Owner's Manual DF20A, DF15A, DF9.9B Inspection And Maintenance

MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY MARINE SI ENGINE REPAIR ESTABLISHMENT OR INDIVIDUAL USING ANY PART WHICH HAS BEEN CERTIFIED UNDER THE PROVISIONS IN THE CLEAN AIR ACT Sec. 207 (a) (2).

MAINTENANCE SCHEDULE

It is important to inspect and maintain your outboard motor regularly. Follow the chart below.

At each interval, be sure to perform the indicated service. Maintenance intervals should be judged by number of hours or number of months, whichever comes first.

Exhaust gas contains carbon monoxide, a dangerous gas that is difficult to detect because it is colorless and odorless. Breathing carbon monoxide can cause death or severe injury.
Never start the engine or let it run indoors or where there is little or no ventilation.

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

Water-separating fuel filter
Replace the filter element every 12-months (or more frequently if recommended by the filter manufacturer).

Improper maintenance or failure to perform recommended maintenance can be hazardous. Poor maintenance or lack of maintenance increases the chance of an accident or equipment damage. Be sure to have maintenance performed according to the schedule in the above chart. Suzuki recommends that only your authorized Suzuki marine dealer or a qualified service mechanic perform maintenance on those items in the chart above which are marked with an asterisk (*). You may perform maintenance on the unmarked items by referring to the instructions in this section if you have mechanical experience. If you are not sure whether you can successfully complete any of the unmarked maintenance jobs, ask your authorized Suzuki marine dealer to do the maintenance for you.

The safety of you and your passengers depends on how well you maintain your outboard motor. Follow all inspection and maintenance instructions carefully. If you do not have prior mechanical experience, do not attempt to perform maintenance on your outboard motor. You could be injured or may damage the motor.

The maintenance intervals in the chart are designed for normal usage of your outboard motor. If your outboard motor is used under severe conditions as outlined below, you may need to perform maintenance more often than indicated 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
• Frequent abrupt acceleration and deceleration
• Frequent shift operation
Failure to perform maintenance more frequently could result in damage.
Consult your authorized Suzuki marine dealer regarding appropriate maintenance intervals for your usage conditions. When replacing parts on your outboard motor, Suzuki strongly recommends that you use genuine Suzuki parts or their equivalent.

TOOL KIT

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

(1) Tool bag

(2) 8 mm Box wrench

(3) 10 × 12 mm Box wrench

(4) 16 mm Box wrench

(5) Combination screw driver

(6) Screwdriver handle

(7) Pliers

(8) Hexagon wrench 8 mm

(9) Emergency starter rope

Your outboard motor comes equipped with the following “standard” spark plug for normal usage.

Non-resistor types of spark plugs will interfere with the function of the electronic ignition, causing misfiring, or causing problems with other electronic boat equipment and accessories.
Use ONLY resistor type spark plugs in your outboard motor.

Your authorized Suzuki Marine Dealer can determine if the standard spark plug is suitable for your type of motor usage by inspecting the color of the plug’s porcelain center electrode insulator after operation.

If the plug tends to run hot (usually evidenced by whitening of the insulator or a burnt electrode), stop using your motor immediately as severe engine damage may result. If the plug tends to run cold (usually evidenced by blackening of the insulator or a wet electrode), performance may suffer. Ask your authorized Suzuki Marine dealer to evaluate either of these problems to determine the cause.

Use of improper spark plugs or improperly tightening spark plugs can cause severe engine damage.
• Do not experiment with other spark plug brands unless you can determine that they are directly equivalent to the specified brand, or you may experience engine damage which will not be covered under warranty. Note that aftermarket cross-reference charts may not be accurate.
• To install a spark plug; seat it as far as possible by hand, then use a wrench to tighten it to either the recommended torque setting or the specified rotation angle.

• Do not overtighten or cross-thread a spark plug, as this will damage the aluminum threads of the cylinder head.

To maintain a strong spark, you should clean and adjust the plug at the interval shown in the maintenance schedule.

Remove carbon deposits from the spark plug using a small wire brush or spark plug cleaner, and adjust the gap as follows:

If the electrode or insulator is damaged, or if either shows excessive wear, then the spark plug should be replaced.

Inspect the breather and fuel line for leaks, cracks, swelling, or other damage. If the breather and fuel line are damaged in any way, they must be replaced. Consult your authorized Suzuki Marine dealer if it is necessary to replace them.

Fuel leakage can contribute to an explosion or fire, resulting in serious personal injury.
Have your authorized Suzuki marine dealer replace the fuel line if there is any evidence of leaking, cracking or swelling.

Never perform any ENGINE OIL procedure with the motor running, as serious injury can occur.
The motor must be shut off before any ENGINE OIL procedures are performed.

Extended trolling can reduce oil life. Your engine may be damaged if you do not change engine oil more frequently under this type of use.
Change your engine oil more frequently if your engine is used for extended trolling.

Engine oil change

The oil should be changed when engine is warm so that the oil will drain thoroughly from the 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).

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

The engine oil temperature may be high enough to burn your fingers when the drain plug is loosened.
Wait until the drain plug is cool enough to touch with bare hands before removing it.

4. Remove the engine oil drain screw (2) and gasket (3), then let the engine oil drain.

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

A previously-used gasket may leak, resulting in engine damage. Do not re-use gaskets. Be sure to always use new gaskets.

6. Fill with recommended engine oil to the upper level.

Oil capacity: 1.0 L (1.1/0.9 US/Imp. qt.)

Engine oil: SAE (or NMMA FC-W) 10W-40 or 10W-30
API (or NMMA FC-W) Classification SG, SH, SJ, SL, SM

7. Check the engine oil level.

To avoid incorrect measurement of engine oil level, check oil level only when the engine has cooled.

8. Reinstall the oil filler cap.

Engine oil can cause injury to people or pets. Repeated, prolonged contact with used engine oil may cause skin cancer. Even brief contact with used oil may irritate skin.
• Keep new and used oil away from children and pets.
• Wear a long-sleeve shirt and waterproof gloves when handling oil.
• Wash with soap if oil contacts your skin.
• Launder any clothing or rags that are wet with oil.

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

To check the gear oil level, adjust the engine to an upright position, remove the gear oil level plug and look into the hole. The oil level should be at the bottom edge of the hole. If the oil level is low, add the specified gear oil until the level reaches the bottom edge of the hole. Then, reinstall and tighten the plug.

Periodic gear oil replacement is essential for long life of your outboard motor.

To change the gear oil:

1. Make sure the motor is in an upright position. Place a drain pan under the lower casing.

2. Remove the gear oil drain plug (1), then remove the gear oil level plug (2).

3. After the oil has drained completely, inject the specified gear oil into the lower drain hole until it just starts to come out of the upper level hole. Approximately 0.25 L (0.3/ 0.2 US/Imp. qt.) will be required.

4. Reinstall and tighten the gear oil level plug (2), then quickly reinstall and tighten the gear oil drain plug (1).

To avoid insufficient injection of gear oil, check the gear oil level 10 minutes after doing the procedure in the step 4. If the oil level is low, slowly inject the gear oil up to the correct level.

Gear oil can cause injury to people or pets. Repeated, prolonged contact with used gear oil may cause skin cancer. Even brief contact with used oil may irritate skin.
• Keep new and used oil away from children and pets.
• Wear a long-sleeve shirt and waterproof gloves when handling oil.
• Wash with soap if oil contacts your skin.
• Launder any clothing or rags that are wet with oil.

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

If fishing line wraps around the rotating propeller shaft, the propeller shaft oil seal can become damaged and can allow water to enter the gear case causing severe damage.
If the gear oil has a milky color, it is contaminated with water. Immediately contact your authorized Suzuki marine dealer for advice. Do not operate your outboard until the oil is changed and the cause of the contamination is corrected.

Proper lubrication is important for the safe, smooth operation and long life of each working part of your outboard motor. The following chart shows the lubrication points of your motor and the recommended lubricant:

Before applying grease through the steering bracket grease nipple, lock the motor in the fully tilted up position.

Your authorized Suzuki Marine Dealer may also have additional recommendations due to regional climate or operating conditions.

Please consult him for advice.

ANODES

The motor is protected from exterior corrosion by anodes. These anodes control electrolysis and help prevent corrosion. The anodes will corrode in place of the parts they are protecting. You should periodically inspect each of the anodes and replace them when 2/3 of the metal has corroded away.

In certain areas of the country, the water is unusually harsh on metal. Additional anti-corrosion measures may be helpful under those conditions. Consult your authorized Suzuki Marine Dealer for details.

If anodes are not properly maintained, underwater aluminum surfaces (such as the lower unit) will suffer galvanic corrosion damage.
• Periodically inspect anodes to make sure they have not become detached.
• Do not paint anodes, as this will render them ineffective.
• Periodically clean anodes with a wire brush to remove any coating which might decrease their protective ability.

Consult your authorized Suzuki Marine Dealer for inspection and replacement of internal
anodes attached to the powerhead.

Bonding wires are used to electrically connect the engine components so they exist in a common ground circuit. This allows them to be protected against electrolysis by the anodes. These wires and their terminals should be checked periodically to be sure they have not been damaged.

If you are using a maintenance-free battery, inspect the window area according to the instructions on the battery to make sure the battery is in good condition.

If you are not using a maintenance-free battery, the battery fluid level should be checked every 100 hours of operation or 12 months. The battery solution level must be kept between the MAX and the MIN level lines at all times. If the level drops below the MIN level line, add DISTILLED WATER ONLY until the battery solution level reaches the MAX level line.

Battery acid is poisonous and corrosive, and can cause severe injury. Avoid contact with eyes, skin, clothing, and painted surfaces. If battery acid comes in contact with any of these, flush immediately with large amounts of water. If acid contacts the eyes or skin, get immediate medical attention.

If you are not careful when checking or servicing the battery, you can cause a short circuit, which could result in an explosion, fire, or circuit damage. Disconnect the negative (black) cable when checking or servicing the battery. Be careful not to allow a metal tool or other metal object to touch the battery’s positive terminal and the motor at the same time.

Battery posts, terminals, and related accessories contain lead and lead compounds that may be hazardous. Wash hands after handling.

If you add diluted sulphuric acid to the battery after it has been initially serviced, you will damage the battery. NEVER add diluted sulphuric acid to the battery after it has been initially serviced. Follow the battery manufacturer’s instructions for specific maintenance procedures.

The engine oil filter must be changed by an authorized Suzuki Marine Dealer periodically.

Replace engine oil filter with a new one at initial 20 hours (1 month).

Replace engine oil filter with a new one at every 200 hours (12 months).

The fuel filter must be inspected by authorized Suzuki Marine Dealer periodically.

Low pressure fuel filter

Inspect low pressure fuel filter at initial 20 hours (1 month).

Inspect low pressure fuel filter at every 100 hours (12 months).

Replace low pressure fuel filter with a new one at every 400 hours (2 years).

The timing belt must be changed by authorized Suzuki Marine Dealer periodically.

Inspect timing belt at every 200 hours (12 months).

Replace timing belt with a new one at every 4 years.

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

ENGINE RUNNING – Vertical position –

Suzuki recommends that you flush the water passages using this method.

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

Exhaust gas contains carbon monoxide, a dangerous gas that is difficult to detect because it is colorless and odorless. Breathing carbon monoxide can cause death or severe injury.
Never start the engine or let it run indoors or where there is little or no ventilation.

Failure to take proper precautions when flushing the water passages can be hazardous.
When flushing the water passages, always take the following precautions:
• Make sure that the engine remains in NEUTRAL. If shifted into gear, the propeller shaft will turn and could cause severe personal injury.
• Make sure the motor is properly clamped to a secure stand or boat, and remain in attendance until flushing is completed.
• Keep children and pets away from the area, and stay clear of all moving parts.