Suzuki DF70A User guide
For ’09 model
DF70A/80A/90A
99505-87L00-01E
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.
* 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 2008 Quality Administration Department
CONTENTS
2
IMPORTANT ........................................................................................................................ 3
SYMBOL .............................................................................................................................. 3
MATERIALS REQUIRED .................................................................................................... 3
HANG TAGS ........................................................................................................................ 4
OUTBOARD MOTOR INSTALLATION ............................................................................... 5
HORSEPOWER SELECTION ...................................................................................... 5
MOTOR DIMENSIONS ................................................................................................. 5
TRANSOM DIMENSIONS ............................................................................................ 6
ESTABLISHING THE CENTER-LINE .......................................................................... 6
LIFTING THE MOTOR ................................................................................................. 8
MOUNTING TO THE TRANSOM ................................................................................. 9
WIRE HARNESS INSTALLATION ...................................................................................... 11
CONTROL CABLES INSTALLATION ................................................................................ 13
REMOTE CONTROL BOX SIDE ................................................................................. 13
ENGINE SIDE ............................................................................................................... 13
DRAG LINK INSTALLATION .............................................................................................. 17
FUEL HOSE ......................................................................................................................... 19
BATTERY ............................................................................................................................ 20
BATTERY REQUIREMENT ......................................................................................... 20
INSTALLATION OF BATTERY ................................................................................... 20
CONNECTION OF BATTERY CABLE ........................................................................ 21
SETTING TILT UP LIMIT POSITION .................................................................................. 22
ENGINE OIL ........................................................................................................................ 24
PROPELLER ....................................................................................................................... 25
WIRING DIAGRAM .............................................................................................................. 26
DIGITAL GAUGE SYSTEM ................................................................................................. 28
3
IMPORTANT
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
messages highlighted by these signal words.
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 and CAUTIONS stated, you must use good judgement and basic mechanical safety principles.
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.
MATERIALS REQUIRED
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in motor damage.
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.
WATER RESISTANT
GREASE
SUZUKI SILICONE
SEAL
99000-25161
(250 g/8.8 oz)
99000-31120
(50 g/1.7 oz)
4
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.
12
1. Tag, Important Break-in
2. Tag, CARB emission
5
OUTBOARD MOTOR INSTALLATION
HORSEPOWER SELECTION
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
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.
Unit: mm (in)
764 (30.1)
818 (32.2)
510 (20.1)
X: 1075 (42.3)
580 (22.8)122 (4.8)
6
14
69.5
14
597 (23.5)
L: 510 (20) X: 637 (25)
L: 1479 (58.2) X : 1606 (63.2)
229 (9.0) 229 (9.0)
339 (13.3) 339 (13.3)
30
30
40 (1.6)
L : 956 (37.6)
78 (3.1)
373 (14.7)
FORWARD
DF70A/80A/90A
6
TRANSOM DIMENSIONS
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
a mark on the transom face at 1/2 of this measurement.
(2) Measure across the transom from strake to strake and
make a second mark on the transom face at 1/2 of this
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.
(4) Drill mounting holes as in a single engine installation.
DF70A/80A/90A
38 (1.5)251 (10)
70 (2.8) 51 (2.0)
13.5 (0.53)
17.5 (0.69)
4-places
327 (12.9)
360 (14.2)
203 (8.0)
5 – 13.5
φ
Unit: mm (in)
Transom top surface
Chine
1/2 1/2
1/2 1/2
Strake
7
For twin engine installation you may use the following procedure: (Minimum engine center-line distance is
660 mm/26 in.)
(1) Following the horizontal line from chine to chine, mark the line at 330 mm (13 in.) on both sides of the
previously established single engine vertical center-line.
(2) Following the horizontal line from strake to strake, mark this line also at 330 mm (13 in.) on both sides
of the vertical center-line.
(3) Align a straightedge with these two sets of marks and draw the vertical center-line for a twin engine
installation.
(4) Drill mounting holes as in a twin engine installation.
NOTE:
Do not drill engine top mounting bolt holes higher than 25.4 mm (1 in.) below top edge of actual boat tran-
som.
Chine
Strake
330 mm
(13 in.)
8
LIFTING THE MOTOR
Attach lift to lifting eye on cylinder block.
Lift engine and align with holes drilled in transom.
Use a hoist which has a minimum lift capacity of at
least 450 kg (1 000 lbs.) when lifting the motor.
Use lifting eye only. Do not lift the motor using a fly-
wheel or crankshaft lifting attachment.
9
MOUNTING TO THE TRANSOM
Contained parts
(1) Center the motor on the transom.
Make sure that anti-cavitation plate is located 0 – 25 mm (0
– 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.
(4) Install motor mounting bolts Awith large diameter flat
washer Bfrom inside of transom and through clamp
bracket.
(5) Install small diameter flat washers Cand nuts Don clamp
bracket side.
(6) Tighten all mounting bolts/ nuts securely.
Mounting bolt/nut: 55 N·m (5.5 kgf-m, 40 lb-ft)
(7) Install cap Eto bolts A.
Item Part name Part number Q’ty
ABolt (M12) 09100-12091 4
BWasher (OD 35 mm) 09160-12044 4
CWasher (OD 22 mm) 09160-12110 4
DNut (M12) 09159-12014 4
ECap 41153-94500 4
38 (1.5)251 (10)
70 (2.8) 51 (2.0)
13.5 (0.53)
17.5 (0.69)
4-places
327 (12.9)
360 (14.2)
203 (8.0)
5 – 13.5
φ
Transom top surface
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