Suzuki · Outboard

Suzuki DF40A / DF50A / DF60A

The DF40A, DF50A and DF60A are one engine: a 941 cm³ in-line three-cylinder four-stroke with twin overhead camshafts, four valves per cylinder, an oil-bathed timing chain and multi-point fuel injection, built since 2010 and rated at 29.4, 36.8 and 44.1 kW. The three share filters, spark plugs, water pump kit, anodes and propellers, so the parts below fit all of them unless a note says otherwise. The High Thrust DF50AV and DF60AV (from 2014) use a larger 2.42:1 gearcase for 14-inch propellers on heavy boats, and the later DF40ASV takes the same 1.05 litres of gear oil; on the AV models the water pump kit, gear oil quantity, propellers and propeller hardware differ. The older DF40 and DF50 (1999–2010) are a different 815 cm³ engine that keeps the gear ratio, gear case seal kit, propellers and propeller hardware of the A models, while the DF60 of 1998–2009 was a 1.3-litre four-cylinder related to the DF70 and is not covered here.

Manuals & documents

The links go to Suzuki’s own documents — some as archived copies of pages the maker has since taken down. We host no manuals or drawings.

Wear parts & part numbers

PartOEM numberAlso fitsNote
Service kit17400-888131,2,3—Suzuki’s 100 h / annual kit for the DF40A, DF50A and DF60A from 2010: water pump kit 17400-88L01, oil filter 16510-87J02, fuel filter 15410-88L00, three DCPR6E plugs, three anodes 55321-87J01, drain plug gaskets, O-rings and a cotter pin. Suzuki’s global kit list has the same contents as 16500-88L00.
Service kit17400-888231,2,3—The same kit for the High Thrust DF50AV and DF60AV (from 2014), with water pump kit 17400-99E12 instead; global number 16500-88L10.
Service kit17400-878231,3—Only for the old DF40 and DF50, late 2006 to 2010.
Water pump repair kit17400-88L011,2,3,5,6Quicksilver 8M60128104DF40A, DF50A and DF60A; also in maintenance kit 17400-88813. Not for the High Thrust AV models.
Water pump repair kit17400-99E121,2,3,5Quicksilver 8M60128117DF50AV and DF60AV (High Thrust gearcase); also in maintenance kit 17400-88823.
Water pump repair kit17400-963541,5—Old DF40 and DF50 (1999–2010); Suzuki lists the same kit for the DF25/DF30.
Raw water pump impeller17461-963128,9replaces 17461-96311replaces 17461-96310replaces 17461-96302—The impeller on its own, as in Suzuki’s DF60A water pump diagram (drive key 09420-04006); WakeBoss lists it for the DF40A, DF50A and DF60A as well as the old DF40/DF50 and the DF25/DF30.
Engine oil filter16510-87J021,2,3,10,11replaces 16510-87J01—Spin-on filter, the same on the old DF40/DF50, the DF25/DF30 and the DF60/DF70. Suzuki USA’s filter chart still shows the earlier 16510-87J01; the kits contain 87J02.
Fuel filter (engine)15410-88L001,2,3,12—Low-pressure filter inside the engine, for the DF40A, DF50A, DF60A and the AV models. A dealer item in the manual: check every 100 h, replace every 400 h or 2 years.
Fuel filter (engine)15410-87J301—Old DF40 and DF50, late 2006 to 2010.
Fuel pre-filter65910-98J0113,12—Element set for Suzuki’s water separator / fuel filter 65900-98J11, which goes in the line between the boat’s tank and the engine; replace the element every 12 months.
Spark plug09482-004461,3,14NGK DCPR6E12,1Three per engine, gap 0.8–0.9 mm, 15–19 N·m; the same plug as in the old DF40/DF50.
Anode (engine)55321-87J013,13,1,15—Small aluminium anode for salt and brackish water, three in the maintenance kit. Suzuki’s parts diagrams place it in the cylinder head and block, sealed with O-ring 09280-22019; the manual leaves these inner anodes to the dealer.
Anode (engine)55321-87J1113,16,15—Magnesium version of the same anode, for fresh water only.
Anode (lower unit)55125-955001,16,17—Trim tab anode (zinc) of the DF40A, DF50A, DF60A and the old DF40/DF50.
Anode (lower unit)55300-9550013,2,16,17—Zinc anode on the gearcase of the DF40A, DF50A and DF60A; not part of the maintenance kit.
Anode (lower unit)55321-90J0113,2,16—Zinc gearcase anode for the DF50AV and DF60AV.
Drain plug gasket09168-120121,3,14—Engine oil drain plug gasket, 12.5 × 20 × 2.5 mm; fit a new one at every oil change (drain plug 09248-12009, 10–15 N·m).
Gear oil plug gaskets09168-100221,3,14—Two per gear oil change, under the drain and the level plug (10 × 17 × 1.5 mm, 9–11 N·m).
Thermostat17670-9395518,19—60 °C thermostat, sold by WakeBoss for the DF40A, DF50A and DF60A. Suzuki’s 2014 DF60A diagram shows 17670-93953 in this place, so give your serial number when ordering.
Lower unit seal kit25700-88L031—Gear case seal kit for the DF40A, DF50A, DF60A and the old DF40/DF50; the job when the gear oil comes out milky.
Propeller hardware kit57630-943011,2,20—Spacer, washer, nut and cotter pin for the DF40A, DF50A and DF60A; the old DF40/DF50 uses the same single parts. Stopper 57632-95320, bushing 58120-88L01, spacer 57633-94301, washer 09160-18028, nut 09141-18005 (50–60 N·m), cotter pin 09204-03003.
Propeller hardware kit57630-90J101,2,20—DF50AV and DF60AV: stopper 57635-90J01, bushing 58105-90J00, washer 09160-18028, nut 09141-18005, cotter pin 09204-03003. Suzuki USA’s list of hardware kits shows 57630-90J00 for these models.
Propeller58100-88LC0-0191,2,20—3-blade aluminium, 11-1/2 × 9 in; DF40A, DF50A, DF60A and the old DF40/DF50.
Propeller58100-88LD0-0191,2,20,21—3-blade aluminium, 11-1/2 × 10 in.
Propeller58100-88LE0-0191,2,20,21—3-blade aluminium, 11-1/2 × 11 in.
Propeller58100-88LA0-0191,2,20,21—3-blade aluminium, 11-5/8 × 12 in.
Propeller58100-88LB0-0191,2,20,21—3-blade aluminium, 11-1/2 × 13 in. Higher pitches: 11-3/8 × 14 (58100-88LQ0-019), 11-1/4 × 15 (88LR0), 11-1/8 × 16 (88LS0), 11 × 17 (88LF0); stainless steel 11-1/8 × 16: 58200-88L30-000.
Propeller58100-87LG1-0192,20—DF50AV and DF60AV only: 3-blade aluminium, 14 × 9 in.
Propeller58100-87LH0-0192,20,22—DF50AV and DF60AV: 14 × 11 in. Further sizes: 13-3/4 × 12 (58100-87LJ0-019), 14 × 13 (87LA1), 13-7/8 × 15 (87LB1), 13-3/4 × 17 (87LC1).
Gear oil990A0-01E81-01Q1,12—Suzuki hypoid gear oil, 1 US quart: enough for one change on the A models (0.61 l) but not on the AV (1.05 l). Suzuki’s gear lube pump 990C0-99002 fits the bottle and the gearcase plugs.

Numbers checked against the sources below on 23 October 2026. Always confirm against your serial number and exact type before ordering.

Service intervals

TaskInterval
First serviceBreak-in 10 h: for the first 2 h warm up and stay below half throttle (about 3000 rpm), for the next hour up to 4000 rpm, and for the remaining 7 h no more than 5 min at a time at full throttle. First service after 20 h or 1 month: change engine oil, oil filter and gear oil; check fuel lines, low-pressure fuel filter, outer anodes, bonding wires, battery, idle speed, propeller nut and pin; grease all points and retighten bolts12,14
Engine oil changeEvery 100 h or yearly, first time after 20 h12,14
Oil filterFirst at 20 h, then every 200 h or yearly (dealer job in the manual)12,14
Gear oil changeEvery 100 h or yearly, first time after 20 h12,14
Spark plugCheck, clean and set the gap every 100 h or yearly; no fixed replacement interval12,14
Fuel filterLow-pressure filter: check at 20 h, then every 100 h or yearly; replace every 400 h or 2 years (dealer)12,14
Fuel pre-filterWater-separating filter between tank and engine: replace the element every 12 months12,23
Raw water impellerCheck every 200 h or yearly; replace every 300 h or 3 years (dealer)12,14
ThermostatCheck every 100 h or yearly (dealer)12,14
AnodeOuter anodes: check at 20 h, then every 100 h or yearly; replace once two thirds are gone. Anodes inside the block and cylinder head: dealer check every 100 h or yearly12,14
Valve clearanceCheck every 300 h or 3 years (dealer)12,14
Idle speed checkCheck at 20 h, then every 200 h or yearly (dealer)12,14
LubricationEvery 100 h or yearly, first time after 20 h12,14
PropellerCheck propeller nut and cotter pin at 20 h, then every 100 h or yearly12,14
Bolted connectionsRetighten at 20 h, then every 100 h or yearly (dealer)12,14
Hoses & clampsBreather and fuel lines: check at 20 h, then every 100 h or yearly12,14
BatteryBattery and bonding wires: check at 20 h, then every 100 h or yearly12,14
WinterisingBefore laying up (2027 edition): change engine and gear oil; check spark plugs, fuel lines, low-pressure fuel filter, outer anodes, wiring, remote control, steering and tilt, battery, idle speed, water pump and impeller, thermostat and propeller, and retighten bolts14
Full serviceFit Suzuki’s maintenance kit every 100 h or yearly (Suzuki’s kit list)3,2

Hours or months, whichever comes first, from Suzuki’s owner’s manual 99011-88LB0 (2022, English section); the 2027 German edition adds an off-season column and keeps the same intervals. Suzuki asks for shorter intervals under hard use: frequent full throttle, long trolling or idling, muddy, sandy or shallow water, or running without warming up; long trolling also calls for more frequent oil changes. The timing chain has no service interval.

Specifications

TypeFour-stroke, DOHC with 4 valves per cylinder; oil-bathed timing chain with automatic hydraulic tensioner; multi-point sequential fuel injection24,25,22
Cylinders3, in line24,12
Displacement941 cc (57.4 cu in)24,12
Bore × stroke72.5 × 76.0 mm12,24
PowerDF60A, DF60AV: 44.1 kW (60 hp) at 5800 rpm; DF50A, DF50AV: 36.8 kW (50 hp) at 5800 rpm; DF40A: 29.4 kW (40 hp) at 5500 rpm26,22,12
Full-throttle rangeDF40A, DF40AS, DF40ASV: 5000–6000 rpm; DF50A, DF50AV, DF60A, DF60AV: 5300–6300 rpm14,12
Idle speed800 ± 50 rpm in neutral14
CoolingRaw water: rubber-impeller pump in the gearcase, thermostat, two water intakes on the gearcase26,25
Engine oil capacity2.7 l according to the owner’s manual; Suzuki USA’s catalogue gives 2.7 l without and 2.9 l with a filter change12,1
Engine oil gradeFour-stroke oil SAE 10W-40 or 10W-30, API SG to SL or NMMA FC-W; SAE 5W-30 below 5 °C; Suzuki recommends its ECSTAR marine oil12
Gear oil capacity0.61 l on the DF40A, DF40AS, DF50A and DF60A; 1.05 l on the DF40ASV, DF50AV and DF60AV14,12
Gear oil gradeSuzuki outboard gear oil or hypoid gear oil SAE 90, API GL-512
Spark plugNGK DCPR6E, 3 per engine12,3
Spark plug gap0.8–0.9 mm12
Valve clearance (cold)Intake 0.18–0.22 mm, exhaust 0.28–0.32 mm12
FuelUnleaded petrol, at least RON 91 (AKI 87), preferably without alcohol; 25 l portable tank12,14,24
GearboxF-N-R; 2.27:1 on the DF40A, DF50A and DF60A (and the old DF40/DF50), 2.42:1 High Thrust gearcase on the DF50AV and DF60AV; exhaust through the propeller hub, rubber hub in the propeller24,27,22,28
Alternator12 V 19 A, about 11.5 A already at 1000 rpm25,24
Shaft lengthS 15 in (381 mm), L 20 in (508 mm); X 25 in (635 mm) on the DF60A, DF50AV and DF60AV24,29,27
Dry weightWithout propeller and oil: DF40A, DF50A, DF60A 102 kg (S), 104 kg (L), 107 kg (X, DF60A only); DF50AV, DF60AV 115 kg (L), 118 kg (X); the Japanese manual gives 110–112 kg for the tiller versions (L)24,29,27,26
VersionsT = remote control with power trim and tilt (e.g. DF60ATL); TH and QH = tiller versions (DF60ATH, DF40AQH); V = High Thrust gearcase (DF50AV, DF60AV, DF40ASV); the last letter gives the shaft: S 15 in, L 20 in, X 25 in30,31,14,24
ModelsModel code on the plate at the clamp bracket: 04003F = DF40A, 05003F = DF50A, 06002F = DF60A26,14
Years builtDF40A, DF50A, DF60A since 2010; DF50AV and DF60AV from the 2014 model year; DF40AS and DF40ASV in the manuals from 2022; still in production3,1,12,32
PredecessorSuzuki DF40 and DF50 (1999–2010): 815 cc in-line three with DOHC, 12 valves and fuel injection, 2.2 l of engine oil; same 2.27:1 gear ratio, propellers and gear case seal kit as the A models, but its own water pump kit. The DF60 of 1998–2009 was a 1.3-litre four-cylinder shared with the DF7028,1,33
Tightening torquesSpark plugs 15–19 N·m (a new plug 1/2–3/4 turn after hand-tight); oil drain plug 10–15 N·m; gear oil plugs 9–11 N·m; propeller nut 50–60 N·m14,12

Good to know

  • Order by gearcase, not by horsepower. The DF40A, DF50A and DF60A have the standard 2.27:1 gearcase: 0.61 l of gear oil, water pump kit 17400-88L01, 11 to 11-5/8 in propellers and hardware kit 57630-94301. The High Thrust DF50AV and DF60AV take 1.05 l, water pump kit 17400-99E12, 14 in propellers, hardware kit 57630-90J10 and zinc anode 55321-90J01, so their maintenance kit is 17400-88823 instead of 17400-88813.1,2,12,13
  • An ad that only says ‘DF50’ or ‘DF60’ can mean three engines: the DF40A/50A/60A from 2010 (941 cm³, three cylinders), the older DF40/DF50 from 1999 to 2010 (815 cm³) or the DF60 of 1998–2009, a 1.3-litre four-cylinder shared with the DF70. Check the model code on the plate at the clamp bracket: 04003F, 05003F or 06002F is an A model. The old DF40/DF50 shares propellers, propeller hardware and the gear case seal kit with the A models but needs water pump kit 17400-96354.33,28,1,26,14
  • The OIL lamp flashes after the first 20 hours, again at 100 hours and then every 100 hours. After the oil change, cancel it: ignition on, pull off the emergency stop plate and pull the stop switch knob up three times within 10 seconds until a short beep sounds. You have to cancel it even if you changed the oil before the lamp came on.12
  • The timing chain runs in oil with an automatic tensioner and has no replacement interval, unlike the toothed belt of the DF25A/DF30A. On a used engine, ask instead for proof of the dealer jobs that are easy to skip: impeller every 300 hours or 3 years, valve clearance every 300 hours or 3 years and oil filter every 200 hours or yearly.25,12,34
  • Suzuki recommends a water-separating fuel filter in the line between the boat’s tank and the engine, with a new element every 12 months; Suzuki’s own unit is 65900-98J11 with element set 65910-98J01. The low-pressure filter 15410-88L00 under the cowling is a dealer item, checked every 100 hours and replaced every 400 hours or 2 years.12,13,1
  • After salt, brackish or muddy water, flush the cooling system. Either with the engine stopped, by screwing a garden hose onto the flushing port (the connector comes with the engine) and running water for about five minutes, or with the engine idling in neutral, propeller removed, using a flushing attachment over the water intakes; on the standard gearcase, tape over the extra intake hole first.12

Videos & how-tos

Links to YouTube, nothing embedded. The maker’s own channel comes first; the rest are channels we found clear and correct for this model.

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Sources

  1. assets.suzukimarine.com/wp-content/uploads/2026/10/02165300/Suzuki-PARTS-Catalog-SEP30202…
  2. suzukimarine.co.nz/images/assets/10883/1/2025_suzuki_genuine_marine_p_and_a_general_1.pdf
  3. globalsuzuki.com/marine/SuzukiUltimateRiggingSelector/2026/pdf/MAINTENANCE%20KITS_2026.pdf
  4. shop.energypowersports.ca/products/8m6012810-8m6012810-impeller-repair-kit-for-select-suz…
  5. brownspoint.com/c-133-4-stroke-water-pump-kits.aspx
  6. wakeboss.com/products/suzuki-water-pump-kit-1
  7. shop.energypowersports.ca/products/8m6012811-8m6012811-impeller-repair-kit-for-select-suz…
  8. wakeboss.com/products/suzuki-17461-96312-water-pump-impeller
  9. crowleymarine.com/suzuki/oem-parts/four-stroke-outboard/serial-range/df60a-410001/water-p…
  10. brownspoint.com/c-142-oil-filters.aspx
  11. wakeboss.com/products/suzuki-oil-filter-16510-87j02-16510-87j01-df25-30-df25-v-twin-df25a…
  12. suzukimarine.fr/documents/68
  13. globalsuzuki.com/marine/SuzukiUltimateRiggingSelector/2026/data/parts.json
  14. marine.suzuki.de/medien/bedienerhandbuecher/27my-owners/bedienerhandbuch_2027_df40a_50a_6…
  15. crowleymarine.com/suzuki/oem-parts/four-stroke-outboard/serial-range/df60a-810001/cylinde…
  16. brownspoint.com/c-62-4-stroke-anodes.aspx
  17. crowleymarine.com/suzuki/oem-parts/four-stroke-outboard/serial-range/df60a-410001/gear-ca…
  18. wakeboss.com/products/suzuki-17670-93955-thermostat-60-degree-c
  19. crowleymarine.com/suzuki/oem-parts/four-stroke-outboard/serial-range/df60a-410001/thermos…
  20. globalsuzuki.com/marine/SuzukiUltimateRiggingSelector/2026/pdf/PROPELLERS_2026.pdf
  21. brownspoint.com/c-118-df-40a-df-50a-df-60a.aspx
  22. assets.suzukimarine.com/wp-content/uploads/2022/06/21101251/DF50AV-60AV-Product-Info-Broc…
  23. marine.suzuki.de/medien/bedienerhandbuecher/k13-e01-owners-manual-all-model/k13-e01-owner…
  24. globalsuzuki.com/marine/lineup/df60a/
  25. assets.suzukimarine.com/wp-content/uploads/2022/06/21101119/SZ_40a50a60a_PIB_Web.pdf
  26. suzukimarine.co.jp/boat/download/DF40A%2050A%2060A%2099011-88LE0-000_20250408180631.pdf
  27. globalsuzuki.com/marine/lineup/df60av-50av/
  28. web.archive.org/web/20030620175032/http://www.suzukimarine.com:80/brochures/images/bro/df…
  29. globalsuzuki.com/marine/lineup/df50a-40a/
  30. marine.suzuki.co.uk/outboards/df60a/
  31. suzukimarine.com/outboard/40-90hp/df60athl/
  32. marine.suzuki.de/service-zubehoer/bedienungsanleitungen
  33. globalsuzuki.com/marine/history/
  34. globalsuzuki.com/marine/files/product-catalog.pdf

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