Suzuki DF9.9 Specifications
| Engine Model: Suzuki DF9.9 |
| Engine Type: 4-stroke 2-cylinder SOHC gasoline outboard engine |
| Total Displacement: 18.4 cu.in (302 cc) |
| Rated Engine Power: 9.9 Hp (7.3 kW) at 5500 rpm |
| Fuel System: Carburetor |
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The Suzuki DF9.9 is recognized for its
lightweight and compact design, which has been achieved through
extensive engineering refinements to make it easier to carry and
transport than its predecessors. The engine is built with a focus on
fuel efficiency, leveraging Suzuki's four-stroke technology to deliver
greater range on less fuel. Its operation is noted for quiet
performance, aided by through-propeller hub exhaust, contributing to a
more comfortable boating experience.
The engine is available in both manual and electric start
configurations, as well as short and long shaft lengths to accommodate
various transom heights. Built with Suzuki's anti-corrosion system, it
is suitable for use in both freshwater and saltwater environments, with
features like a freshwater flush port for easy maintenance after
saltwater use. It is an ideal power source for small fishing boats, jon
boats, tenders, and inflatable craft.
Engine Model - Suzuki DF9.9, DF9.9E, DF9.9R
Engine Type - 4-stroke two-cylinder SOHC gasoline outboard engine
Number of Cylinders - 2
Displacement - 302 cc (18.4 cu-in)
Cylinder Bore - 58.0 mm (2.28 in)
Piston Stroke - 57.0 mm (2.24 in)
Maximum Engine Power - 7.3 kW (9.9 hp)
Full Throttle Operating Range - 4900 - 5500 r/min
Idle Speed - 850 - 950 r/min (900±50)
Compression Ratio - 9.0:1
Fuel System Type - Carburetor
Carburetor Model - Keihin BCM 23-11.5
Fuel Type - Unleaded gasoline (87 or 91 octane minimum)
Ignition System - Digital CDI
Cooling System - Water-cooled
Exhaust System - Through propeller hub
Starting System - Manual recoil or electric
Choke System - Manual or automatic
Throttle Control - Twist grip or remote control
Gear Shift - Forward - Neutral - Reverse
Gear Ratio - 2.08:1
Steering System - Tiller Handle or Remote Control
Trim and Tilt System - Manual, 5 tilt pin positions
Transom Height (Short Shaft) - 381 mm (15 in)
Transom Height (Long Shaft) - 508 mm (20 in)
Trim Angle - 4-20 degrees
Maximum Tilt Angle - 67 degrees
Dry Weight (Short Shaft, Manual) - 44.0 kg (97.0 lbs)
Dry Weight (Short Shaft, Electric) - 48.0 kg (105.7 lbs)
Dry Weight (Long Shaft, Manual) - 45.0 kg (99.0 lbs)
Dry Weight (Long Shaft, Electric) - 49.0 kg (108.0 lbs)
Alternator Rating - 12V 6A (12A on some models)
The powerhead is constructed around an inline two-cylinder configuration
with a displacement of 302 cc. The cylinder bore inside diameter
measures 58.000-58.015 mm, with a maximum permissible out-of-round of
0.050 mm. The piston skirt diameter is 57.965-57.980 mm, resulting in a
piston-to-cylinder clearance of 0.0271-0.0425 mm. The piston pin outside
diameter is 13.995-14.000 mm, with a piston pin bore inside diameter of
14.002-14.008 mm, providing a clearance of 0.002-0.013 mm.
The connecting rod big end inside diameter is 29.025-29.034 mm, with a
crank pin outside diameter of 28.989-29.000 mm, resulting in an oil
clearance of 0.025-0.045 mm. Connecting rod side clearance at the big
end is 0.10-0.20 mm. The crankshaft journal outside diameter is
31.989-32.000 mm with an oil clearance of 0.020-0.047 mm. Maximum
crankshaft runout is 0.040 mm and crankshaft thrust play is 0.6 mm.
The piston rings include a top ring, second ring, and oil ring. The top
and second rings have a width of 1.21-1.23 mm. The top and second ring
end gap is 0.10-0.25 mm. Top and second ring side clearance is 0.02-0.06
mm. The engine mounting utilizes a shear mount design to isolate and
dampen vibration from the hull.
The cylinder head incorporates a Single OverHead Camshaft (SOHC) valve
train with two valves per cylinder. The SOHC is mounted over the
cylinder head and driven by the crankshaft through a timing belt. This
design allows for more direct valve movement without the delay
associated with pushrod systems. The cylinder head warp limit is 0.050
mm. Intake valve head diameter is 26.0 mm, and exhaust valve head
diameter is 22.0 mm.
Minimum valve head thickness for both valves is 0.50 mm. The intake
valve stem outside diameter is 5.475-5.490 mm, while the exhaust valve
stem is 5.450-5.465 mm. Valve guide inside diameter for both valves is
5.500-5.512 mm. Intake valve stem-to-guide clearance is 0.010-0.037 mm,
and exhaust clearance is 0.035-0.062 mm. Valve seat width for both
intake and exhaust is 0.9-1.1 mm.
The valve spring free length is 32.52 mm. Intake cam height is
23.394-23.454 mm, and exhaust cam height is 23.397-23.457 mm. Camshaft
journal outside diameter is 24.959-24.980 mm for the upper journal and
22.959-22.980 mm for the lower, with an oil clearance of 0.020-0.062 mm.
Valve clearance is set to 0.18-0.22 mm for both intake and exhaust
valves.
The DF9.9 features a reliable carburetted fuel delivery system using a
Keihin BCM 23-11.5 carburetor. A mechanical fuel pump draws fuel from a
standard 12-liter remote fuel tank. For cold starts, a choke system is
employed - manual for the standard models and automatic on some
electric-start variants.
The fuel system also includes a fuel filter that requires periodic
inspection. The engine is designed to run on unleaded gasoline with a
minimum octane rating of 87. A twist-grip throttle on tiller models
allows for smooth and precise engine speed control.
The lubrication system is a pressure-fed wet sump design utilizing a
trochoid-type cam-driven oil pump to ensure reliable oil delivery to all
critical engine components. This pressurised system reduces friction and
wear, enhancing engine longevity.
The engine includes a replaceable cartridge-style oil filter. Engine oil
capacity is 1.00 liter of SAE 10W-40 oil, meeting API service
classifications SE through SJ. A low oil pressure warning system
protects the engine from operation with insufficient oil pressure. An
oil level check is facilitated through a dipstick.
Engine temperature is regulated by a water-cooled system. Cooling water
is drawn into the engine through intakes on the gearcase and circulated
by a rubber impeller water pump. A thermostat maintains optimal
operating temperature for combustion efficiency and performance.
The system includes a fresh water flushing port, allowing owners to
easily flush cooling passages with fresh water after use in salt or
polluted water. An overheat warning system alerts the operator to
cooling system malfunctions. A tell-tale port provides visible
confirmation that the cooling system is operational.
| Mid Section and Lower Unit |
The mid-section houses the driveshaft and provides the mounting
interface to the transom bracket via the engine mounting system. The
lower unit contains the gearcase, which is filled with 0.17 liters of
Suzuki Outboard Motor Gear Oil or GL5 SAE 90 gear oil.
The gears provide a reduction ratio of 2.08:1, optimizing propeller
speed for effective thrust. The shift mechanism enables smooth and
positive engagement of Forward, Neutral, and Reverse gears. Exhaust
gases are expelled through the propeller hub for quieter operation.
Trim and tilt adjustments are performed manually with 5 tilt pin
positions. The manual tilt system uses a pin in one of several
adjustment positions on the transom bracket, allowing the operator to
select the optimal trim angle for the boat's running attitude under
various load and water conditions.
The trim angle range is 4-20 degrees, with a maximum tilt angle of 67
degrees. A tilt release lever disengages the lock for tilting the engine
out of the water for beaching, trailering, or storage.
The DF9.9 is designed to use three-bladed aluminum propellers. The
propeller diameter is 235 mm (9.25 in). A wide range of propeller
pitches is available from 7 inches to 11 inches to accommodate different
boat and loading conditions.
Selecting the correct pitch is crucial for allowing the engine to
operate within its recommended full-throttle RPM range of 4900-5500 for
optimal performance and efficiency.
The overall length is 668.0 mm (26.3 in), overall width is 323.0 mm
(12.7 in). The short shaft model, designed for a 381 mm (15 in) transom,
has an overall height of 1095.0 mm (43.1 in) and a dry weight of 44.0 kg
(97.0 lbs) for the manual start version.
The long shaft model, for a 508 mm (20 in) transom, has an overall
height of 1220.0 mm (48.0 in) and a dry weight of 45.0 kg (99.0 lbs)
with manual start. Electric start models are heavier, with the short
shaft version weighing 48.0 kg (105.7 lbs) and the long shaft version
weighing 49.0 kg (108.0 lbs).
Every 100 hours of operation or 12 months, the following tasks should be
performed: change engine oil, change gear oil, check and clean the spark
plug (adjusting the gap to 0.7-0.8 mm or 0.028-0.031 in), inspect the
fuel line and breather for leaks or cracks, check the fuel filter,
inspect the condition of the sacrificial anodes, verify thermostat
operation, check the carburetor, and check the propeller nut and cotter
pin. On electric start models, the battery should also be checked.
Every 200 hours, in addition to the 100-hour checks, the engine requires
replacement of the oil filter, inspection and adjustment of valve
clearance, inspection of the timing belt, checking and adjusting the
idle speed, inspecting the water pump and its impeller, and replacement
of the spark plug.
Every 400 hours, the in-line fuel filter should be replaced. Engine oil
capacity is 1.00 liter of SAE 10W-40 oil meeting API SE through SJ.
Gearcase capacity is 0.17 L of Suzuki Outboard Motor Gear Oil or GL5 SAE
90. Spark plug type is NGK BKR6E with a gap of 0.7-0.8 mm. Valve
clearance (cold) is 0.18-0.22 mm for both intake and exhaust. Ignition
timing is 5-30 degrees BTDC.
0Cylinder head bolt - 27 Nm (20.0 lb-ft)
Cylinder head cover bolt - 10 Nm (7.0 lb-ft)
Crankcase bolt - 14 Nm (10.5 lb-ft)
Connecting rod cap bolt - 12 Nm (8.5 lb-ft)
Flywheel nut - 80 Nm (58.0 lb-ft)
Spark plug - 10-12 Nm (7.5-9.0 lb-ft)
Valve adjusting lock nut - 11 Nm (8.0 lb-ft)
Intake manifold bolt - 23 Nm (16.5 lb-ft)
Carburetor mounting bolt - 10 Nm (7.0 lb-ft)
Fuel pump mounting bolt - 10 Nm (7.0 lb-ft)
Engine oil drain plug - 13 Nm (9.5 lb-ft)
Power unit mounting bolt - 23 Nm (16.5 lb-ft)
Clamp bracket shaft nut - 43 Nm (31.0 lb-ft)
Tiller handle pivot bolt - 17 Nm (12.5 lb-ft)
Gearcase bolt - 23 Nm (16.5 lb-ft)
Propeller nut - 18 Nm (13.0 lb-ft)
Water pump case bolt - 8 Nm (6.0 lb-ft)
The Suzuki DF9.9 is engineered for a wide variety of small watercraft.
Its compact size, light weight, and reliable performance make it an
ideal primary power source for small fishing boats, aluminum boats, jon
boats, dinghies, and inflatable craft including RIBs.
It is a popular and dependable choice as an auxiliary motor for larger
fishing boats or sailboats, providing reliable power and
maneuverability. With its 9.9 hp output and efficient four-stroke
design, it is well-suited for recreational boaters and anglers seeking
an efficient, quiet, and reliable outboard for various water conditions.
The engine is saltwater rated and suitable for use in both freshwater
and saltwater environments when properly maintained.
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