$ET"UP

ffiAilUA[

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 IMPORTANT
..--/
AWARNINGICAUTION/NOTE
Ptease
readthismanual Toemphasize
carefully,
andfollowitsinstructions information,
special thesymbolA
andthewordsWARNING, CAUTION andNOTEhavespecial meanings. attention
Payspecial to themes-
bythesesignalwords.
sageshighlighted

Indicatesa potentlalhazardthat could result in deathor Iniury.

CAUTION
Indicatesa potentialhazardthat could result in motor damage.

NOTE:
lndicatesspecialinformationto makemaintenanceeasieror instructiansclearer.

Pleasenote,however, that the warningsand cautionscontainedin this manualcannotpossiblycoverall

potentialhazardsrelatingto the servicing,or lack of servicing,of the outboardmotor.In additionto the
WARNINGS andCAUTIONS stated,youmustusegoodjudgement andbasicmechanical safetyprinciples.

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 FOREWORD
Thisoutboardmotorhasbeendesigned andproduced utilizing
Suzuki's
mostmoderntechnology.Thefinest
cannotperformproperlyunlessit is correctly
product,however, assembled Thisset-upmanual
andserviced.
hasbeenproducedto aid youin properlyassembling andservicingthisoutboardmotor.
. This manualhas beenpreparedon the basisof the
latestspecifications
at the timeof publication.
lf
modificationshavebeenmadesincethen,differences mayexistbetweenthe contentof this manual
andthe actualoutboardmotor.
. lllustrations
in this manualare usedto showthe basicprinciples
of operation andworkprocedures
and maynot representthe actualoutboardmotorexactlyin detail.
t Thismanualis intended forthosewhohaveenoughknowledge andskillsto serviceSUZUKIoutboard
motors.Withoutsuchknowledge you
andskills, shouldnotattemptservicingby relyingon thismanual
only.lnstead,pleasecontactyournearbyauthorizedSUZUKIoutboardmotordealer.

Apprenticemechanicsor do-it-yourselfmechanicsthat don't have the proper tools and equlp-

ment rnay not be able to properlyperformthe servicesdescribedin this manual.lmproperas-
semblyand/orservicing may result in injury to the mechanieand may renderthe engine unsafe
for the boat operatorand passengers.

CONTENTS
SYMBOL. ........,.........
I
MATERIALSREAURED ......,...1
OUTBOARDMOTOR INSTALLATION ......2
HORSEqOWERSELECTTON ............. .......,.......
2
MOTORDIMENSIONS ,,...2
MOUNTINGTO THE TRANSOM .,..... g
TRANSOMDTMENSIIONS .................
s
CONT4OLCABLES INSTALLATTON .......4
REMOTECONTROLBOX SiDE .......4
ENGTNESIDE ......,............
4
WIRE HARNESSINSTALLATION ...........,.8
DRAGLINK TNSTALLATTON g
.........,-..........
couNTER ROTAnONMODELOR DUAL ENGINE,T\E-RODKtT (O?T\ONAL ?ARTS)
iN9TALLATION........ ..................
11
INSTALLATION
WITHTHE PRE-RIGGEDITEMSFOR 2 CYCLEMODEL............,..14
wtRtNc DTAGRAM .....,...........
16
WIRINGDIAGRAMFOR DUAL ENGINE .................
17

SUZUKI MOTORCORPORATION
O COPYRIGHT
SUZUKIMOTOBCORPORATION
2OO1 Marine& PowerproductsDivision

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 SYMBOL
- Listedin thetablebeloware symbolsindicatingspecialinstructionsandotherimportantinformation
neces-
saryforproperservicing.
Please noiethe definitionforeachsymbol.Youwillfindthesesymbols
usedthrough-
outthismanual,Fleferbackto thistableif you are notsureof anysymbol(s)meanings.

SYMBOL DEFINITION SYMBOL DEFINITION

Torquecontrolrequired.
g Data besideit indicatesspecified
.-
ApplyTHHEADLOCK"1342".
1J1E13l
torque.

ApplySUZUKIWATERFIESISTANT
@ GREASE. @ Usespecialtool,

@ ApplySUZUKISILICONE
SEAL.

MATERIALS
REOUIRED
SUZUKISILICONESEAL

99000-31120
(50 g/1.7oz)

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 OUTBOARDMOTORINSTALLATION
HORSEPOWER
SELECTION

Do not overpoweryour boat. Neverinstall an outboardmotor wlth horsepowerexceedingthe

boat manufacturer'srecommendedmaximum.Excessivehorsepowerwill havean adverseeffect
on hull safety and may causeoperating/handlingdifficulties.

NOTE:
' Stafe the maximumhorsepoweroutboardmotor that can be safelyused on that boat.Thereis severe
productliabilitypotentialconnectedwithriggingand sellinga boat withan outboardmotorexceedingthe
horsepower capacityIimitatian.
' The rig shouldnot be underpowered,as this will not allow the performancebalanceyou are trying to
achieve.Determinethe customefs needs,applicatianand use of the perspectiverig to make the best
overalI horsepower recommendation.

MOTORDIMENSIONS

L:998(39.3)
UL:1116(43.9)

t
$

@
F.

^cY
N (o J
FN J
:>(O
6(O
6(o
-i5

2
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 .MOUNTINGTOTHE TRANSOM
t--lContained parts

Item Partname Part number Q'ty

@ Bolt(M12) 09100-12083 4
@ Washer(Large) 09160-12044 4
@ Washer(Small) 09160-12066 4
o Lockwasher 09162-12005 4
{ F)
Nut 09140-12028 4
r F!
v cap 41153-94500 4

[l r.rutO: 55N.m(5.skg-m,40.0
tb-ft]

Drillthe upperholesat least2s mn (1.0 in)awayfromthe transomtop surface.

lnstallthe largediameterwasher@ on the transomboardside.
Toensurea water-tightengineinstallation,sealant(SUZUKISTLICONE SEAL or equivalent)shouldbe
appliedto all bolt holes.
lf tighteningtorquecannotreachta the specifiedtorquedue to weak transommaterial,it is necessaryto
reinforcethe transomboardwithan attachmentplate.

'\--ITRANSOMDIMENSIONS

Transomtop surlace

"l

3
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 CONTROLCABLESINSTALLATION
Containedparts

Part name Part number Q'ty

Remotecontrolbox 67200-99E10-0EP 1

ForU.S.A.model,remotecontrolboxis optional.
Requiredparts
Part name Part number Q'ty Part name Part number Q'ty
Controlcable7ft (2.1m) 67320-89J00 2 Controlcable16ft(a.9m) 67320-89J50 2
Controlcable8ft @A m) 67320-89J10 z Controlcable18ft(5.5m) 67320-89J60 2
Controlcable10ft(3.1m) 67320-89J20 2 Controlcable2oft(6.1m) 67320-89J70 2
Controlcable12fi(8.7m) 67320-89J30 2 Controlcable22ft(6.7m) 67320-89J80 2
Controlcable14ft(a.Bm) 67320-89J40 2

Ghooseone itemwhichis matchedto the boatin length.

REMOTE CONTROL BOX SIDE

Fortheprocedure to connectthethrottlecontrolcableandclutchcontrolcableto the remotecontrolbox,refer
to the "REMOTE CONTROLBOXSET-UPINSTRUCTION'that comessuppliedwith each unitof remote
controlbox.(forRemotecontrolmodelonly)

ENGINESIDE

Containedparts (Remotecontrol model)

Item Part name Part number Q',ty
@ Grommet 61124-90J00 1
@ Cablestopper 67343-90J01 1
6\
v Bolt 01550-06257 J

@ Cableconnector 67467-89J01 2 /A\

\E/.
@ Washer 09160-06055

V
I
o Lockpin 0938s-0601
2 2

NOTE:
Beforeperformingthe foltowingprocedures,be sure that the
\
throttle/clutchcontrol cablesare instattedin the remotecontrol
box accordingto the "REMOTECONTROLBOX SET-{JPtN- b
STRUCTION". (for Remotecontrolmodelonty)

4
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 Procedure
. /1) Removethe nine(9) bolts,thenremovethe bothsidelower
coversfromthe outboardmotor.

'2\ Installthe clutchcontrolcableO and throttlecontrolcable

,_-,/ @ to tne grommet@.
(3) SecurethecableO and@ in tne cableholder@ oy titting
grooveon the cableintoa sloton the holder.

NOTE:
Referto thepageI for installingwireharnessto the grommet.

(4) Installthe cablestopper@ by the bolt @.

(5) Positionthe remotecontrolhandleinto "NEUTRA|-'.

$:
r--.-..-...-

5
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 I

- Clutchcontrolcable-
(6) Makesurethatthe clutchcontrolarm @ is in the neutralposition.
\-:
(7) Threadtheconnector O ontotheclutchcontrolcable holealignswiththepivotpin
C untiltheconnector
@ on the clutchcontrolarm @.
(8) Settheconnector@ ontothe pivotpin@ withtheflat sideof connectortowardstne arm.
washer(p and lockpin@ , thentightenthetocknut@,
(9) Installthe
(10)Makesurethatbothforwardand reversegearcanbe engagedwiththe sameangleof remotecontrol
handletravelfrom"NEUTRAHoosition,

- Throttlecontrolcable-
(11)Makesurethatthethrottlelever@ is fullyclosed.(TheCTP
svvitch@ mustbe in "ON- pushed"position.)
Alsomakesurethatthe stitmarkon the throttlecontrolarm
@ alignswiththe slit markon the bracket@.
(12)Whilepushingthe throttlecontrolcable@ as shownby ar-
row,threadtheconnector @ ontothecableuntiltheconnec-
torholealignswiththe pivotpin@ on thethrottlecontrolarm
@.
(13)Settheconnector @ ontothepivotpin@ withtheflatsideof
connector towardsthe arm.
(14)lnstallthe washer@ and lockpin @ , thentightenthe lock
nut@,
(15)Movethe remotecontrolhandle to thefullyopenedposition
andreturnit to the neutralposition
again.Makesurethatthe
throttleis fullyclosed.

CAUTION
Cableconnectorsand turnbacklesmust be threadedat
least8 mm (0.3in) onto cable.

NOTE:
After assembly,make sure that the cablesare not stretchedor
otherwisesfressedwhenthe outboardmotoris turnedallthe wav
to the rightand left.

Aftercompleting step No.15mentioned above,performthe fol-

lowingprocedure to verifythattheCTP(Closed
ThrottlePosition)
switchis correctlyadjusted.

(1) Removethe CTP switchharnessleadand connecta Volt-

Ohmmeterto the switchterminalandto engineground,

(2) Movetheremotecontrolhandteoncemoreto tnetuilyopened

position,
thenreturnit slowlyto the fullyclosedthrottle,in
gearidleposition(lowerunitstillengagedin fonvardgear
withthrottleat fullclose.)

6
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 '(3) Checkthemeterconnected to theCTPswitch.lt mustindicatetheswitchhasturnedto the"ON"oosition
(meierwill indicatecontinuity).
-_-/
(4) lf the CTPswitchis in the "OFF"position(Nocontinuity)
at the in gearidleposition,loosenthe remote
controlcableconnector locknutand readjustthe cableconnector slightlyuntiltheCTPswitchis in the
"ON"condition(continuity indicated).

(5) Afterreadjusting
thecableconnector, tightenthelocknutandmovetheremotecontrolhandleto thefully
opened positionand backto the in gearidle positionto confirmthatthe CTP switchis now correctly
adjusted(switchin the "ON"position, indicated).
continuity

.'-.{6) Whencorrectswitchadjustmenthas beenconfirmed,removethe volt-Ohmmeterand reconnectthe

CTPswitchharnesslead.

Neutral
N

NOTE:
Failureto properlyadjustthe CTP switchmay cause the engineto stallwhenretrurnedto the in-gearidle
position.Thismay occur to non-activationof the ECM electricdash-potfunctionwhichis controltedby the
CTPswitch's"ON"/ "OFF"position.

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 WIRE HARNESSINSTALLATION
Contalnedparts
Item Partname Part number Q'ty
@ Monitor-tachometer 34200-99E00 1
@ Monitorgaugewire 36682-92E00 1
/6r
\r' Trimmeterwire harness 36682-90J00 1
@ lnstrument
wire harness 36630-92E00 1

Procedure
(1) Removethe bothsidelowercovers.(Seepage5.)
(2) Boutethefollowingitemsthroughthe grommete as shown
position.
. Remotecontrolwireharness@.
. Monitorgaugewireharness@.
.Trimmeterwireharness@.
.Batterycable@.
. Speedmeterpickuptube @.

NOTE:
For the procedureto installoptionaltrim sender/meterand re-
lated parts,referto the'TRIM SENDERKIT TNSTALLATION lN-
STRUCTIONS" that comessuppliedwitheachunitof trimsender
kit.

(3) Connectthe monitorgaugewireharness@ to the engine

side,thenpressfit theconnector
intotheholder@.
(4) Connectthe remotecontrolwire harness@ and PTTwires
@ to the engineside,then pressfit the connectorintothe
holder@.Routethemonitorgaugewireharness@ andPTT
wires@ behindthe connectorol @.
(5) Pushthe grommetO intothe frontpanel.

NOTE:
For the remotecontrolbox/meter/wireharnessconnection,refer
to the WIRINQDIAGRAMon page 16.

I
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 1RAG LINK INSTALLATION

lf the drag link and related parts are not Installedcor-

rectly the steeringsystemmay bind,causingthe opera-
Jtor to lose steeringcontrol of the boat.

NOTE:
These instructionsare for connectinga mechanicalpush-pull
steeringsystemwith the followingspecifications:
.
, Singlecable
v Starboardcableentryinto the motor tilt tube.
. Steeringcablemeetingthe currentAmericanBoat and Yacht
CouncilESafetystandard(P-17).

Containedparts
Item Partname Pad number Q'ty l.D.mark:
67711-90J00
Draglinkassy 67701-90J00
@ . Draglink . Notavailableseparately 1
@ . Spacer .67721-99E00 1
/Fr
\r' . Bolt .67725-99E00 1
@ . Safetynut .67726-99E00 2
\EJ . Washer .67728-99E00 4
@ Steeringcableseal 41161-94400 1

CAUTION
Neverreusethe safetynut (D afterit havebeenthreaded
into position and torqued.

Procedure
(1) Threadthesteeringcableseal@ ontothe portsideendof
the motortilttrrrbe
O.
\*-(2) ApplySUZUKIWATEBRESISTANT GREASEto the steer-
ingcable@.
(3) Insertthecable@ intothetubeO fromthestarboard side,
nut@ to thetorquespecified
thentightenthecableretaining
by the cablemanufacturer.

NOTE:
On mostoutboardmotor installations, it will be necessaryto in-
siaiithesieeringcabieprior io ihe ouiboarcirrptot'irisiailation.

I
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 (4) Connectthe drag link @ to the steeringcableend @ with
washers@ andsafetynutO as shown'Tighten thenut@ to
torque,thenBAGKTHENUTOFF1/BTURN'
thespecified

[t satety nut (D : 10 N'm (1.0kg-m,7'0lb-ft)

(s) Movethe steeringcableuntilthe holeof draglink@ aligns

withthe rearthreadholeon the steeringbracket@'
(6) Connectthe draglinkto thesteeringbracket@ bytightening
thebolt@ withthe spacer@ andwashers@ as shown'

[l aon @ : 34 N'm (3.4kg-m,24'slb'ft)

T-'\
\ ,, Tightenthe safe$ nut @ withthe washer@'

[l Satetynut (D :34 N'm (3.4 kg-m,24'5 lb-ft)

NOTE:
Afterassembly,checkfor smoothand free steeringoperationby
turningthe steeringwheet all thewayto the rightand tefl'

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 couNTER ROTATTON KtT (OpilONAL
MODELOR DUAL ENG|NE,TTE-ROD
- PARTS)TNSTALLATTON
KIT(OPTIONAL
TIE-ROD PARTS) parts
Contained
Item Part Name Q'ty

1 TIE.RODASSY 1
2 BRACKET, TIE-ROD 2
3 BOLT,TrE-ROD(UNF) z
4 NUI TIE-ROD 2
5 BOLI TIE-ROD 2)
BRACKET(MI 4
o WASHER.TIE-RODBRACKET 4
7 SPACER.
TIE.ROD 2
8 INSTRUCTION,
TIE-ROD 4

I TAPE 1

Suzukirecommends Suzukioutboardmotordealerora qualifiedservicemechanic

thatonlyauthorized pertorminstallation
of thiskit.

Parts installationProcedure

(1) lnstaltthetie-rodbracket@ on the endof steeringbracketusingthe bolts@ andwashers@.

[t eot @ : 85 N'm (8.5kg-m,61.0lb-ft)

'- (2) Installthe tie-rodassye on the bottomsideof tie-rodbracket@ withthe spacer@ positioned
in
between usingthebolt@.
[! aon @ : 5o N.m(5.0kg--, 36.0lb-ft)

(3) Tightenthenut@ to tneendof bolt@ thathasbeeninstalled

in thestep2) above.(Whentightening
the
\/. nut@, holdthe bolt@ securelyso as notto comeloose.)
S ttut @ : 30 N'm(3.0kg-m,21.5lb-ft)

11
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 AdjustmentProcedureof tie-rod length
(1) LoosenthenutsA and B.
(2) Adjustthetie-rodtengthby turningtheturnbuckte.
(3) lvhen thetie-rodlengthhasbeenadjusted, tightenthe nutsA andB.
Q Hur 85 N.m(8.5kg-m,61.0tb-ft)

Therequired
lengihof tie-roddependson thecondition.Adjustthelengthso thatthebestresultcanbe
obtained.
The followingis an exampleof adjustment
to obtaintheoptimumresult.

Example: Toe-out position

(1) Adjustthetie-rodlengthso thatthetwoenginecenterlines
in
forwarddirectionare awayfromeachotherwiththe differen-
tialL1 - L2 within25 mm (1 inch).

NOTE:
The center to center distancefor twin engine instailationis mini-
mum 635mm (25 in.).
Toe-outposition

(2) Thetwoenginewakesshouldmeettogetherat approximately

20rn- 25mbehindthem.

Recommendrigging procedure
Forthe bestresult,it is recommended
thatthe following
be
checked,

(1) Asshowninillustration, cutfourpiecesoftape@ whichcomes

providedin this kit and stickthemat the swivelstopperarea
of boththe STBDand PORTsideengines.

Prior to sticking the tape, make sure to degreasethe at-

taching surfacethoroughly.

ON
For Increasedadhesion,press and scrape the tape sur-
face. At this time, however,use caution not to cause
wrinkle,scratch,etc.on the tape.

t2
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 to makesure that all the boltsand nut are tightenedproperlyto the specified
(2) Performdouble-check
torque.

performanothercheckto makesurethatall theboltsandnutsaretightened

(3) Afteronehourof operation,
proplerly
to thespecified
torque.

..-.(a) Afteranotheronehourof operation furtherto the above,checkagainvisuallyforthe surfaceconditionof

aluminum tape.lf allthe fouraluminum tapesshowthe signof equalcontact,it showsthe rigginghas
beenaccomplished lf any
successfully. difference is found,adjustthetie-rodlength
in contactcondition
observingthefollowing instructions;

@ Requiring shortertie-rodlength:
Thereis a damageon thestarboard sidealuminum sideengineas wellas on
tapeof thestarboard
the portsidetapeof the port sideengine.

@ Requiringlongertie-rodlength:
sideengineas wellas on the
Thereis a damageon theportsidealuminumtapeof thestarboard
starboardsidetapeof the portsideengine'

(s) presents,
lf anyof theaboveconditions adjustthetie-rodlengthto eithershorteror longeras appropri-
ate by approximately5 mm at a time.Repeatthe procedures in the steps(1)to (4) untilall the four
aluminum tapesshowthe equalcontactcondition.

Damagedaluminumtapes can no longer be used for the subsequentadiustmentand therefore

shouicibe repiaceci.

Withtheprocedures
aboveperformed,
the riggingcompletes.

O Dependingon the boat and adjustment conditlon, the initial setting of toe-in can turn to toe-out
later. Especially when the boat is equipped with outrigger, such a variation may become more
evident.
O Double-checkall the bolts and nuts for proper Installationand tightness.
O After two hours of operation, perform another check to make sure that all the bolts and nuts are
tightened properly to the.specified torque.
O At the end of every 50 hours of operation, lubricate and check all the parts for wear, installation
conditionand tightening torque.

13
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 INSTALLATION
WITHTHE PRE-RIGGED
ITEMSFOR2 CYCLEMODEL
Whenthe DF90/115 on theboatwhichhasalreadybeenriggedwiththe itemsfor 2 cyclemodel,\
is installed
performriggingby usingthe followingitems.

Requiredparts

Item Part name Part number Q'ty

@ Adapterwireharness(meterside) 34711-99E00 {T
@ Adapterwireharness(engineside) 36661-99E00 1
/Fr
\:,/ Flemo-conlinkplate 67220-95630 1

NOTE:
Followingprocedureare basedon the boat which hasatreadybeenriggedwith"J4700-92E1. ".
"34200-92E0.", "36660-g2EI " and "67200-g7D3.(pull-to-open-type)".
-
Procedure
- Wireharnessand Meter-
(1) Remove the monitorgaugeO, thenplugthemounthole.
(2) Removethetachometer @.
(3) connectthe adapterwire harness@ betweenthe monitor-tachometerO and monitorgaugewirehar-
ness@ as shown.
(4) Installthemonitor-tachometer
@ to the holeof originaltachometer
@.
(5) Connectthe adapterwire harness@ betweenthe engineand the monitorgaugewire harness as
@
snown.

Instrument wire harness

Lbr€
P-Ef,
t- - -- - -- -
Y-GF 3 42 o 0 - 9 2 E o. - - - = - - t
l=-R/c
E--B-
RiG_G-R/G
w - I= B-B_B
Ef_B
EFGr

34700-92E1
1
36660-92E

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 -Remotecontrolbox-
_..(6) Removethe screws,backcover@ and@.
(7) Removethe warm-upleverscrews@.

(B) Removethe drum@, then reinstall

the drum@ with 180'
\-,' turnedpositionby the screws@.

(e) Afterdisconnectingthe throttlecontrolcable,removethe origi-

nal link plate@ (forpull-to-open).
( 1 0)Installthelink plate@ (for push{o-open).
. . - ( ' t 1)lnstallthe upper back cover @ by the screws.
( 1 2)After connectingthe throttlecontrolcable,installthe lower
|,l2p14 6rlryor 6 hrr fhe e^rori/q

NOTE:
. For theprocedureto connectthe controlcablesto the remote
controlbox, refer to the "REMOTECONTROLBOX SETUP
INSTRUCTION" thatcomessuppliedwitheachunitof remote
controlbox.
. Be carefulnot to missany items (washer,spaceretc.) when
reassembling the remotecontrolbox.
. Afterassembly,checkfor smoothoperation.

15
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 WIRINGDIAGRAM
(Forremotecontrotbox/meterfuiire
harness)

c o
@
., q)
q) 0, OE
@ .zo
tr E oo
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F

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otr
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ig

16
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 WIRINGDIAGRAMFOR DUAL ENGINE

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17
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 Prepared
by

SUZUKI IIOTOR CORPORATION

Marine & Power Products Division

D ecember,2U U l
Part No. 99505-92J00-0lE
Printed in Jaoan

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