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• Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the outboard motor.

• To avoid eye injury, always wear protective goggles when filing metals, working on a grinder, or doing other work, which could cause flying material particles.

• When 2 or more persons work together, pay attention to the safety of each other.

• When it is necessary to run the outboard motor indoors, make sure that exhaust gas is vented outdoors.

• When testing an outboard motor in the water and on a boat, ensure that the necessary safety equipment is on board. Such equipment includes: flotation aids for each person, fire extinguisher, distress signals, anchor, paddles, bilge pump, first-aid kit, emergency starter
rope, etc.

• When working with toxic or flammable materials, make sure that the area you work in is well-ventilated and that you follow all of the material manufacturer’s instructions.

• Never use gasoline as a cleaning solvent.

• To avoid getting burned, do not touch the engine, engine oil or exhaust system during or shortly after engine operation.

• Oil can be hazardous. Children and pets may be harmed from contact with oil. Keep new and used oil away from children and pets. To minimize your exposure to oil, wear a long sleeve shirt and moisture-proof gloves (such as dishwashing gloves) when changing oil. If oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil. Recycle or properly dispose of used oil.

• After servicing fuel, oil/engine cooling system and exhaust system, check all lines and fittings related to the system for leaks.

• Carefully adhere to the battery handling instructions laid out by the battery supplier.

• If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent.

• When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

• Be sure to use special tools when instructed.

• Make sure that all parts used in assembly are clean and also lubricated when specified.

• When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type.

• When removing the battery, disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable.

• When performing service to electrical parts, if the service procedures do not require using battery power, disconnect the negative cable at the battery.

• Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller diameter, Always tighten from inside to outside diagonally, to the specified tightening torque.

• Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, locking nuts, cotter pins, circlips, and certain other parts as specified, always replace them with new. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.

• Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.

• Use a torque wrench to tighten fasteners to the torque values when specified. Remove grease or oil from screw / bolt threads unless a lubricant is specified.

• After assembly, check parts for tightness and operation.


Suzuki Models / Horsepower / Model Years

DF4 DF4 DF6 DF9.9 DF15 DF25 DF30 DF40 DF50 DF50 DF40QH DF50QH DF40T DF50T DF40Y DF50Y DF70 DF80 DF90 DF100 DF115 DF175 QH T Y 4HP 5HP 6HP 9.9HP 15HP 25HP 30HP 40HP 50HP 60HP 70HP 90HP 115HP 140HP 150HP 175HP 4 5 6 9.9 15 25 30 40 50 60 70 90 100 115 140 150 175 HP 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 99 00 01 02 03 04 05 06 07 08 09 10 11 Service Manual Repair Owner's Guide Diy Boat Engine Four Stroke 4-Stroke How To Fix.