Suzuki DF200AP Specifications
| Engine Model: Suzuki DF200AP |
| Engine Type: 4-stroke inline 4-cylinder DOHC 16-valve gasoline outboard engine |
| Total Displacement: 175 cu.in (2.9 L) |
| Rated Engine Power: 200 Hp (147 kW) at 6000 rpm |
| Fuel System: Multi point sequential electronic fuel injection |
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The Suzuki DF200AP is a technologically
advanced 200 Hp outboard that redefines expectations for inline
four-cylinder performance. It is built around a large-displacement "big
block" inline four-cylinder powerhead with a 2,867 cc displacement and a
high 10.2:1 compression ratio, drawing upon Suzuki's extensive
motorsports experience to generate impressive acceleration and low-end
torque.
The powerhead features a DOHC 16-valve design with a maintenance-free
self-adjusting timing chain and Variable Valve Timing (VVT) that
optimizes intake valve timing to maximize torque across the low and
mid-range, delivering powerful acceleration throughout the entire
powerband. The integration of the Suzuki Lean Burn Control System,
utilizing an O2 sensor feedback loop, optimizes the air-fuel mixture for
significant fuel savings, achieving up to 19 percent greater fuel
efficiency compared to the original V6 DF200, particularly in the
cruising range around 70 percent of maximum speed.
A secondary balancer system effectively counters inherent inline
four-cylinder vibrations for exceptionally smooth engine operation
across the entire rpm range. With exclusive features including Suzuki
Precision Control drive-by-wire, a convenient keyless start system with
immobilizer, and the world-first Suzuki Selective Rotation lower unit
for perfect twin-engine setups, the DF200AP is engineered to satisfy the
demands of serious boaters seeking a reliable, efficient, and
high-performing outboard.
Engine Model: Suzuki DF200AP
Engine Type: 4-Stroke, DOHC (Double Overhead Camshaft), 16-Valve
Number of Cylinders: In-Line 4
Valve Train Drive: Self-adjusting oil-bathed timing chain with automatic
hydraulic tensioner
Bore and Stroke: 97.0 mm x 97.0 mm (3.81 in x 3.81 in)
Piston Displacement: 2867 cc (175 cu. in)
Maximum Output: 147 kW (200 Hp)
Full Throttle Operating Range: 5500-6100 rpm
Idle Speed: 600-700 rpm
Fuel Delivery System: Multi-Point Sequential Electronic Fuel Injection
with Lean Burn Control
Alternator: 12V 44A
Trim Method: Power Trim and Tilt
Gear Ratio: 2.50:1 with Two-Stage Gear Reduction
Gear Shift: F-N-R (Forward-Neutral-Reverse) via Suzuki Precision Control
Control System: Suzuki Precision Control (Digital Drive-by-Wire)
Exhaust: Through Prop Hub Exhaust
Propeller Selection: 15"-27.5" (Standard Rotation); 17"-26" (Counter
Rotation)
Starting System: Electric with Suzuki Keyless Start System
Ignition System: Fully-transistorized
Engine Lubrication: Trochoid pump pressure lubrication
Engine Oil Capacity: 8.0 L (8.5/7.0 US/Imp. qt.)
Spark Plug: NGK LKR6E
Spark Plug Gap: Standard: 0.8-0.9 mm (0.031-0.035 in)
Valve clearance (Intake): 0.23-0.27 mm (0.009-0.011 in) (cold)
Valve clearance (Exhaust): 0.30-0.34 mm (0.012-0.013 in) (cold)
Fuel Type: Alcohol-free unleaded gasoline
Minimum Fuel Octane Rating: 87 (Research method)
Compression Ratio: 10.2:1
The DF200AP is built upon a robust inline four-cylinder block with a
large displacement of 2,867 cc, making it the largest available
displacement in the 200 Hp four-cylinder four-stroke class. This
substantial "big block" displacement has a direct effect on acceleration
and torque, delivering the performance expected of a V6 outboard from a
more compact powerplant. The block is combined with a high compression
ratio of 10.2:1, drawing on Suzuki's extensive motorsports experience to
obtain great performance from a compact engine. The powerhead features a
DOHC configuration with four valves per cylinder for optimal airflow and
combustion efficiency.
A key feature is the maintenance-free, self-adjusting oil-bathed timing
chain with an automatic hydraulic tensioner, ensuring precise valve
timing over the engine's life without requiring periodic adjustments.
The Variable Valve Timing (VVT) system, hydraulically controlled by oil
pressure, optimizes intake valve timing to maximize torque in the low
and mid-range. The system starts with an innovative cam profile designed
for delivering maximum output and performance at high rpm, with VVT used
to vary intake timing with the camshaft to optimize timing for low to
mid-range operation, allowing the engine to deliver maximum power output
across its entire operating range.
To neutralize the secondary vibration inherent to high-rpm operation in
inline four-cylinder engines, Suzuki engineers utilize a secondary
balancer system that counters the piston's movement with a horizontal
motion. The balancer is divided into left and right sections, each
rotating in an opposite direction at twice the speed of the crankshaft,
effectively countering the secondary vibrations and producing remarkably
smooth engine operation.
The offset driveshaft design, pioneered by Suzuki, positions the
crankshaft in front of the driveshaft, moving the outboard's center of
gravity forward. This contributes greatly to the outboard's overall
compactness and improved weight distribution on the boat's transom,
while also moving the engine's axis of inertia up over the upper engine
mount, thus greatly reducing vibration. A combination of soft-type and
high-thrust rubber mounts on both the upper and lower mounts further
reduces engine vibration and provides stable operation, with soft mounts
absorbing vibrations in the idle through 2,000 rpm range while
high-thrust mounts deliver stable operation under high loads.
The DF200AP's fuel system is highlighted by the Suzuki Lean Burn Control
System, an intelligent fuel delivery technology that achieves remarkable
improvements in fuel consumption. Monitoring engine performance and
operating conditions in real time, the system uses a 32-bit onboard
Engine Control Module (ECM) to predict fuel needs and deliver a leaner,
more precise fuel mixture across the outboard's operating range. The
results show significant improvements in fuel economy across the entire
powerband, including the cruising range where the engine is used a
majority of the time. Comparing the DF200AP with the original V6 DF200,
tests show up to a 19 percent increase in fuel efficiency mainly in the
cruising range around 70 percent of maximum speed.
The Multi-Point Sequential Electronic Fuel Injection system precisely
meters fuel to each cylinder for optimal combustion. The O2 Sensor
Feedback Control system monitors engine operating conditions to provide
input to the ECM, allowing it to manage the fuel-air mixture for maximum
performance across the engine's full operating range. A Knock Sensor
monitors combustion to provide the ECM with information needed for
precise management of engine timing for optimum performance, maximizing
power output while also helping to increase engine durability.
A specially designed cowl incorporates a semi-direct air intake system
that delivers cooler air directly to the engine's tuned multi-stage
induction module. Engines breathing cooler air are able to increase
operating efficiency, resulting in greater acceleration and top-end
speed. The cowl's design also helps reduce the temperature inside the
engine with ports that allow the rotating flywheel to push warm air to
the outside.
The engine also features an air intake resonator that reduces noise
generated by air being sucked at high velocities into the intake
manifold, keeping operation exceptionally quiet. In a noise comparison
test between the DF200A and a competing 200 Hp inline four-stroke
outboard, the results clearly show that the DF200AP runs quieter than
its competitor.
The DF200AP employs a trochoid pump pressure lubrication system to
ensure consistent pressurized oil delivery to all critical engine
components, including the crankshaft, connecting rods, and the valve
train with its VVT components. The engine has a substantial oil capacity
of 8.0 liters.
Engine temperature is managed by a reliable water-cooled system. A water
pump, located in the lower unit, draws water from the surrounding
environment and circulates it through water jackets in the cylinder
block and powerhead. For post-operation maintenance, the Fresh Water
Flushing System with dual freshwater flush ports allows easy connection
of a garden hose to rinse salt, sand, and other debris from the cooling
passages, protecting the engine from corrosion.
With one port located on the port side of the down housing and a second
on the front panel, access is convenient whether the boat is in or out
of the water. The Suzuki Water Detecting System utilizes a
water-detecting fuel filter to alert the operator with both visual and
audio warnings when water is present in the fuel, preventing issues like
poor combustion, power loss, and corrosion.
| Mid Section and Lower Unit |
The mid-section houses the offset driveshaft, which contributes to the
engine's forward center of gravity and compact mounting footprint. The
lower unit features a robust gearcase designed for the innovative Suzuki
Selective Rotation system, available exclusively on the DF200AP model.
This world-first technology incorporates a special, unified design of
gears, shafts, and bearings in the lower unit that allow the outboard to
operate reliably and efficiently in either standard or counter-rotation
direction.
For boats equipped with twin outboards, this eliminates the need to
purchase a dedicated counter-rotation model; the DF200AP can be switched
to counter-rotation mode by installing an optional activation switch
that connects to a circuit inside the engine compartment plus the
installation of a counter-rotation propeller.
The lower unit utilizes a two-stage gear reduction system designed to
take maximum advantage of the power produced by the high-performance
engine. Providing a final drive ratio of 2.50:1, one of the largest in
its class, it delivers powerful torque for quick acceleration and great
top-end speed. The Multi-Stage Induction (MSI) system ensures the engine
gets the right amount of air by utilizing two intake manifold pipes per
cylinder.
At low rpm, air enters the combustion chamber through a longer, curved
manifold pipe designed to improve combustion and boost low-end torque.
As rpm increases, valves open on the direct intake pipes, which are
shorter and lack resistance, allowing a greater volume of air into the
chamber for higher power output during high-speed operation. Exhaust
gases are channeled through the propeller hub for quieter operation.
The Power Trim and Tilt (PTT) system provides hydraulic control over the
outboard's angle, allowing the operator to adjust boat trim for optimal
performance, fuel efficiency, and ride comfort. The system consists of
an electric motor, pump unit, fluid reservoir, and trim/tilt cylinders.
The Tilt Limit System incorporates a user-adjustable tilt limit switch
that prevents the outboard from tilting beyond a predetermined point,
protecting both the engine and boat from damage that can occur when
tilting the motor.
The system includes an impact relief valve as a safety feature to
protect the gearcase and prevent internal PTT pressure build-up in the
event of an underwater impact. When pressure from a sudden impact makes
the impact relief valve open, oil from the upper area of the tilt
cylinder flows into the area between the tilt rod piston and the free
piston, allowing the tilt rod to extend. A manual release valve allows
the engine to be raised or lowered manually in case of electrical system
failure.
Proper trim angle adjustment is critical for maintaining steering
stability. If engine speed exceeds approximately 1500 r/min when
operating in shallow water drive mode, a relief valve opens to allow
high internal pressure to be relieved and the engine slowly tilts
downward until it reaches the highest position in the trim range.
The DF200AP is designed to work with a range of high-performance
stainless steel propellers to match various boat types and load
conditions. The recommended propeller pitch selection ranges from 15
inches to 27.5 inches for standard rotation models, and from 17 inches
to 26 inches for counter-rotation applications.
All propellers are of the three-blade type. The Watergrip Propeller,
featuring an interchangeable square-shaped bush, offers efficient
conversion of engine power to propulsion resulting in better grip and
performance.
Transom Height (Long Shaft - L): 508 mm (20 in)
Transom Height (Extra Long Shaft - X): 635 mm (25 in)
Dry Weight (Long Shaft - L): 236 kg (520 lbs)
Dry Weight (Extra Long Shaft - X): 241 kg (530 lbs)
Engine Mounting: Shear Mount system with rubber dampers
Initial Service: Perform at 20 hours or 1 month.
Engine Oil: Change every 100 hours or 12 months.
Engine Oil Capacity: 8.0 L (8.5 US qt.) with filter; 8.5 L (9.0 US qt.)
when replacing filter.
Engine Oil Filter: Replace every 200 hours or 12 months.
Recommended Engine Oil: 4-stroke motor oil, NMMA certified FC-W oil, or
API classification SG, SH, SJ, SL, SM.
Viscosity rating SAE 10W-40 or 10W-30, NMMA FC-W 10W-40 or 10W-30.
Gear Oil: Replace every 100 hours or 12 months.
Gear Oil Capacity: 1,100 ml (37.2 US oz).
Recommended Gear Oil: Suzuki Outboard Motor Gear Oil or API
classification GL5.
Viscosity rating SAE 90 Hypoid gear oil.
Spark Plugs: NGK LKR6E. Inspect every 100 hours or 12 months.
Spark Plug Gap: Standard: 0.8-0.9 mm (0.031-0.035 in).
Spark Plug Torque: 17 Nm (12.3 lb-ft).
Valve Clearance (Intake): 0.23-0.27 mm (0.009-0.011 in) (cold); inspect
every 300 hours or 36 months.
Valve Clearance (Exhaust): 0.30-0.34 mm (0.012-0.013 in) (cold); inspect
every 300 hours or 36 months.
Low Pressure Fuel Filter: Inspect every 100 hours or 12 months; replace
every 400 hours or 2 years.
High Pressure Fuel Filter: Replace every 1,000 hours.
Water Pump Impeller: Inspect every 200 hours or 12 months; replace every
300 hours or 36 months.
Balancer Chain: Replace every 1,600 hours.
Anodes (external): Inspect every 100 hours or 12 months.
Battery: Check fluid level every 100 hours or 12 months if not using a
maintenance-free battery; add distilled water only as needed.
Engine Oil Drain Plug: 13 Nm (9.5 lb-ft)
Engine Oil Filter: 14 Nm (10.0 lb-ft)
Spark Plugs: 17 Nm (12.3 lb-ft)
The Suzuki DF200AP is an exceptionally versatile outboard, suitable for
a wide range of boat types. Its design emphasis on low-end torque, light
weight (30 kg less than the V6 version), compact dimensions, and the
availability of Selective Rotation makes it a preferred choice for many
applications. Bass Boats and High-Performance Fishing Boats: An ideal
primary power source for bass boats, bay boats, and center consoles in
the 18 to 23-foot range, where the light weight and powerful
acceleration deliver exceptional performance.
Pontoon Boats: A popular choice for powering pontoon boats, where its
strong torque provides excellent acceleration and efficient cruising for
leisurely days on the water with family and friends. Lightweight
Cruisers and Deck Boats: Suitable for smaller cabin cruisers and deck
boats where a balance of power, weight, and fuel economy is essential.
Repowering Older Boats: An excellent choice for those wanting to upgrade
older boats originally fitted with V6 two-stroke engines, giving them
the latest in four-stroke technology and economy without sacrificing
weight or power.
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