DF25 -- DF250

DF25 -- DF250
2006 RIGGING MANUAL
2006 RIGGING MANUAL
99518-03060-01E

Printed in Japan TK 99518-03060-01E

1
 FOREWORD
This rigging manual details the set-up and pre-deliv-
ery procedures for all 2006 model Suzuki outboard
GROUP INDEX
motor and accessories.
These instructions and recommendations have
been drawn up to assist your technicians in all vital UNCRATING 1
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
MOTOR DIMENSIONS 2
most straightforward and time-saving installation
method.
Due to the importance of the material herein, we
MOTOR INSTALLATION 3
highly recommend that this manual be kept readily
accessible in your workshop area, where it can be REMOTE CONTROLS 4
referred to by the personnel concerned.
CONTROL CABLE/WIRING HARNESS
Proper set-up each outboard motors have less war-
ranty problems and satisfied customers. INSTALLATION ON ENGINE SIDE 5
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.
DRAG LINK 6
NOTE:
This manual may include information on models not ACCESSORIES 7
designated for your market.
Therefore, before commencing, check the applica-
bility of the contents to outboard motors sold in your
FUEL LINE 8
country.

• This Manual has been prepared by using the

BATTERY 9
latest specifications available at the time of
publication. PROPELLER 10
Differences may exist between the content of
this manual and the actual outboard motor.
• Illustrations in this manual are used to show PRE-DELIVERY 11
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.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2006

2
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 Apply THREAD LOCK “1342”.
torque.

Apply SUZUKI WATER RESISTANT

Use special tool.
GREASE.

Apply SUZUKI SILICONE SEAL.

3
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.

THREAD TIGHTENING TORQUE

TYPE OF BOLT
DIAMETER 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

MATERIALS REQUIRED
WATER RESISTANT SUZUKI SILICONE
GREASE SEAL

99000-25160 99000-31120
(250 g/8.8 oz) (50 g/1.7 oz)
4
 UNCRATING 1-1

UNCRATING
1
CONTENTS
UNCRATING PROCEDURES .......................................................................1- 2
DF200/225/250 .......................................................................................1- 2

5
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 3. Lift the carton B by two or more operators to

• Wrench (12 mm/14 mm) remove it.
• Wrench (17 mm/19 mm)
• Scissors Do not place heavy objects on
top of the crate.
'') fork length.
Use a minimumu of 1.2 mm(48

Wrench Wrench
(17 mm·19 mm) (12 mm·14 mm) Scissors

4. Remove the parts C which come supplied in

1. Check damage due to vibration or impact dur-
the crate.
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.

crate.
objects on top of the
Do not place heavy
1.2 mm(48'') fork length.
Use a minimumu of

6
 UNCRATING 1-3

5. Remove the bolts D that tighten the steel 8. Remove the engine cover G.
frame shown with in the illustration at 8
places in total, right and left.

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

each, and remove the binding strap H.

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

tors to remove it.

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

7. Remove styrofoam block F. points, using cushion J so as not to damage
the flywheel cover.

NOTE:
Use a hook that has a lifting capacity of at least
450 kg.

7
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.
8
 UNCRATING 1-5

LIFTING ENGINE


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
EXAMPLE OF LIFTING DF200/225/250
personal injury or cause damage to the engine block.

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.


Use a hoist which has a minimum lift capacity of at
least 450 kg (1 000 lbs.) when lifting the motor .
EXAMPLE OF LIFTING DF90/115/140

9
 MOTOR DIMENSIONS 2-1

MOTOR DIMENSIONS

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

10
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˚

11
 MOTOR DIMENSIONS 2-3

DF9.9/15 Unit: mm

Shallow drive
1st position: 27˚
2nd position: 42˚

315
160
163

315

12
2-4 MOTOR DIMENSIONS

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

DF200/225/250
Unit: mm

L3
L5 L4

L2 L1
H4

H3
H5

H1
H2
A1
A2

W3
A3

W1
W2
A4

W4

13
 MOTOR DIMENSIONS 2-5

MAJOR DIMENSIONS Unit: mm

DF200
DF25 DF40 DF60 DF90 DF150
Code DF25-V2 DF140 DF225
DF30 DF50 DF70 DF115 DF175
DF250
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
H1
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
S: 412.7 S: 414 S: 401
L: 539.7 L: 541 L: 528 L: 520 L: 539 L: 539 L: 500
H2
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
H: 145 QR·T: 33.9
L2 137 131 132 132 168 159
R: 110.1 Q·QE: 144
L3 517.5 Q·QE: 508 QH: 776 TH: 748
S: 755.9 S: 781 S: 805
L: 860.6 L: 889 L: 914 L: 991 L: 998 L: 998 L: 1 038
L4
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
QR·T: 377
L5 301.8 405 502 575 575 678 612
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

14
2-6 MOTOR DIMENSIONS

CODE DEFINITION
Code Definition and Description
Minimum angle from transom board and bracket clamp (transom angle)
A1
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
Distance from centerline to the farthest point on the body when steered to the maximum
W3
angle on STBD side
Distance from centerline to the farthest point on the body when steered to the maximum
W4
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
Vertical distance measured from the datum plane to the outermost radius of the engine when
H4
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
Distance from datum point to the front end of tiller handle, when the handle is in horizontal
L3
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

15
 MOTOR INSTALLATION 3-1

MOTOR INSTALLATION

CONTENTS
HORSEPOWER SELECTION .........................................................................3- 2
CLAMP BRACKET DIMENSIONS ..................................................................3- 3
DF4/5/6 ...................................................................................................3- 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 6
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
16
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.

17
 MOTOR INSTALLATION 3-3

CLAMP BRACKET DIMENSIONS

DF4/5/6 Unit: mm

(HOLES)
(2 PLACES)

DF9.9/15

(HOLES)
(2 PLACES)

18
3-4 MOTOR INSTALLATION

DF25-V2 Unit: mm

(HOLES)
(4 PLACES)

DF25/30, DF40/50

(HOLES)
(8 PLACES)

19
 MOTOR INSTALLATION 3-5

DF60/70, DF90/115 Unit: mm

HOLES
(10 PLACES)

HOLES
(2 PLACES)

HOLES
(2 PLACES)

DF140

HOLES
(10 PLACES)

HOLES
(2 PLACES)

HOLES
(2 PLACES)

20
3-6 MOTOR INSTALLATION

DF150/175 Unit: mm

HOLES
(20 PLACES)

DF200/225/250

HOLES
(20 PLACES)

21
 MOTOR INSTALLATION 3-7

MINIMUM SPACE
DF25/30 SINGLE MOTOR

B C
D E

840 mm 230 mm
A Minimum D Minimum
33 inch 9 inch
190 mm 230 mm
B Maximum E Minimum
7.4 inch 9 inch
190 mm
C Maximum
7.4 inch

22
3-8 MOTOR INSTALLATION

DF25/30 DUAL MOTOR

G E F G
F

C D

1 401 mm 181 mm
A Minimum E Minimum
55 inch 7.1 inch
561 mm 190 mm
B Minimum F Maximum
22 inch 7.4 inch
230 mm 190 mm
C Minimum G Maximum
9 inch 7.4 inch
230 mm
D Minimum
9 inch

23
 MOTOR INSTALLATION 3-9

DF40/50 SINGLE MOTOR

B C

D E

838 mm 230 mm
A Minimum D Minimum
33 inch 9 inch
189 mm 230 mm
B Maximum E Minimum
7.4 inch 9 inch
189 mm
C Maximum
7.4 inch

24
3-10 MOTOR INSTALLATION

DF40/50 DUAL MOTOR

A

F G F G
C E
D

1 397 mm 181 mm
A Minimum E Minimum
55 inch 7.1 inch
559 mm 189 mm
B Minimum F Maximum
22 inch 7.4 inch
230 mm 189 mm
C Minimum G Maximum
9 inch 7.4 inch
230 mm
D Minimum
9 inch

25
 MOTOR INSTALLATION 3-11

DF60/70 SINGLE MOTOR

B C

D E

838 mm 200 mm
A Minimum D Minimum
33 inch 7.9 inch
219 mm 200 mm
B Maximum E Minimum
8.6 inch 7.9 inch
219 mm
C Maximum
8.6 inch

26
3-12 MOTOR INSTALLATION

DF60/70 DUAL MOTOR

C E D
F G F G

1 397 mm 121 mm
A Minimum E Minimum
55 inch 4.8 inch
559 mm 219 mm
B Minimum F Maximum
22 inch 8.6 inch
200 mm 219 mm
C Minimum G Maximum
7.9 inch 8.6 inch
200 mm
D Minimum
7.9 inch

27
 MOTOR INSTALLATION 3-13

DF90/115/140 SINGLE MOTOR

B C

D E

838 mm 179 mm
A Minimum E Minimum
33 inch 7 inch
240 mm
B Maximum
9.4 inch
240 mm
C Maximum
9.4 inch
179 mm
D Minimum
7 inch

28
3-14 MOTOR INSTALLATION

DF90/115/140 DUAL MOTOR

A

F G F G

C D
E

1 498 mm 180 mm
A Minimum E Minimum
59 inch 7 inch
660 mm 240 mm
B Minimum F Maximum
26 inch 9.4 inch
179 mm 240 mm
C Minimum G Maximum
7 inch 9.4 inch
179 mm
D Minimum
7 inch
Counter-rotation (DF140)
The counter-rotation is recommended to install on port-side
29
 MOTOR INSTALLATION 3-15

DF200/225/250 SINGLE MOTOR

B C

D E

940 mm 184 mm
A Minimum D Minimum
37 inch 7.2 inch
286 mm 184 mm
B Maximum E Minimum
11.3 inch 7.2 inch
286 mm
C Maximum
11.3 inch

30
3-16 MOTOR INSTALLATION

DF200/225/250 DUAL MOTOR

A

F G F G

C E D

1 626 mm 114 mm
A Minimum E Minimum
64 inch 4.5 inch
686 mm 286 mm
B Minimum F Maximum
27 inch 11.3 inch
184 mm 286 mm
C Minimum G Maximum
7.2 inch 11.3 inch
184 mm
D Minimum
7.2 inch
Counter-rotation
The counter-rotation is recommended to install on port-side
31
 MOTOR INSTALLATION 3-17

TRANSOM CENTERLINE
SINGLE MOTOR
1. Prepare a tape measure, marking pen and long ruler.
2. On the transom surface, measure the horizontal distance from chine to chine. Measure the center (1/2)
of the chine-to-chine distance and mark B that position on the transom surface.
3. Measure the horizontal distance between the two garboard stripes. Measure the center (1/2) of the
stripe-to-stripe distance and mark C that position on the transom surface.
4. Using a ruler, mark the vertical line A intersecting with the two marks on the transom surface. This line is
the centerline used when installing a single engine.

1/2 1/2

1/2 1/2

Reference

Chine Chine

Stripe Stripe

32
3-18 MOTOR INSTALLATION

SINGLE MOTOR
Checking of vertical line A.
Check that the right and left spaces divided by vertical line A are equal.
1. Check that the length of lines D and D” are equal.
2. Check that the length of lines E and E” are equal.

E D D” E”

33
 MOTOR INSTALLATION 3-19

DUAL MOTOR
For the distance between the centers, refer to minimum space of the previous section.
1. On the horizontal chine-to-chine distance, mark B the point at 1/2 of the distance between the engine
centers away from and on each side of the vertical line A that has been previously measured for single
engine mounting.
2. On the horizontal stripe-to-stripe distance, mark C the point at 1/2 of the distance between the engine
centers away from and on each side of the vertical line A that has been previously measured for single
engine mounting.
3. Using a ruler, mark the vertical centerline intersecting with the two marks for mounting the dual engines.

Distance between centers

B
A

Reference

Chine Chine

Stripe Stripe

34
3-20 MOTOR INSTALLATION

TRANSOM DRILLING TEMPLATE INSTRUCTIONS

Tool name Part number Applicable model
Transom Drilling Template 09914-89510 DF25/30 – DF200/225/250

TRANSOM DRILLING TEMPLATE

There are two sizes, A and B, of the drilled hole.

Hole name Model Drill bit diameter

B DF25/30 12.5 mm A A

B DF40/50 12.5 mm B

A
B

B DF60/70 12.5 mm
B DF90/115 12.5 mm
B DF140 12.5 mm
A DF150/175 13 mm (17/32 in)
B B
A DF200/225/250 13 mm (17/32 in) A A

TRANSOM DRILLING TEMPLATE DIMENSIONS Unit: mm

35
 MOTOR INSTALLATION 3-21

DF25/30, DF40/50 BOLT HOLE POSITION Unit: mm

DF25/30, DF40/50
Clamp bracket

DF60/70, DF90/115, DF140 BOLT HOLE POSITION

DF60/70, DF90/115, DF140

Clamp bracket
3-22 MOTOR INSTALLATION

DF150/175 BOLT HOLE POSITION Unit: mm

DF150/175
Clamp bracket

DF200/225/250 BOLT HOLE POSITION

DF200/225/250
Clamp bracket
 MOTOR INSTALLATION 3-23

USE OF TRANSOM DRILLING TEMPLATE

1. Get ready for a tape measure, water-based marking pen and
long ruler.
2. On the transom surface, measure the horizontal distance
from chine to chine. Measure the center (1/2) of the
chine-to-chine distance and mark that position on the tran-
som surface.
3. Measure the horizontal distance between the two garboard
stripes. Measure the center (1/2) of the stripe to stripe dis-
tance and mark that position on the transom surface.

4. With a ruler, mark the vertical line A intersecting with the two
marks on the transom surface.

5. Marked line on the transom surface.

A
3-24 MOTOR INSTALLATION

6. Install the Transom Drilling Template to transom board so

that its center two holes are fitted to the vertical centerline A.

Centerline A
Transom Drilling
Template Hole

Centerline A
Transom Drilling
Template Hole

7. Adjust the height and horizontal position of Transom Drilling

Template with its wing bolts.

8. Tighten the transom clamp arm nut to secure the Transom

Drilling Template.
 MOTOR INSTALLATION 3-25

9. Recheck the transom height from the upper edge of the tran-
som board where there is a cutout of Transom Drilling Tem-
plate using a tape measure.
• In other words, confirm the position of the anti-Cavitation
Plate.

10. Drill the bolt holes into the transom board through the drilling
guide hole on the Transom Drilling Template.

NOTE:
Transom top surface A is to be even, when Transom Drilling
Template is attached.
3-26 MOTOR INSTALLATION

LIFTING MOTOR


DO NOT USE FRONT LIFT EYE

WHEN UNCRATING THE MOTOR
The front lift eye is not designed nor intended to be
used for removing the motor 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 per-
EXAMPLE OF LIFTING DF200/225/250
sonal injury or cause damage to the engine block.

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.


Use a hoist which has a minimum lift capacity of at
least 450 kg (1 000 lbs.) when lifting the motor.
EXAMPLE OF LIFTING DF90/115/140

WEIGHT BY MODEL SPECIFICATION

Weight by model specification Weight by model specification
S 69 kg DF90 L 189 kg
Manual Electric
L 72 kg DF115 X 194 kg
DF25-V2
S 74 kg L 186 kg
Electric DF140 Electric
L 77 kg X 191 kg
DF25Q S 93 kg L 211 kg
Manual DF150 Electric
DF30Q L 96 kg X 215 kg
DF25Q S 95 kg L 211 kg
Electric DF175 Electric
DF30Q L 98 kg X 215 kg
DF25T S 93 kg DF200 Electric X 263 kg
Electric
DF30T L 96 kg X 263 kg
DF225 Electric
S 108 kg XX 268 kg
DF40QH Electric
L 111 kg X 263 kg
DF250 Electric
S 107 kg XX 268 kg
DF50TH Electric
L 110 kg
DF40 S 107 kg
Electric
DF50 L 110 kg
DF60 L 162 kg
Electric
DF70 X 167 kg
 MOTOR INSTALLATION 3-27

ENGINE MOUNT
MOUNTING TO THE TRANSOM
DF25V2
Contained parts
Item Part name Part number Q’ty
A Bolt (M10 x 110 mm) 09100-10309 2
B Washer no.1 (Large) 35 x 10.5 09160-10139 2
C Washer no.1 (Small) 18 x 10.5 09160-10140 2
D Nut 09159-10050 2
E Cap 41153-95J00 2
 Nut D: 40 N·m (4.0 kgf-m, 29.0 lb-ft)
NOTE:
• Clamp bracket top side of two bolt holes is optional.
• Drill the top holes at lest 25 mm(1.0 in) away from the transom top
surface.
• Drill the mounting holes vertically to the transom board.
• To ensure water-proofness, sealant should be applied to all bolt holes.
Apply the sealant to shanks of bolts, but not threads.
• Do not use an impact tool to tighten or loosen the transom nuts.
• If tightening torque can not reach to the specified torque due to weak transom material, it is necessary to put the
transom board with an reinforcement plate between the transom board and the washer, to reinforce the tran-
som, contact the boat manufacturer as needed.

MOUNTING TO THE TRANSOM

DF25/30, DF40/50
Contained parts
Item Part name Part number Q’ty
A Bolt (12 mm) 09100-12093 4
B Washer (Large) 09160-12044 4
C Washer (Small) 09160-12110 4 Manual
D Nut 09159-12014 4 release
valve
E Cap 41153-94500 4
 Nut D: 55 N·m (5.5 kgf-m, 40.0 lb-ft)
NOTE:
• Drill the upper holes center at least 25 mm (1.0 in) away from
the transom top surface.
• For power trim & tilt model, drill the lower holes at the position
where the lower bolt does not interfere with the operation for
manual release valve.
• Install the large washer B on the transom board side.
• To ensure a water-tight engine installation, sealant (SUZUKI SILICONE SEAL or equivalent) should be
applied to all bolt holes.
• If tightening torque cannot reach to the specified torque due to weak transom material, it is necessary to
reinforce the transom board with an attachment plate.
3-28 MOTOR INSTALLATION

MOUNTING TO THE TRANSOM

DF60/70, DF90/115, DF140
Contained parts
Item Part name Part number Q’ty
Bolt (12 mm) for
A 09100-12091 4
DF60/70, DF90/115
Bolt (12 mm) for
A 09100-12090 4
DF140
B Washer (Large) 09160-12044 4
C Washer (Small) 09160-12110 4
D Nut 09159-12014 4
E Cap 41153-94500 4
 Nut D: 55 N·m (5.5 kgf-m, 40.0 lb-ft)
NOTE:
• Drill the upper holes center at least 25 mm (1.0 in) away from
the transom top surface.
• Install the large diameter washer B on the transom board
side.
• To ensure a water-tight motor installation, sealant (SUZUKI
SILICONE SEAL or equivalent) should be applied to all bolt
holes.
• If tightening torque cannot reach to the specified torque due to
weak transom material, it is necessary to reinforce the tran-
som board with an attachment plate.

MOUNTING TO THE TRANSOM

DF150/175, DF200/225/250
Contained parts
Item Part name Part number Q’ty
A Bolt (1/2-20 UNF) 09100-12086 6
Washers
B 09160-13017 4
(Large: OD45 mm)
Washers
C 09160-13016 6
(Small: OD26 mm)
D Nut 09159-12062 6
E Cap 41153-94500 6
F Washer (with 2 holes) 41153-93J00 2
SUZUKI highly recommend to use six mounting bolts for a
rigid-hull inflatable boat or similar application.
 MOTOR INSTALLATION 3-29

Six bolts to mount to the boat transom.

 Nut D: 80 N·m (8.0 kgf-m, 58.0 lb-ft)

NOTE:
• Drill the mounting holes vertically to the transom board face.
• Drill the upper holes center at least 25 mm (1.0 in) down from the transom top surface.
• To ensure a water-tightness, sealant (SUZUKI SILICONE SEAL or equivalent) should be applied to all bolt
holes. Apply the sealant to shanks of bolts, but not threads.
• Do not use an impact tool to tighten or loosen the transom nuts.
• If tightening torque cannot reach to the specified torque due to weak transom material, it is necessary to
put the transom board with an reinforcement plate. Install the reinforcement plate between the transom
board and the washer B and F. To reinforce the transom, contact the boat manufacturer as needed.

Never reuse the nut D after it has been threaded into position and torqued.

NOTE:
• If there is a clearance between the clamp bracket and the tran-
som top surface, place a proper spacer on the transom top
surface so that motor weight can be supported by the transom
through the spacer. Spacer


After completing a break-in operation (10 hours),
retighten the transom nuts by the specified torque.
 Item A B C D E F
3-30

Q’ty Q’ty Q’ty Q’ty Q’ty Q’ty

Model Bolts Washer (Large) Washer (Small) Nuts Cap transom bolt Plate, Transom
41153-94500
DF25/30 09100-12093 (STD) 4 09160-12044 4 09160-12110 4 09159-12014 4 4
Color: White

09100-12093 (STD) 4 41153-94500

DF40/50 09160-12044 4 09160-12110 4 09159-12014 4 Color: White 4
09100-12091 (OPT) 4

09100-12091 (STD) 4 41153-94500

MOTOR INSTALLATION

DF60/70 09160-12044 4 09160-12110 4 09159-12014 4 4

09100-12090 (OPT) 4 Color: White

09100-12091 (STD) 4
41153-94500
DF90/115 09160-12044 4 09160-12110 4 09159-12014 4 4
09100-12090 (OPT) 4 Color: White

09100-12090 (STD) 4
41153-94500
DF140 09160-12044 4 09160-12110 4 09159-12014 4 4
09100-12091 (OPT) 4 Color: White

DF150/175 09100-12086 (STD) 4

09160-13017 6 09160-13016 6 09159-12062 6 41153-93J00 6 41155-93J00 2
DF200/225/250 Color: Black
09100-12092 (OPT) 4

09100-12093 09100-12091 09100-12090

BOLT TRANSOM TABLE (’06 MODEL)

09100-12092 09100-12086 41155-93J00