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Suzuki Marine DF40A User Manual

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ENGLISH
DF40A
DF50A
DF50AV
DF60A
DF60AV
OWNER’S MANUAL
EN

Table of Contents

Questions and Answers:

Suzuki Marine DF40A Specifications

General IconGeneral
BrandSuzuki Marine
ModelDF40A
CategoryOutboard Motor
LanguageEnglish

Summary

Important Safety and Operational Notices

Signal Word Definitions

Explains the meaning of signal words like WARNING, CAUTION, NOTICE, and NOTE for emphasis.

Break-In Information

Details the importance of the first 10 hours of operation for engine life and performance.

Owner's Important Notices

Provides critical safety warnings and pre-operation checks for owners and passengers.

Foreword

Manual Usage and Disclaimer

Outlines the manual's purpose for care, maintenance, and Suzuki's right to change specifications.

Environmental Responsibility and Safety

Nature Preservation and Safety Class

Encourages environmental protection and recommends taking a boating safety class.

California Proposition 65 Warning

Informs about chemicals in engine exhaust known to cause cancer or birth defects.

Fuel and Oil Information

Gasoline Recommendations and Filling

Details acceptable gasoline types, octane ratings, and the procedure for filling the fuel tank.

Engine and Gear Oil Specifications

Engine Oil Requirements

Specifies recommended engine oil types, viscosity grades, and API classifications.

Gear Oil Requirements

Recommends SUZUKI HYPOID GEAR OIL or equivalent SAE 90 GL-5 rated oil.

Safety Label Locations and Meanings

Label Identification

Illustrates the location of safety labels on the outboard motor and fuel tank.

Label Symbol Meanings

Explains the meaning of various warning, caution, and operational symbols used on labels.

Outboard Motor Parts Identification

Component Identification

Diagrams identifying key external parts of the outboard motor.

Control Box and Gauge Details

Illustrations of the side mount and top mount remote control boxes and monitor-tachometer.

Motor Installation Procedures

Motor Installation and Limitations

Advises on proper motor installation, horsepower limits, and dealer recommendations.

Battery Installation Guidelines

Battery Requirements and Installation

Specifies battery requirements and provides instructions for safe installation.

Propeller Selection and Installation

Propeller Selection Criteria

Guides on selecting the correct propeller based on boat characteristics and performance.

Propeller Installation Procedure

Step-by-step instructions for safely installing or removing the propeller.

Motor Adjustments for Performance

Trim Angle and Tab Adjustment

Explains how to adjust trim angle and trim tabs for optimal steering and performance.

Throttle Tension and Idle Speed

Details adjustments for throttle tension and factory idle speed settings.

Tilt Limit Setting Procedures

Setting and Canceling Tilt Limits

Provides procedures for setting and canceling the tilt upper limit position.

Caution System Alerts

Caution System Functionality

Explains the purpose of caution systems and the risk of relying solely on them.

Indicator Check on Startup

Describes the initial check of warning lamps and buzzer when the ignition is turned on.

Over-Revolution Caution System

System Activation and Reset

Details when the system activates, its effect on engine speed, and how to reset it.

Oil Pressure and Cooling Water Caution Systems

Oil Pressure Caution System

Explains the system for low oil pressure, including warnings and automatic shutdown.

Cooling Water Caution System

Describes the system for high water temperature, its warnings, and automatic shutdown.

Battery Voltage and Diagnostic Systems

Battery Voltage Caution System

Alerts to low battery voltage that may affect motor performance and provides precautions.

Diagnostic System Operation

Explains how the self-diagnostic system warns of sensor abnormalities and troubleshooting.

Oil Change Reminder System

System Activation and Cancellation

Details how the system notifies for oil changes and the procedure to cancel the notification.

Engine Stalling Caution System

System Notification

Informs the operator when the motor stalls, using a caution buzzer.

Operation of Tilting Systems

Power Trim and Tilt Operation

Explains how to operate the power trim and tilt switch for raising or lowering the motor.

Manual Tilting and Tilt Lever

Describes manual tilting procedures and the function of the tilt lever for support.

Pre-Boating Inspection Checklist

Inspection Items

Lists essential checks before boating, including fuel, oil, battery, propeller, and mounting.

Checking Engine Oil Level

Step-by-step guide on how to check the engine oil level using the dipstick.

Engine Break-In Procedure

Break-in Period and Guidelines

Details the 10-hour break-in period, including warm-up and speed limitations.

Engine Operation Procedures

Preparation Before Starting

Steps to prepare the motor before attempting to start, including lowering and venting.

Starting the Engine

Starting Procedure and Cooling Check

Instructions for starting the engine, including priming, ignition, and checking cooling water.

Emergency Starting Procedure

Procedure Overview and Warnings

Explains how to start the engine using the emergency method and highlights safety warnings.

Shifting and Speed Control

Gear Shifting and Speed Control

Details how to shift gears and control speed using the remote control handle.

Stopping the Engine

Engine Shutdown Procedure

Provides steps for safely stopping the engine, including cooling off and key removal.

Mooring and Shallow Water Operation

Mooring and Shallow Water Precautions

Guidelines for mooring in shallow water and operating the motor at higher trim angles.

Troll Mode Operation (Optional)

Troll Mode Setup and Cancellation

Explains how to set up, adjust speed, and cancel the optional troll mode system.

Operation in Specific Conditions

Salt Water and Freezing Weather Operation

Precautions for operating in salt water and freezing temperatures.

Motor Removal and Transporting

Removal and Transport Guidelines

Recommends dealer for removal and provides guidelines for transporting the motor.

Boat and Motor Trailering

Trailering Precautions

Advises on proper trailering positions and the use of transom savers.

Inspection and Maintenance Schedule

Maintenance Service Intervals

A chart detailing inspection and service intervals based on operating hours or months.

Spark Plug Service

Spark Plug Maintenance

Instructions for removing, inspecting, cleaning, and gapping spark plugs.

Breather and Fuel Line Inspection

Inspection for Damage

How to inspect breather and fuel lines for leaks, cracks, or swelling.

Engine Oil Change Procedure

Oil Change Preparation and Execution

Steps for preparing the motor and executing the engine oil change.

Gear Oil Level Check and Change

Gear Oil Procedures

Instructions for checking and changing the gear oil level.

Lubrication and Corrosion Prevention

Lubrication Points

Chart detailing lubrication points and recommended lubricants for motor components.

Anode and Bonding Wire Care

Guidelines for inspecting and maintaining anodes and bonding wires for corrosion prevention.

Battery Maintenance and Care

Instructions for maintaining battery fluid levels and handling precautions.

Filter Maintenance

Engine Oil Filter Replacement

Specifies when the engine oil filter should be replaced.

Fuel Filter Service Intervals

Details the intervals for inspecting and replacing the low-pressure fuel filter.

Flushing the Water Passages

Flushing Procedures (Engine Running/Not Running)

Step-by-step instructions for flushing the motor's water passages.

Procedure for Submerged Motor

Immediate Steps After Submersion

Provides immediate actions to take if the motor is accidentally submerged in water.

Motor Storage Procedure

Preparing Motor for Storage

Steps for preparing the motor for long-term storage, including oil changes and fuel stabilization.

Battery Storage and Post-Storage Steps

Guidelines for storing the battery and procedures for returning the motor to operation.

General Information and Warranties

Warranty Information (USA)

References the separate booklet for US warranty coverage, rights, and responsibilities.

Identification Number Location

Locating Model and Serial Numbers

Shows where to find model, identification, and ignition key numbers for reference.

Emission Control Information

Engine Emission Certification

States engine certification for unleaded gasoline and details the exhaust emission control system.

Troubleshooting Common Issues

Troubleshooting Guidance and Fuses

Provides guidance for common complaints like starting issues, and how to check fuses.

Engine Specifications

Model Specifications Table

Presents detailed technical specifications for DF40A, DF50A/50AV, and DF60A/60AV models.

Operating Hours and Oil Change System

Total Operating Hours Indication Chart

Chart correlating total operating hours with monitor-tachometer needle and lamp indications.

Oil Change Reminder System Flowchart

Visual flowchart illustrating the activation and cancellation steps of the oil change reminder system.

Wiring Diagram

Electrical System Schematics

Detailed wiring diagram showing the electrical connections of the outboard motor system.

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