Suzuki DF5A Specifications
| Engine Model: Suzuki DF5A |
| Engine Type: 4-stroke 1-cylinder OHV gasoline outboard engine |
| Total Displacement: 8.4 cu.in (138 cc) |
| Rated Engine Power: 5 Hp (3.7 kW) at 5500 rpm |
| Fuel System: Carburetor |
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The Suzuki DF5A is a technologically advanced
portable outboard that redefines expectations for small four-stroke
engines. It is engineered to deliver surprising low- and mid-range
torque for quick acceleration while maintaining the fuel efficiency and
quiet operation characteristic of four-stroke design. Owners benefit
from innovative features including a three-way storage system that
allows the engine to be laid on any side without fuel or oil leaks, an
overhead integral fuel tank that enables gravity-fed starting even after
long-term storage, and a redesigned tiller handle that minimizes
vibration transmission.
The engine's compact dimensions and lightweight construction, with the
short shaft model weighing only 24.0 kg, make it exceptionally easy to
transport and operate. Whether powering small inflatables, yacht
tenders, or fishing dinghies, the Suzuki DF5A combines modern technology
with proven durability to elevate the small boat experience.
The Suzuki DF5A is built around a single-cylinder overhead valve
four-stroke powerhead utilizing a carbureted fuel delivery system. This
engine represents a complete redesign of Suzuki's portable outboard
lineup, achieving a one-kilogram weight reduction compared to previous
models while maintaining the same 138 cc displacement. The engine is
available in both short shaft and long shaft configurations to
accommodate different transom heights.
Engine Model: Suzuki DF5A
Engine Type: Single-cylinder, 4-stroke OHV gasoline outboard engine
Number of Cylinders: 1
Displacement: 8.42 cu in (138 cc)
Cylinder Bore: 2.38 in (60.4 mm)
Piston Stroke: 1.89 in (48.0 mm)
Maximum Engine Power: 5.0 hp (3.7 kW) at the propeller
Maximum Engine Speed: 4500-5500 RPM
Idle Speed: 1250-1350 RPM
Fuel System Type: Carburetor with manual choke
Fuel Pump Type: Mechanical
Fuel Type: Unleaded gasoline, 91 octane minimum RON
Fuel Tank Capacity: 1.1 quarts (1.0 liter) integral overhead tank
Lubrication System: Trochoid pump with forced lubrication and oil filter
Engine Oil Capacity: 0.75 quarts (0.70 liters)
Engine Oil Type: SAE 10W-30 or 10W-40
API Service Classifications: SH, SG, SJ, SM, SL, and SN
Cooling System: Water-cooled with thermostat and fresh water flushing
system
Ignition System: Digital CDI microcomputer with over-rev limiter
Starting System: Manual recoil start
Choke System: Manual
Electrical System Rating: 12 Volts
Charging System: Optional alternator
Alternator Rating: 12V 5A optional
Steering System: Tiller handle with vibration mitigation design
Gear Shift: Forward-Neutral-Reverse (F-N-R)
Gear Ratio: 1.92:1
Gear Oil Capacity: 0.20 quarts (0.19 liters)
Gear Lubricant Type: Suzuki Outboard Motor Gear Oil or GL5 SAE 90
Exhaust System: Above propeller exhaust
Trim System: Manual trim and tilt with five tilt pin positions
Transom Height (Short Shaft): 15 inches (381 mm)
Transom Height (Long Shaft): 20 inches (508 mm)
Outboard Weight (Short Shaft): 52.8 lbs (24.0 kg) dry weight, not
including propeller and engine oil
Outboard Weight (Long Shaft): 55 lbs (25.0 kg) dry weight
Spark Plug Type: NGK CPR6EA-9 resistor type
Spark Plug Gap: 0.031-0.035 in (0.8-0.9 mm)
Valve Lash (Intake): 0.005-0.007 in (0.13-0.17 mm) cold
Valve Lash (Exhaust): 0.005-0.007 in (0.13-0.17 mm) cold
Propeller Selection Range: 6 to 7 inches of pitch
Emissions Compliance: CARB 3-Star, EU compliant, conforms to world's
strictest standards
The powerhead of the Suzuki DF5A features a single-cylinder block with
an overhead valve (OHV) design. The cylinder bore measures 60.4 mm, and
the piston stroke is 48.0 mm, contributing to the engine's 138 cc
displacement. An innovative offset crankshaft design positions the
crankshaft slightly off-center of the cylinder, reducing lateral
pressure against the cylinder wall as the piston moves up and down,
resulting in smoother piston movement and improved operating efficiency.
The valve train includes intake and exhaust valves with rocker arms, and
the rocker arm design has been modified to eliminate excessive play,
contributing to reduced noise levels. The crankshaft bearing utilizes a
plane type rather than a common ball type, further reducing noise and
vibration. The cylinder head is secured with bolts requiring proper
torque during service. Valve lash for both intake and exhaust valves
must be maintained at 0.13 to 0.17 mm cold, requiring periodic
inspection and adjustment.
The fuel system is centered around a carburetor with manual choke
control. A revolutionary overhead integral fuel tank with a capacity of
1.0 liter is positioned directly above the carburetor, enabling gravity
fuel supply without requiring a primer bulb or external tank.
This gravity-fed system allows the engine to start instantly right after
filling fuel, even after extended storage periods, without opening the
engine cover. The fuel tank incorporates a one-way valve and redesigned
fuel cap with integrated venting. The fuel system includes a mechanical
fuel pump and an in-line fuel filter requiring inspection every 100
hours and replacement every 400 hours.
The breather and fuel lines must be checked every 100 hours for leaks,
cracks, swelling, or other damage. The new fuel system design, combined
with the advanced lubrication system, enables the three-way storage
capability that allows the outboard to be transported or stored on any
of three sides (port, starboard, or front) without fuel or oil leakage.
Lubrication is managed by a trochoid pump providing forced lubrication
throughout the engine. The system incorporates an additional oil passage
to the upper and lower crankshaft and connecting rod big end, ensuring
all critical components receive adequate lubrication. A first-in-class
oil filter greatly increases the reliability of the lubrication system.
The oil pan has a capacity of 0.70 liters, and a strategically
positioned oil window allows for visual confirmation of the actual
lubricating condition. Recommended engine oil is SAE 10W-30 or 10W-40
meeting API service classifications SH, SG, SJ, SM, SL, or SN. Engine
oil must be changed every 100 hours of operation, with the oil filter
replaced every 200 hours.
To change engine oil, the motor must be placed in a vertical position
with the engine warm, the oil filler cap removed, and the engine oil
drain plug removed to allow thorough draining. A new gasket must be used
when reinstalling the drain plug to prevent leaks.
The cooling system is a water-cooled design with thermostat regulation
to maintain optimal operating temperature and includes a fresh water
flushing system. A water pump, driven by the driveshaft, circulates
water from the surrounding environment through cooling passages in the
cylinder block and cylinder head. The system includes a fresh water
flushing port for easy maintenance after saltwater use.
The thermostat must be checked every 100 hours as part of routine
maintenance. The water pump and water pump impeller require inspection
every 200 hours, with the impeller scheduled for replacement every 300
hours to maintain proper cooling system performance.
When flushing the water passages, the engine should be run at about 1500
RPM in neutral for five minutes with water supplied to the cooling
system. Severe engine damage can occur in as little as 15 seconds if the
engine is started without supplying water to the cooling system.
| Mid Section and Lower Unit |
The mid-section houses the driveshaft and exhaust tube, connecting the
powerhead to the lower unit. The exhaust system routes exhaust gases
above the propeller hub. The lower unit contains the gearcase with a
1.92:1 reduction ratio and forward-neutral-reverse shifting mechanism.
The gearcase has a lubricant capacity of 0.19 liters (0.20 quarts) and
requires Suzuki Outboard Motor Gear Oil or GL5 SAE 90 gear lubricant. To
change gear oil, the motor must be in an upright position, both the
drain plug and upper level plug removed, and after complete drainage,
new oil injected into the lower drain hole until it just starts to come
out of the upper hole. Approximately 190 ml of oil will be required.
If fishing line wraps around the rotating propeller shaft, the propeller
shaft oil seal can become damaged and allow water to enter the gear case
causing severe damage; if the gear oil has a milky color, it is
contaminated with water. The propeller shaft incorporates an anode for
corrosion protection, with the propeller nut and pin requiring
inspection every 100 hours.
The Suzuki DF5A is equipped with manual trim and tilt adjustment. The
system features a tilt pin that can be repositioned in one of five holes
to achieve the desired trim angle. To adjust the trim angle, the motor
is held in the fully tilted up position, the tilt pin is repositioned in
the desired holes, and the motor is lowered back down.
Moving the pin towards the boat lowers the bow, while moving the pin
away from the boat raises the bow. The tilt system offers different
up-and-down paths of the shallow drive arm compared to previous models,
with three locking positions when raised and smooth lowering without
locking.
Proper trim angle is essential for steering stability and performance;
an incorrect angle can cause the boat to plow, porpoise, or chine walk,
potentially resulting in loss of steering control. The motor must not be
operated with the tilt pin removed. The steering tension can be adjusted
using the steering tension adjuster to achieve smooth operation with
slight resistance.
Proper propeller selection is critical to allow the engine to operate
within its specified full-throttle RPM range of 4500 to 5500 RPM under
normal load conditions. The propeller selection range is 6 to 7 inches
of pitch. All propellers for this model are three-blade type.
The standard propeller material is aluminum. The propeller nut and
retaining pin must be checked every 100 hours to ensure secure
attachment. Specific propeller details should be confirmed with local
dealers for exact applications.
Overall Weight (Short Shaft): 52.8 lbs (24.0 kg) dry weight, not
including propeller and engine oil
Overall Weight (Long Shaft): 55 lbs (25.0 kg) dry weight
Shaft Length (Short Shaft Model): 15 inches (381 mm)
Shaft Length (Long Shaft Model): 20 inches (508 mm)
Propeller Diameter: 7.5 inches (190 mm) standard
Propeller Pitch: 6 to 7 inches selection range
Every 100 hours or 12 months:
Change engine oil
Change gear oil
Check spark plug condition and gap
Check breather and fuel line condition
Check fuel filter for contamination
Check anodes for corrosion
Check thermostat operation
Check carburetor adjustment and condition
Check propeller nut and pin security
Every 200 hours or 12 months:
Replace oil filter
Check and adjust valve lash
Check and adjust idle speed
Check water pump operation
Check water pump impeller condition
Inspect and tighten bolts and nuts
Every 300 hours or 36 months:
Replace spark plug
Replace water pump impeller
Every 400 hours or 2 years:
Replace fuel filter
Recommended Fuel: Unleaded gasoline, 91 octane minimum RON
Recommended Engine Oil: SAE 10W-30 or 10W-40 meeting API SH, SG, SJ, SM,
SL, or SN
Engine Oil Capacity: 0.75 quarts (0.70 liters)
Recommended Gear Lubricant: Suzuki Outboard Motor Gear Oil or GL5 SAE 90
Gearcase Capacity: 0.20 quarts (0.19 liters)
Spark Plug Type: NGK CPR6EA-9 resistor type
Spark Plug Gap: 0.031-0.035 in (0.8-0.9 mm)
The Suzuki DF5A is a highly versatile powerplant suitable for a broad
spectrum of small boat types and boating activities. It is an ideal
choice for small inflatables, fishing dinghies, and yacht tenders up to
approximately 3.5 meters in length. The engine is perfect for
square-stern canoes or small sailboats needing a light auxiliary power
source. Its compact size and lightweight construction make it excellent
for camping and water trekking where portability and easy transport are
paramount. The engine is well-suited for beginner boaters thanks to its
simple handling and reliable operation.
The DF5A can be easily carried and mounted by one person, making it
ideal for solo boaters and those with limited physical assistance. The
integrated carrying handle in the lower cover, combined with an
additional front grip, provides convenient two-handed carrying
capability. With its four-stroke efficiency, the engine sips fuel and
runs cleanly, meeting all emission standards while providing strong
low-end torque for planing small boats.
The 180-degree steering capability allows the engine to swivel a full
circle for reverse thrust, enhancing maneuverability in tight quarters.
The redesigned tiller handle successfully mitigates vibrations that
contribute to fatigue and stress during operation, particularly
excelling in the mid-range. Whether navigating small lakes, exploring
coastal waters, fishing backwaters, or providing reliable auxiliary
power, the Suzuki DF5A offers the power, precision, and efficiency to
elevate any small boat experience.
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