OUTBOARD MOTOR

DF25A/AR/AT/AQ
DF30A/AR/AT/AQ
Applicable model and effective serial number:
02504F-510001 and later
03003F-510001 and later

99505-94L10-01E
1
 FOREWORD
This outboard motor has been designed and produced utilizing
Suzuki’s most modern technology. The finest product, however,
cannot perform properly unless it is correctly assembled and
serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this outboard motor.

NOTE:
This Set-up manual has been prepared exclusively for following
models.
Applicable model and effective serial number:
02504F-510001 and later
03003F-510001 and later

* This manual has been prepared on the basis of the latest

specifications at the time of publication. If modifications
have been made since then, differences may exist
between the content of this manual and the actual out-
board motor.
* Illustrations in this manual are used to show the basic
principles of operation and work procedures and may not
represent the actual outboard motor exactly in detail.
* This manual is intended for those who have enough
knowledge and skills to service SUZUKI outboard
motors. Without such knowledge and skills, you should
not attempt servicing by relying on this manual only.
Instead, please contact your nearby authorized SUZUKI
outboard motor dealer.


Apprentice mechanics or do-it-yourself mechanics
that don’t have the proper tools and equipment may
not be able to properly perform the services described
in this manual. Improper assembly and/or servicing
may result in injury to the mechanic and may render
the engine unsafe for the boat operator and passen-
gers.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2014 Outboard Motor Engineering Department

1
 CONTENTS

IMPORTANT ............................................. 3 CONTROL CABLES AND WIRE

SYMBOL ................................................... 4 HARNESS INSTALLATION ....................20
REMOTE CONTROL BOX SIDE .....20
MATERIALS REQUIRED ......................... 4
ENGINE SIDE ..................................20
GENERAL INFORMATION ...................... 5
STEERING SYSTEM ...............................26
HANG TAGS ..................................... 5
DRAG LINK INSTALLATION ..........26
EMISSION-RELATED
INSTALLATION INSTRUCTIONS .... 6 BATTERY ................................................28
BATTERY REQUIREMENT .............28
OUTBOARD MOTOR INSTALLATION .... 7
INSTALLATION OF BATTERY .......28
HORSEPOWER SELECTION ........... 7
CONNECTION OF BATTERY
MOTOR DIMENSIONS ...................... 7
CABLE .............................................29
TRANSOM DIMENSIONS ............... 12
PROPELLER ...........................................30
ESTABLISHING
THE CENTER-LINE ........................ 13 OPTIONAL PARTS INSTALLATION ......31
LIFTING THE MOTOR .................... 14 TRIM SENDER INSTALLATION .....31
MOUNTING TO THE TRANSOM (For CAUTION BUZZER
DF25A/AE/AR, DF30A/AE/AR) ...... 15 INSTALLATION ...............................34
MOUNTING TO THE TRANSOM (For WIRING DIAGRAM .................................35
DF25AT/Q, DF30AT/Q) ................... 17 Side Mount Remote Control ..........35

2
IMPORTANT
WARNING/CAUTION/NOTICE/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
 and the words WARNING, CAUTION, NOTICE and NOTE have special meanings. Pay special attention
to the messages highlighted by these signal words.

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

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

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

NOTE:
Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the
WARNINGS, CAUTIONS and NOTICE stated, you must use good judgement and basic mechanical safety
principles.

3
SYMBOL
Listed in the table below are symbols indicating special instructions and other important information neces-
sary for proper servicing. Please note the definition for each symbol. You will find these symbols used
throughout this manual. Refer back to this table if you are not sure of any symbol(s) meanings.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.
 Data beside it indicates specified  Apply THREAD LOCK “1342”.
torque.

 Apply SUZUKI WATER RESISTANT

GREASE.
 Use special tool.

 Apply SUZUKI SILICONE SEAL.

MATERIALS REQUIRED
WATER RESISTANT SUZUKI SILICONE
GREASE EP2 SEAL

99000-25350 93691-80030
(250 g/8.8 oz) (100 g/3.5 oz)

4
GENERAL INFORMATION
HANG TAGS
It is mandatory that every new Suzuki outboard motor be
assembled and serviced in accordance with the instructions in
the set-up manual.
A critical step in the set-up and pre-delivery process of every
outboard motor is to attach the hang tags to the outboard motor.
Hang tags are required to remain on the motor until it is deliv-
ered to the customer.
Be sure the hang tags are attached to the outboard motor as
shown.

1. Tag, CARB emission

5
EMISSION-RELATED INSTALLATION INSTRUCTIONS
Fuel lines and fuel tanks used for a vessel must meet the requirements of federal law (40 CFR 1045.112
and 40 CFR 1060).

If you install the engine in a way that makes the engine’s emission control information label hard to read dur-
ing normal engine maintenance, you must place a duplicate label on the vessel, as described in 40 CFR
1068.105

Failing to follow these instructions when installing a certified engine in a vessel violates federal
law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.

6
OUTBOARD MOTOR INSTALLATION
HORSEPOWER SELECTION

Overpowering your boat may cause operating/handling difficulties which could result in a crash.
The boat may also sustain hull damage or other damage due to stress.

• Do not overpower your boat.

• Never install an outboard motor with horsepower exceeding the boat manufacturer’s recom-
mended maximum horsepower.
NOTE:
• State the maximum horsepower outboard motor that can be safely used on that boat. There is severe
product liability potential connected with rigging and selling a boat with an outboard motor exceeding the
horsepower capacity limitation.
• The rig should not be underpowered, as this will not allow the performance balance you are trying to
achieve. Determine the customer’s needs, application and use of the perspective rig to make the best
overall horsepower recommendation.

MOTOR DIMENSIONS
S: 767 (30.2)
DF25A/30A 547 (21.5) L: 878 (34.6)
416 (16.4) 525 (20.7)
201 (7.9)

502 (19.8)

S: 1230 (48.4), L: 1357 (53.4)

.3)
185 (7

S: 728 (28.7)
L: 855 (33.7)

33 – 6
S: 422 (16.6)
L: 549 (21.6)

(1.3 – 2
2.4)
12
696 (27.4)

.5
45 61
45
8
8
197 (7.8) 197 (7.8) Shallow drive:
1st position: 29
355 (14.0) 355 (14.0)
2nd position: 43
Unit: mm (in)

7
 DF25AR/30AR S: 767 (30.2)
L: 878 (34.6)
416 (16.4) 525 (20.7)
120 (4.7)
112 (4.4)

502 (19.8)
S: 1230 (48.4), L: 1357 (53.4)
.3)
185 (7

S: 156 (6.1)
S: 728 (28.7) L: 216 (8.5)
33 – 6

S: 422 (16.6)
L: 549 (21.6)
(1.3 – 2
2.4)

L: 855 (33.7)
12

.5
45 61
45
8
8
197 (7.8) 197 (7.8)
Shallow drive:
355 (14.0) 355 (14.0) 1st position: 29
2nd position: 43
Unit: mm (in)

8
DF25A/30A-QH
517 (20.4) S: 782 (30.8) L: 894 (35.2)
405 (16.0) 555 (21.9)
141 (5.6)

502 (19.8)
S: 1230 (48.4) L: 1357 (53.4)
3.3)
337 (1

S: 422 (16.6)
L: 549 (21.6)

S: 122 (4.8)
L: 181 (7.1)
35 – 7

S: 728 (28.7)
L: 855 (33.7)
(1.4 – 0 12
2.8)
696 (27.4)

.2
45 62
45

12
197 (7.8) 197 (7.8) 4
Unit: mm (in)
355 (14.0) 355 (14.0)

9
 DF25A/30A-TH
517 (20.4) S: 782 (30.8) L: 895 (35.2)
408 (16.1) 555 (21.9)
141 (5.6)

502 (19.8)
S: 1230 (48.4) L: 1357 (53.4)
3.3)
337 (1

S: 422 (16.6)
L: 549 (21.6)

S: 115 (4.5)
L: 173 (6.8)
35 – 7

S: 728 (28.7)
L: 855 (33.7)
(1.4 – 0 12
2.8)
696 (27.4)

.8
45 62
45

12
197 (7.8) 197 (7.8) 4
Unit: mm (in)
355 (14.0) 355 (14.0)

10
DF25A/30A-T
118 (4.6) S: 782 (30.8) L: 895 (35.2)
408 (16.1) 555 (21.9)
90 (3.5)

502 (19.8)
S: 1230 (48.4) L: 1357 (53.4)
3.3)
337 (1

S: 422 (16.6)
L: 549 (21.6)

S: 115 (4.5)
L: 173 (6.8)
35 – 7

S: 728 (28.7)
L: 855 (33.7)
(1.4 – 0 12
2.8)

.8
45 62
45
12
197 (7.8) 197 (7.8)
4
355 (14.0) 355 (14.0) Unit: mm (in)

11
TRANSOM DIMENSIONS

DF25A/30A

176 (6.9)

Transom top surface

2-M14 × P2.0
(Clamp screw)
55 (2.2)

57 (2.2)

87 (3.4)
4– φ 10.5

231 (9.1)
Unit: mm (in)

12
 DF25A/30A-T/TH 159 (6.3) 141 (5.6)
DF25A/30A-Q
221 (8.7)

Transom top surface 2-M14 × P2.0

(Clamp screw)

3 – 17.5 (0.7)

53 (2.1)

103.5 (4.1)

296.5 (11.7)
8 – φ 13.5
52.5 (2.1)

R
4–

2 – 13.5 (0.5)

251 (9.9)

327 (12.9) Unit: mm (in)

ESTABLISHING THE CENTER-LINE

To establish the center of the transom you may use the following
procedure:
(1) Measure across the transom from chine to chine and make
1/2 1/2
a mark on the transom face at 1/2 of this measurement.
Chine 1/2 1/2
(2) Measure across the transom from strake to strake and
make a second mark on the transom face at 1/2 of this Strake

measurement.
(3) Align a straightedge with the marks on the transom face
and draw a line. This is the vertical center-line of the tran-
som for a single engine installation.

13
LIFTING THE MOTOR

Lifting the outboard motor using a hoist with insuffi-
cient capacity can result in serious injury and/or dam-
age to the outboard motor.

Use a hoist which has a minimum lift capacity of at

least 450 kg (1000 lbs.) when lifting the motor.


Failure to use the proper attachment point for lifting
the outboard motor can result in severe injury and/or
damage to the outboard motor.

Use the lifting eye only. Do not lift the motor using a
flywheel lifting attachment.

NOTE: 2
Attempting to lift the motor from its horizontal crated position
using the lifting eye, use any protector between engine hook and
air duct to protect the air duct from damage.

4 3

1. Protector
2. Air duct
3. Lifting eye
4. Engine hook

(1) Attach lift to lifting eye on cylinder block, then lift the engine.

14
MOUNTING TO THE TRANSOM (For DF25A/AE/AR,
DF30A/AE/AR)
Contained parts
Item Part name Part number Q’ty
A Bolt (M 10 × 110 mm) 09100-10309 2
B Washer No.1 (Large) φ 35 × φ 1 0 .5 09160-10139 2
C Washer No.2 (φ 18 × φ 1 0 .5) 09160-10140 2
D Nut 09159-10050 2

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

Be sure to bolt the motor to the transom. The motor

may come off if it is held only by the clamp screws.
Occasionally check the clamp screws for tightness.

(1) Center the motor on the transom and secure it by alter-

nately tightening the clamp screws by hand.
Make sure that anti-cavitation plate is located 0 – 25 mm (0 Clamp
– 1 in.) below the boat bottom. screw

(2) Install motor mounting bolts with large diameter flat washer
from inside of transom and through clamp brackets.
(3) Install flat washers and nuts on clamp bracket side.
(4) Tighten all mounting bolts securely.
 Mounting bolt/nut: 38 N·m (3.8 kgf-m, 27.5 lb-ft)

NOTICE
Never reuse the lock nut D after it has been threaded
into position and torqued.

Once you have tightened the lock nut D, it will no

longer have the necessary fastening performance if
you reuse it.

15
NOTE:
• Drill the mounting holes vertically to the transom board.
• To insure water-tightness, sealant (SUZUKI SILICONE SEAL
or equivalent) should be applied to all bolt holes. Apply the
sealant to the shanks of the bolts, but not the threads.
• Do not use an impact tool to tighten or loosen the transom
nuts.
• If the specified tightening torque can not be reached due to
weak transom material, it may be necessary to install a rein-
forcement plate between the transom board and washer B. If
a reinforcement plate is required, contact the boat manufac-
turer for recommendations.

NOTE:
Make sure that there is no clearance on matting surfaces
between the transom board and motor clamp brackets.
Otherwise, the motor clamp brackets may be damaged.

16
MOUNTING TO THE TRANSOM (For DF25AT/Q, DF30AT/Q)
Contained parts

Item Part name Part number Q’ty

A Bolt (M12 × 100) 09100-12093 4
B Washer (OD 35 mm) 09160-12044 4
C Washer (OD 22 mm) 09160-12110 4
D Nut (M12) 09159-12014 4

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

Be sure to bolt the motor to the transom. The motor

may come off if it is held only by the clamp screws.
Occasionally check the clamp screws for tightness.

(1) Center the motor on the transom and secure it by alter-

nately tightening the clamp screws by hand.
Make sure that anti-cavitation plate is located 0 – 25 mm (0 Clamp
screw
– 1 in.) below the boat bottom.

(2) Mark four position of motor mounting bolt on the transom

board.
(3) Drill the mounting holes using 12 mm drill bit.

NOTE:
• Drill the mounting holes vertically to transom board.
• Drill the upper holes at least 25 mm (1 in.) down from the tran-
som top surface.
• Do not drill engine top mounting bolt holes higher than 25.4
mm (1 in.) below top edge of actual boat transom.
• For power trim & tilt model, drill the lower holes at the position
where the lower bolt don’t disturb operation for manual release
valve.

17
(4) Install motor mounting bolts A with large diameter flat
washer B from inside of transom and through clamp
bracket.

(5) Install small diameter flat washers C and nuts D on clamp

bracket side.

(6) Tighten all mounting bolts/ nuts securely.

 Mounting bolt/nut: 55 N·m (5.5 kgf-m, 40 lb-ft)

NOTE:
• To insure water-tightness, sealant (SUZUKI SILICONE SEAL
or equivalent) should be applied to all bolt holes. Apply the
sealant to the shanks of the bolts, but not the threads.
• Do not use an impact tool to tighten or loosen the transom
nuts.
• If the specified tightening torque can not be reached due to
weak transom material, it may be necessary to install a rein-
forcement plate to the transom board. If a reinforcement plate
is required, contact the boat manufacturer for recommenda-
tions. The transom reinforcement plate should be installed
between the transom surface and the washer B.

NOTICE
Never reuse the lock nut D after it has been threaded
into position and torqued.

Once you have tightened the lock nut D, it will no

longer have the necessary fastening performance if
you reuse it.

NOTE:
If there is a clearance between the clamp bracket and the tran-
som top surface, place a proper spacer on the transom top sur-
Spacer
face so that the motor weight can be supported by the transom
through the spacer.

NOTE:
Make sure that there is no clearance on matting surfaces
between the transom board and motor clamp brackets.
Otherwise, the motor clamp brackets may be damaged.

18
NOTICE
If the motor is not properly secured to the transom, it
can come off.

After completing break-in operation (10 hours), re-

tighten the transom nuts to the specified torque.

19
CONTROL CABLES AND WIRE HARNESS INSTALLATION
Contained parts (Remote control model)
R model

Item Part name Part number Q’ty

A Remote control box 67200-94J20 1
B Remote control harness 36620-94L00 1

T model

Item Part name Part number Q’ty

A Remote control box 67200-93J50 1
B Remote control harness 36620-94L10 1

Required parts (Remote control model)

Part name Part number Q’ty Part name Part number Q’ty
Control cable 8ft (2.4 m) 67320-93J00 2 Control cable 18ft (5.4 m) 67320-93J50 2
Control cable 10ft (3.1 m) 67320-93J10 2 Control cable 20ft (6.0 m) 67320-93J60 2
Control cable 12ft (3.7 m) 67320-93J20 2 Control cable 22ft (6.7 m) 67320-93J70 2
Control cable 14ft (4.2 m) 67320-93J30 2 Control cable 24ft (7.3 m) 67320-93J80 2
Control cable 16ft (4.8 m) 67320-93J40 2
Choose one item which is matched to the boat in length.

REMOTE CONTROL BOX SIDE

For the procedure to connect the throttle control cable and shift control cable to the remote control box, refer
to the “REMOTE CONTROL BOX SET-UP INSTRUCTION” that comes supplied with each unit of remote
control box.

ENGINE SIDE
Contained parts (Remote control model)

Item Part name Part number Q’ty

A Cable connector 67467-89J01 2
B Cable stopper 67343-94L00 1
C Cable stopper bolt 09116-06225 1
D Cushion 09352-70103-600 2

NOTE:
Before performing the following procedures, be sure that the
throttle/shift control cables are installed in the remote control box
according to the “REMOTE CONTROL BOX SET-UP
INSTRUCTION”.

20
Routing of control harness
(1) Remove the STBD engine side cover.

(2) Route the remote control harness 1 through the grommet

2 as shown.

(3) Connect the remote control harness to the engine side,

then press fit the connector 3 into the connector holder.

NOTE:
Route the remote control harness under the fuel hose and cau-
tion lamp lead wire.

NOTICE
Do not connect the sub-battery cable to the remote
control harness.
For this model, it is not necessary to connect the sub-
battery cable to provide power for operation of the
engine control system.

If you connect the sub-battery cable, the sub-battery

fuse will blow.

21
Installation of control cable
(1) Remove the STBD engine side cover.
(2) Install the cable cushions D to cable stopper B.

(3) Install the throttle control cable 4 and clutch control cable
5 through the grommet 3 as shown in figure.
(4) Secure the cable 4 and 5 in the cable holder 6 by fitting
groove on the cable into a slot on the holder as shown fig-
ure.
(5) Install the cable stopper 2 using the bolt 1 to secure the
clutch control cable and throttle control cable.

(6) Position the remote control handle into “NEUTRAL”.


If the cable connector is not threaded far enough onto
the cable, the cable connector could break causing a
loss of control and a crash.

Thread the cable connector at least 8 mm (0.3 in.) onto

cable.

22
— Shift control cable —
(7) Remove the lock pin 7 and washer 8 from clutch control
lever.

(8) Make sure that clutch control lever 9 is in the neutral posi-
tion.
(9) While pushing cable end as shown by arrow X, thread the
connector A onto the shift control cable 5 until the con-
nector hole aligns with the pivot pin 0 on the clutch control
lever 9.
(10) Set the connector A onto the pivot pin 0 with the flat side
of connector towards the lever.

(11) Install the washer 8 and lock pin 7, then tighten the lock
nut A.

(12) Make sure that both forward and reverse gear can be Neutral
Forward Reverse
engaged with the same angle of remote control handle
32˚ 32˚
travel from “NEUTRAL” position.
Throttle
range
Throttle
range Fully
opened
Fully opened

23
— Throttle control cable —
(13) Remove the lock pin 7 and washer 8 from throttle control
lever.

(14) Position the remote control handle into “NEUTRAL”.

(15) Check that throttle is fully closed position. “a”
(16) Turn the throttle control lever B counterclockwise until the
clearance “a” exists.

Clearance “a” 1 – 2 mm

(17) Thread the throttle cable connector A onto the throttle

cable end.
(18) While pushing cable end as shown by arrow X, adjust the
connector A until the center of connector hole aligns with
the pivot pin C on the throttle control lever B.

(19) Set the connector A onto the pivot pin C with the flat side
of connector towards the throttle control lever.
(20) Install the washer 8 and lock pin 7, then tighten the lock
nut D.

24
(21) Move the remote control handle to fully opened position,
then return the remote control handle to the neutral posi- “a”
tion.
Check that the throttle is in fully closed position.
Also make sure the clearance “a” exists between the inter-
link lever E and the link lever F with throttle control fully
closed position.

Clearance “a” 1 – 2 mm

(22) Reinstall the engine side covers.

NOTE:
After assembly, make sure that the cables are not stretched or
otherwise stressed when the outboard motor is turned all the
way to the right and left.

25
STEERING SYSTEM

Selection of an improper steering system or improp-
erly installing a steering system on the outboard
motor can cause steering/handling difficulties, result-
ing in loss of control and a crash.

Be sure to follow the steering system manufacturer’s

instructions for proper selection and installation.

DRAG LINK INSTALLATION

NOTE:
These instructions are for connecting a mechanical push-pull
steering system with the following specifications:
• Single cable
• Starboard cable entry into the motor tilt tube.
• Steering cable meeting the current American Boat and Yacht
Council’s Safety standard (P-17).

Contained parts (Remote control model)

Item Part name Part number Q’ty

Drag link assembly 67701-94L00 I.D. mark:
67711-99J0
A • Drag link • Not available separately 1
B • Spacer • 67721-94L00 1
C • Bolt • 67725-95J00 1
D • Safety nut • 67726-99E00 2
E • Washer • 67728-99E00 4
F Steering cable seal 41161-94400 1
NOTICE
Never reuse the lock nut D after it has been threaded
into position and torqued.

Once you have tightened the lock nut D, it will no

longer have the necessary fastening performance if
you reuse it.

26
Procedure
(1) Thread the steering cable seal F onto the port side end of
the motor tilt tube 1.
(2) Apply SUZUKI WATER RESISTANT GREASE to the steer-
ing cable 2.
(3) Insert the cable 2 into the tube 1 from the starboard side,
then tighten the cable retaining nut 3 to the torque speci-
fied by the cable manufacturer.

NOTE:
On most outboard motor installations, it will be necessary to
install the steering cable prior to the outboard motor installation.

(4) Connect the drag link A to the steering cable end 2 with
washers E and safety nut D as shown. Tighten the nut D
to the specified torque, then BACK THE NUT OFF 1/8
TURN.

 Safety nut D: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

(5) Move the steering cable until the hole of drag link A aligns
with the thread hole on the attachment 4.
(6) Connect the drag link to the attachment 4 by tightening the
bolt C with the spacer B and washer E as shown.

 Bolt C: 34 N·m (3.4 kgf-m, 24.5 lb-ft)

(7) Install the washer E and nut D, then tighten the safety nut
D.

 Safety nut D: 34 N·m (3.4 kgf-m, 24.5 lb-ft)

NOTE:
After assembly, check for smooth and free steering operation by
turning the steering wheel all the way to the right and left.

27
BATTERY
BATTERY REQUIREMENT
Suzuki recommends a 12-volt cranking-type lead acid battery for the DF25A/30A.
Minimum battery requirement for starting the engine is provided below.
The battery must satisfy one of the specifications described below.
650 Marine Cranking Amps (MCA)/ABYC,
or 512 Cold Cranking Amps (CCA)/SAE
or 160 Reserve Capacity (RC) Minutes/SAE
or 12 V 70 AH
NOTE:
• The specifications listed above are the minimum battery rating
requirements for starting the engine.
• Additional electrical loads from the boat will require larger
capacity batteries.
• Dual-purpose (Cranking/Deep Cycle) batteries can be used if
they meet the minimum specifications listed above (MCA,
CCA, or RC).
• Do not use a Deep Cycle battery for the main cranking battery.
• The use of Maintenance-Free, sealed, or Gel-Cell batteries is
not recommended because they may not be compatible with
Suzuki’s charging system.
• When connecting batteries in parallel, they must be of the
same type, capacity, manufacturer, and of similar age. When
replacement is necessary, they should be replaced as a set.
INSTALLATION OF BATTERY

Failure to take proper precautions when handling the
battery may cause severe injury.

Be sure to take the following precautions when han-

dling the battery:
• Never expose the battery to open flames or electric
sparks as batteries generate gas which is flammable
and explosive.
• Do not place the battery near the fuel tank.
• Battery acid is poisonous and corrosive. Avoid con-
tact with eyes, skin, clothing and painted surfaces.
If you come in contact with battery acid, flush imme-
diately with large amounts of water and seek
immediate medical attention.
• Batteries should always be kept out of reach of chil-
dren.
• When checking or servicing battery, disconnect the
negative (black) cable. Be careful not to cause a
short circuit by allowing metal objects to contact the
battery posts and motor at the same time.
• Wear approved eye protection.

28
Store the battery free from splash of water, etc. and fix it Red tube Black tube
securely to the hull with a battery band or the like to prevent it
from falling down during boating.

NOTE:
It is recommended that the battery be installed in an enclosed
battery case.

NOTE:
When extending the battery cable, use a cable of diameter
Battery cable Battery cable
larger than equivalence of AV8 (AWG8).

CONNECTION OF BATTERY CABLE

• First connect positive battery cable to positive battery termi- Red lead

nal, then connect negative battery cable to negative battery

Black
terminal. lead

NOTE:
When connecting batteries, hexagon-nuts must be used to
secure battery leads (cables) to battery terminals.

Hexagon-nut

29
PROPELLER
Selection
Select propellers as shown below so that the specified engine
rpm is obtained with the throttle fully opened.

Recommended full DF25A 5 000 – 6 000 r/min

throttle speed range DF30A 5 300 – 6 300 r/min

Propeller size chart

Blade × Dia. (in.) × Pitch (in.)
3 × 10 and 1/4 × 9
3 × 10 and 1/4 × 10
3 × 10 and 1/4 × 11
3 × 10 and 1/4 × 12
3 × 10 and 1/4 × 13
3 × 10 and 1/4 × 14
3 × 10 and 1/4 × 15

Installation of propeller
(1) Coat the propeller shaft 1 with the SUZUKI water-resistant
grease.
(2) Place the stopper 2 on the propeller shaft.
(3) Slide the propeller 3 onto the propeller shaft.
(4) Place the spacer 4 and washer 5 on the propeller shaft.
(5) Tighten the propeller nut 6 to the specified torque.
 Propeller nut: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
(6) Push the cotter pin 7 through the nut and shaft, then bend
to secure.

30
OPTIONAL PARTS INSTALLATION
TRIM SENDER INSTALLATION
(1) Raise the engine to the full tilt up position and lower the
manual tilt lock lever 1.


Failure to take proper precaution when servicing a
trim sender can cause severe personal injury.

During the removal or installation of trim sender, the

engine must be firmly secured and its weight fully
supported by the hoist. (See right)

(2) Install the trim sender 2 and the clamp 3 to STBD clamp
bracket, then tighten two bolts 4 securely.
Fix the sender cable with clamp as shown.
 Trim sender bolt: 10 N·m (1.0 kgf-m, 7.2 lb-ft)

31
(3) Route the trim sender cable 5 through Port clamp bracket
6.
Fix the trim sender cable and PTT motor cable 7 with
clamps 8 as shown.
Make sure that the sender cable don’t touch the tilt pin and
swivel bracket when full trim down.

(4) Remove the lower side cover.

Cut off the hatched area on rubber grommet 9 shown in
illustration.

(5) Route the trim sender cable through the lower cover (rub- “A”
ber grommet 9).
“B”

(6) Connect the trim sender cable connector 0 to the main

harness.

“C”

5: Trim sender cable

“A”. Joint connector
“B”. Main harness
“C”. Battery cable

32
(7) Bind the sender cable and main harness with cable tie as “A”
“B”
shown in the illustration.

5: Trim sender cable

“A”; Joint connector
“B”; Main harness

(8) Bind the sender cable and PTT motor cable with cable ties
as shown in the illustration.

33
CAUTION BUZZER INSTALLATION
(1) Pull the buzzer connector 1 of main harness out of con-
nector holder.
Remove the dummy plug from buzzer connector.

(2) Connect the caution buzzer lead 2 to the connector of

main harness.
Press the connector into connector holder as shown.

(3) Install the rubber part of the buzzer 3 onto mounting post
4 of the connector holder as shown.
The buzzer surface with holes should be downward.

34
 WIRING DIAGRAM
Side Mount Remote Control

R-model

Item Part name Part number

1 Remote control box 67200-94J20
2 Remote control wire harness 36620-94L00
3 Tachometer w/monitor (Black) 34200-93J00
Tachometer w/monitor (White) 34200-93J12
Tachometer (Black) 34200-93J20
Tachometer (White) 34200-93J32

T-model

Item Part name Part number

1 Remote control box 67200-93J50
2 Remote control wire harness 36620-94L10
3 Tachometer w/monitor (Black) 34200-93J00
Tachometer w/monitor (White) 34200-93J12
Tachometer (Black) 34200-93J20
Tachometer (White) 34200-93J32
4 Trim gauge (White) 34800-93J11
Trim gauge (Black) 34800-93J00

35
 Prepared by

Outboard Motor Engineering Department

May, 2014
Part No. 99505-94L10-01E
Printed in Japan

36
1 TK