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Old 07-10-2020, 03:48   #1
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Convert Suzuki DF4 to DF6

Hi ...
I have a 2013 Suzuki DF4 and wanted to try to convert it to a DF6.
Read a heap of stuff on different forums, but couldn't come up with anything definitive that someone else had tried and succeeded ....
So, I tried and ............... it worked a treat !!!
First off went through the parts manuals to see what is different, and the answer is "not much"
Other than the external fuel tank attachment, the only parts that I could find that are different are ....

Carburetor (DF6 has a noticeably bigger through diameter)
Intake Manifold (only difference is the mounting section for the throttle cables)
Thermostat (42c instead of 50c)

So I ordered those parts which including shipping came to about US$150.
Installing them was pretty straight forward.
The DF4 is only designed to run to 5000 rpm whereas the DF6 goes to 5750 rpm and that's where the extra (hp) power comes from.
On this version (2013) there is an overspeed protection for both models at 6000 rpm but in later versions the different models have individual overspeed limits with the DF4 being lower (off memory around 5200 rpm). I tried to see what part it is that changes the limit, but couldn't work it out, so if your planning to try this with those later versions, not sure if it will work without solving that.
Anyhow, the result is that the engine revs noticeably higher and my 2.6m inflatable with soft bottom goes WAY FASTER ! Now easily planes 2 up at 3/4 throttle whereas before it would not plane 2 up at all.
You would also want to order a new manifold to cylinder head gasket and carburetor to manifold gasket as both were stuck hard to the old manifold.

Hope this helps someone ... cheers
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Old 07-10-2020, 04:52   #2
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Re: Convert Suzuki DF4 to DF6

Congratulations. This is the first time I've heard of success in such a project.
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Old 07-10-2020, 12:36   #3
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Re: Convert Suzuki DF4 to DF6

Quote:
Originally Posted by johnny666 View Post
Hi ...
I have a 2013 Suzuki DF4 and wanted to try to convert it to a DF6.
Read a heap of stuff on different forums, but couldn't come up with anything definitive that someone else had tried and succeeded ....
So, I tried and ............... it worked a treat !!!
First off went through the parts manuals to see what is different, and the answer is "not much"
Other than the external fuel tank attachment, the only parts that I could find that are different are ....

Carburetor (DF6 has a noticeably bigger through diameter)
Intake Manifold (only difference is the mounting section for the throttle cables)
Thermostat (42c instead of 50c)

So I ordered those parts which including shipping came to about US$150.
Installing them was pretty straight forward.
The DF4 is only designed to run to 5000 rpm whereas the DF6 goes to 5750 rpm and that's where the extra (hp) power comes from.
On this version (2013) there is an overspeed protection for both models at 6000 rpm but in later versions the different models have individual overspeed limits with the DF4 being lower (off memory around 5200 rpm). I tried to see what part it is that changes the limit, but couldn't work it out, so if your planning to try this with those later versions, not sure if it will work without solving that.
Anyhow, the result is that the engine revs noticeably higher and my 2.6m inflatable with soft bottom goes WAY FASTER ! Now easily planes 2 up at 3/4 throttle whereas before it would not plane 2 up at all.
You would also want to order a new manifold to cylinder head gasket and carburetor to manifold gasket as both were stuck hard to the old manifold.

Hope this helps someone ... cheers

Well done & thanks for posting. I cant use your mod but it's a good read & something to keep in mind.
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Old 14-03-2021, 19:06   #4
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Re: Convert Suzuki DF4 to DF6

I have a 2020 model year DF4 that I just upgraded with a carb from a DF6. It works up to about 3/4 throttle but then it seems to bounce off the rev limiter at full throttle. Here is a quick video of the issue: https://photos.app.goo.gl/5wxnoWxDQEmvpA7cA

Is there a way to get this resolved or do I just go back to the old carb?
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Old 15-03-2021, 11:37   #5
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Re: Convert Suzuki DF4 to DF6

If you can hit the rev limiter aren't you under prop'ed? (Sp?)
That's to say, you need more pitch.
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Old 15-03-2021, 11:53   #6
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Re: Convert Suzuki DF4 to DF6

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Originally Posted by fourlyons View Post
If you can hit the rev limiter aren't you under prop'ed? (Sp?)
That's to say, you need more pitch.
That's what I figured out after some more research... The DF6 has a 7 pitch vs. 6 pitch on my DF4. I purchased the 7 pitch prop and will test it out soon!
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