SUZUKI DF25 DF250 Instruments 3

ACCESSORIES 7-1
ACCESSORIES
CONTENTS
TACHOMETER KIT .............................................................................................. 7- 2

METER DIMENSIONS ................................................................................ 7- 2
INSTALL INSTRUCTIONS .......................................................................... 7- 3
TACHOMETER KIT .............................................................................................. 7- 5
SPEEDOMETER KIT ............................................................................................ 7- 8
TRIM METER KIT ................................................................................................. 7-11
METER DIMENSIONS ................................................................................ 7-11
INSTALL INSTRUCTIONS .......................................................................... 7-12
6
HOUR METER KIT ................................................................................................ 7-14
7
FUEL GAUGE METER KIT ................................................................................... 7-17
VOLTAGE METER KIT ......................................................................................... 7-20
WATER PRESSURE GAUGE KIT ........................................................................ 7-23
DF25/30 WATER PRESSURE GAUGE SUB KIT
DF90/115/140 WATER PRESSURE GAUGE SUB KIT
SINGLE IGNITION SWITCH PANEL KIT ............................................................. 7-38
DUAL IGNITION SWITCH PANEL KIT ................................................................ 7-41
WIRlNG DIAGRAM ..................................................................................... 7-43
IGNITION & EMERGENCY STOP SWITCH PANEL KIT ..................................... 7-44
WIRlNG DIAGRAM ..................................................................................... 7-47
LIGHTING SWITCH PANEL KIT .......................................................................... 7-48
EMERGENCY STOP SWITCH KIT ....................................................................... 7-50
WIRlNG DIAGRAM ..................................................................................... 7-52
PTT SWITCH KIT .................................................................................................. 7-53
WIRlNG DIAGRAM ..................................................................................... 7-55
RIGGING HOSE ADAPTER KIT ........................................................................... 7-56
1
7-2 ACCESSORIES
TACHOMETER KIT
Part number Part name Applicable model
34200-93J00 Tachometer kit (Black)
DF40/50/60/70/90/115/140/150/175/200/225/250
34200-93J10 Tachometer kit (White)
Make a copy of the meter photograph below and arrange the meter location on the dash panel.
34200-93J10 (White) 34200-93J00 (Black)
METER DIMENSIONS 10.6 65 29

NOTE: 4.3 3
The pictures are full scale.
¬86.2
¬84.5
¬93
2
ACCESSORIES 7-3
INSTALL INSTRUCTIONS
CONTENTS
Ref. Part number Part name Q’ty
1 34200-93J00, 93J10 Tachometer kit 1
2 09471-12077 • Bulb 1
TOOLS REQUIRED
Ref. Description
1 Electric drill
2 86 mm (3 3/8 in) Hole saw
3 8 mm Wrench
PREPARATION PRIOR TO INSTALLATION

Identify each part listed above.

For safety, always disconnect the battery when
removing or installing electrical equipment. To dis-
connect the battery cable, first disconnect the nega-
tive - terminal and then the positive + terminal.
When reconnecting, turn the main switch off, connect
the positive + terminal and then the negative - termi-
nal.
1. Select a location on the instrument panel which provides the

recommended gauge installed angle (Fig. 1) and easy view-
ing by the boat operator.
2. Using hole saw, drill through the instrument panel.
3. Connect the leads as shown in the following connection sec-
tion.
4. Install the tachometer 1 to the instrument panel.
3
7-4 ACCESSORIES
TACHOMETER CONNECTION
4
ACCESSORIES 7-5
TACHOMETER KIT
34200-93J20 Tachometer kit (Black)
DF9.9/15/25/30
34200-93J30 Tachometer kit (White)
34200-93J30 (White) 34200-93J20 (Black)
METER DIMENSIONS 10.6 65 29
4.3 3
¬86.2
¬84.5
¬93
5
7-6 ACCESSORIES
CONTENTS
1 34200-93J20, 93J30 Tachometer kit 1
2 09471-12028 • Bulb 1
TOOLS REQUIRED
Ref. Description
1 Electric drill
3 8 mm Wrench


For complete safety, always disconnect the battery
when removing or installing electrical equipment. To
disconnect the battery cable, first disconnect the neg-
ative - terminal and then the positive + terminal.
nal.

tion.
4. Install the tachometer 1 to the instrument panel.
6
ACCESSORIES 7-7
TACHOMETER CONNECTION
7
7-8 ACCESSORIES
SPEEDOMETER KIT
34100-93J00/93J10 Speedometer kit, 80 MPH (130 km/h)
DF9.9/15/25/30/40/50/60/70/90/115/140/
34100-93J20/93J30 Speedometer kit, 50 MPH (80 km/h)
150/175/200/225/250
34100-93J40/93J50 Speedometer kit, 45 KNOTS (80 km/h)
34100-93J10 130 km/h and 80 mph White 34100-93J00 130 km/h and 80 mph Black
34100-93J30 80 km/h and 50 mph White 34100-93J20 80 km/h and 50 mph Black
34100-93J50 45 knots and 80 km /h White 34100-93J40 45 knots and 80 km/h Black
METER DIMENSIONS 10.2 70.6

4.3 3
¬86.2
¬84.5
¬93
93.9
8
ACCESSORIES 7-9
CONTENTS
1 34300-93J00, 10, 20, 30, 40, 50 Speedometer kit 1
2 09471-12108 • Bulb 1
3 34191-92E00 • Tube 1
4 34192-92E00 • Band 2
TOOLS REQUIRED
Ref. Description
1 Electric drill
3 8 mm Wrench


nal.
9
7-10 ACCESSORIES

tion.
4. Install the speedometer 1 to the instrument panel.
SPEEDOMETER CONNECTION
CAUTION:
1. Make sure the tube connections do
not leak.
2. If the tube becomes clogged with dirt
readings will be no longer accurate.
Disconnect the tube at point A and
use an air compressor to blow into the
tube in the direction of the arrow. Make
sure air pressure does not exceed 85
psi (6 kg/cm2) during this procedure.
10
ACCESSORIES 7-11
TRIM METER KIT

34800-93J00 Trim meter kit (Black) DF25/30/40/50/60/70/90/115/140/150/175/
34800-93J10 Trim meter kit (White) 200/225/250
34800-93J10 (White) 34800-93J00 (Black)
METER DIMENSIONS
8.3 32.8 39.2

3 43.6
7
¬62
¬59
¬58
¬52
11
7-12 ACCESSORIES
CONTENTS
1 34800-93J00, 93J10 Trim meter kit 1
2 09471-12108 • Bulb 1
TOOLS REQUIRED
Ref. Description
1 Electric drill
2 52.5 mm (2-1/16 in) Hole saw
3 7 mm Wrench


nal.

tion.
4. Install the trim meter 1 to the instrument panel.
12
ACCESSORIES 7-13
TRIM METER KIT CONNECTION
13
7-14 ACCESSORIES
HOUR METER KIT

34500-93J00 Hour meter kit (Black) DF25/30/40/50/60/70/90/115/140/150/175/
34500-93J10 Hour meter kit (White) 200/225/250
34500-93J10 (White) 34500-93J00 (Black)
METER DIMENSIONS
8.3 71.4 33
3 80
¬62
¬59
¬58
¬52
85.3
14
ACCESSORIES 7-15
CONTENTS
1 34500-93J00, 93J10 Hour meter kit 1
2 09471-12103 • Bulb 1
TOOLS REQUIRED
Ref. Description
1 Electric drill
2 52.5 mm (2-1/16 in) Hole saw
3 7 mm Wrench


nal.

tion.
4. Install the hour meter 1 to the instrument panel.
15
7-16 ACCESSORIES
HOUR METER KIT CONNECTION
16
ACCESSORIES 7-17
FUEL GAUGE METER KIT

34300-93J00 Fuel gauge meter kit (Black) DF25/30/40/50/60/70/90/115/140/150/175/
34300-93J10 Fuel gauge meter kit (White) 200/225/250
34300-93J10 (White) 34300-93J00 (Black)
METER DIMENSIONS
8.3 32.8 39.2

3 43.6
7
¬62
¬59
¬58
¬52
17
7-18 ACCESSORIES
CONTENTS
1 34300-93J00, 93J10 Fuel gauge meter kit 1
2 09471-12103 • Bulb 1
3 34310-92E00 • Cord assy 1
4 34360-92E00 • Adaptor comp 1
TOOLS REQUIRED
Ref. Description
1 Electric drill
2 52.5 mm (2-1/16 in) Hole saw
3 7 mm Wrench


nal.
18
ACCESSORIES 7-19

tion.
4. Install the fuel gauge meter 1 to the instrument panel.
FUEL GAUGE METER KIT CONNECTION
19
7-20 ACCESSORIES
VOLTAGE METER KIT

34600-93J00 Voltage meter kit (Black) DF25/30/40/50/60/70/90/115/140/150/175/
34600-93J10 Voltage meter kit (White) 200/225/250
34600-93J10 (White) 34600-93J00 (Black)
METER DIMENSIONS
8.3 32.8 39.2

3 43.6
7
¬62
¬59
¬58
¬52
20
ACCESSORIES 7-21
CONTENTS
1 34600-93J00, 93J10 Voltage meter kit 1
2 09471-12103 • Bulb 1
TOOLS REQUIRED
Ref. Description
1 Electric drill
2 52.5 mm (2-1/16 in) Hole saw
3 7 mm Wrench


nal.

tion.
4. Install the voltage meter 1 to the instrument panel.
21
7-22 ACCESSORIES
VOLTAGE METER KIT CONNECTION
22
ACCESSORIES 7-23
WATER PRESSURE GAUGE KIT

34650-93J20 Water pressure gauge kit (Black) DF25/30/40/50/60/70/90/115/140/150/175/
34650-93J30 Water pressure gauge kit (White) 200/225/250
34650-93J30 (White) 34650-93J20 (Black)
METER DIMENSIONS
8.3 31.8 39.2
3
7
¬62
¬59
¬58
¬52
23
7-24 ACCESSORIES
CONTENTS
1 34650-93J20, 93J30 Water pressure gauge kit 1
2 09471-12103 • Bulb 1
3 34191-92E00 • Hose 1
4 34192-92E00 • Band 2
TOOLS REQUIRED
Ref. Description
1 Electric drill
2 52.5 mm (2-1/16 in) Hole saw
3 8 mm Wrench


nal.
24
ACCESSORIES 7-25

tion.
4. Install the water pressure gauge 1 to the instrument panel.
WATER PRESSURE GAUGE KIT CONNECTION
25
7-26 ACCESSORIES

34660-89J00 Water pressure gauge sub kit DF25/30
COMPONENTS INCLUDED IN KIT

Ref. Part name Q’ty
1 Hose (140 mm) 1
2 Hose (70 mm) 1
3 3-way joint 1
4 Clip 4
5 Hose (7 000 mm)* 1
6 Band* 1
* These parts are included in the water pressure gauge kit avail-
able separately.
NOTE:
This water pressure gauge sub kit is required when installing the
water pressure gauge available separately to DF25/30. Hose (L: 7 000) × 1
Band × 2
INSTALLING WATER PRESSURE GAUGE SUB KIT AND HOSE


When installing the hoses, use care not to allow them to contact the link system including the
throttle and the shift and not to allow them to bend excessively.
For installation, refer to the drawing on the attached sheet and follow the procedure described below.
1. Make a cut in the thin film of the cable grommet and through the cut draw in the hose 5 into inside of the
engine cover. (See the figure viewed in the arrow A direction.)
2. Pass the hose 5 under the connector in the connector holder (See the figure viewed in the arrow B
direction.) and route it along the oil filter.
3. Pass the hose 5 through the cut in the side cover seal (See the figure showing the upper part of the
section marked C.) and draw it in toward the oil pan.
(See the figure viewed in the arrow B direction) and route it along the oil filter.
4. Remove the water inspection hose connecting the unions A and B on the side of the oil pan, connect
hose 1 to the union A and the hose 2 to the union B and then fix them with clips 4.
5. Connect the 3-way joint 3 to hoses 1 and 2 as shown in the figure and fix them with clips 4.
To the other end, install the hose 5 drawn to the oil pan side in step 3 and fix it by tightening the band
6.

Make sure to tighten each clip and band securely.
26
ACCESSORIES 7-27
27
7-28 ACCESSORIES

34660-87J00 Water pressure gauge sub kit DF40/50
PARTS IN KIT
1 Hose (250 mm) 1
2 Hose (70 mm) 1
3 3-way joint 1
4 Clip 4
5 Clamp 1
6 Hose (7 000 mm)* 1
7 Band* 1
able separately.

Hose (L: 7 000) × 1
Before starting the operation, confirm the shape of the
union mounted on the engine holder. (See Fig. A.)
Band × 2
• In the case of L-type union, cut the hose 1 to the
length of 190 mm for using it.
• In the case of straight union, no cutting is neces-
sary.
NOTE:
water pressure gauge available separately to DF40/50.


Follow the procedure described below while referring to the attached drawing.
1. Remove the water hose connecting the engine holder with 3-way joint A then install the hose 1 (L-type
union: 190 mm, and straight type union: 250 mm) to engine holder side and the hose 2 to 3-way joint A
side respectively. Secure these hoses by using clips 4.
2. Connect each hose to 3-way joint 3 as shown in enlarged view of C Part, and secure the assembly by
using the clip 4.
3. Cut a slit on the thin section of cable grommet, and pass hose 6 to the inside of engine cover through
this slit, then route hose 6 as shown in photo.
4. Secure the hose 6 with a clamp 5 as shown in enlarged view of B Part.
5. Install hose 6 to 3-Way joint 3 as shown in enlarged view of C Part, then secure it with a band 7.

28
Cable grommet
Hose 2
Hose 6
Clip 4
3-way joint 3 Hose 1

Clip 4
Band 7 Hose 6 Cable grommet
Clamp 5 Hose 6
Detail of view “D”
VIEW C
Detail of view “B” Detail of view “C”
3-way joint 3 Clip 4

Clip 4 Band 7
Hose 2 Hose 6
3-way joint A
D
Hose 1
E Cable grommet
Hose 6
Clamp 5
Hose 1
Detail of view “E” A B
Engine holder connection union, straight type Engine holder connection union, L type
to 3-way joint to 3-way joint Hose 1
Hose 2 Hose 1 Hose 2
to water pressure to water pressure
gauge gauge
3-way 3-way
joint 3 joint 3 Cable grommet
Cable grommet
Hose 6 Hose 1 Hose 6 Hose 1
HOSE ROUTING Detail of view “A” HOSE ROUTING
( Part additions are to be made) Detail of view “A”
ACCESSORIES
( Part additions are to be made)

Connection union, straight type
Connection union, L type
7-29
29
7-30 ACCESSORIES

34660-99E00 Water pressure gauge sub kit DF60/70
PARTS IN KIT
1 Hose (110 mm) 1
2 Hose (30 mm) 1
3 3-way joint 1
4 Clip 4
5 Hose (7 000 mm)* 1
6 Band* 1
* These parts are included in the water pressure gauge kit, avail-
able separately.
NOTE:
water pressure gauge available separately to DF60/70. Hose (L: 7 000) × 1
Band × 2


1. Cut the thin film of the cable grommet and pass the hose 5 through that cut and pull it inside of the
engine cover. (See the figure A viewed from A.)
2. Hook the hose 5 onto the silent cover. (See the section drawing B.)
3. Route the hose 5 through the bottom of electric parts holder (See the section drawing C.), behind the
wiring harness and beside the oil filter.
4. Pass the hose 5 through the gap between the oil pan and the engine holder and inside cover seal.
(See the figure of top view D.)
5. Remove the water inspection hose connecting the exhaust manifold and oil pan, connect the hose 2 to
the exhaust manifold and the hose 1 to the oil pan and then fix them with a clip 4 respectively.
6. Connect the hoses 1 and 2 to the 3-way joint 3 as shown in the figure and fix them with clips 4.
Then connect the hose 5 from 4 to the remaining end of the 3-way joint and fix it by fastening the band
6.

30
ACCESSORIES 7-31
31
7-32 ACCESSORIES

34660-90J00 Water pressure gauge sub kit DF90/115/140
PARTS IN KIT
1 Hose (210 mm) 1
2 Hose (160 mm) 1
3 3-way joint 1
4 Clip 4
5 Hose (7 000 mm)* 1
6 Band* 1
able separately.
NOTE:
NOTE:This water pressure gauge sub kit is required when
installing the water pressure gauge available separately to Hose (L: 7 000) × 1
DF90/115/140.
Band × 2
32
ACCESSORIES 7-33


1. Remove 3-way joint D and the water hose that is connected to the lower side of crankcase water jacket.
Install hose 1 to 3-way joint D and hose 2 to the crankcase water jacket respectively.
Then, secure the connection using clip 4.
2. Place hose 1 under the oil filter, behind the fuel hose and through clamp E on which the fuel hose is
secured. (See enlarged drawing A.)
3. Position hose 2 between boss F that is used for holding the front panel and the under cover seal.
(See arrow view B.)
4. Connect each of hoses 1 and 2 to 3-way joint 3 as shown in the drawing. Secure the connections
using clip 4.
5. Cut a slit on the thin section of cable grommet and pass hose 5 to the inside of engine cover through
this slit. (See arrow view C.)
6. Connect the other end of hose 5 as installed in (5) above to 3-way joint 3 to which hoses 1 and 2
have been already connected. Secure the connection using band 6.

NOTE:
3-way joint D original equipped.
33
7-34
Cable grommet
ACCESSORIES
Speedmeter hose
Battery cable
Hose
Detail of view “C”

A Speedmeter hose
Battry cable Front panel bos
B Hose 3-way
joint
Band
Battery cable Clip
3-way joint
Clip
Hose Hose Side cover seal Clip

Fuel Clamp Crankcase
hose Side cover seal
Oil filter water jacket
Clip Detail of view “B”
3-way joint Detail of view “A”
34
ACCESSORIES 7-35

34660-93J00 Water pressure gauge sub kit DF200/225/250
PARTS IN KIT
Ref. Part name Q’ty Ref. Part name Q’ty
1 Hose (750 mm) 1 5 Clip 4
2 Hose (110 mm) 1 6 Hose (7 000 mm)* 1
3 3-way joint 1 7 Band* 1
4 Protector (390 mm) 1
Hose (L: 7 000) × 1
Band × 2
* These parts are included in the water pressure gauge kit available separately.
NOTE:
This water pressure gauge sub kit is required when installing the water pressure gauge available separately
to DF200/225/250.
35
7-36 ACCESSORIES


1. Remove the water hose connecting the oil pan with lower side of the crankcase water jacket, then install
the hose 1 (L = 750 mm) to oil pan side, and the hose 2 (L = 110 mm) to lower side of the crankcase
water jacket, respectively. Secure these hoses using clips.
2. Pass the hose 1 through side cover seal and cramp.
3. Connect the respective hose to 3-way joint as shown by arrow view B and secure them with clips.
4. Cut a slit on the thin section of cable grommet, and pass the hose (water pressure gauge hose) to the
inside of engine cover through this slit.
5. Pass the hose through protector and route the hose as shown by arrow view B.

Take care so that the hose should pass below the remote control cable for shifting.
6. Install the hose to 3-way joint and secure it with a band.


Protector (390 mm)
Hose 6 Cable grommet
Hose 2
Speedometer
hose
Clip
Band
3-way joint
Clip
Hose 1
Detail of view “B”

Protector (390 mm)
Cable grommet
Hose 6
Hose 6
C
6
Speedometer hose
Hose 2
Detail of view “C” A
Hose
Protector (390 mm) To crankcase Hose 2
Cable grommet
Clip
Band
To oil pan
Clip
Band
Hose 6 3-way joint Hose 1
Side cover seal
Clip
HOSE ROUTING 3-way joint
( Part additions are to be made)
ACCESSORIES
Detail of view “A”

7-37
7-38 ACCESSORIES
SINGLE IGNITION SWITCH PANEL KIT

Part number Part name Years Applicable model
37100-96J00 Single ignition switch panel From 2005
All electric starter model (for single)
37100-99E00 kit Up to 2004
Make a copy of the switch panel picture below and use it for determining the location of meter on the dash
panel.
70
50
30˚
30˚
OFF
ON
START
70
50
R3
OPT: SWITCH (MODEL: 05, 06)

1 2
1 37100-96J00 Single ignition switch panel kit 1
2 37139-99E00 • Ignition switch panel 1
2A 38500-93J90 • Warning buzzer 1
2B 09407-08401 • Clamp buzzer 1
2B
2A
ACCESSORIES 7-39
COMPONENT PARTS
Ref. Part name Part number Q’ty
37110-93J00 or
1 Switch assy 1
37110-99E00
37141-99E00
2 Key (#931 – 942) 2
(00 – B0)
3 Panel 37139-99E00 1
4 Screw 03122-05165 4
* Key number location
1. Tools required
4 × 3.5 mm
• 51 mm (2.0 in) hole saw (9/64 in)
• 3.5 mm (9/64 in) drill bit 51 mm
• Phillips (+) screw driver (2.0 in)
• Drill motor
2. Using hole saw and bit, drill holes through the dash panel at
the center marks (×) shown.
3. Connect all wires, matching their color to the remote control

extension cable.
4. Install the ignition switch through the hole and fasten on the
panel with the screws provided.
54 mm (2.1 in) 33 mm (1.3 in) 54 mm (2.1 in) 33 mm (1.3 in)

180 mm (7.1 in)
W 150 mm (5.9 in)
G Br
Or Br
Br L
Gr Gr
B
Gr
G
Gr
B
B
450 mm (17.7 in)
100 mm (3.9 in)
REMOTE CONTROL
EXTENSION HARNESS
36620-92E00 (6.5 m)
36620-95610 (7.5 m) B L REMOTE CONTROL
Or Br G Gr WIRE HARNESS
W WR
36620-93J00 (6.5 m)
37100-99E00 37100-93J00
7-40 ACCESSORIES

• When selecting a location for installing the switch panel, ensure the location is convenient for
the operator.
• Avoid locating where water or spray is likely to splash the panel.
• It is recommended that the switch panel be installed at an angle of 10° or more for proper
drainage.
• If the switch assy is removed from the panel, it must be reinstalled with the flat surface below
the key slot facing down.
• For complete safety, always disconnect the battery when removing or installing electrical
equipment.
To disconnect the battery cable, first disconnect the negative - terminal and then the posi-
tive + terminal. When reconnecting, turn the main switch off, connect the positive + terminal
and then the negative - terminal.
ACCESSORIES 7-41
DUAL IGNITION SWITCH PANEL KIT

37100-96J00 From 2005
Dual ignition switch panel kit All electric starter model (for dual)
37100-99E00 Up to 2004
panel.
141
121
86
OFF OFF
ON EMERGENCY STOP ON
START START
94
74
4
OPT: SWITCH (MODEL: 05, 06) 18

22
18 37100-96J10 Dual ignition switch panel kit 1
19
19 37110-93J00 • Ignition switch assy 2
20 37820-93J90 • Emergency switch assy 1
21 37139-99E10 • Panel 1 20
22 03121-05163 • Screw 4 21
23 38500-93J90 • Warning buzzer 1 19
24 09407-08401 • Clamp buzzer 1

23 24
7-42 ACCESSORIES
COMPONENT PARTS
37110-93J00 or
1 Ignition switch 2
37110-99E00
37820-93J90 or
2 Emergency switch 1
37820-92E90
3 Panel 37139-99E10 1
4 Screw 03122-05165 4
Ignition key 37141-99E00 * Key number location
5
(#931 – 942) (00 – B0)
4 × 3.5 mm (9/64 in)
1. Tools required
• Electric drill
• 70 mm (2-3/4 in) hole saw 70 mm 70 mm
• 3.5 mm (9/64 in) drill bit (2 3/4 in) (2 3/4 in)
• Phillips (+) screw driver
65 mm
3. Connect the leads, matching their color, as shown in the fol-
lowing wiring diagram.
4. Attach the panel to the dashboard.

• When selecting a location for installing the switch panel, ensure the location is convenient for
the operator.
drainage.
• If the switch assy is removed from the panel, it must be reinstalled with the flat surface below
the key slot facing down.
equipment.
ACCESSORIES 7-43
WIRlNG DIAGRAM
REMOTE CONTROL REMOTE CONTROL

EXTENSION HARNESS WIRE HARNESS
36620-92E00 (6.5 m) 36620-93J00 (6.5 m)
36620-95610 (7.5 m)
REMOTE CONTROL
WIRE HARNESS
REMOTE CONTROL 36620-93J00 (6.5 m)
EXTENSION HARNESS
36620-92E00 (6.5 m)
36620-95610 (7.5 m)
37100-99E10 37100-96J10
7-44 ACCESSORIES
IGNITION & EMERGENCY STOP SWITCH PANEL KIT

37100-96J20 Ignition & emergency stop From 2005
All electric starter model (for single)
37100-99E20 switch panel kit Up to 2004
Make a copy of the switch panel picture below and use it for determining the arrangement of meter on the
dash panel.
R3
70 4-
50
OFF
ON
35
START
115
95
50
EMERGENCY
STOP
ACCESSORIES 7-45
NOTE: 9
The pictures are full scale.
15

10
Ignition & emergency stop
9 37100-96J20 1
switch panel kit
10 37110-93J00 • Ignition switch assy 1 12
11-1 37141-99E00 • • Key (931) 1
11-2 37141-99E10 • • Key (932) 1
11-3 37141-99E20 • • Key (933) 1
11-4 37141-99E30 • • Key (934) 1 13
11-5 37141-99E40 • • Key (935) 1
11-6 37141-99E50 • • Key (936) 1 11 16 17
11-7 37141-99E60 • • Key (937) 1
11-8 37141-99E70 • • Key (938) 1
11-9 37141-99E80 • • Key (939) 1
11-10 37141-99E90 • • Key (940) 1
11-11 37141-99EA0 • • Key (941) 1
11-12 37141-99EB0 • • Key (942) 1
12 37143-99E00 • • Key cap 1
13 37820-93J00 • Emergency switch assy 1
14 37139-99E20 • Panel 1
15 03121-05163 • Screw 4
16 38500-93J90 • Warning buzzer 1
17 09407-08401 • Clamp buzzer 1
7-46 ACCESSORIES
COMPONENT PARTS
37110-93J00 or
1 Ignition switch 2
37110-99E00
37820-93J00 or
2 Emergency switch 1
37820-92E00
3 Panel 37139-99E20 1
4 Screw 03122-05165 4
Ignition key 37141-99E00
5
(#931 – 942) (00 – B0)
* Key number location
4 × ¬ 3.5 mm (9/64 in)
1. Tools required
¬ 51 mm (2.0 in)
• Electric drill
• 51 mm (2.0 in) hole saw
• 3.5 mm (9/64 in) drill bit
50 mm (2.0 in)
• Phillips (+) screw driver
¬ 51 mm (2.0 in)

• When selecting the switch panel position on the dashboard, ensure the location is convenient
for the operator and provides freedom of operator movement with the stop switch cord clip
attached.
• Avoid locating the panel where water or spray is likely to splash the panel.
drainage.
equipment.
ACCESSORIES 7-47
WIRlNG DIAGRAM
REMOTE CONTROL
WIRE HARNESS
REMOTE CONTROL 36620-93J00 (6.5 m)
EXTENSION HARNESS
36620-92E00 (6.5 m)
36620-95610 (7.5 m)
37100-99E20 37100-96J20
7-48 ACCESSORIES
LIGHTING SWITCH PANEL KIT

37210-93J00 Lighting switch panel kit All models All models
panel.
70
50
ON
70
50
OFF
4-
R3
7
7 37210-93J00 Lighting switch panel kit 1 8
8 37212-93J00 • Lighting switch panel 1
ACCESSORIES 7-49
COMPONENT PARTS
1 Switch assy lighting 37211-92E00 1
2 Panel, lighting switch 37212-93J00 1
3 Screw 03122-05165 4
1. Tools required
• 35 mm (1 1/2 in) hole saw
4 × 3.5 mm
• 3.5 mm (9/64 in) drill bit (9/64 in)
• Electric drill
35 mm
• Phillips (+) screw driver (1 1/2 in)
the center mark (×) shown.
3. Install the ignition switch panel at a suitable position on the

dashboard.
4. Connect the wires, matching their color.

• When selecting the switch panel position on the dashboard, ensure that the location is conve-
nient for the operator. Avoid locating where water or spray is likely to splash the panel.
equipment.
7-50 ACCESSORIES
EMERGENCY STOP SWITCH KIT

37803-93J00 Emergency stop switch kit From 2005
All models
37803-99E00 Emergency stop switch kit Up to 2004
Make a copy of the stop switch picture below and use it for determining the location of meter on the dash
panel.
70
50
EMERGENCY STOP
70
50
R3
3
3 37803-93J00 Emergency stop switch kit 1
4 37825-99E00 • Emergency switch panel 1
ACCESSORIES 7-51
COMPONENT PARTS
Switch assy, 37820-93J00 or
1 1
Emergency stop 37820-99E00
Panel emergency
2 37825-99E00 1
stop switch
3 Screw 03122-05165 4
1. Tools required
• Electric drill
4 × 3.5 mm
• 35 mm (1 1/2 in) hole saw (9/64 in)
35 mm

• When selecting a location for installing the stop switch panel, ensure the location is conve-
nient for the operator, allowing the operator to have freedom of movement with the cord clip
attached.
drainage.
equipment.
7-52 ACCESSORIES
WIRlNG DIAGRAM
IGNITION SWITCH PANEL ASSY

(37100-99E00)
REMOTE CONTROL WIRE HARNESS

36620-92E00 (6.5 m)
36620-95610 (7.5 m)
EMERGENCY SWITCH PANEL ASSY

(37803-99E00)
IGNITION SWITCH PANEL ASSY

(37100-93J00)
REMOTE CONTROL WIRE HARNESS

36620-93J00 (6.5 m)
EMERGENCY SWITCH PANEL ASSY

(37803-93J00)
ACCESSORIES 7-53
PTT SWITCH KIT

37805-93J00 PTT switch kit From 2005
PTT models
37805-99E00 PTT switch kit Up to 2004
Make a copy of the PTT switch picture below and use it for determining the location of meter on the dash
panel.
70
50
70
50
3
R
4-

5
5 37805-93J00 PTT switch kit 1
6 37855-99E00 • PTT switch panel 1 6
7-54 ACCESSORIES
COMPONENT PARTS
37850-93J00 or
1 Switch assy, PTT 1
37850-92E00
2 Panel, PTT switch 37855-99E00 1
3 Screw 03122-05165 4
1. Tools required
• Electric drill
4 × 3.5 mm
• 55 mm (2-1/4 in) hole saw (9/64 in)
55 mm

• When selecting the switch panel position on the dashboard, ensure that the location is conve-
nient for the operator. Avoid locating where water or spray is likely to splash the panel.
equipment.
ACCESSORIES 7-55
WIRlNG DIAGRAM
PTT SWITCH PANEL KIT

(37805-99E00)
REMOTE CONTROL
EXTENSION
36620-92E00 (6.5 m)
36620-95610 (7.5 m)
ENGINE SWITCH PANEL KIT
(37100-99E20)
PTT SWITCH PANEL KIT

(37805-93J00)
REMOTE CONTROL
WIRE HARNESS
36620-93J00 (6.5 m)
ENGINE SWITCH PANEL KIT

(37100-93J20)
7-56 ACCESSORIES
RIGGING HOSE ADAPTER KIT

67300-93J00 Rigging hose adapter kit From 2006 DF150/175, DF200/225/250
Adapter hose (rigging) 67361-93J00
(56)
24.75 4 – ¬2
DEPTH 2
R2
¬55
7
)
4.5
(¬4
45˚
R2
8
R2
5
UP/93J
¬49.5
¬44.5
¬60
¬58
¬57
¬64
¬70
(¬28)
(4 – 3)
UP/93J
16
9
6
3
7.5
40.5
1.5˚
ACCESSORIES 7-57
Plug, grommet hole 09250-21003
¬28
¬21
10
65
7
3.5
¬14
¬20
¬24
INSTRUCTIONS FOR INSTALLING HOSE ADAPTER (RIGGING) KIT TO DF150/175, DF200/225/250
(APPLIABLE TO ’06 MODEL AND AFTER)
TABLE 1. KIT, HOSE ADAPTER (RIGGING)

[P/NO. 67300-93J00] COMPONENT

1 67361-93J00 Adapter, Hose (rigging) 1
2 09250-21003 Plug, Grommet hole 1
3 67369-93J00 Instruction 1
7-58 ACCESSORIES
1. Remove cover side STBD.
2. Mount plug, grommet hole 2 on panel, front as shown in the figure.
3. Remove stopper, R/CON cable 4 mounted on the engine.
4. Pass R/CON cable, battery cable through adapter, hose (rigging) 1.
5. Mount R/CON cable to holder, R/CON cable 3.
6. Mount stopper, R/CON cable 4 to holder, R/CON cable 3 pressing the R/CON cable from above by
using bolt, R/CON cable stopper 6.
Be sure to place washer, R/CON cable stopper 7 under the bolt, R/CON cable stopper 2.
7. Mount adapter, hose (rigging) 1 to the position indicated by the figure when cover, side STBD is
installed. At this time, mount it with the embossed letter [UP/93J] side facing upward.
Panel, front
Cover side STBD
Cushion
R/CON cable
R/CON cable
Part of holder, R/CON cable for model ’06 and after
R/CON cable
R/CON cable
Part of holder, R/CON cable for model ’05 and before

Fix without fail the shift/throttle cable outer by using the remote control cable stopper, when
rigging is made using the hose adapter. If the remote control cable stopper is not installed, the
remote control cable may slip out accidentally and this would make shift and throttle operation
impossible, causing accidents involving a human life.
ACCESSORIES 7-59
INSTRUCTIONS FOR INSTALLING HOSE ADAPTER (RIGGING) KIT, AND R/CON CABLE
HOLDER KIT AND STOPPER TO DF200 – 250 (APPLICABLE UP TO ’05 MODEL)
TABLE 2. KIT, R/CON CABLE HOLDER & STOPPER [P/NO. 67300-93J10] COMPONENT
SEE TABLE 1 FOR COMPONENTS OF KIT, HOSE ADAPTER (RIGGING)

3 67341-93J20 Holder, R/CON cable 1
4 67343-93J20 Stopper, R/CON cable 1
5 09352-70103-014 Cushion, R/CON cable stopper 2
6 01570-06107 Bolt, R/CON cable stopper 1
7 09160-06047 Washer, R/CON cable stopper 1
1. Remove cover, side STBD.
2. Remove holder, R/CON cable 8 and grommet, R/CON cable 9 mounted on the engine.
3. Remove protector, R/CON CA HLDR 0 mounted on the removed holder, R/CON cable 8.
4. Mount the removed protector, R/CON CA HLDR 0 to holder, R/CON cable 8.
5. Mount holder, R/CON cable 8 mounted on protector, R/CON CA HLDR 0, to the engine.
6. Mount plug, grommet hole 2 on panel, front to the position indicated in the figure.
7. Mount cushion, R/CON cable stoppers 5 (Q’ty: 2) to stopper, R/CON cable 4.
8. Pass R/CON cable, battery cable, etc. through adapter, hose (rigging) 1.
9. Attach R/CON cable to holder, R/CON cable 3.
10. Mount stopper, R/CON cable 4 to holder, R/CON cable 3 pressing the R/CON cable from above by
using bolt, R/CON cable stopper 6.
Be sure to place washer, R/CON cable stopper 7 under the bolt, R/CON cable stopper 6.
11. Mount adapter, hose (rigging) 1 to the position indicated by the figure when cover, side STBD is
installed. At this time, mount it with the embossed letter [UP/93J] side facing upward.
FUEL LINE 8-1
FUEL LINE
CONTENTS
FUEL LINE ROUTING ON THE HULL ............................................................8- 2

INTRODUCTION ....................................................................................8- 2
ENGINE FAILURE RESULTING FROM IMPROPER ROUTING ..........8- 2
SPECIFICATIONS OF FUEL HOSE ASSY ...........................................8- 3
FUEL HOSE INSIDE DIAMETER AND OVERALL LENGTH ................8- 5
FUEL HOSE ROUTING ..........................................................................8- 6
SELECTION OF 3-WAY JOINT & COCK ..............................................8- 6
SELECTION OF GASOLINE FUEL FILTER/WATER
SEPARATORS .......................................................................................8- 8 6
6
Cautions for handling fuel lines on boat (tank, tube, hose, etc.) 8

Gasoline is a flammable material that can cause fire hazard.
When working near gasoline or carrying out operations that are dealt with in this
guide, make sure to observe the following.
* Keep away from smoke, fire, spark or flammable material.
* Prior to performing inspection or other operations that do not require battery
power, disconnect the battery cable from the battery.
8-2 FUEL LINE
FUEL LINE ROUTING ON THE HULL

INTRODUCTION
This chapter deals with information for proper fuel line routing that is extending from the fuel tank on the hull
(mainly built-in fuel tank) to the outboard motor. Also given is the advice for prevention of engine failures or
troubles that may result from improper selection or routing of fuel lines.
ENGINE FAILURE RESULTING FROM IMPROPER ROUTING

If the routing is performed improperly, fuel feed may become insufficient for engine requirement.
Such a condition can lead to improper idling or trolling and engine overheat at mid or high speed.
In the worst case, this may cause pre-ignition possibly resulting in spark plug or piston damage.
The following gives examples that can cause insufficient fuel supply to the engine.
INSIDE DIAMETER OF PIPE IN FUEL TANK

If the inside diameter is inappropriate, the following problems
may be caused:
• When too large:
Because the fuel pump capacity decreases at the engine idle
or trolling, amount of fuel that is required by the engine may
not be pumped up sufficiently. As another cause for insuffi-
Pipe inside
cient fuel feed, fuel once pumped up may come down to the diameter
tank, possibly resulting in idling or trolling failure.
Strainer
• When too small:
The fuel flow resistance may become too large for the engine
requirement possibly leading to poor acceleration or problems
at mid or high speed.
Recommended fuel pipe inside diameter

7.3 mm (Sectional area: 42 mm2) – 15 mm (Sectional area: 177 mm2)
Inside diameter Inside diameter of pipe in fuel tank

FUEL LINE 8-3
STRAINER IN FUEL TANK

Sometimes the strainer’s rated through flow does not meet the flow requirement by the engine.
Such a case can cause engine performance problems.
• When the rated through flow is insufficient:
Because the fuel pump capacity decreases at the engine idle or trolling, amount of fuel that is required by
the engine may not be pumped up sufficiently, possibly resulting in idling or trolling failure.
• A wire mesh type strainer is recommended
The paper filter is not recommended.
Since foreign particles within the fuel are to be removed by the water separator or the fuel filter in the
engine, it is recommended, inside the tank, to use a wire mesh type strainer that has small resistance or
loss of flow.
(A wire mesh filter only effective enough for removing weld spatters formed at the time of manufacturing
the metal tank or burrs in the plastic tank.)
SPECIFICATIONS OF FUEL HOSE ASSY

Applicable model Part name Part number Part name Part number Q’ty
DF25/30 • Socket, fuel hose 65750-87J10 1
DF40/50 Fuel hose assy 65700-87J10 • Socket, fuel hose 65750-95504 1
DF60/70 • Pump, squeeze 65770-95504 1
• Clip 65781-98500 4
¬7.3 ¬12.5
3 3
700 1 100 27.8
95
1 970
48
¬9.1
27.8
16.7
¬8
¬5.5
¬23
12.2
¬13
¬13
¬8
¬9
34.5
80
65750-87J10 65750-95500
8-4 FUEL LINE
Applicable model Part name Part number Part name Part number Q’ty
DF90/115/140 Fuel hose assy 65700-90J00 • Socket, fuel hose 65750-95500 1
• Pump, squeeze 65770-95504 1
• Clip 65781-98500 3
¬12.5 ¬7.3
3 3
700 1 100 27.8
95
1 929
48
27.8
16.7
¬5.5
¬23
¬13
¬13
¬8
¬9
65750-95500
Applicable
Part name Part number Part name Part number Q’ty Remarks
model
• Pump, Tank to joint
DF200/225/250 Fuel hose assy 65700-87D00 65770-87D00 1
squeeze fuel hose
¬14.0 ¬9.0
3 3
750 120 2 250
3 126
FUEL LINE 8-5
FUEL HOSE INSIDE DIAMETER AND OVERALL LENGTH

IN THE CASE OF USING A COMMERCIALLY AVAILABLE
FUEL HOSE
In selecting the fuel hose, compare the inside diameter and
overall length with those of the genuine hose. (Refer to specifi-
cation of fuel hose assy)
If the inside diameter or the overall length of the fuel hose is not Hose inside
diameter
appropriate, the following problems may result:
• Too large inside diameter:
Air trapped in the fuel hose at the time of idling or trolling may
cause an airlock condition due to weak suction of fuel pump.
This in turn causes insufficient fuel supply for engine require-
ment, possibly resulting insufficient fuel supply for engine
requirement, possibly resulting an idling or trolling problem.
• Too small inside diameter:
Fuel flow decreases due to increased flow resistance, causing
insufficient fuel supply for the engine requirement. This
causes a lean-burn condition which can lead to pre-ignition
due to heated spark plug. The result may be a burnt piston.
• Use of Suzuki genuine parts fuel hose is recommended even
in the case of boat with built-in fuel tank.
Specification of Suzuki genuine parts hose: Heat resistance
100 °C
Rubber hardness 70degrees: Oil & gasoline resistance 40%
volumetric properties/70 hours.
• In the case of using commercially available fuel hose, select
one that is equivalent to the genuine parts fuel hose.
• Recommended fuel hose inside diameter:
Inside diameter: 7.3mm (Sectional area: 42mm2) to 9 mm
(Sectional area: 64mm2)
• Use a fuel hose that satisfies the requirements of resistance
properties such as pressure, oil, gasoline, seawater and
weather resistances.
• Too long fuel hose:
When the fuel hose is too long, fuel flow resistance increases
with a resultant decrease of fuel flow, fuel cannot be supplied
sufficiently for engine requirement. As a result, idling or troll-
ing failure may occur.
At mid or high speed, the spark plug temperature rises to
pre-ignition range leading to piston failure.
NOTE:
Do not use an excessively long fuel hose wound in a coil.
Always cut the hose to the appropriate length.
8-6 FUEL LINE
FUEL HOSE ROUTING

• If a part of fuel hose is located higher than the fuel pump of
the outboard motor, air inside the line/hose cannot be bled
completely, possibly causing an airlock.
When this condition occurs, insufficient fuel flow may be
caused.
Therefore, do not let the hose of any part position higher than
the fuel pump.
SELECTION OF 3-WAY JOINT & COCK

The line connection either in Fig.C or D is recommended and not
Fig.A or B.
* Example of not recommended 3-way joint
Fig: A
When the outboard motor is operated with either side of the two tanks empty, air is sectioned into the fuel
line from the empty tank causing a lean mixture condition, which possibly results failure in idling/trolling to
mid/high speed range.
Fig: A 3-way joint
Fuel tank
Fuel tank
Fig: B
In this example, only one fuel outlet is used from the fuel tank and it is then branched into two lines for each
engine with a 3-way joint. In this case, the two engines do not necessarily draw same amount of fuel.
Therefore, one side of engine with fuel suction weaker may experience failure in idling/trolling to mid/high
speed range.
Fig: B 3-way joint
Fuel tank
FUEL LINE 8-7
Fig: C
Recommended 3-way cock and its connection.
* Example of recommended 3-way cock
Fig: C Recommendation: replace the 3-way joint in Fig: A with the 3-way cock Fig: C
Recommended: up to DF70
Fuel tank
Fuel tank
Recommended 3-way cock inside diameter.

Inside diameter: 7.3mm (Sectional area: 42mm2) to 9mm (Sectional area: 64mm2)
Fig: D
Recommended fuel tank piping two outlets are provided on one
fuel tank, each connected to one engine with independent fuel
hose.
Fig: D
Fuel tank
8-8 FUEL LINE
SELECTION OF GASOLINE FUEL FILTER/WATER SEPARATORS

Confirm the specification and performance when you install gasoline fuel filter/water separators.
REFERENCE
*Part number is in US market only.
*99105-20006-ASY *99105-20005-ASY
DEMAND PERFORMANCE TABLE

99105-20006-ASY 99105-20005-ASY
DF40/50 DF60/70 DF90/115/140 DF150/175 DF200/225/250
Maximum flow rate LPH 40: or Over 50: or Over 90: or Over 114: or Over 150: or Over
Clean pressure drop Kpa 1.03: or Less 1.03: or Less 1.03: or Less 1.03: or Less 4.23: or Less
BATTERY 9-1
BATTERY
CONTENTS
RECOMMENDED BATTERY ..........................................................................9- 2
RECOMMENDED BATTERY CABLE .............................................................9- 3
RECOMMENDED BATTERY SWITCH ...........................................................9- 4
DF150/175 INSTALLATION OF DUAL BATTERY ISOLATOR LWEAD .......9- 5
9
9-2 BATTERY
RECOMMENDED BATTERY
Model Recommended battery Type Recommended battery capacity
DF9.9/15 12 Volt 40 AH or over CCA/SAE 330 Amperes or over
DF25-V2 RC/SAE 70-minutes or over
DF25/30 20HR/IEC 40 AH or over
DF40/50 12 Volt 70 AH or over CCA/SAE 389 Amperes or over
RC/SAE 115-minutes or over
20HR/IEC 70 AH or over
DF90/115/140 12 Volt 100 AH or over CCA/SAE 512 Amperes or over
DF200/225/250 RC/SAE 190-minutes or over
CCA: Cold Cranking Ampere
SAE: Society of Automotive Engineers
RC: Reserve Capacity
IEC: International Electrotechnical Commission

Avoid using deep cycle battery, maintenance-free battery or gel cell battery.
NOTE:
Parallel connection of batteries (dual battery installation)
In the case of parallel connection, two batteries used should be of the specification.
The cable connecting the two batteries should be of the equivalent specification or better than the main bat-
tery cable.
NOTE:
Parallel charging of batteries
Do not charge batteries of different specification connected in parallel.
Make sure to connect the batteries of the same type and the same capacity.
BATTERY 9-3
RECOMMENDED BATTERY CABLE

If the length of battery cable that is provided as a standard equipment on the outboard is insufficient, select
and install the appropriate cable in accordance with the following table.
Depending on the length and diameter (sectional area) of the battery cable, a significant voltage drop may
be caused, which can lead to an accidental trouble on the outboard motor.
If the battery cable of standard equipment is too short to reach the battery, select an appropriate cable refer-
ring to the following table.
Battery cable of standard American wire gauge

Model equipment AWG 4 AWG 2 AWG 0
JIS Length AV 20 AV 30 AV 50
DF9.9/15, DF25/30 AV8 2.0 m 5.2 m 9.0 m 14.0 m
DF25-V2, DF40/50 AV15 3.0 m 4.7 m 8.0 m 12.3 m
DF60/70 AV15 3.0 m 4.7 m 8.0 m 12.3 m
DF90/115/140 AV20 3.0 m 3.0 m 4.7 m 7.9 m
DF150/175
AV30 4.0 m — 4.0 m 7.0 m
DF200/225/250
NOTE:
The positive + and negative - cable are of the same length.
NOTE:
Fit and solder the battery cable terminal securely.

If the battery is not connected properly, and/or the cable is extended by adding another cable
the electrical system on the outboard motor may not function as designed.
If the length exceeds the recommendation, some failure may occur in the electrical system.
9-4 BATTERY
RECOMMENDED BATTERY SWITCH

The battery switch is an effective device as a current breaker to prevent the battery from being discharged
due to parasitic current within the outboard motor or electrical equipment on the boat during unused period.
However, care should be needed because the switch can become the cause of an accidental failure
depending on how it is selected.
Calculate the total transient current of the motor and boat equipment at the time of starting and select a bat-
tery switch that has an enough capacity for such a current.
Model Recommended battery switch capacity

Steady-state At least 400 A
DF25 – DF250
Transient At least 600 A
A
Transient
Current
Regulary
Hr
Amount of time
NOTE:
The cable connecting the battery switch and the battery should be of the equivalent specification or better
than the standard battery cable of the outboard motor.
NOTE:
Perform the periodic inspection on the battery switch, as it is an expendable item.
BATTERY 9-5
DF150/175 INSTALLATION OF DUAL BATTERY ISOLATOR LEAD

If the battery isolator lead assy installed and the position of 30A fuse changed from standard single to option, dual
battery charging system will be effective.
At the same time, the negative terminals of main and second batteries (of 12 Volts 100 AH or over) need to be
connected by the battery cable (of AWG2 or AWG0). In case of dual battery, total out put of electric equipment to
be connected to the second battery charged by the isolator lead, always need to be kept below 30A.
In case of triple battery for twin outboard motor, total out put of the second battery always need to be kept below
60A.
Required Parts
1. Isolator Assy
Item Part number Part name Q’ty

1 33830-96J00 Lead Assy, battery isolator
(1) • Lead, battery isolator 1
(2) • Clamp, isolator lead 1
(3) • Instruction 1
2. Battery Cable
American Wire Gauge AWG2 AWG2

Length of Battery Cable 4.0 m (STD) 7.0 m
3. Battery
Recommended battery Type Capacity

CCA/SAE 670 Amperes or over
12 Volt 100 AH or over RC/SAE 190-minutes or over
CCA: Cold Cranking Ampere

SAE: Society of Automotive Engineers
RC: Reserve Capacity
IEC: International Electrotechnical Commission
Installation
Dual Battery Triple Battery for twin motor
Motor Motor Motor
1 Battery Cable (+)

2 Battery Cable (-)
3 Sub-battery Cable
4 Isolator Lead
5 Additional Cable
Main Battery for Second Battery for Main Battery Second Battery Main Battery for negative (-) poles
Outboard Motor Accessory
9-6 BATTERY
(1) Take off the coupler cover of isolator lead on the engine
side.
(2) Connect the coupler of battery isolator lead with the coupler
on engine side.
Isolator lead coupler
STD (single bettery) Option (dual/triple battery)
(3) Change the position of 30A fuse from STD single to Option
dual.
(4) Pass the isolator lead through the grommet near the battery Battery cable
cables. Isolator lead
(5) Clamp the lead and cables just at the end of grommet.
(6) Secure the isolator lead onto positive (+) pole of the second
battery for accessory.
(7) Set the battery cable (+) to positive (+) pole onto the main
battery. And also set the battery cable (-) onto negative (-)
pole of the main battery.
(8) Connect the negative pole of main battery with that of sec-
ond battery, by the additional cable.
PROPELLER 10-1
PROPELLER
CONTENTS
PROPELLER SELECTION ............................................................................10- 2
10
10-2 PROPELLER
PROPELLER SELECTION
DF25-V2
DF115
DF140
DF150
DF175
DF200
DF225
DF250
Propeller selection Model
DF2.5
DF9.9
DF15
DF25
DF30
DF40
DF50
DF60
DF70
DF90
DF4
DF5
DF6
Part No. Blade × Diam × Pitch
58111-97J00-019 3 × 188 × 135
58111-98465-019 3 × 188 × 115
58110-91J00-019 3 × 7-1/2 × 6
58100-91J10-019 3 × 7-1/2 × 6-1/2
58100-91J20-019 3 × 7-1/2 × 7
58100-93703-019 3 × 9-1/4 × 7
58100-93723-019 3 × 9-1/4 × 9
58100-93733-019 3 × 9-1/4 × 10
58100-93743-019 3 × 9-1/4 × 11
58100-91D00-019 3 × 9-1/4 × 8
58100-93763-019 3 × 9-1/4 × 9
58100-93773-019 3 × 9-1/4 × 10
58100-96410-019 3 × 10-1/4 × 10
58100-96420-019 3 × 10-1/4 × 11
58100-96430-019 3 × 10-1/4 × 12
58100-96440-019 3 × 10-1/4 × 13
58200-96400 3 × 10-1/4 × 13
58100-95D00-019 3 × 10-1/4 × 14
58100-96370-019 3 × 10-1/4 × 9
58100-94302-019 3 × 11-1/2 × 9
58100-95212-019 3 × 11-1/2 × 10
58100-95222-019 3 × 11-1/2 × 11
58100-95393-019 3 × 11-5/8 × 12
58100-94313-019 3 × 11-1/2 × 13
58100-95353-019 3 × 11-3/8 × 14
58100-95363-019 3 × 11-1/4 × 15
58100-95373-019 3 × 11-1/8 × 16
58100-99E00-019 3 × 13-3/4 × 13
58100-99E10-019 3 × 4 × 11
58100-94500-019 3 × 13-1/2 × 15
58100-94512-019 3 × 13-1/4 × 17
58100-94522-019 3 × 13 × 19
58100-94532-019 3 × 13 × 21
58100-94554 3 × 13-1/2 × 15
58100-94581 3 × 13-1/4 × 17
58100-94561 3 × 13 × 19
58100-94571 3 × 13 × 21
58100-90J01-019 3 × 14 × 17
58100-90J11-019 3 × 14 × 19
58100-90J21-019 3 × 14 × 21
58100-90J31-019 3 × 14 × 23
58100-90J41-019 3 × 14 × 15
58200-90J00 3 × 14 × 18
58200-90J10 3 × 14 × 20
58200-90J20 3 × 14 × 22
58200-90J30 3 × 14 × 24
58200-92J00 3 × 14 × 18 Z
58200-92J10 3 × 14 × 20 Z
58200-92J20 3 × 14 × 22 Z
58200-92J30 3 × 14 × 24 Z
58200-96J00 3 × 15.5 × 17
58200-96J10 3 × 15.25 × 19
58200-96J20 3 × 14.75 × 21
58200-96J30 3 × 14.75 × 23
58200-96J40 3 × 14.5 × 25
58200-96J50 3 × 14.5 × 27
58200-96JA0 3 × 15.5 × 17 Z Z Z Z Z
58200-96JB0 3 × 15.25 × 19 Z Z Z Z Z
58200-96JC0 3 × 14.75 × 21 Z Z Z Z Z
58200-96JD0 3 × 14.75 × 23 Z Z Z Z Z
58200-96JE0 3 × 14.5 × 25 Z Z Z Z Z
58200-96JF0 3 × 14.5 × 27 Z Z Z Z Z
58200-93J00 3 × 16 × 17
58200-93J10 3 × 16 × 18.5
58200-93J20 3 × 16 × 20
58200-93J30 3 × 16 × 21.5
58200-93J40 3 × 16 × 23
58200-93J50 3 × 16 × 24.5
58200-93J60 3 × 16 × 26
58200-93J70 3 × 16 × 27.5
58200-93JA0 3 × 16 × 18.5 Z Z Z Z Z
58200-93JB0 3 × 16 × 20 Z Z Z Z Z
58200-93JC0 3 × 16 × 21.5 Z Z Z Z Z
58200-93JD0 3 × 16 × 23 Z Z Z Z Z
58200-93JE0 3 × 16 × 17 Z Z Z Z Z
58200-93JF0 3 × 16 × 24.5 Z Z Z Z Z
58200-93JG0 3 × 16 × 26 Z Z Z Z Z
5 500 – 6 100
5 000 – 6 000
Recommended
5 000 – 6 000
4 000 – 5 000
4 500 – 5 500
4 750 – 5 750
4 900 – 5 500
5 400 – 6 000
4 700 – 5 300
5 000 – 5 600
5 200 – 5 800
5 900 – 6 500
4 700 – 5 300
5 200 – 5 800
4 500 – 5 500
5 600 – 6 200
5 000 – 6 000
5 500 – 6 100
5 000 – 6 000
5 000 – 6 000
5 500 – 6 100
Operating
Aluminum
Range
r/min
Stainless steel
Z Counter rotation (Stainless steel)
PRE-DELIVERY 11-1
PRE-DELIVERY
CONTENTS
PRE-DELIVERY INSPECTION SHEET .........................................................11- 2
11
11-2 PRE-DELIVERY
PRE-DELIVERY INSPECTION SHEET
Engine Model ( single/port ): Engine Model ( starboard ):
Engine No ( single/port ): Engine No ( starboard ):
Propeller model ( single/port ): Propeller model ( starboard ):
Key No ( single/port ): Key No ( starboard ):
Boat manufacture/Model: Hull ID No ( HIN ):
Steering system manufacture/Model: Steering calbe/Oil hose • Length:
Remote control Box manufacture/Model: Remote control cable • Length:
IMPORTANT: Please tick each item as completed, or mark as N/A. Do not leave blank. Failure to provide a
correctly completed PDI checklist when requested could affect customer’s warranty rights.
Before Operation
♦Transom Bolts Standard equipment-All items correct
♦Steering System Transom bolts/nuts tightened by specified torque
Draglink adjustment correct/with no restriction
Steering cable tightened by specified torque/with no restriction
Check system be maneuvered smoothly and securely
♦Engine Oil Fill with correct grade of oil to correct leve.
♦Fuel Tank (Built-in Tank) Fuel gauges/fuel filter/water separator/air vent system cirtified by ABYC
Recomended fuel grade
♦Fuel Line (Fuel Hose) Hose size/cirtified grade/alignment
Cramped correctly with no kink
No leakage
♦Gear Oil Check oil level
♦Remote Control Box Correctly installed and adjusted
Gears are smoothly engaged by lever to/from
FORWARD/NEUTRAL/REVERSE
♦Throttle/Shift Cable Securely connected/correctly adjusted
Cable wrength and routing correct.
♦Wireharness/Synchronaization NSI function and NSI synchronization in-between Outboard Motor and
Remote Control Box are correct
Wireharness connected, routed safely, and cramped securely
♦Choke System Operative
♦Anode/Bonding Wire (Option) Suitable anode with bonding wire installed
♦Spark Plug Recomended spark plug with correct torque
♦Starter Motor Operative smoothly
♦Battery Recommended type, grade and capacity
Cable connected securely
♦Power Trim & Tilt Check operation
Check fluid level, if necessary
Operation (Run)
♦Engine Starting Start smoothly.
Check NSI function/synchronization
♦Idle & Trolling Check the idle RPM PRM ( single/port ): PRM ( starboard ):
Check the trolling RPM PRM ( single/port ): PRM ( starboard ):

♦Emergency Stop Switch Operative correctly
♦Cooling Water Check water discharge from pilot hole
Check water cuirculation
PRE-DELIVERY 11-3
♦Fuel Line No leakge found on fuel line from tank to Outboard Motor
♦Warning Lights/Buzzer Operative
♦Tachometer Operative
♦Speedmetor Operative
♦Other Instrumentation Operative
♦Shift/Throttle Shifting smoothly and acurately
by Remote control Throttle response All right
♦Steering Operative smoothly and securely.
♦Trim Tab Adjusted correctly
♦Power Trim & Tilt Operative correctly
♦Max Engine RPM ( single/port ): Max Engine RPM ( starboard ):
♦Max Boat Speed (Km/h):

After Run
♦Fuel/Cooling Water etc. No leakage found on fuel/cooling water/exhaust/oil/fluid
♦Bolts/Nuts etc Check bolts, screws, nuts, and fasteners, etc. for tightness
Recheck transom bolts/nuts
Recheck propeller/s
♦Engine oil Check oil level
♦Gear oil Check oil level
♦Painting and decal Check for any defect as damage, etc.
Dealer’s Name Phone Number Dealer Code
Address City State
RIGGING
Rigging undertaken by dealer Yes No (If, No, Please refer to “Customer Delivery”)
Ensure that the engine is rigged using the FUEL LINES-correctly installed, no restrictions
correct engine set-up manual FUEL FILTER-Fitment is recommended for permanent installations
CUSTOMER DELIVERY
OPERATION of the outboard demonstrated to customer, Customer guided through owner’s manual highlighting:
including warning systems Warning & caution symbols
(ENGINE NOT RIGGED) – customer advised to obtain Break-in procedure from new
professional assistance before using engine Operation after storage and/or derigging
USE OF TOOL KIT, including emergency start procedure, Servicing requirements
explained to customer Fuel and requirements
SUZUKI WARRANTY – Discussed with purchaser, and The importance of reading the owner’s manual before
mandatory service requirements explained using outboard
Need for correct propellor selection
I certify that this Suzuki outboard motor has been prepared for delivery in accordance with Suzuki’s recommendations.
Dealers signature
(Print Name) Date
CUSTOMER ACCEPTANCE
I have visually inspected the outboard motor and it meets The items listed in the “Customer Delivery” section
with my satisfaction of this PDI check list have been covered to my
satisfaction and I understand them
I have received the Owner’s Manual, Warranty Book,
Tool Kit and Keys
Customer Signature
(Print Name) Date
Remarks:
DF25 -- DF250
DF25 -- DF250
2006 RIGGING MANUAL
2006 RIGGING MANUAL
99518-03060-01E
Printed in Japan TK 99518-03060-01E

SUZUKI DF25 DF250 Instruments 3

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SUZUKI DF25 DF250 Instruments 3

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ACCESSORIES 7-1

TACHOMETER KIT .............................................................................................. 7- 2

34200-93J10 (White) 34200-93J00 (Black)

METER DIMENSIONS 10.6 65 29

PREPARATION PRIOR TO INSTALLATION

1. Select a location on the instrument panel which provides the

34200-93J30 (White) 34200-93J20 (Black)

METER DIMENSIONS 10.6 65 29

PREPARATION PRIOR TO INSTALLATION

1. Select a location on the instrument panel which provides the

METER DIMENSIONS 10.2 70.6

PREPARATION PRIOR TO INSTALLATION

1. Select a location on the instrument panel which provides the

TRIM METER KIT

34800-93J10 (White) 34800-93J00 (Black)

8.3 32.8 39.2

PREPARATION PRIOR TO INSTALLATION

1. Select a location on the instrument panel which provides the

TRIM METER KIT CONNECTION

HOUR METER KIT

34500-93J10 (White) 34500-93J00 (Black)

PREPARATION PRIOR TO INSTALLATION

1. Select a location on the instrument panel which provides the

HOUR METER KIT CONNECTION

FUEL GAUGE METER KIT

34300-93J10 (White) 34300-93J00 (Black)

8.3 32.8 39.2

PREPARATION PRIOR TO INSTALLATION

1. Select a location on the instrument panel which provides the

FUEL GAUGE METER KIT CONNECTION

VOLTAGE METER KIT

34600-93J10 (White) 34600-93J00 (Black)

8.3 32.8 39.2

PREPARATION PRIOR TO INSTALLATION

1. Select a location on the instrument panel which provides the

VOLTAGE METER KIT CONNECTION

WATER PRESSURE GAUGE KIT

34650-93J30 (White) 34650-93J20 (Black)

8.3 31.8 39.2

PREPARATION PRIOR TO INSTALLATION

1. Select a location on the instrument panel which provides the

WATER PRESSURE GAUGE KIT CONNECTION

DF25/30 WATER PRESSURE GAUGE SUB KIT

COMPONENTS INCLUDED IN KIT

INSTALLING WATER PRESSURE GAUGE SUB KIT AND HOSE

DF40/50 WATER PRESSURE GAUGE SUB KIT

INSTALLING WATER PRESSURE GAUGE SUB KIT AND HOSE

3-way joint 3 Hose 1

3-way joint 3 Clip 4

( Part additions are to be made)

DF60/70 WATER PRESSURE GAUGE SUB KIT

INSTALLING WATER PRESSURE GAUGE SUB KIT AND HOSE

DF90/115/140 WATER PRESSURE GAUGE SUB KIT

INSTALLING WATER PRESSURE GAUGE SUB KIT AND HOSE

Detail of view “C”

Battry cable Front panel bos

Hose Hose Side cover seal Clip

DF200/225/250 WATER PRESSURE GAUGE SUB KIT

Hose (L: 7 000) × 1

INSTALLING WATER PRESSURE GAUGE SUB KIT AND HOSE

6. Install the hose to 3-way joint and secure it with a band.

Detail of view “B”

Detail of view “A”