DF40A/50A/60A - Supplementary Service Manual - Foreword, Applicable Models and Table of Contents

Oct 23, 2026

Supplementary service manual covering DF40A/50A/60A outboard motor variants with effective serial numbers from 310001 onward. States that it supplements the SUZUKI DF60A SERVICE MANUAL and describes only information that differs from the main manual and earlier supplementary manuals. Directs technicians to consult this manual first for applicable models (DF40AT/QH, DF40AST, DF50AT/TH, DF60AT/TH/QH). Provides general guidance for inspection and proper service, includes safety notice levels (WARNING/CAUTION/NOTICE/NOTE), and lists the table of contents section structure.

LanguageEnglish

CategoryResearch & Report

FormatPDF

Pages52

Reading Time2 h 11 min

AccessFree to download

Precautions

General Information

Maintenance and Tune-Up

Power Head

Engine Control

Engine Electrical Devices

Fuel System

Ignition System

Starting System

Charging System

Mid Unit

Housing and Bracket

Power Trim and Tilt

Lower Unit

Right Hand Rotation Unit

Wire / Hose Routing

Wire Routing

Fuel / Water Hose Routing

DF40A/50A/60A (310001 and later) DF40A/50A/60A (310001 and later) FOREWORD This SUPPLEMENTARY SERVICE MANUAL is a supplement to SUZUKI DF60A SERVICE MANUAL. It has been prepared exclusively for the following models. Applicable Model and Effective Serial No.: DF40AT/QH (04003F-310001 and Later) DF40AST (04004F-310001 and Later) DF50AT/TH (05003F-310001 and Later) DF60AT/TH/QH (06002F-310001 and Later) 7 This supplementary service manual describes only service information which differ from that of the main manual and previously issued supplementary manual. Therefore, whenever servicing the above applicable model, consult this supplementary service manual first. And for any section, item or description not found in this manual, refer to the main manual below. Main Manual: | Manual Name | Manual No. | | --- | --- | | DF60A SERVICE MANUAL | 99500-88L00-01 E | Supplementary Manual: | Manual Name | Manual No. | | --- | --- | | DF40A/50A/60A SUPPLEMENTARY SERVICE MANUAL (2010-1) | 99501-88L00-01E | Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the outboard motor and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you to know the outboard motor better so that you can assure your customers of fast and reliable service. * This manual has been prepared using the latest information available at the time of publication. Differences may exist between the content of this manual and the actual outboard motor. * Illustrations in this manual are used to show the basic principles of operation and work procedures and may not represent the actual outboard motor in exact detail. * This manual is intended for use by technicians who already possess the basic knowledge and skills to service SUZUKI Outboard motors. Persons without such knowledge and skills should not attempt to service Suzuki Outboard engines by relying on this manual only and should contact an authorized SUZUKI Outboard motor dealer. © COPYRIGHT SUZUKI MOTOR CORPORATION 2013 IMPORTANT NOTICE 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. ! WARNING , | Indicates a potential hazard that could result in death or serious injury. | | --- | | ! CAUTION | | Indicates a potential hazard that could result in minor or moderate injuly. | | 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 WARNING CAUTION , and NOTICE stated, you must also use good judgment and observe basic mechanical safety principles. ! WARNING This service manual is intended for authorized Suzuki outboard motor dealers and qualified service technicians only. 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 repair may result in injury to the mechanic and may render the engine unsafe for the boat operator and passengers. TABLE OF CONTENTS NOTE For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same sections of the service manual mentioned in the “FOREWORD” of this manual. Precautions............................................................... 00-* Precautions ............................................................. 00-

FAQs

What is the purpose of this supplementary service manual?

It supplements the SUZUKI DF60A SERVICE MANUAL and describes only service information that differs from the main manual and previously issued supplementary manuals.

Which outboard motor models and serial number ranges are applicable?

Applicable models are DF40AT/QH, DF40AST, DF50AT/TH, and DF60AT/TH/QH, each with effective serial numbers listed in parentheses starting from 04003F-310001, 04004F-310001, 05003F-310001, and 06002F-310001 respectively.

Where should technicians look for information not found in this manual?

For any section, item, or description not included here, refer to the main manual (DF60A SERVICE MANUAL, manual no. 99500-88L00-01 E).

Oct 23, 2026

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