Suzuki DF250 2006 Rigging Manual

99518-03060-01E

Printed in Japan

TK

2006 RIGGING MANUAL

DF25 -- DF250

2006 RIGGING MANUAL

DF25 -- DF250

99518-03060-01E

11

GROUP INDEX

UNCRATING

1

MOTOR DIMENSIONS

2

MOTOR INSTALLATION

3

REMOTE CONTROLS

4

CONTROL CABLE/WIRING HARNESS

INSTALLATION ON ENGINE SIDE

5

DRAG LINK

6

ACCESSORIES

7

FUEL LINE

8

BATTERY

9

PROPELLER

10

PRE-DELIVERY

11

FOREWORD

This rigging manual details the set-up and pre-deliv-

ery procedures for all 2006 model Suzuki outboard

motor and accessories.

These instructions and recommendations have

been drawn up to assist your technicians in all vital

areas of installing and setting up SUZUKI outboard

motors. If used in conjunction with the relevant

model set-up manual, the manual will ensure the

most straightforward and time-saving installation

method.

Due to the importance of the material herein, we

highly recommend that this manual be kept readily

accessible in your workshop area, where it can be

referred to by the personnel concerned.

Proper set-up each outboard motors have less war-

ranty problems and satisfied customers.

All information in this manual was current at the time

of publication. Suzuki reserves the right to make

changes at any time, without prior notice.

NOTE:

This manual may include information on models not

designated for your market.

Therefore, before commencing, check the applica-

bility of the contents to outboard motors sold in your

country.



• This Manual has been prepared by using the

latest specifications available at the time of

publication.

Differences may exist between the content of

this manual and the actual outboard motor.

• Illustrations in this manual are used to show

the basic principles of operation and work

procedures and may not represent the actual

outboard motor in exact detail.

• This manual is intended to be used by tech-

nicians who already possess the basic

knowledge and skills to service SUZUKI out-

board motors. Persons without such knowl-

edge and skills should not attempt service

SUZUKI outboard motors by relying on this

manual only and should contact an autho-

rized SUZUKI outboard motor dealer.

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the

services described in this manual.

Improper repair may result in injury to the

mechanic and may render the motor unsafe

for the boat operator and passengers.

22

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed on the previous page in a

GROUP INDEX. Select the section needed for reference.

3. Holding the manual as shown at the right will allow you to

find the first page of the section easily.

4. The first page of each section contains a table of contents to

easily locate the item and page you need.

SYMBOL

Listed in the table below are the symbols indicating instructions and other important information necessary

for proper servicing. Please note the definition for each symbol. You will find these symbols used throughout

this manual. Refer back to this table if you are not sure of any symbol(s) meanings.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Data beside it indicates specified

torque.

Apply THREAD LOCK “1342”.

Apply SUZUKI WATER RESISTANT

GREASE.

Use special tool.

Apply SUZUKI SILICONE SEAL.

33

GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol

and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-

sages highlighted by these signal words.



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



Indicates a potential hazard that could result in motor damage.

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

WARNING and CAUTION stated, you must always have right judgement and observation based upon the

mechanical safety principles.

TIGHTENING TORQUE

These value are only applicable when torque for a general bolt.

MATERIALS REQUIRED

TYPE OF BOLT

THREAD

DIAMETER

TIGHTENING TORQUE

N·m kg-m lb-ft

5 mm 2 – 4 0.2 – 0.4 1.5 – 3.0

6 mm 4 – 7 0.4 – 0.7 3.0 – 5.0

8 mm 10 – 16 1.0 – 1.6 7.0 – 11.5

(Conventional or “4” marked bolt) 10 mm 22 – 35 2.2 – 3.5 16.0 – 25.5

5 mm 2 – 4 0.2 – 0.4 1.5 – 3.0

6 mm 6 – 10 0.6 – 1.0 4.5 – 7.0

8 mm 15 – 20 1.5 – 2.0 11.0 – 14.5

(Stainless steel bolt) 10 mm 34 – 41 3.4 – 4.1 24.5 – 29.5

5 mm 3 – 6 0.3 – 0.6 2.0 – 4.5

6 mm 8 – 12 0.8 – 1.2 6.0 – 8.5

8 mm 18 – 28 1.8 – 2.8 13.0 – 20.0

(7 marked or marked bolt) 10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5

WATER RESISTANT

GREASE

SUZUKI SILICONE

SEAL

99000-25160

(250 g/8.8 oz)

99000-31120

(50 g/1.7 oz)

44

1

UNCRATING 1-1

CONTENTS

UNCRATING

UNCRATING PROCEDURES .......................................................................1- 2

DF200/225/250 .......................................................................................1- 2

55

1-2 UNCRATING

UNCRATING PROCEDURES

DF200/225/250

The following explains the uncrating procedures for models DF200/225/250.

The procedures are also applicable to other models packed with steel frame.



Metal crates may have sharp edges and may cause injury.

The operators should wear appropriate clothing, including long sleeve shirt, long pants, safety

glove and safety gear for handling crates.

Handling crates requires two or more operators.

Tools for uncrating

• Wrench (12 mm/14 mm)

• Wrench (17 mm/19 mm)

• Scissors

1. Check damage due to vibration or impact dur-

ing transportation. If there are any abnormal

condition found, take photograph in the pres-

ence of the carrier and notify to the Suzuki

distributor.

2. Cut the strap A with scissors.

3. Lift the carton B by two or more operators to

remove it.

4. Remove the parts C which come supplied in

the crate.

Wrench

(17 mm·19 mm)

Wrench

(12 mm·14 mm)

Scissors

Do not place heavy objects on top of the crate.

Use a minimumu of 1.2 mm(48 ) fork length.

''

Do not place heavy objects on top of the crate.

Use a minimumu of 1.2 mm(48 ) fork length.

''

66

UNCRATING 1-3

5. Remove the bolts D that tighten the steel

frame shown with in the illustration at 8

places in total, right and left.

6. Lift the steel frame E by two or more opera-

tors to remove it.

7. Remove styrofoam block F.

NOTE:

Use a hook that has a lifting capacity of at least

450 kg.

8. Remove the engine cover G.

9. Loosen two bolts I, on the right and left

each, and remove the binding strap H.

10. Attach sling straps to the hooks K, at two

points, using cushion J so as not to damage

the flywheel cover.

77

1-4 UNCRATING

11. Lift the outboard motor up close to upright

position using a hoist or crane so that the end

plate L of the base plate P may not be lifted

off the floor.

12. Loosen three bolts M marked with in the

illustration and remove the fixing bracket N.

Make sure to perform this work with two or

more operators, one holding the base plate P

securely.

13. Loosen four bolts O marked with in the

illustration and remove the outboard motor

from the base plate. Make sure to perform this

work with two or more operators, one holding

the base plate P securely.

14. Remove the base plate P. Make sure to per-

form this work with two or more operators,

one removing the base plate and the other

holding the outboard motor securely.

15. Loosen three bolts marked with in the illus-

tration and remove the fixing brackets Q and

R.

88

UNCRATING 1-5

LIFTING ENGINE



MOVING THE MOTOR

IN A VERTICAL POSITION

All three lifting eyes should be used after the engine has been

removed from the crate and is in a vertical position.



DO NOT USE FRONT LIFT EYE

WHEN UNCRATING THE ENGINE

The front lift eye is not designed nor intended to be

used for removing the engine from its horizontal posi-

tion in the shipping crate. Attempting to lift the motor

from its horizontal crated position using the front lift

eye creates a chain or sling angle which can cause the

motor to swing when it is lifted. This may result in

personal injury or cause damage to the engine block.

Use a hoist which has a minimum lift capacity of at

least 450 kg (1 000 lbs.) when lifting the motor .

EXAMPLE OF LIFTING DF200/225/250

EXAMPLE OF LIFTING DF90/115/140

99

2

6

MOTOR DIMENSIONS 2-1

CONTENTS

MOTOR DIMENSIONS

MOTOR DIMENSIONS ....................................................................................2- 2

DF4/5/6 ...................................................................................................2- 2

DF9.9/15 .................................................................................................2- 3

DF25-V2, DF25/30, DF40/50, DF60/70, DF90/115/140,

DF150/175, DF200/225/250 ...................................................................2- 4

MAJOR DIMENSIONS ....................................................................................2- 5

CODE DEFINITION .........................................................................................2- 6

1010

2-2 MOTOR DIMENSIONS

MOTOR DIMENSIONS

DF4/5/6

Unit: mm

Tilt 1st position: 0˚

Tilt 2nd position: 4˚

Tilt 3rd position: 8˚

Tilt 4th position: 12˚

Tilt 5th position: 16˚

Shallow 1st position: 32˚

Shallow 2nd position: 44˚

Maximum tilt: 74˚

1111

MOTOR DIMENSIONS 2-3

DF9.9/15

Unit: mm

Shallow drive

1st position: 27˚

2nd position: 42˚

315315

160

163

1212

2-4 MOTOR DIMENSIONS

DF25-V2, DF25/30, DF40/50, DF60/70, DF90/115/140, DF150/175,

DF200/225/250

Unit: mm

L3

H4

H5

L5 L4

L2 L1

A1

A2

H3

H2

H1

W3

W1

A3

A4

W2

W4

1313

MOTOR DIMENSIONS 2-5

MAJOR DIMENSIONS

Unit: mm

Code DF25-V2

DF25

DF30

DF40

DF50

DF60

DF70

DF90

DF115

DF140

DF150

DF175

DF200

DF225

DF250

H1

S: 117.5 S: 1 215 S: 1 263

L: 1 302.4 L: 1 342 L: 1 390 L: 1 493 L: 1 558 L: 1 611 L: 1 714

X: 1 396.4

X: 1 469 (UL) X: 1 620 (UL) X: 1 683 (UL) X: 1 738 (UL) X: 1 841 (UL) X: 1 834 (UL)

XX: 1 961

H2

S: 412.7 S: 414 S: 401

L: 539.7 L: 541 L: 528 L: 520 L: 539 L: 539 L: 500

X: 633.7 X: 668 (UL) X: 647 (UL) X: 666 (UL) X: 666 (UL) X: 627 (UL) X: 632 (UL)

XX: 759

H3 457.4 494 530 585 629 691 778 766

H4 678.3 740 776 824 811 908 1 037 1 041

H5 231 330 325 370 370 353 353 405

L1 495.5 562 619 661 568 568 671 722

L2

H: 145 QR·T: 33.9

137 131 132 132 168 159

R: 110.1 Q·QE: 144

L3 517.5 Q·QE: 508 QH: 776 TH: 748

L4

S: 755.9 S: 781 S: 805

L: 860.6 L: 889 L: 914 L: 991 L: 998 L: 998 L: 1 038

X: 938.1 X: 998 (UL)

X: 1 110 (UL) X: 1 116 (UL) X: 1 116 (UL) X: 1 158 (UL) X: 1 148 (UL)

XX: 1 263

L5 301.8

QR·T: 377

405 502 575 575 678 612

Q·QE: 387

A1 14° 14° 14° 14° 14° 14° 14° 14°

A2 65.5° 59° 59° 69° 69° 69° 70° 64°

A3 40° 40° 32° 30° 30° 30° 30° 30°

A4 40° 40° 32° 30° 30° 30° 30° 30°

W1 207.3 190 189 219 240 240 259 286

W2 207.3 190 189 219 240 240 259 286

W3 346.7 366 331 373 346 346 395 458

W4 346.7 366 331 373 346 346 395 458

1414

2-6 MOTOR DIMENSIONS

CODE DEFINITION

Code Definition and Description

A1

Minimum angle from transom board and bracket clamp (transom angle)

Note: ABYC recommends boat transom angle be 14° ± 2°

A2 Maximum tilt-up angle

A3 Maximum steering angle on STBD side from centerline of motor body

A4 Maximum steering angle on PORT side from centerline of motor body

W1 Distance from centerline to the outermost end of the outboard motor on STBD side

W2 Distance from centerline to the outermost end of the outboard motor on PORT side

W3

Distance from centerline to the farthest point on the body when steered to the maximum

angle on STBD side

W4

Distance from centerline to the farthest point on the body when steered to the maximum

angle on PORT side

H1 Overall height

H2 Vertical distance from Transom height (datum point to cavitation plate undersurface)

H3 Vertical distance from datum point to highest point of engine with cover installed

H4

Vertical distance measured from the datum plane to the outermost radius of the engine when

tilted up and locked

H5 Distance from datum point to bracket clamp lowest end

L1 Horizontal distance from datum point to rearmost point of engine cover

L2 Horizontal distance from datum point to the front end of steering bracket

L3

Distance from datum point to the front end of tiller handle, when the handle is in horizontal

position

L4 Horizontal distance from datum point to rearmost point when motor is in tilted up position

L5 Horizontal distance from datum point to the front end when motor is in tilted up position

1515

3

6

MOTOR INSTALLATION 3-1

CONTENTS

MOTOR INSTALLATION

HORSEPOWER SELECTION .........................................................................3- 2

CLAMP BRACKET DIMENSIONS ..................................................................3- 3

DF4/5/6 ...................................................................................................3- 3

DF9.9/15 .................................................................................................3- 3

DF25-V2 ..................................................................................................3- 4

DF25/30, DF40/50 ..................................................................................3- 4

DF60/70, DF90/115 ................................................................................3- 5

DF140 .....................................................................................................3- 5

DF150/175 ..............................................................................................3- 6

DF200/225/250 .......................................................................................3- 6

MINIMUM SPACE ............................................................................................3- 7

DF25/30 SINGLE MOTOR .....................................................................3- 7

DF25/30 DUAL MOTOR .........................................................................3- 8

DF40/50 SINGLE MOTOR .....................................................................3- 9

DF40/50 DUAL MOTOR .........................................................................3-10

DF60/70 SINGLE MOTOR .....................................................................3-11

DF60/70 DUAL MOTOR .........................................................................3-12

DF90/115/140 SINGLE MOTOR ............................................................3-13

DF90/115/140 DUAL MOTOR ................................................................3-14

DF200/225/250 SINGLE MOTOR ..........................................................3-15

DF200/225/250 DUAL MOTOR ..............................................................3-16

TRANSOM CENTERLINE ...............................................................................3-17

SINGLE MOTOR ....................................................................................3-17

SINGLE MOTOR ....................................................................................3-18

DUAL MOTOR ........................................................................................3-19

TRANSOM DRILLING TEMPLATE INSTRUCTIONS .....................................3-20

TRANSOM DRILLING TEMPLATE DIMENSIONS ................................3-20

DF25/30, DF40/50 BOLT HOLE POSITION ..........................................3-21

DF60/70, DF90/115, DF140 BOLT HOLE POSITION ............................3-21

DF150/175 BOLT HOLE POSITION ......................................................3-22

DF200/225/250 BOLT HOLE POSITION ...............................................3-22

USE OF TRANSOM DRILLING TEMPLATE .........................................3-23

LIFTING MOTOR .............................................................................................3-26

EXAMPLE OF LIFTING DF200/225/250.................................................3-26

EXAMPLE OF LIFTING DF90/115/140...................................................3-26

WEIGHT BY MODEL SPECIFICATION .................................................3-26

ENGINE MOUNT .............................................................................................3-27

MOUNTING TO THE TRANSOM DF25V2 .............................................3-27

MOUNTING TO THE TRANSOM DF25/30, DF40/50 ............................3-27

MOUNTING TO THE TRANSOM DF60/70, DF90/115, DF140 ..............3-28

MOUNTING TO THE TRANSOM DF150/175, DF200/225/250 .............3-28

BOLT TRANSOM TABLE (’06 MODEL) .........................................................3-30

1616

3-2 MOTOR INSTALLATION

HORSEPOWER SELECTION

• States the maximum horsepower of 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.





Do not overpower your boat. Never install an outboard motor with horsepower exceeding the

boat manufacturer’s recommended maximum. Excessive horsepower will have an adverse

effect on hull safety and may cause operating/handling difficulties.

To ensure a water-tight motor installation, water-proof sealer must be used on all motor mount-

ing bolts.

The lock-nut and C-ring must be replaced with new ones, if removed.

1717

MOTOR INSTALLATION 3-3

CLAMP BRACKET DIMENSIONS

DF4/5/6

Unit: mm

DF9.9/15

(HOLES)

(2 PLACES)

(HOLES)

(2 PLACES)

1818

3-4 MOTOR INSTALLATION

DF25-V2

Unit: mm

DF25/30, DF40/50

(HOLES)

(4 PLACES)

(HOLES)

(8 PLACES)

1919

MOTOR INSTALLATION 3-5

DF60/70, DF90/115

Unit: mm

DF140

HOLES

(10 PLACES)

HOLES

(2 PLACES)

HOLES

(2 PLACES)

HOLES

(10 PLACES)

HOLES

(2 PLACES)

HOLES

(2 PLACES)

2020

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