.

NOTE:If a fuse is blown, try to determine the rootcause and correct it.If the cause is not corrected, the fuse may beblown again.

WARNING

If you replace a blown fuse with a fuse havinga different amperage rating or with a substi-tute such as aluminum foil or a wire, extensiveelectrical system damage and a fire mayresult.

Always replace a blown fuse with a fuse of thesame type and rating.

NOTICE

If a new fuse blows in a short time after instal-lation, you may have a major electrical systemproblem.

Consult your SUZUKI marine dealer.

Normal fuse Blown fuse

64

SPECIFICATIONS

INFORMATION REGARDING EC – DIRECTIVE(For European countries)

Sound Pressure Level

Sound pressure level is measured according to ISO 14509-1:2008.

Vibration on tiller handle gripTiller handle grip vibration total value of this motor measured under related EC Directive does notexceed 2.5m/s2. The vibration measurement is performed specified in ISO 5349-1986.

Item DF9.9B DF15A DF20A

Engine Type 4 Stroke

Number of Cylinders 2

Bore and Stroke 60.4 × 57.0 mm (2.38 × 2.24 in.)

Piston Displacement 327 cm3 (20.0 cu. in.)

Maximum output 7.3kW (9.9PS) 11.0 kW (15 PS) 14.7 kW (20 PS)

Full Throttle Operating Range 4700 – 5700r/min. (min–1)

5000 – 6000r/min. (min–1)

5300 – 6300r/min. (min–1)

Ignition System Digital CDI

Engine Lubrication Trochoid pump pressure lubrication

Engine Oil Capacity 1.0 L (1.1/0.9 US/lmp. qt.)

Gear Oil Capacity 0.25 L (0.3/0.2 US/Imp. qt.)

Spark Plug NGK MR6K-9

Spark Plug Gap 0.8 – 0.9 mm (0.031 – 0.035 in.)

Valve Clearance (Lash) IN. : 0.16 – 0.20 mm (0.006 – 0.008 in.)EX.: 0.16 – 0.20 mm (0.006 – 0.008 in.)

Fuel Type Alcohol-free unleaded gasoline

Minimum Fuel Octane Rating 91 (Research method)

Regulation Sound pressure level limit

2013 / 53 / EU67 dB (A): DF9.9B72 dB (A): DF15A/20A

65

FLOWCHART OF OIL CHANGE REMINDER SYSTEM

*1: Lapse of initial 20 hour’s operation*2: Lapse of 80 hour’s operation*3: Lapse of 100 hour’s operation*4: When performing cancellation before system activation

Action

Starting operation

CancellationIndication

(*1) (*4)




Repeat

(*2) (*4)

(*3) (*4)

(*3) (*4)

WIRING DIAGRAMDF9.9B/15A/20A (RECOIL STARTER MODEL)

WIR

E C

OL

OR

B...

......

.B

r....

....

Gr.

......

.Lg

......

..O

......

...P

......

....

R...

......

.W

......

...Y

......

....B

lack

Bro

wn

Gra

yLi

ght g

reen

Ora

nge

Pin

kR

edW

hite

Yel

low

B/B

r....

..B

/G...

...B

/O...

....

B/R

......

.B

/W...

...B

/Y...

....

BI/O

......

BI/R

......

BI/Y

......

Br/

Bl..

...

Bla

ck w

ith B

row

n tr

acer

Bla

ck w

ith G

reen

trac

erB

lack

with

Ora

nge

trac

erB

lack

with

Red

trac

erB

lack

with

Whi

te tr

acer

Bla

ck w

ith Y

ello

w tr

acer

Blu

e w

ith O

rang

e tr

acer

Blu

e w

ith R

ed tr

acer

Blu

e w

ith Y

ello

w tr

acer

Bro

wn

with

Blu

e tr

acer

Br/

R...

...B

r/W

.....

O/B

......

.R

/B...

....

Y/B

......

.Y

/Bl..

.....

Y/G

......

.Y

/R...

....

Y/W

......

W/B

.....

Bro

wn

with

Red

trac

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row

n w

ith W

hite

trac

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rang

e w

ith B

lack

trac

erR

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ith B

lack

trac

erY

ello

w w

ith B

lack

trac

erY

ello

w w

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lue

trac

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w w

ith G

reen

trac

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w w

ith R

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acer

Yel

low

with

Whi

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acer

Whi

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lack

trac

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HI

LO

MA

PS

EN

SO

R

TH

RO

TT

LE

SE

NS

OR

W R B

Br/

Bl

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BB

l/R B P

RR

YY

W B

W

WW B

B

B B Br

Y/G

B Y/W

B Gr

Y/R Y

B O

Bl/Y

B/W B/Y

B/R

B Lg Gr

O/B Gr

B/B

r

BY

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Gr

Gr

W/B

Y/B

Y/WB/OR/BBr/RBr/W

PBl/OGrBR

Br/BlWLg

W/BO/BB/BrY/Bl

BB/WB/YB/RBl/Y

OY/RY

Y/B

B

B B/O

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Br/

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B R/B

BB

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MA

GN

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M P

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TR

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AL

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ITIO

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#1 #2

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R &

RE

GU

LA

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R

BA

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TR

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ITC

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O

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F

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PR

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SU

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H

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MP

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EL

INJE

CT

OR

#1 #2

CM

P S

EN

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R

Em

erg

ency

sto

p s

wit

ch:

Lo

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late

IN

RU

N

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pla

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UT

S

TO

PE

ng

ine

sto

p s

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ch:

Bu

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ST

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TO

P &

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Op

tio

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par

ts

CA

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LA

MP

Br/

WB

r/R

B/W

R/B

DF9.9BE/15AE/20AE (ELECTRIC STARTER MODEL)

WIR

E C

OL

OR

B...

......

.B

r....

....

Gr.

......

.Lg

......

..O

......

...P

......

....

R...

......

.W

......

...Y

......

....B

lack

Bro

wn

Gra

yLi

ght g

reen

Ora

nge

Pin

kR

edW

hite

Yel

low

B/B

r....

..B

/O...

....

B/R

......

.B

/W...

...B

/Y...

....

BI/O

......

BI/R

......

BI/Y

......

Br/

Bl..

...

Bla

ck w

ith B

row

n tr

acer

Bla

ck w

ith O

rang

e tr

acer

Bla

ck w

ith R

ed tr

acer

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ith W

hite

trac

erB

lack

with

Yel

low

trac

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lue

with

Ora

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trac

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lue

with

Red

trac

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lue

with

Yel

low

trac

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row

n w

ith B

lue

trac

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O/B

......

P/B

......

R/B

......

.Y

/B...

....

Y/B

l.....

..Y

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...Y

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....

Y/W

......

W/B

......

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with

Bla

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acer

Pin

k w

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trac

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trac

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trac

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MA

PS

EN

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R

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NS

OR

STA

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ITC

HP

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H

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M

HI

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BB

l/R

W/R Br

R Br

B PY Y Y W

Y Y Y W

WW R

R

B

B B

Br

Y/G

B Y/W

B Gr

Y/R Y

B O

Bl/Y

B/W B/Y

B/R

B Lg Gr

O/B Gr

B/B

r

BY

/Bl

Gr

Gr

W/B

Y/B

P/BY/WB/OW

R/BP

Bl/OGrBR

Br/BlWLg

W/BO/BB/BrY/Bl

BB/WB/YB/RBl/Y

OY/RY

Y/B

P/B

R

R

W

R

R R

R

B

B

Y/W

Br

R

R

B

B B/O

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B/W

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B R/B

BB

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CA

UT

ION

LA

MP

MA

GN

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P S

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R

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10A

FU

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30A

CY

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TR

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SIG

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#1 #2

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LA

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R

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TT

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G

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EL

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CH

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PR

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H

Br

Br

DF9.9BTH/15ATH/20ATH (POWER TILT MODEL)

HI

LO

WIR

E C

OL

OR

B...

......

.B

r....

....

Gr.

......

.Lg

......

.Lb

l.....

..O

......

...P

......

....

R...

......

.W

......

...Y

......

....B

lack

Bro

wn

Gra

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Ligh

t blu

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rang

eP

ink

Red

Whi

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w

B/B

r....

..B

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....

B/R

......

.B

/W...

...B

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....

BI/O

......

BI/R

......

BI/Y

......

Br/

Bl..

...O

/B...

...

Bla

ck w

ith B

row

n tr

acer

Bla

ck w

ith O

rang

e tr

acer

Bla

ck w

ith R

ed tr

acer

Bla

ck w

ith W

hite

trac

erB

lack

with

Yel

low

trac

erB

lue

with

Ora

nge

trac

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lue

with

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trac

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lue

with

Yel

low

trac

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row

n w

ith B

lue

trac

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rang

e w

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trac

er

P/B

......

R/B

......

.Y

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....

Y/B

l.....

..Y

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...Y

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....

Y/W

......

W/B

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Pin

k w

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trac

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lack

trac

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w w

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trac

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trac

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w w

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trac

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w w

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with

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trac

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with

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trac

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ST

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CH

PU

SH

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B PY Y Y W

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B

B B Br

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Y/R Y

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l

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R

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PR

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SU

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ITC

H

Br/

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RR

DF9.9BR/15AR/20AR (REMOTE CONTROL MODEL)

WIR

E C

OL

OR

B...

......

.B

r....

....

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......

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O...

......

P...

......

.R

......

....

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......

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......

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row

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ray

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t gre

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w

B/B

l.....

.B

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B/O

......

.B

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....

B/W

......

B/Y

......

.B

I/O...

..B

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r/B

l.....

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trac

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with

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wn

trac

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with

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trac

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with

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trac

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HI

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DF9.9BT/20AT (POWER TILT MODEL)

WIR

E C

OL

OR

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......

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l.....

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r....

....

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trac

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en df9 - suzuki.hu€¦ · suzuki recommends the use of suzuki out-board motor gear oil. if it is...

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