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Setup Manual DF300 Outboard Motor Installation

Setup Manual DF300 Outboard Motor Installation
99505-98J00-01E
Suzuki Marine

Sections:

HORSEPOWER SELECTION

Do not overpower your boat. Never install an outboard motor with horsepower exceeding the boat manufacturer’s recommended maximum. Excessive horsepower will have an adverse effect on hull safety and may cause operating/handling difficulties.

• State the maximum horsepower outboard motor that can be safely used on that boat. There is severe product liability potential connected with rigging and selling a boat with an outboard motor exceeding the horsepower capacity limitation.
• The rig should not be underpowered, as this will not allow the performance balance you are trying to achieve. Determine the customer’s needs, application and use of the perspective rig to make the best overall horsepower recommendation.

MOTOR DIMENSIONS

TRANSOM DIMENSIONS

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 a mark on the transom face at 1/2 of this measurement.
(2) Measure across the transom from strake to strake and make a second mark on the transom face at 1/2 of this measurement.
(3) Align a straightedge with the marks on the transom face and draw a line. This is the vertical center-line of the transom for a single engine installation.
(4) Drill mounting holes as in a single engine installation.

For twin engine installation you may use the following procedure: (Minimum engine center-line distance is 686 mm/27 in.)
(1) Following the horizontal line from chine to chine, mark the line at 343 mm (13.5 in.) on both sides of the previously established single engine vertical center-line.
(2) Following the horizontal line from strake to strake, mark this line also at 343 mm (13.5 in.) on both sides of the vertical center-line.
(3) Align a straightedge with these two sets of marks and draw the vertical center-line for a twin engine installation.
(4) Drill mounting holes as in a twin engine installation.

Do not drill engine top mounting bolt holes higher than 25.4 mm (1 in.) below top edge of actual boat transom.

LIFTING MOTOR

DO NOT USE FRONT LIFT EYE
WHEN UNCRATING THE MOTOR
The front lift eye is not designed nor intended to be used for removing the motor from its horizontal position in the shipping crate. Attempting to lift the motor from its horizontal crated position using the front lift eye creates a chain or sling angle which can cause the motor to swing when it is lifted. This may result in personal injury or cause damage to the engine block.

MOVING THE MOTOR IN A VERTICAL POSITION
All three lifting eyes should be used after the engine has been removed from the crate and is in a vertical position.

Use a hoist which has a minimum lift capacity of at least 450 kg (1 000 lbs.) when lifting the motor.

MOUNTING TO THE TRANSOM

Contained parts

Item Part name Part number Q’ty
(A) Bolt (1/2-20UNF) 09100-12086 6
(B) Washer (OD 45 mm) 09160-13017 4
(C) Washer (OD 26 mm) 09160-13016 6
(D) Washer (with 2 holes) 41155-93J00 2
(E) Nut 09159-12062 6
(F) Cap 41153-93J00 6

This kit for DF300, DF200/225/250, and DF150/175 models only.

Depending on boat type, use the appropriate mounting method A) or B) as shown below.

Suzuki highly recommends the use of six mounting bolts (method B) for rigid-hull inflatable boats or similar applications.

A)Using FOUR bolts to mount to the transom.

When using FOUR bolts it is recommended that a transom reinforcement
plate be installed as shown in the diagram below (Item (1)).

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

B)Using SIX bolts to mount to the transom. Refer to the diagram below.

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

• Drill the mounting holes vertically to the transom board.
• Drill the upper holes at least 25 mm (1.0 in) down from the transom top surface.
• 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 reinforcement plate to the transom board. If a reinforcement plate is required, contact the boat manufacturer for recommendations. The transom reinforcement plate should be installed between the transom surface and the washer (B) and /or (D).

When using the FOUR bolt mounting method be sure to install a transom reinforcement plate between washer (B) and the transom surface. See reference illustration for reinforcement plate right.

Never reuse the nut (E) after it has been threaded into position and torqued.

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

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.

After complating a break-in operation (10 hours), retighten the transom nuts by the specified torque.

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