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| Home / Outboard Engines / Suzuki Engines / Suzuki DF4 |
Suzuki DF4 Specifications
The Suzuki DF4 is a 4-stroke 1-cylinder OHV (overhead valve) gasoline outboard engine with a rated power of 4 hp (2.9 kW) at 4000-5000 rpm. The engine cylinder bore is 2.44" (62 mm) and piston stroke is 1.81" (46 mm). A 8.4 cubic inches (138 cc) outboard motor has a carburetor fuel system, wet sump lubrication by trochoid pump, starting system with recoil starter, pointless electronic ignition system, manual tilt, and tiller handle steering. The fuel tank capacity is 0.4 gal (1.5 liters). The propeller is made of aluminum and it has three blades.
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| General Technical Data |
Engine Model ................ Suzuki DF4
Engine Type ................ 4-stroke single-cylinder OHV gasoline outboard engine
Number of Cylinders ................ 1
Displacement, cu.in (cc) ................ 8.4 (138)
Cylinder Bore, in (mm) ................ 2.44 (62.0)
Piston Stroke, in (mm) ................ 1.81 (46.0)
Maximum Engine Power, hp (kW) ................ 4.0 (2.9)
Maximum Engine Speed, rpm ................ 4000-5000
Idle Speed, rpm ................ 1300±50
Compression Ratio ................ 9.2:1
Lubrication System ................ Wet sump by trochoid pump
Exhaust System ................ Through prop
Cooling System ................ Water-cooled
Ignition System ................ Pointless electronic ignition (PEI)
Starting System ................ Recoil starter
Choke System ................ Manual
Throttle Control ................ Twist grip
Electrical System Rating, Volts ................ 12
| Dimensions and Weight |
Overall Length, in (mm) ................ 21.8 (554.0)
Overall Width, in (mm) ................ 12.2 (309.0)
Overall Height (Long Shaft), in (mm) ................ 46.9 (1190.0)
Overall Height (Short Shaft), in (mm) ................ 41.9 (1064.0)
Transom Height (Long Shaft), in (mm) ................ 20 (508)
Transom Height (Short Shaft), in (mm) ................ 15 (381)
Outboard Weight (Long Shaft), lbs (kg) ................ 57.3 (27.0)
Outboard Weight (Short Shaft), lbs (kg) ................ 55.1 (26.0)
| Fuel System |
Fuel System Type ................ Carburetor
Carburetor Model ................ Keihin BC19-13.5
Fuel Type ................ Unleaded gasoline (87 or 91 octane minimum)
Fuel Tank Capacity, qts (L) ................ 1.58 (1.50)
| Gear Housing |
Gear Shift ................ F-N-R
Reduction System ................ Bevel gear
Gear Ratio ................ 1.92:1
Gear Oil Capacity, qts (L) ................ 0.20 (0.19)
| Mid Section |
Trim System ................ Manual Trim and Tilt
Number of Tilt Pin Position ................ 5
Transom Height (Long Shaft), in (mm) ................ 20 (508)
Transom Height (Short Shaft), in (mm) ................ 15 (381)
Steering System ................ Tiller
Trim Angle, deg ................ 4-20
Tilt Angle (Max), deg ................ 71
| Propeller Information |
Diameter, in (mm) ................ 7.5 (190)
Pitch, in (mm) ................ 6 (152), 6.5 (165), 7 (177)
Number Of Blade ................ 3
Material ................ Aluminum
| Cylinder Block |
Cylinder Bore Inside Diameter, in (mm) ................ 2.4409-2.4415 (62.000-62.015)
Cylinder Bore (Max Out of Round), in (mm) ................ 0.002 (0.050)
Crank Pin Outside Diameter, in (mm) ................ 1.1020-1.1024 (27.990-28.000)
Crank Pin Width, in (mm) ................ 0.945-0.953 (24.00-24.20)
Crankshart Runout (Maximum), in (mm) ................ 0.002 (0.050)
Crankshaft Journal Outside Diameter, in (mm) ................ 0.9826-0.9835 (24.959-24.980)
Crankshaft Journal Oil Clearance, in (mm) ................ 0.0008-0.0024 (0.020-0.062)
Connecting Rod Inside Diameter (Big End), in (mm) ................ 1.1030-1.1033 (28.015-28.025)
Connecting Rod Oil Clearance (Big End), in (mm) ................ 0.0006-0.0014 (0.015-0.035)
Connecting Rod Side Clearance (Big End), in (mm) ................ 0.008-0.035 (0.20-0.90)
Connecting Rod Width (Big End), in (mm) ................ 0.917-0.937 (23.30-23.80)
Connecting Rod Inside Diameter (Small End), in (mm) ................ 0.7089-0.7092 (18.006-18.014)
Piston Skirt Diameter, in (mm) ................ 2.4400-2.4406 (61.975-61.990)
Piston to Cylinder Clearance, in (mm) ................ 0.0004-0.0016 (0.010-0.040)
Piston Pin Outside Diameter, in (mm) ................ 0.7085-0.7087 (17.995-18.000)
Piston Pin Bore Inside Diameter, in (mm) ................ 0.7089-0.7092 (18.006-18.014)
Piston to Piston Pin Clearance, in (mm) ................ 0.0002-0.0007 (0.006-0.019)
Top Ring Width, in (mm) ................ 0.048-0.049 (1.22-1.24)
Second Ring Width, in (mm) ................ 0.048-0.049 (1.22-1.24)
Oil Ring Width, in (mm) ................ 0.099-0.100 (2.51-2.53)
Top Ring End Gap, in (mm) ................ 0.008-0.014 (0.20-0.35)
Second Ring End Gap, in (mm) ................ 0.014-0.020 (0.35-0.50)
Top Ring Side Clearance, in (mm) ................ 0.001-0.003 (0.03-0.07)
Second Ring Side Clearance, in (mm) ................ 0.001-0.003 (0.03-0.07)
| Cylinder Head and Valves |
Cylinder Head Warp Limit ................ 0.002 (0.050)
Valve Head Diameter (Intake), in (mm) ................ 0.94 (24.0)
Valve Head Diameter (Exhaust), in (mm) ................ 0.87 (22.0)
Valve Head Thickness (Intake), in (mm) ................ 0.04 (1.00)
Valve Head Thickness (Exhaust), in (mm) ................ 0.04 (1.00)
Valve Stem Outside Diameter (Intake), in (mm) ................ 0.2150-0.2156 (5.460-5.475)
Valve Stem Outside Diameter (Exhaust), in (mm) ................ 0.2142-0.2148 (5.440-5.455)
Valve Guide Inside Diameter (Intake), in (mm) ................ 0.2165-0.2170 (5.500-5.512)
Valve Guide Inside Diameter (Exhaust), in (mm) ................ 0.2165-0.2170 (5.500-5.512)
Valve Stem To Valve Guide Clearance (Intake), in (mm) ................ 0.0010-0.0020 (0.025-0.052)
Valve Stem To Valve Guide Clearance (Exhaust), in (mm) ................ 0.0018-0.0028 (0.045-0.072)
Valve Seat Width (Intake), in (mm) ................ 0.03-0.04 (0.8-1.0)
Valve Seat Width (Exhaust), in (mm) ................ 0.04-0.05 (1.0-1.2)
Valve Spring Free Length, in (mm) ................ 1.16 (29.50)
Camshaft Journal Outside Diameter (Upper), in (mm) ................ 0.5892-0.5899 (14.966-14.984)
Camshaft Journal Outside Diameter (Lower), in (mm) ................ 0.6286-0.6293 (15.966-15.984)
Camshaft Journal Oil Clearance, in (mm) ................ 0.0006-0.0024 (0.016-0.062)
Cam Height (Intake), in (mm) ................ 1.2756-1.2780 (32.401-32.461)
Cam Height (Exhaust), in (mm) ................ 1.2810-1.2834 (32.538-32.598)
| Maintenance Data |
Engine Fuel Type ................ Unleaded 87 or 91 octane minimum
Engine Oil Type ................ SAE 10W-40
API Service Classifications ................ SE, SF, SG, SH, and SJ
Engine Oil Capacity, qts (L) ................ 0.73 (0.70)
Gear Lubricant Type ................ Suzuki Outboard Motor Gear Oil or GL5 SAE 90
Gearcase Capacity, qts (L) ................ 0.20 (0.19)
Ignition Timing, degrees ................ 3-28 BTDC
Spark Plug Type ................ NGK BPR6ES
Spark Plug Gap, in (mm) ................ 0.028-0.031 (0.7-0.8)
Valve Clearance (Intake), in (mm) ................ 0.001-0.003 (0.03-0.07)
Valve Clearance (Exhaust), in (mm) ................ 0.001-0.003 (0.03-0.07)
| Service Intervals |
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 Fuel Filter ................ Every 100 hours
Check Anodes ................ Every 100 hours
Check Thermostat ................ Every 100 hours
Check Carburetor ................ Every 100 hours
Check Propeller Nut and Pin ................ Every 100 hours
Check Valve Clearance ................ Every 200 hours
Check Idle Speed ................ Every 200 hours
Check Water Pump ................ Every 200 hours
Check Water Pump Impeller ................ Every 200 hours
Replace Spark Plug ................ Every 300 hours
Replace Water Pump Impeller ................ Every 300 hours
Replace Fuel Filter ................ Every 400 hours
| Tightening Torques |
Cylinder head cover bolt, Nm (lb-ft) ................ 8 (6.0)
Cylinder head bolt, Nm (lb-ft) ................ 28 (20.5)
Crankcase bolt, Nm (lb-ft) ................ 10 (7.0)
Connecting rod cap bolt, Nm (lb-ft) ................ 21 (15.0)
Valve adjusting lock nut, Nm (lb-ft) ................ 11 (8.0)
Intake pipe bolt, Nm (lb-ft) ................ 10 (7.0)
Carburetor mounting bolt, Nm (lb-ft) ................ 10 (7.0)
Flywheel nut, Nm (lb-ft) ................ 50 (36.0)
Fuel pump mounting bolt, Nm (lb-ft) ................ 8 (6.0)
Engine oil drain plug, Nm (lb-ft) ................ 10 (7.0)
Power unit mounting bolt, Nm (lb-ft) ................ 10 (7.0)
Tiller handle pivot bolt, Nm (lb-ft) ................ 12 (8.5)
Steering bracket cover bolt, Nm (lb-ft) ................ 10 (7.0)
Swivel bracket cover bolt, Nm (lb-ft) ................ 10 (7.0)
Gearcase bolt, Nm (lb-ft) ................ 17 (12.5)
Water pump case bolt, Nm (lb-ft) ................ 8 (6.0)
Propeller shaft bearing housing bolt, Nm (lb-ft) ................ 8 (6.0)
Spark plug, Nm (lb-ft) ................ 10-12 (7.5-9.0)
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| Engines Technical Specifications |