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DF9.9B/BE/BR/BT
DF15A/AE/AR/AT
DF20A/AE/AR/AT
Applicable model and effective serial number:
00995F-410001 and later
01504F-410001 and later
02002F-410001 and later
99505-89L10-01E
1
FOREWORD
This outboard motor has been designed and produced utilizing
Suzuki’s most modern technology. The finest product, however,
cannot perform properly unless it is correctly assembled and
serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this outboard motor.
NOTE:
This Set-up manual has been prepared exclusively for following
models.
Applicable model and effective serial number:
00995F-410001 and later
01504F-410001 and later
02002F-410001 and later
Apprentice mechanics or do-it-yourself mechanics
that don’t have the proper tools and equipment may
not be able to properly perform the services described
in this manual. Improper assembly and/or servicing
may result in injury to the mechanic and may render
the engine unsafe for the boat operator and passen-
gers.
1
CONTENTS
2
IMPORTANT
WARNING/CAUTION/NOTICE/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION, NOTICE and NOTE have special meanings. Pay special attention
to the messages highlighted by these signal words.
Indicates a potential hazard that could result in death or serious injury.
NOTICE
Indicates a potential hazard that could result in damage to the motor or boat.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the
WARNINGS, CAUTIONS and NOTICE stated, you must use good judgement and basic mechanical safety
principles.
3
SYMBOL
Listed in the table below are symbols indicating special instructions and other important information neces-
sary for proper servicing. Please note the definition for each symbol. You will find these symbols used
throughout this manual. Refer back to this table if you are not sure of any symbol(s) meanings.
MATERIALS REQUIRED
WATER RESISTANT SUZUKI SILICONE
GREASE EP2 SEAL
99000-25350 93691-80030
(250 g/8.8 oz) (100 g/3.5 oz)
4
GENERAL INFORMATION
HANG TAGS
It is mandatory that every new Suzuki outboard motor be
assembled and serviced in accordance with the instructions in
the set-up manual.
A critical step in the set-up and pre-delivery process of every
outboard motor is to attach the hang tags to the outboard motor.
Hang tags are required to remain on the motor until it is deliv-
ered to the customer.
Be sure the hang tags are attached to the outboard motor as
shown.
5
EMISSION-RELATED INSTALLATION INSTRUCTIONS
Fuel lines and fuel tanks used for a vessel must meet the requirements of federal law (40 CFR 1045.112
and 40 CFR 1060).
If you install the engine in a way that makes the engine’s emission control information label hard to read dur-
ing normal engine maintenance, you must place a duplicate label on the vessel, as described in 40 CFR
1068.105
Failing to follow these instructions when installing a certified engine in a vessel violates federal
law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.
6
OUTBOARD MOTOR INSTALLATION
HORSEPOWER SELECTION
Overpowering your boat may cause operating/handling difficulties which could result in a crash.
The boat may also sustain hull damage or other damage due to stress.
MOTOR DIMENSIONS
337 (13.3)
193 (7.6)
600 (23.6)
410 (16.1)
12
35 – 6
(1.4 – 0
2.4)
64
45 45
Shallow drive:
1st position: 31
167 (6.6) 167 (6.6) 2nd position: 46
Unit: mm (in)
329 (13.0) 329 (13.0)
7
DF9.9BR/DF15AR/DF20AR
S: 707 (27.8)
337 (13.3) L: 818 (32.2)
600 (23.6)
410 (16.1)
S: 1093 (43.0), L: 1220 (48.0)
S: 422 (16.6)
L: 549 (21.6)
64
8
45 8
45
8
DF9.9BT/15AT/20AT
S: 722 (28.4)
309 (12.2) L: 834 (32.8)
80 (3.1) 532 (20.9)
633 (24.9)
410 (16.1)
60
45 6
45 6
Unit: mm (in)
9
DF9.9BTH/15ATH/20ATH S: 722 (28.4)
309 (12.2) L: 834 (32.8)
507 (20.0) 532 (20.9)
152 (6.0)
633 (24.9)
410 (16.1)
60
6
6
45
45
Unit: mm (in)
10
TRANSOM DIMENSIONS
DF9.9B/15A/20A
DF9.9BR/15AR/20AR
Transom top surface
2-M14 × P2.0
50 (2.0)
(Clamp screw)
87 (3.4)
105 (4.1)
149 (5.9)
4–φ 9
196 (7.7)
Unit: mm (in)
DF9.9BT/15AT/20AT
Unit: mm (in)
DF9.9BTH/15ATH/20ATH Transom top surface
2 – M14 × P2.0
58 (2.3)
(Clamp Screw)
69 (2.7)
3– φ 9
18 (0.71)
(2 place)
230 (9.1)
161 (6.3)
149 (5.9)
196 (7.7)
R
4–
16.5 (0.65)
9 (0.35)
11
ESTABLISHING THE CENTER-LINE
To establish the center of the transom you may use the following
procedure:
(1) Measure across the transom from chine to chine and make
1/2 1/2
a mark on the transom face at 1/2 of this measurement.
Chine 1/2 1/2
(2) Measure across the transom from strake to strake and
make a second mark on the transom face at 1/2 of this Strake
measurement.
(3) Align a straightedge with the marks on the transom face
and draw a line. This is the vertical center-line of the tran-
som for a single engine installation.
Failure to use the proper attachment point for lifting
the outboard motor can result in severe injury and/or
damage to the outboard motor.
Use the lifting eye only. Do not lift the motor using a
flywheel lifting attachment.
(1) Install the lifting eye on cylinder block, then securely tighten
it with bolt.
11291-91B50: Engine hook (Lifting eye)
01550-08207: Bolt
(2) Attach lift to lifting eye on cylinder block, then lift the engine.
12
MOUNTING TO THE TRANSOM
Contained parts
Item Part name Part number Q’ty
A Bolt (M 8 × 90 mm) 09100-08311 2
B Washer No.1 (Large) φ 23 × φ 8 .5 41154-91J00 2
C Washer No.2 (φ 16 × φ 8 .5) 09160-08170 2
D Lock washer (φ 15 × φ 8 ) 29162-93J10 2
E Nut 09140-08016 2
If the motor is not properly secured to the transom, it
can come off.
(2) Install motor mounting bolts with large diameter flat washer
from inside of transom and through clamp brackets.
(3) Install flat washers, lock washers and nuts on clamp
bracket side.
(4) Tighten all mounting bolts securely.
Mounting bolt/nut: 13 N·m (1.3 kgf-m, 9.5 lb-ft)
13
NOTE:
• Drill the mounting holes vertically to the transom board.
• To insure water-tightness, sealant (SUZUKI SILICONE SEAL
or equivalent) should be applied to all bolt holes. Apply the
sealant to the shanks of the bolts, but not the threads.
• Do not use an impact tool to tighten or loosen the transom
nuts.
• If the specified tightening torque can not be reached due to
weak transom material, it may be necessary to install a rein-
forcement plate between the transom board and washer B. If
a reinforcement plate is required, contact the boat manufac-
turer for recommendations.
NOTE:
Make sure that there is no clearance on matting surfaces
between the transom board and motor clamp brackets.
Otherwise, the motor clamp brackets may be damaged.
14
CONTROL CABLES AND WIRE HARNESS INSTALLATION
Contained parts (Remote control model)
R model
Part name Part number Q’ty Part name Part number Q’ty
Control cable 8ft (2.4 m) 67320-93J00 2 Control cable 18ft (5.4 m) 67320-93J50 2
Control cable 10ft (3.1 m) 67320-93J10 2 Control cable 20ft (6.0 m) 67320-93J60 2
Control cable 12ft (3.7 m) 67320-93J20 2 Control cable 22ft (6.7 m) 67320-93J70 2
Control cable 14ft (4.2 m) 67320-93J30 2 Control cable 24ft (7.3 m) 67320-93J80 2
Control cable 16ft (4.8 m) 67320-93J40 2
Choose one item which is matched to the boat in length.
ENGINE SIDE
Contained parts (Remote control model)
NOTE:
Before performing the following procedures, be sure that the
throttle/shift control cables are installed in the remote control box
according to the “REMOTE CONTROL BOX SET-UP
INSTRUCTION”.
15
Procedure
(1) Remove the STBD engine side cover.
(2) Position the remote control handle into “NEUTRAL”.
If the cable connector is not threaded far enough onto
the cable, the cable connector could break causing a
loss of control and a crash.
(4) Route the shift cable 3, then secure the cable in the cable
holder 4 by fitting groove on the cable into a slot on the
holder.
(5) Make sure that clutch control lever 5 is in the neutral posi-
tion.
(6) While pushing cable end as shown by arrow X, thread the
connector A onto the shift control cable 3 until the con-
nector hole aligns with the pivot pin 6 on the clutch control
lever 5.
(7) Set the connector A onto the pivot pin 6 with the flat side
of connector towards the lever.
16
(8) Install the washer 2 and lock pin 1, then tighten the lock
nut 7.
(9) Make sure that both forward and reverse gear can be
NEUTRAL
engaged with the same angle of remote control handle 32˚ 32˚
travel from “NEUTRAL” position.
REVERSE
FORWARD
Clearance “a” 1 – 2 mm
17
(15) Thread the throttle cable connector A onto the cable end.
(16) While pushing cable end as shown by arrow X, adjust the
connector A until the center of connector hole aligns with
the pivot pin A on the throttle control lever 0.
(17) Set the connector A onto the pivot pin A with the flat side
of connector towards the throttle control lever.
(18) Install the washer 2 and lock pin 1, then tighten the lock
nut B.
Clearance “a” 1 – 2 mm
NOTE:
Do not attempt to adjust the throttle valve opening such as by
turning the throttle stop screw G.
18
(21) Install grommet H. R model
(22) Reinstall the engine side covers.
T model
NOTE: R model
Before installing side cover, confirm that the remote control har-
b a
ness and PTT motor cable are properly routed and they must
not contact with the remote control cable holder. c
If the harness touches with the cable holder, pull the harness
outward at its grommet.
Clamp
19
— Remote control wire harness —
(23) Connect the coupler of the remote control wire harness to
the coupler in the engine side.
NOTE:
After assembly, make sure that the cables are not stretched or
otherwise stressed when the outboard motor is turned all the
way to the right and left.
NOTICE
On the T model;
Do not connect the sub-battery cable to the remote
control harness.
20
STEERING SYSTEM
Selection of an improper steering system or improp-
erly installing a steering system on the outboard
motor can cause steering/handling difficulties, result-
ing in loss of control and a crash.
21
Procedure
(1) Thread the steering cable seal F onto the port side end of
the motor tilt tube 1.
(2) Apply SUZUKI WATER RESISTANT GREASE to the steer-
ing cable 2.
(3) Insert the cable 2 into the tube 1 from the starboard side,
then tighten the cable retaining nut 3 to the torque speci-
fied by the cable manufacturer.
NOTE:
On most outboard motor installations, it will be necessary to
install the steering cable prior to the outboard motor installation.
(4) Connect the drag link A to the steering cable end 2 with
washers E and safety nut D as shown. Tighten the nut D
to the specified torque, then BACK THE NUT OFF 1/8
TURN.
(5) Move the steering cable until the hole of drag link A aligns
with the thread hole on the attachment 4.
(6) Connect the drag link to the attachment 4 by tightening the
bolt C with the spacer B and washer E as shown.
NOTE:
After assembly, check for smooth and free steering operation by
turning the steering wheel all the way to the right and left.
22
BATTERY
BATTERY REQUIREMENT
Suzuki recommends a 12-volt cranking-type lead acid battery for the DF9.9B/15A/20A.
Minimum battery requirement for starting the engine is provided below.
The battery must satisfy one of the specifications described below.
450 Marine Cranking Amps (MCA)/ABYC,
or 330 Cold Cranking Amps (CCA)/SAE
or 70 Reserve Capacity (RC) Minutes/SAE
or 12 V 35 AH
NOTE:
• The specifications listed above are the minimum battery rating
requirements for starting the engine.
• Additional electrical loads from the boat will require larger
capacity batteries.
• Dual-purpose (Cranking/Deep Cycle) batteries can be used if
they meet the minimum specifications listed above (MCA,
CCA, or RC).
• Do not use a Deep Cycle battery for the main cranking battery.
• The use of Maintenance-Free, sealed, or Gel-Cell batteries is
not recommended because they may not be compatible with
Suzuki’s charging system.
• When connecting batteries in parallel, they must be of the
same type, capacity, manufacturer, and of similar age. When
replacement is necessary, they should be replaced as a set.
INSTALLATION OF BATTERY
Failure to take proper precautions when handling the
battery may cause severe injury.
23
Store the battery free from splash of water, etc. and fix it Red tube Black tube
securely to the hull with a battery band or the like to prevent it
from falling down during boating.
NOTE:
It is recommended that the battery be installed in an enclosed
battery case.
NOTE:
When extending the battery cable, use a cable of diameter
Battery cable Battery cable
larger than equivalence of AV8 (AWG8).
NOTE:
When connecting batteries, hexagon-nuts must be used to
secure battery leads (cables) to battery terminals.
Hexagon-nut
24
WIRING DIAGRAM
Side Mount Remote Control
R-model
T-model
25
26
REMOTE CONTROL BOX MAP SENSOR
W
R
B
R-model
THROTTLE IAT SENSOR
B
SENSOR
B
B
Lg/R
Gr
R/G
Br/Bl
FUSE 10A R
B
PUSH FREE ST IG OFF Gr
CAUTION IAC VALVE
IGNITION W/B
GND B BUZZER
R
SWITCH
STOP G
Gr
O/B #1
BATT W
B
FUEL INJECTOR
IG Gr Gr
SUZUKI
B/Br #2
START Br
B.Z O
BZ B
Y/Bl
RESET Gr CMP SENSOR
Gr
EMERGENCY STOP SWITCH PUSH TURN
Bl,Bl/Y
Lock plate OFF STOP Br Br
O O
Gr Gr Gr B/Bl
B G G G W W
B B B B Bl Bl
Br Br
O
Y Y/B
G Bl/O
B B
R
R
B
B
STARTING
M B/W
MOTOR B/Y FUEL PUMP
B/R
R
BATTERY
R
MAGNETO B Gr
Y Y P P
CAUTION
Y Y
RECTIFIER & LAMP
Y Y
REGULATOR
W W
B
OIL PRESSURE SWITCH
CKP SENSOR Bl/Y
14.7 4.9 kPa
(0.15 0.05 kgf/cm2)
MAIN STARTER B/W B
R/B R/B ON
RELAY RELAY FUSE 10A
B/Bl B/Bl #1
B
B
O
FUSE 30A
CYLINDER TEMP W R
SENSOR B B #2
B B/O
IGNITION COIL
NEUTRAL SWITCH
B
R
W
W
Br
B/Bl
Y/W
Br
B/Bl, W
B
N ON Y/G Y/W
F.R OFF B
Gr
Y/R SDS
Y
WIRE COLOR
P
Y
B
R
B
O
Gr
Y/B
B/Y
Y/R
R/B
B/R
B/O
O/B
Y/W
W/B
Y/Bl
B/W
Bl/Y
B/Bl
Bl/O
B/Br
Lg/R
Br/Bl
B.......... Black B/Bl...... Black with Blue tracer Lg/R..... Light green with Red tracer
Br........ Brown B/Br......Black with Brown tracer O/B...... Orange with Black tracer
Gr........ Gray B/O.......Black with Orange tracer R/B.......Red with Black tracer
O......... Orange B/R.......Black with Red tracer Y/B....... Yellow with Black tracer
P.......... Pink B/W...... Black with White tracer Y/Bl...... Yellow with Blue tracer ENGINE CONTROL
R.......... Red B/Y....... Black with Yellow tracer Y/G...... Yellow with Green tracer MODULE
W......... White BI/O..... Blue with Orange tracer Y/R.......Yellow with Red tracer
Y.......... Yellow BI/Y...... Blue with Yellow tracer Y/W...... Yellow with White tracer
Br/Bl..... Brown with Blue tracer W/B...... White with Black tracer
MAP SENSOR
W
R
B
IAT SENSOR
T-model
B
Lg/R
Br/Bl
R
B
PT SWITCH Gr
W/B
IAC VALVE
THROTTLE
R
DN UP
SENSOR
REMOTE CONTROL BOX Gr
O/B #1
B
FUEL INJECTOR
Gr
W TUBE B/Br #2
B
B
Gr
R/G
Lbl Lbl
B
Lg W/R FUSE 15A Y/Bl
CMP SENSOR
Gr
R P Gr
PUSH FREE ST IG OFF
IGNITION
GND B
SWITCH B B
P B/W B/W
Bl, Bl/Y
STOP G Lbl
P
R PT MOTOR
BATT W B M
B
PT
Lbl
IG Gr
SUZUKI
RELAY
W
START Br
B.Z O
BZ
Lbl Lbl
RESET W/R W/R
P P
EMERGENCY STOP SWITCH PUSH TURN
W/R W/R
Lock plate IN RUN W W
Gr Bl Bl Bl Lbl Lbl
Lock plate OFF STOP Br Br P P
O O
Gr Gr Gr B/Bl
B G G G W W
B B B B Bl Bl
Br Br
O
Y Y/B
G Bl/O
B B
R
R
B
B
M STARTING
MOTOR
B/W
R
R
BATTERY B/Y FUEL PUMP
B/R
R
Lbl
UP
MAGNETO
Y Y B Gr
P P Lbl
W W/R PT SWITCH
Y Y CAUTION P
RECTIFIER &
Y Y LAMP P
DN
REGULATOR
W W
B
CKP SENSOR OIL PRESSURE SWITCH
Bl/Y
14.7 4.9 kPa
B/W B (0.15 0.05 kgf/cm2)
MAIN STARTER R/B R/B
RELAY RELAY ON
FUSE 10A
B/Bl B/Bl #1
B
B
O
FUSE 30A
CYLINDER TEMP W R
SENSOR B B #2
B B/O
IGNITION COIL
B
R
W
NEUTRAL SWITCH
Br
B/Bl
Y/W
B/Bl, W
Br B
N ON Y/G Y/W
F.R OFF B
Gr
Y/R SDS
Y
WIRE COLOR
P
Y
B
R
B
O
Gr
B.......... Black P.......... Pink B/W..... Black with White tracer Y/B....... Yellow with Black tracer
Y/B
B/Y
Y/R
R/B
B/R
B/O
O/B
Y/W
W/B
Y/Bl
B/W
Bl/Y
B/Bl
Bl/O
B/Br
Lg/R
Br/Bl
Bl........ Blue R.......... Red B/Y...... Black with Yellow tracer Y/Bl.......Yellow with Blue tracer
Br........ Brown W......... White BI/O..... Blue with Orange tracer Y/G...... Yellow with Green tracer
G......... Green Y.......... Yellow BI/Y...... Blue with Yellow tracer Y/R.......Yellow with Red tracer
Gr........ Gray B/Bl...... Black with Blue tracer Br/Bl..... Brown with Blue tracer Y/W...... Yellow with White tracer
ENGINE CONTROL
Lbl....... Light blue B/Br..... Black with Brown tracer Lg/R..... Light green with Red tracer W/B..... White with Black tracer
MODULE
Lg........ Light green B/O.......Black with Orange tracer O/B...... Orange with Black tracer W/R..... White with Red tracer
O......... Orange B/R...... Black with Red tracer R/B.......Red with Black tracer
27
Prepared by
March, 2013
Part No. 99505-89L10-01E
Printed in U.S.A.
28
1 TK