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Suzuki DF4 / DF5 / DF6 service guide

Oil, gear oil, spark plugs and the service schedule for the Suzuki DF4 / DF5 / DF6 (4 to 6 hp, four-stroke), from the factory service manual, plus how we service it in Hawaiʻi.

Models covered: Suzuki DF4 (prefix 00401F), DF5 (00501F) and DF6 (00601F) four-strokes, 1 cylinder OHV, 138 cm³, carburetor, manual start, tiller.

Quick answers

How much oil does a Suzuki DF4 / DF5 / DF6 take?
0.7 L (0.74/0.62 US/Imp. qt).
What engine oil does a Suzuki DF4 / DF5 / DF6 use?
API SE, SF, SG, SH or SJ, SAE 10W-40.
What gear oil does a Suzuki DF4 / DF5 / DF6 use, and how much?
Suzuki Outboard Motor Gear Oil or SAE #90 hypoid gear oil. Quantity: 190 ml (6.4/6.7 US/Imp. oz).
What spark plug does a Suzuki DF4 / DF5 / DF6 use?
NGK BPR6ES (resistor type only), qty 1. Gap: 0.7 to 0.8 mm (0.028 to 0.031 in).
How often should a Suzuki DF4 / DF5 / DF6 be serviced?
The factory schedule lists: Initial 20 hours; Every 50 hours; Every 100 hours; Every 200 hours. In Hawaiʻi's salt water we do a full yearly service every 200 hours or 1 year, whichever comes first, and a new engine needs its first (break-in) service.
When should the water pump impeller be replaced on a Suzuki DF4 / DF5 / DF6?
The factory schedule says to replace it at 200 hours, and we follow that. In any case we never let it go longer than a year in Hawaiʻi's salt water.
What is the idle speed of a Suzuki DF4 / DF5 / DF6?
DF4/DF5: 1300 ± 50 r/min (in gear approx. 1150); procedure says 1250 to 1350 r/min. DF6 Mikuni carb: 1350 ± 50 (in gear approx. 1250); DF6 Keihin carb: 1300 ± 50 (in gear approx. 1200).
What is the propeller nut torque on a Suzuki DF4 / DF5 / DF6?
Nut and cotter pin; Use a new cotter pin and bend it securely.

Maintenance specs

Engine oilAPI SE, SF, SG, SH or SJ, SAE 10W-40
Engine oil quantity0.7 L (0.74/0.62 US/Imp. qt)
Engine oil filterInside the crankcase (power unit must come off); inspect and clean every 200 hours, replace if needed.
Engine oil drain plug10 N·m (1.0 kg-m, 7.0 lb-ft), new gasket
Gear oilSuzuki Outboard Motor Gear Oil or SAE #90 hypoid gear oil
Gear oil quantity190 ml (6.4/6.7 US/Imp. oz)
Gearcase leak test100 kPa (1.0 kg/cm², 14.2 psi), hold 5 minutes; do not exceed 110 kPa (15.6 psi)
Spark plugNGK BPR6ES (resistor type only), qty 1
Spark plug gap0.7 to 0.8 mm (0.028 to 0.031 in)
Spark plug torque28 N·m (2.8 kg-m, 20.0 lb-ft)
Idle speed, neutralDF4/DF5: 1300 ± 50 r/min (in gear approx. 1150); procedure says 1250 to 1350 r/min. DF6 Mikuni carb: 1350 ± 50 (in gear approx. 1250); DF6 Keihin carb: 1300 ± 50 (in gear approx. 1200)
ThermostatOperating temperature 48 to 52 °C (118 to 126 °F)
Propeller nutNut and cotter pin; Use a new cotter pin and bend it securely
Valve clearance, coldIN and EX 0.03 to 0.07 mm (0.001 to 0.003 in); lock nut 11 N·m (1.1 kg-m, 8.0 lb-ft)

Service schedule

The factory maintenance intervals, with what is replaced and what is checked at each. Rows marked Hawaiʻi are our shop's yearly service for salt water use.

  1. Initial 20 hours

    Replace: engine oil, oil drain plug gasket, gear case oil, gear case plug gaskets, propeller cotter pin

  2. Every 50 hours

    Replace: gear case plug gaskets

    Check: anodes

  3. Every 100 hours

    Replace: engine oil, oil drain plug gasket, gear case oil, gear case plug gaskets, propeller cotter pin

    Check: anodes

  4. Every 200 hours

    Replace: engine oil, oil drain plug gasket, spark plugs, gear case oil, gear case plug gaskets, propeller cotter pin, water pump impeller

    Check: oil filter, anodes

Source: Suzuki DF4/5 service manual, 99500-91J00-01E; Suzuki DF4/5/6 supplementary service manual for the 2004 K4 model, 99501-91J10-01E. Specs can change by model year and serial number, so always confirm your exact model from the serial tag on the clamp bracket.

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