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Suzuki DF25A Specifications
The Suzuki DF25A is a four-stroke three-cylinder single overhead cam gasoline outboard engine. This engine has a wet sump lubrication, electronic fuel injection, integral fuel pump, water cooled with thermostat, and digital CDI ignition system. A 29.9 cu.in (490 cc) outboard motor has a cylinder bore of 2.38" (60.4 mm), piston stroke of 2.24" (57 mm), and maximum power of 25 hp (18.4 kW) at 5000-6000 rpm. The boat motor is equipped with a manual or electric starting system, 3-blades aluminum standard propeller, manual or power trim and tilt, and tiller handle or remote control steering system. The fuel tank has a capacity of 6.6 gal (25 liters).
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| General Technical Data |
Engine Model ................ Suzuki DF25A, DF25AE, DF25AR, DF25AQ, DF25AT, DF25ATH
Engine Type ................ 4-stroke three-cylinder SOHC gasoline outboard engine
Number of Cylinders ................ 3
Displacement, cu.in (cc) ................ 29.9 (490)
Cylinder Bore, in (mm) ................ 2.38 (60.4)
Piston Stroke, in (mm) ................ 2.24 (57.0)
Maximum Engine Power, hp (kW) ................ 25.0 (18.4)
Maximum Engine Speed, rpm ................ 5000-6000
Idle Speed, rpm ................ 850±50
Compression Ratio ................ 10.0:1
Lubrication System ................ Wet sump by trochoid pump
Exhaust System ................ Through prop
Cooling System ................ Water-cooled
Ignition System ................ Digital CDI
Starting System ................ Recoil or electric starter
Choke System ................ Manual or electric
Electrical System Rating, Volts ................ 12
Charging System ................ Alternator
Alternator Rating, Amps ................ 14
| Dimensions and Weight |
Overall Length, in (mm) ................ 27.4 (695.0)
Overall Length (DF25AR), in (mm) ................ 25.4 (645.0)
Overall Length (DF25AT), in (mm) ................ 26.5 (673.0)
Overall Width, in (mm) ................ 15.5 (395.0)
Overall Height (Long Shaft), in (mm) ................ 53.4 (1355.0)
Overall Height (Short Shaft), in (mm) ................ 48.4 (1230.0)
Transom Height (Long Shaft), in (mm) ................ 20 (508)
Transom Height (Short Shaft), in (mm) ................ 15 (381)
Outboard Weight (DF25A, Long Shaft), lbs (kg) ................141.0 (64.0)
Outboard Weight (DF25A, Short Shaft), lbs (kg) ................139.0 (63.0)
Outboard Weight (DF25AE, Long Shaft), lbs (kg) .................148 (67.0)
Outboard Weight (DF25AE, Short Shaft), lbs (kg) ................145.0 (66.0)
Outboard Weight (DF25AR, Long Shaft), lbs (kg) ................ 145.0 (66.0)
Outboard Weight (DF25AR, Short Shaft), lbs (kg) ................141.0 (64.0)
Outboard Weight (DF25AQ, Long Shaft), lbs (kg) ................ 156.0 (71.0)
Outboard Weight (DF25AQ, Short Shaft), lbs (kg) ................152.0 (69.0)
Outboard Weight (DF25AQE, Long Shaft), lbs (kg) ................163.0 (74.0)
Outboard Weight (DF25AQE, Short Shaft), lbs (kg) ................161.0 (73.0)
Outboard Weight (DF25ATH, Long Shaft), lbs (kg) ................ 165.0 (75.0)
Outboard Weight (DF25ATH, Short Shaft), lbs (kg) ................163.0 (74.0)
Outboard Weight (DF25AT, Long Shaft), lbs (kg) ................ 161.0 (73.0)
Outboard Weight (DF25AT, Short Shaft), lbs (kg) ................ 159.0 (72.0)
| Fuel System |
Fuel System Type ................ Electronic Fuel Injection
Fuel Pump Type ................ Integral
Fuel Type ................ Unleaded gasoline (87 or 91 octane minimum)
Fuel Tank Capacity, gal (L) ................ 6.6 (25.0)
| Gear Housing |
Reversing System ................ Gear
Gear Shift ................ F-N-R
Gear Ratio ................ 2.09:1
Reduction System ................ Bevel gear
Gear Oil Capacity, qts (L) ................ 0.35 (0.33)
| Mid Section |
Trim System (DF25A, DF25AE, DF25AR) ................ Manual Trim/Tilt
Trim System (DF25AQ, DF25AQE) ................ Manual and Gas-Assisted Trim/Tilt
Trim System (DF25ATH, DF25AT) ................ Power Trim/Tilt
Number of Tilt Pin Position ................ 5
Transom Height (Short Shaft), in (mm) ................ 15 (381)
Transom Height (Long Shaft), in (mm) ................ 20 (508)
Steering System ................ Tiller Handle or Remote Control
Trim Angle, deg ................ 0-16
Tilt Angle (Max), deg ................ 69
| Propeller Information |
Diameter, in (mm) ................ 10.25 (260)
Pitch, in (mm) ................ 9 (228), 10 (254), 11 (280), 12 (304), 13 (330), 14 (355), 15 (381)
Number Of Blade ................ 3
Material ................ Aluminum
| Cylinder Block |
Cylinder Bore Inside Diameter, in (mm) ................ 2.3780-2.3785 (60.400-60.415)
Cylinder Bore (Max Out of Round), in (mm) ................ 0.002 (0.050)
Crank Pin Outside Diameter, in (mm) ................ 1.1413-1.1417 (28.989-29.000)
Crank Pin Width, in (mm) ................ 0.7913-0.7953 (20.100-20.200)
Crankshart Runout (Maximum), in (mm) ................ 0.0016 (0.040)
Crankshaft Journal Outside Diameter, in (mm) ................ 1.2594-1.2598 (31.986-32.000)
Crankshaft Journal Oil Clearance, in (mm) ................ 0.0008-0.0020 (0.020-0.051)
Connecting Rod Inside Diameter (Big End), in (mm) ................ 1.1427-1.1431 (29.025-29.034)
Connecting Rod Oil Clearance (Big End), in (mm) ................ 0.0010-0.0019 (0.025-0.049)
Connecting Rod Side Clearance (Big End), in (mm) ................ 0.0039-0.0098 (0.100-0.250)
Connecting Rod Width (Big End), in (mm) ................ 0.7854-0.7874 (19.950-20.000)
Connecting Rod Inside Diameter (Small End), in (mm) ................ 0.6302-0.6304 (16.006-16.014)
Piston Skirt Diameter, in (mm) ................ 2.3766-2.3772 (60.365-60.380)
Piston to Cylinder Clearance, in (mm) ................ 0.0011-0.0017 (0.0271-0.0425)
Piston Pin Outside Diameter, in (mm) ................ 0.6297-0.6299 (15.995-16.000)
Piston Pin Bore Inside Diameter, in (mm) ................ 0.6300-0.6302 (16.002-16.008)
Piston to Piston Pin Clearance, in (mm) ................ 0.0001-0.0005 (0.002-0.013)
Top Ring Width, in (mm) ................ 0.040-0.041 (1.02-1.04)
Second Ring Width, in (mm) ................ 0.048-0.049 (1.21-1.23)
Oil Ring Width, in (mm) ................ 0.079-0.080 (2.01-2.03)
Top Ring End Gap, in (mm) ................ 0.0047-0.0098 (0.12-0.25)
Second Ring End Gap, in (mm) ................ 0.0102-0.0154 (0.26-0.39)
Top Ring Side Clearance, in (mm) ................ 0.0012-0.0028 (0.030-0.070)
Second Ring Side Clearance, in (mm) ................ 0.0008-0.0024 (0.02-0.06)
| Cylinder Head and Valves |
Cylinder Head Warp Limit ................ 0.002 (0.050)
Valve Head Diameter (Intake), in (mm) ................ 1.14 (29.0)
Valve Head Diameter (Exhaust), in (mm) ................ 1.02 (26.0)
Valve Head Thickness (Intake), in (mm) ................ 0.02 (0.50)
Valve Head Thickness (Exhaust), in (mm) ................ 0.02 (0.50)
Valve Stem Outside Diameter (Intake), in (mm) ................ 0.1959-0.1965 (4.975-4.990)
Valve Stem Outside Diameter (Exhaust), in (mm) ................ 0.1950-0.1957 (4.955-4.970)
Valve Guide Inside Diameter (Intake), in (mm) ................ 0.1969-0.1973 (5.000-5.012)
Valve Guide Inside Diameter (Exhaust), in (mm) ................ 0.1969-0.1973 (5.000-5.012)
Valve Stem To Valve Guide Clearance (Intake), in (mm) ................ 0.0004-0.0015 (0.010-0.037)
Valve Stem To Valve Guide Clearance (Exhaust), in (mm) ................ 0.0012-0.0022 (0.030-0.057)
Valve Seat Width (Intake), in (mm) ................ 0.035-0.043 (0.9-1.1)
Valve Seat Width (Exhaust), in (mm) ................ 0.035-0.043 (0.9-1.1)
Valve Spring Free Length, in (mm) ................ 1.35 (34.29)
Cam Height (Intake), in (mm) ................ 1.0012-1.0035 (25.430-25.490)
Cam Height (Exhaust), in (mm) ................ 0.9898-0.9921 (25.140-25.200)
Camshaft Journal Outside Diameter (Upper), in (mm) ................ 1.0614-1.0622 (26.959-26.980)
Camshaft Journal Outside Diameter (Center), in (mm) ................ 1.3563-1.3573 (34.450-34.475)
Camshaft Journal Outside Diameter (Lower), in (mm) ................ 0.9039-0.9047 (22.959-22.980)
Camshaft Journal Oil Clearance, in (mm) ................ 0.0008-0.0024 (0.020-0.062)
| Maintenance Data |
Engine Fuel Type ................ Unleaded 87 or 91 octane minimum
Engine Oil Type ................ SAE 10W-30, 10W-40
API Service Classifications ................ SG, SH, SJ, SL, or SM
Engine Oil Capacity, qts (L) ................ 1.58 (1.50)
Gear Lubricant Type ................ Suzuki Outboard Motor Gear Oil or GL5 SAE 90
Gearcase Capacity, qts (L) ................ 0.35 (0.33)
Ignition Timing, degrees ................ 7-25 BTDC
Spark Plug Type ................ NGK CPR6EA-9
Spark Plug Gap, in (mm) ................ 0.031-0.035 (0.8-0.9)
Valve Lash (Intake), in (mm) ................ 0.007-0.009 (0.18-0.22)
Valve Lash (Exhaust), in (mm) ................ 0.008-0.009 (0.20-0.24)
| Service Intervals |
Check Battery ................ Every 100 hours
Change Engine Oil ................ Every 100 hours
Change Gear Oil ................ Every 100 hours
Check Spark Plug ................ Every 100 hours
Check Breather and Fuel Line ................ Every 100 hours
Check Low Pressure Fuel Filter ................ Every 100 hours
Check Anodes ................ Every 100 hours
Check Thermostat ................ Every 100 hours
Check Propeller Nut and Pin ................ Every 100 hours
Replace Oil Filter ................ Every 200 hours
Check Valve Lash ................ Every 200 hours
Check Timing Belt ................ Every 200 hours
Check Idle Speed ................ Every 200 hours
Check Water Pump ................ Every 200 hours
Check Water Pump Impeller ................ Every 200 hours
Check Air Cleaner Element ................ Every 200 hours
Replace Spark Plug ................ Every 300 hours
Replace Water Pump Impeller ................ Every 300 hours
Replace Fuel Filter ................ Every 400 hours
Check Low Pressure Pump Filter ................ Every 1000 hours
| Tightening Torques |
Cylinder head cover bolt, Nm (lb-ft) ................ 10 (7.2)
Cylinder head bolt, Nm (lb-ft) ................ 30 (21.7)
Crankcase bolt (Inside), Nm (lb-ft) ................ 28 (21.0)
Crankcase bolt (Outside), Nm (lb-ft) ................ 11 (8.0)
Conrod cap bolt, Nm (lb-ft) ................ 10 (7.2)
Flywheel nut, Nm (lb-ft) ................ 100 (75.5)
Camshaft pulley bolt, Nm (lb-ft) ................ 30 (22.0)
Crankshaft timing pulley nut, Nm (lb-ft) ................ 50 (36.0)
Rocker arm shaft bolt, Nm (lb-ft) ................ 6 (4.4)
Valve adjusting screw lock nut, Nm (lb-ft) ................ 10 (8.0)
Intake manifold bolt/nut, Nm (lb-ft) ................ 23 (16.5)
Oil pressure regulator, Nm (lb-ft) ................ 27 (19.5)
Throttle body, Nm (lb-ft) ................ 11 (8.0)
Low pressure fuel pump bolt, Nm (lb-ft) ................ 11 (8.0)
Starter motor mounting bolt, Nm (lb-ft) ................ 23 (16.5)
Oil pump bolt, Nm (lb-ft) ................ 11 (8.0)
Engine oil filter, Nm (lb-ft) ................ 14 (10.5)
Water pump case nut, Nm (lb-ft) ................ 6 (4.3)
Power unit mounting bolt, Nm (lb-ft) ................ 23 (16.5)
Driveshaft housing bolt, Nm (lb-ft) ................ 23 (16.5)
Propeller nut, Nm (lb-ft) ................ 25 (18.0)
Gearcase bolt, Nm (lb-ft) ................ 23 (16.5)
Tiller handle bolt, Nm (lb-ft) ................ 23 (16.5)
Spark plug, Nm (lb-ft) ................ 10-12 (7.5-9.0)
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