Suzuki DF 25 Guida alla configurazione

GENERAL INFORMATION 1-1

CONTENTS

GENERAL INFORMATION

WARNING / CAUTION / NOTE .....................................................................1- 2

GENERAL PRECAUTIONS ...........................................................................1- 2

IDENTIFICATION NUMBER LOCATION ......................................................1- 4

FUEL AND OIL ..............................................................................................1- 4

GASOLINE RECOMMENDATION .........................................................1- 4

ENGINE OIL ...........................................................................................1- 5

ENGINE BREAK-IN .......................................................................................1- 6

WARM-UP RECOMMENDATION ..........................................................1- 6

THROTTLE RECOMMENDATION .........................................................1- 6

PROPELLERS ...............................................................................................1- 7

SPECIFICATIONS .........................................................................................1- 8

SERVICE DATA..............................................................................................1-10

TIGHTENING TORQUE .................................................................................1-14

SPECIAL TOOLS ..........................................................................................1-15

MATERIALS REQUIRED ..............................................................................1-17

1-2 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 also use good judgement and observe basic mechanical safety

principles.

GENERAL PRECAUTIONS



• Proper service and repair procedures are important for the safety of the service mechanic

and the safety and reliability of the outboard motor.

• To avoid eye injury, always wear protective goggles when filing metals, working on a grinder,

or doing other work, which could cause flying material particles.

• When 2 or more persons work together, pay attention to the safety of each other.

• When it is necessary to run the outboard motor indoors, make sure that exhaust gas is vented

outdoors.

• When testing an outboard motor in the water and on a boat, ensure that the necessary safety

equipment is on board. Such equipment includes: flotation aids for each person, fire extin-

guisher, distress signals, anchor, paddles, bilge pump, first-aid kit, emergency starter rope,

etc.

• When working with toxic or flammable materials, make sure that the area you work in is well-

ventilated and that you follow all of the material manufacturer’s instructions.

• Never use gasoline as a cleaning solvent.

• To avoid getting burned, do not touch the engine, engine oil or exhaust system during or

shortly after engine operation.

• Oil can be hazardous. Children and pets may be harmed from contact with oil. Keep new and

used oil away from children and pets. To minimize your exposure to oil, wear a long sleeve

shirt and moisture-proof gloves (such as dishwashing gloves) when changing oil. If oil con-

tacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet

with oil. Recycle or properly dispose of used oil.

• After servicing fuel, oil/engine cooling system and exhaust system, check all lines and fit-

tings related to the system for leaks.

• Carefully adhere to the battery handling instructions laid out by the battery supplier.

GENERAL INFORMATION 1-3



• If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiv-

alent.

• When removing parts that are to be reused, keep them arranged in an orderly manner so that

they may be reinstalled in the proper order and orientation.

• Be sure to use special tools when instructed.

• Make sure that all parts used in assembly are clean and also lubricated when specified.

• When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the spec-

ified type.

• When removing the battery, disconnect the negative cable first and then the positive cable.

When reconnecting the battery, connect the positive cable first and then the negative cable.

• When performing service to electrical parts, if the service procedures do not require using

battery power, disconnect the negative cable from the battery.

• Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending

with smaller diameter. Always tighten from inside to outside diagonally to the specified tight-

ening torque.

• Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, locking nuts,

cotter pins, circlips, and certain other parts as specified, always replace them with new. Also,

before installing these new parts, be sure to remove any left over material from the mating

surfaces.

• Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger

than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is

completely seated in its groove and securely fitted.

• Use a torque wrench to tighten fasteners to the specified torque.

Wipe off grease and oil it a threads is smeared with them.

• After reassembly, check parts for tightness and proper operation.

• To protect the environment, do not unlawfully dispose of used motor oil, other fluids, and bat-

teries.

• To protect the Earth’s natural resources, properly dispose of used motor and parts.

1-4 GENERAL INFORMATION

IDENTIFICATION NUMBER LOCATION

MODEL, PRE-FIX, SERIAL NUMBER

The MODEL, PRE-FIX and SERIAL NUMBER of the motor are

stamped on a plate attached to the driveshaft housing.

Example

ENGINE SERIAL NUMBER

A second engine serial number plate is pressed into a boss on

the cylinder block.

FUEL AND OIL

GASOLINE RECOMMENDATION

Suzuki highly recommends that you use alcohol-free unleaded

gasoline with a minimum pump octane rating of 87 (R/2 + M/2

method) or 91 (Research method). However, blends of

unleaded gasoline and alcohol with equivalent octane content

may be used.

Allowable maximum blend of a single additive (not combination):

5% Methanol, 10% Ethanol, 15% MTBE



THAI SUZUKI MOTOR CO.,LTD.

MADE IN THAILAND FABRIQUE AU THAILANDE

DF 2.5

2 5

If leaded gasoline is used, engine damage may result.

Use only unleaded gasoline.

GENERAL INFORMATION 1-5

ENGINE OIL

Use only oils that are rated SE, SF, SG, SH or SJ under the API

(American Petroleum Institute) classification system.

The viscosity rating should be SAE 10W-40.

If an SAE 10W-40 motor oil is not available, select an alternative

according to the chart at right.

1-6 GENERAL INFORMATION

ENGINE BREAK-IN

The first 10 hours are critically important to ensure correct run-

ning of either a brand new motor or a motor that has been recon-

ditioned or rebuilt. How the motor is operated during this time

will have direct bearing on its life span and long-term durability.

Break-in period: 10 hours

WARM-UP RECOMMENDATION

Allow sufficient idling time (more than 5 minutes) for the engine

to warm up after cold engine starting.

THROTTLE RECOMMENDATION

NOTE:

Avoid maintaining a constant engine speed for an extended

period at any time during the engine break-in by varying the

throttle position occasionally.

1. FIRST 2 HOURS

For first 15 minutes, operate the engine in-gear at idling

speed.

During the remaining 1 hour and 45 minutes, operate the

engine in-gear at less than 1/2 (half) throttle (3 000 r/min).

NOTE:

The throttle may be briefly opened beyond the recommended

setting to plane the boat, but must be reduced to the recom-

mended setting immediately after planing.

2. NEXT 1 HOUR

Operate the engine in-gear at less than 3/4 (three-quarter)

throttle (4 000 r/min).

3. LAST 7 HOURS

Operate the engine in-gear at desired engine speed.

However, do not operate continuously at full throttle for more

than 5 minutes.

GENERAL INFORMATION 1-7

PROPELLERS

An outboard motor is designed to develop its rated power within

a specified engine speed range. The maximum rated power

delivered by the DF2.5 models are shown below.

If the standard propeller fails to meet the above requirement,

use another pitch propeller to hold the engine speed within the

range specified above.

Propeller selection chart



Recommended operating

range 5 250 – 5 750 r/min

Code Number Blade × Diameter × Pitch

A400

A510

3 × 188 mm (7-3/8 in) × 115 mm (4-1/2 in)

3 × 188 mm (7-3/8 in) × 135 mm (5-3/8 in)

Installing a propeller with pitch either too high or too

low will cause incorrect maximum engine speed,

which may result in severe damage to the motor.

1-8 GENERAL INFORMATION

* SPECIFICATIONS * These specifications are subject to change without notice.

DIMENSIONS & WEIGHT

PERFORMANCE

POWER HEAD

Item Unit Data

DF2.5

PRE-FIX 00251F

Overall length

(front to back) mm (in) 437 (17.2): with tiller handle raised

Overall width

(side to side) mm (in) 262 (10.3)

Overall height S mm (in) 963 (37.9)

Weight

(without engine oil) S kg (lbs) 13.0 (28.7)

Transom height Smm

(inch type) 435 (15)

Maximum output kW (PS) 1.8 (2.5)

Recommended operating

range r/min 5 250 – 5 750

Idle speed r/min 1 900 ± 100 (in-gear: approx. 1 500)

Engine type 4-stroke OHV

Number of cylinders 1

Bore mm (in) 48.0 (1.89)

Stroke mm (in) 38.0 (1.50)

Total displacement cm3(cu. in) 68 (4.1)

Compression ratio : 1 9.0

Spark plug NGK CR6HSA

Ignition system Transistorized ignition

Fuel supply system Carburetor

Exhaust system Above prop exhaust

Cooling system Water cooled

Lubrication system Wet sump by trochoid pump

Starting system Manual

Choke system Manual

Throttle control Twist grip

GENERAL INFORMATION 1-9

FUEL & OIL

BRACKET

LOWER UNIT

Item Unit Data

DF2.5

Fuel Suzuki highly recommends that you use alcohol-free unleaded

gasoline with a minimum pump octane rating of 87 (R/2 + M/2

method) or 91 (Research method). However, blends of unleaded

gasoline and alcohol with equivalent octane content may be used.

Fuel tank capacity

(Built-in tank)

(US/lmp. gal) 1.0 (0.26/0.22)

Engine oil API classification SE, SF, SG, SH, SJ

Viscosity rating SAE 10W-40

Engine oil amounts L

(US/lmp. qt) 0.38 (0.40/0.33)

Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil)

Gearcase oil amounts

(US/lmp. oz)

60 (2.0/2.1)

Trim angle Degrees 6 – 20

Number of tilt pin position 4

Maximum tilt angle Degrees 74 (from lowest tilt pin position)

Reversing system Gear

Transmission Forward-Neutral

Reduction system Bevel gear

Gear ratio 13 : 28 (2.15)

Drive line impact protection Shear pin

Propeller Blade × Diam. × Pitch

3 × 188 mm (7-3/8 in) × 115 mm (4-1/2 in) (A400)

3 × 188 mm (7-3/8 in) × 135 mm (5-3/8 in) (A510)

1-10 GENERAL INFORMATION

* SERVICE DATA * These service data are subject to change without notice.

POWER HEAD

* Figures shown are guidelines only, not absolute service limit.

CARBURETOR

CYLINDER HEAD/CAMSHAFT

Item Unit Data

DF2.5

Recommended operating

range r/min 5 250 – 5 750

Idle speed r/min 1 900 ± 100 (in-gear: approx. 1 500)

* Cylinder compression kPa

(kg/cm2, psi) 960 – 1 400 (9.6 – 14.0, 137 – 199)

Engine oil API classification SE, SF, SG, SH, SJ

Viscosity rating SAE 10W-40

Engine oil amounts

L (US/lmp. qt)

0.38 (0.40/0.33)

Thermostat operating

temperature °C (°F) 48 – 52 (118 – 126)

Type Walbro LMJ-26

I.D mark 97J10

Main jet # 70

Pilot jet # 32

Pilot screw

Turns open

Pre-set

Float height mm 10 ± 2

Cylinder head

distortion Limit mm (in) 0.05 (0.002)

Cam

height

IN,

STD mm (in) 28.480 – 28.680 (1.1213 – 1.1291)

Limit mm (in) 28.180 (1.1094)

Rocker

arm shaft

hole

diameter

STD mm (in) 4.015 – 4.027 (0.1581 – 0.1585)

Rocker

arm shaft

outside

diameter

STD mm (in) 3.990 – 4.005 (0.1571 – 0.1577)

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