Owner's Manual DF4, DF6 Operation

Using BUILT-IN FUEL TANK

1. The motor has been lowered into the water.

2. Twist the air-vent screw on the fuel tank cap counterclockwise to open the vent.

3. Turn the fuel cock lever to right.

When turning the fuel cock lever to right, fuel flow from the built-in tank.

4. Make sure that the motor is in “NEUTRAL”.

The recoil starter can not be operated when the motor is in gear. To prevent damage to the recoil starter, make sure that the motor is in “NEUTRAL” before pulling the starter rope.

5. Make sure the lock plate (A) is in place and the emergency stop switch cord is fastened securely to your wrist or appropriate clothing area such as your belt.

• The emergency stop switch cord should be fastened securely to the operator’s wrist or to an appropriate
clothing area (belt etc.). In this way, in an emergency, or if the operator is thrown overboard, the detached cord will stop the motor quickly.
• Ensure that no obstructions impede or restrict emergency stop switch operation.
• Take care not to pull the stop switch cord or knock out the lock plate during normal operation. The motor will stop abruptly, and the loss of forward motion may unexpectedly throw occupants forward.

There is a spare plastic lock plate for temporary use only. Remove it from the cord and place in a safe place on the boat. However, the original cord and lock plate should be replaced as soon as possible.

Using SEPARATE FUEL TANK (For DF6)

1. The motor has been lowered into the water.

2. The fuel hose is securely connected to the fuel tank and the motor.

3. Twist the both air-vent screws on the fuel tank caps counterclockwise to open the vent.

4. Turn the fuel cock lever to left.

When using the separate tank, turn the fuel cock lever to left to flow to the carburetor from the separate tank.

5. Make sure that the motor is in “NEUTRAL”.

The recoil starter can not be operated when the motor is in gear. To prevent damage to the recoil starter, make sure that the motor is in “NEUTRAL” before pulling the starter rope.

6. Make sure the lock plate (A) is in place and the emergency stop switch cord is fastened securely to your wrist or appropriate clothing area such as your belt.

• The emergency stop switch cord should be fastened securely to the operator’s wrist or to an appropriate
clothing area (belt etc.). In this way, in an emergency, or if the operator is thrown overboard, the detached cord will stop the motor quickly.
• Ensure that no obstructions impede or restrict emergency stop switch operation.
• Take care not to pull the stop switch cord or knock out the lock plate during normal operation. The motor will stop abruptly, and the loss of forward motion may unexpectedly throw occupants forward.

There is a spare plastic lock plate for temporary use only. Remove it from the cord and place in a safe place on the boat. However, the original cord and lock plate should be replaced as soon as possible.

7. Squeeze the fuel line priming bulb several times until you feel resistance.

Do not squeeze the priming bulb while the engine is running, as the carburetor may over-flow.

Only for DF6
When starting the engine on gasoline from the built-in fuel tank after the separate fuel tank becomes empty:

1. Disconnect the fuel line of the separate fuel tank from the fuel connector on the engine side.
2. Pour fuel into the built-in fuel tank and wait about 1/3 minute before starting.
3. Turn the fuel cock lever to right.

• Never start the engine or let it run indoors or where there is little or no ventilation. Exhaust gas contains carbon monoxide, a gas that is colorless and odorless and can cause death or severe injury.
• Before starting the engine, make sure that you have enough fuel and oil to complete your intended trip.

If the engine fails to start, check the emergency stop switch lock plate. If the lock plate is not in position, the engine cannot be started.

1. If the engine is cold:
   Pull the choke knob (1) fully out. Align the arrow mark on the throttle control grip (2) with the position (A).

If the engine is warm:
Align the arrow mark on the throttle control grip (2) with the position (A). Do not use the choke.

You may need to use the choke when restarting a warm engine. If your engine does not start quickly when warm, follow the procedure for cold starting.

2. Firmly grasp the starter grip (3) and pull slowly until resistance is felt. When you feel it engage, pull the rope sharply to start the engine. Do not release the rope when it is pulled out. Hold the rope and allow it to recoil slowly.

Never pull the starter grip while the engine is running, as the starter system could be damaged.

3. After starting, use the throttle control grip (2) to bring the engine to idle.

4. Push the choke knob in.

In cold weather, you may have to leave the choke knob out for a longer period of time for the engine to warm up.

5. Warm up the engine for about 5 minutes.

Cooling water check

As soon as the engine starts, water should spray out of the pilot water hole, indicating that the water pump and cooling system are working properly. If you notice that water does not spray out of the pilot water hole, stop the engine as soon as possible and consult your authorized Suzuki Marine Dealer.

• Never operate your outboard motor
when there is no water coming out of
the pilot water hole, or severe damage
can result.
• Before setting off, be sure that emergency stop switch operates properly.

If you must get the engine running, but are unable to do so because of recoil starter failure, you can use the emergency starting procedure to start the engine.

When rope-starting the engine, do not touch electrical components such as ignition coils or spark plug leads. Contact with these items may result in a severe electric shock.

To start the engine when the starter system fails:

1. Make sure that the motor is in “NEUTRAL” and the emergency stop switch lock plate is removed.

When using the emergency starting procedure, the start-in-gear protection system will not work. If the shift lever is not in the “NEUTRAL” position, the boat can start off unexpectedly when the engine is started, causing personal injury.

2. Remove the motor cover.

3. Remove the bolts securing the recoil starter in place.

4. Loosen the lock nut (1), take off the NSI cable from the bracket and separate the end of cable from the cam (2).

5. Lift off the recoil starter assembly.

6. Tie a knot in one end of the emergency starter rope located in the tool kit. Tie the other end around the screw-driver handle in the tool kit.

7. Hook the knotted end of the rope in the pulley notch and wind the rope around the pulley in a clockwise direction.

8. Put the emergency stop switch lock plate in place.

9. After following steps of the normal starting procedure, pull the emergency starter rope sharply to start the engine.

• Do not re-install the recoil starter assembly or motor cover after starting the engine, or you may be injured.
• When the engine is running, keep your hands, hair, clothing, etc., away from the engine.
• Be sure to have the starter system repaired as soon as possible. You
should not continue to use the emergency starting procedure for routine
engine starting.

• Before shifting from “FORWARD” to “REVERSE” or from “REVERSE” to “FORWARD”, stop at the “NEUTRAL” position and allow the engine speed to return to idle.
• Exercise caution and use minimal speed when operating the boat in reverse. Be sure the handle is in the desired position before accelerating.

Avoid shifting into gear when the engine is not running, or the shifting mechanism can be damaged.

Shifting

To shift the motor into “FORWARD”, set the throttle control grip to the idle position and pull the shift lever towards you firmly.

To shift into “REVERSE”, set the throttle to the idle position, and push the shift lever away from you firmly.

Speed Control

After shifting, control the engine speed by twisting the throttle control grip.

To stop the engine, twist the throttle control grip to the idle position, shift into “NEUTRAL”, and hold in the stop button (A) until the engine stops.

To make sure that the emergency stop switch operates properly, stop the engine occasionally by pulling out the lock plate, while operating the engine at idling speed.

The motor should be tilted up out of the water when you moor the boat in shallow water or if the motor will not be used for some time, to protect it from damage by underwater obstacles at low tide or corrosion from salt water.

Refer to the TILT UP LOCK ARM section for details on how to tilt up the motor.

Disconnect the fuel line whenever you leave the motor tilted up for a long period of time, or fuel may leak out. (DF6).

Do not allow your motor to rub against quay walls, piers or other boats when the boat is tied up.

When operating your outboard motor in shallow water, use the shallow water position to tilt the motor slightly from the normal trim angle. When using the shallow water position, however, you should only operate the motor at slow speeds. After returning to deep water, be sure to release the shallow water position.

To tilt the motor slightly, set the tilt up lock arm as outlined in the TILT UP LOCK ARM section.

When the shallow water position is used, the tilt lock will not work. Therefore, forces such as propeller thrust during operation in “REVERSE” gear, rapid deceleration, and striking an underwater object can cause the motor to lift out of the water, resulting in personal injury. To avoid such injury, proceed with caution and only at very low speeds when the shallow water position is used.

• When you operate your motor in shallow water using the shallow water position, make sure that the water intake
holes remain in the water at all times and that water is always spraying out of the water discharge hole.
• Do not allow your motor to hit bottom particularly when operating it in “REVERSE” gear, or serious damage can result. When the motor hits bottom while operating in “REVERSE” gear, the shock acts directly on the transom, and both the motor and the boat could be damaged.

After operating the motor in salt water, you should flush the water passages with clean, fresh water as outlined in the FLUSHING THE WATER PASSAGES section. If you do not flush the water passages, salt can corrode the motor and shorten its life.

When operating your outboard motor in freezing temperatures, you should keep the lower unit submerged in the water at all times.
When taking motor out of the water, stand it up in a vertical position until the cooling system drains completely.

If you leave your outboard motor out of the water in freezing temperatures with water still in the cooling system, the water can freeze and expand, causing severe damage to the motor.