Suzuki DF140A Owner's Manual
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Suzuki DF140A Owner's Manual

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DF115A
EN
DF115AS
DF140A
OWNER'S MANUAL
ENGLISH
1

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Summary of Contents for Suzuki DF140A

  • Page 1 DF115A DF115AS DF140A OWNER’S MANUAL ENGLISH...
  • Page 2 California Proposition 65 Warning NOTE: Indicates special instructions to make mainte-  WARNING nance easier or instructions clearer. Operating, servicing and maintain- BREAK-IN INFORMATION ing an outboard motor can expose FOR YOUR OUTBOARD MOTOR you to chemicals including engine The first 10 hours are the most important in the exhaust, carbon monoxide, phtha- life of your engine.
  • Page 3 • Instruct your passengers on how to manual carefully before operating your operate the boat, how to deal with new Suzuki and review the manual from emergencies, and how to operate time to time. It contains important infor- mation on safety, operation, and mainte- safety and emergency equipment.

  • Page 4: Table Of Contents

    800-336-BOAT (2628). PASSCODE CONFIRMATION.... Your state’s department of boating and your PROPELLER SELECTION AND Suzuki Marine dealer can supply you with addi- INSTALLATION........22 tional information on boating safety and regula- PROPELLER SELECTION ....tions, or you can call the U.S. Coast Guard PROPELLER INSTALLATION ...
  • Page 5 KEYLESS START SYSTEM CAUTION LOW PRESSURE FUEL FILTER..SYSTEM LUBRICATION ........(IF EQUIPPED WITH ....33 CORROSION PREVENTION ....KEYLESS START SYSTEM) KEY-FOB CAUTION SYSTEM ... ANODES..........KEY-FOB BATTERY CAUTION BONDING WIRES ....... SYSTEM ..........BATTERY..........KEYLESS CONTROL UNIT ENGINE OIL FILTER ......CAUTION SYSTEM......

  • Page 6: Fuel And Oil

    GASOLINE in your outboard motor if the ethanol content is Suzuki highly recommends that you use alco- not greater than 10%. hol-free unleaded gasoline whenever possible, with a minimum pump octane rating of 87 Fuel Pump Labeling ((R+M)/2 method).

  • Page 7: Filling The Fuel Tank

    FILLING THE FUEL TANK 3. Turn the air-vent screw 1 on top of the fuel To fill the fuel tank: tank cap 2 fully counterclockwise to open 1. Always stop the engine before refilling the the vent. tank. 2. Remove the portable fuel tank from the boat NOTE: to refill it.

  • Page 8: Engine Oil

    Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Suzuki recommends the use of SAE 10W-40 or 10W-30 SUZUKI MARINE 4-CYCLE ENGINE OIL. If SUZUKI MARINE 4-CYCLE ENGINE OIL is not available, select a NMMA certified...

  • Page 9: Location Of Safety Labels

    LOCATION OF SAFETY LABELS Read and follow all of the labels on your out- Keep the labels on your outboard motor or fuel board motor or fuel tank. Make sure you under- tank. Do not remove them for any reason. stand all of the labels.
  • Page 10 Label symbol meanings : Engine start These symbols mean as follows; : Hazard caused by fire : General warning symbol : Hazard caused by laying (Caution or Warning) the motor on its side : Read owner’s manual carefully : Remote control lever/gear shift lever operation-two direction;...

  • Page 11: Location Of Parts

    LOCATION OF PARTS Motor cover Power trim and tilt (P.T.T.) switch (Reverse side) MONITOR-TACHOMETER Engine oil drain plug Clamp bracket Pilot water hole Flush plug Anode (Reverse side) PRIMING BULB Gear oil level plug Anti-cavitation plate Water intake hole Trim tab Gear oil drain plug SIDE MOUNT TYPE Power trim and tilt...

  • Page 12: Motor Installation

    Suzuki marine dealer. He has the tools, described in 40 CFR 1068.105. the facilities, and the know-how to do the job correctly.

  • Page 13: Battery Installation

    Consult tive battery terminal. your Suzuki dealer to determine the proper battery sizing for your boat and engine com- bination. Red lead •...

  • Page 14: Sub Battery Cable

    • Be sure to attach battery leads cor- rectly. Suzuki recommends that you install the termi- • Do not disconnect battery leads from nal cap on the positive battery terminal to pre- the battery while the engine is running.

  • Page 15: Suzuki Keyless Start System (If Equipped With Keyless Start System)

    Two (2) key-fobs are supplied with the Keyless Start System. Keyless control unit NOTE: Please consult with a Suzuki Marine Dealer for the installation of the Keyless Start System. Also refer to the “Keyless Start System Instruc- tion Manual” supplied with the product for detailed operating instructions.
  • Page 16 • If the key-fob and the emergency key are lost, immediately contact your authorized Suzuki Do NOT attempt to disassemble (except Marine Dealer. for battery replacement), repair, or modify •...

  • Page 17: Key-Fob Battery Replacement

    Switching the communication mode of NOTICE the key-fob Press and hold the lock button 1 on the key-fob for more than one second to switch between To prevent damage to the key-fob, be ON mode and OFF mode. careful when replacing the battery. NOTE: •...
  • Page 18 2. Remove the O-ring 1. 4. Replace the battery so its + terminal faces the cover side as shown in the illustration. Lithium disc type battery: CR2025 or equiva- lent. Confirm that the O-ring is placed in position on the body side. NOTE: The O-ring may be fitted on the cover side.

  • Page 19: Setting And/Or Changing The Passcode

    SETTING AND/OR CHANGING THE PASS- CODE If equipped with top mount type By setting a 4-digit passcode, the engine can remote control box: (Main switch panel) be started by entering the passcode even if the key-fob battery has run down or the key-fob is PUSH PUSH lost.
  • Page 20 After the buzzer emits 10 sounds, it emits one Hold it for five (5) seconds. long sound before to returning to stand-by PUSH PUSH START START mode for the second passcode digit. ON & OFF ON & OFF ON & OFF STOP STOP (3) Repeat Step 2 to enter the second, third and...

  • Page 21: Passcode Confirmation

    PASSCODE CONFIRMATION Hold it for five (5) seconds. 1. Confirm that the engine is stopped. PUSH PUSH 2. Make sure the emergency switch lock plate START START ON & OFF ON & OFF ON & OFF STOP STOP is in place. 3.

  • Page 22: Propeller Selection And Installation

    5000 – 6000 DF115A/115AS r/min. (min –1 5600 – 6200 DF140A r/min. (min –1 If the engine speed is not within this range, con- sult your authorized Suzuki Marine Dealer to determine which propeller size is best for you.

  • Page 23: Propeller Installation

    To install a propeller on your outboard motor, use the following procedure: 1. Coat the propeller shaft splines 1 liberally with Suzuki water resistant grease to help prevent corrosion. 2. Place the stopper 2 on the shaft. 3. Align the propeller 3 with the propeller shaft splines and slide the propeller onto the shaft.

  • Page 24: Adjustments

    ADJUSTMENTS TRIM ANGLE ADJUSTMENT To help maintain steering stability and good performance, always maintain the proper trim angle as shown in the illustration. The appropri- ate trim angle varies depending on the combi- nation of the boat, engine, and propeller, as well as operating conditions.

  • Page 25: Trim Tab Adjustment

    2. If the boat tends to veer to port, move the NOTICE rear end of the trim tab toward the port side. If the boat tends to veer to starboard, move the rear end of the trim tab toward the star- If you operate the boat with the motor board side.

  • Page 26: Throttle Tension Adjustment

    Turn the ignition key to the “ON” position. IDLE SPEED ADJUSTMENT The idle speed has been factory adjusted between 650 – 750 r/min. in neutral. NOTE: If idle speed cannot be set within the specified range, contact your authorized Suzuki Marine Dealer.
  • Page 27 2. Pull out the emergency stop switch lock 4. Top mount type plate. Using the throttle only function of the remote control box, move the control handle forward until the caution buzzer sounds one time. Side mount type Using the throttle only function of the remote control box, move the warm-up lever upward until the caution buzzer sounds one time.

  • Page 28: Motor Cover Fastening Adjustment

    MOTOR COVER FASTENING 12. Press the “UP” side of PTT switch three ADJUSTMENT times within three seconds. The buzzer will sound one time briefly indicating the setting If you feel motor cover fastening is loose or too has been accepted. tight when locking the levers, adjust as follows: 13.

  • Page 29: Caution System

    “ON & OFF” position and then turning it exist in the system circuit. Consult your back to the “PUSH START/STOP” position, four authorized Suzuki marine dealer. lamps – the REV LIMIT 1, the OIL 2, the TEMP 3 and the CHECK ENGINE 4 in the...

  • Page 30: Over-Revolution Caution System

    Revolution Caution System. dition that can cause damage to your out- board motor. Consult your authorized Suzuki marine dealer if the Over-Revolution Caution If any of the four lamps does not come on System activates for no apparent reason.

  • Page 31: Oil Pressure Caution System

    3 minutes after beginning of the Before checking the oil level, stop the above CAUTION system activation. engine and remove the motor cover. Check the oil level and add oil if necessary. If the oil level is correct, consult your authorized Suzuki Marine Dealer.
  • Page 32 Be aware that the red TEMP lamp may light again if engine temperature rises abnormally. If either of the above situations arises, your authorized Suzuki Marine Dealer must be con- sulted as soon as possible. NOTE: If pilot hole water discharge is sufficient, buzzer and TEMP lamp may still operate until engine temperature decreases.

  • Page 33: Battery Voltage Caution System

    “BATTERY INSTALLATION” section of cated by the Keyless Start System. • If this caution system activates continuously, this manual. contact your authorized Suzuki Maine Dealer. NOTE: • A marginal battery may have enough power to start your engine, yet may still cause this...

  • Page 34: Key-Fob Battery Caution System

    BATTERY • If this system activates, check the following: REPLACEMENT section.) – The 12 volt battery is in sound condition. – Contact failure of the battery terminal. • If this caution system activates continuously, consult your authorized Suzuki Maine Dealer.

  • Page 35: Diagnostic System

    Consult your authorized Suzuki marine Also incorporated is a fail-safe provision that dealer for repair of the control system.

  • Page 36: Oil Change Reminder System

    OIL CHANGE REMINDER PUSH PUSH START START SYSTEM ON & OFF ON & OFF STOP STOP This system informs the operator of the time for replacing engine oil on the basis of the mainte- nance schedule. The system is designed to register the total operating hours of the outboard motor and function its operation when the preprogrammed hours have reached.

  • Page 37: Engine Stalling Caution System

    NOTE: do so, and check the fuel filter/water separator • Canceling of the system activation is possible for water. Or consult your authorized Suzuki regardless of whether or not the engine oil marine dealer. has been replaced. Once the system has...

  • Page 38: Operation Of Tilting Systems

    OPERATION OF TILTING NOTE: If equipped with Top Mount remote control box SYSTEMS in case of Dual engine; Both engines can be operated together on PTT POWER TRIM AND TILT switch 1 at the port control lever grip. The “Power Trim and Tilt” is operated by press- Each engine can be operated by the switches ing the switch.

  • Page 39: Manual Tilting

    Tilt “DOWN” switch, until the motor is supported by the Tilt Lever.  CAUTION The motor is very heavy. When you tilt it 4. For DF115AS/DF140A: manually, you could injure your back or Continue to operate the Power Trim and Tilt slip and fall causing injury.
  • Page 40 If not equipped with Keyless Start System: NOTICE  CAUTION If you do not retract the trim rams completely when mooring, they may become deteriorated The remote Power Trim and Tilt switch or corroded. will work when the ignition switch is off. If Be sure to retract the trim rams completely someone activates the switch while you when mooring.

  • Page 41: Inspection Before Boating

    INSPECTION BEFORE 1. Place the motor in a vertical position, then remove the motor cover 1 by unlocking the BOATING lever 2 and 3.  WARNING Failure to inspect your boat and motor before beginning a trip can be hazardous. Before boating, always perform the inspections described in this section.
  • Page 42 The oil on the dipstick should be between • Check the battery solution level. the upper and lower limits shown on the dip- The level should be kept between the MAX stick. If the oil level indication is near the and the MIN level lines at all times.

  • Page 43: Break-In

    BREAK-IN 2. For the next 1 hour: Safe boating conditions permitting, operate the engine in gear at 4000 r/min. or at three- Proper operation during this break-in period will quarter throttle. Avoid running the engine at help ensure maximum life and performance full throttle.

  • Page 44: Operation

    PUSH START relieve the fuel pressure in fuel tank. STOP For handling the fuel tank cap, refer to the “FUEL AND OIL/FILLING FUEL TANK” section in this manual. NOTE: SUZUKI genuine portable fuel tanks have a semi-auto air vent.
  • Page 45 3. Make sure that the motor fuel hose and the 6. Make sure the lock plate is in place and the hose from the boat’s fuel tank are securely emergency stop switch cord is fastened attached and clamped. securely to your wrist or appropriate clothing area such as your belt.

  • Page 46: Starting The Engine

    If equipped with Keyless Start System:  WARNING 1. Squeeze the fuel line priming bulb several times until you feel resistance. Failure to properly attach the emergency stop switch cord or to take proper pre- cautions to help ensure that the emer- gency stop switch works as intended may result in serious injury or death to the operator or passengers.
  • Page 47 NOTICE PUSH PUSH START START ON & OFF ON & OFF STOP STOP If you hold in the main switch to start the engine, the starter system can be dam- aged. Push the main switch and release it to start the engine. The engine will crank continuously for 4 seconds or until the * If equipped with top mount type engine starts.
  • Page 48 If not equipped with Keyless Start System: 1. Squeeze the fuel line priming bulb several times until you feel resistance. NOTICE If you hold the ignition key at the 2. Side mount type: “START” position to start the engine, the Make sure the warm-up lever is in the fully starter system can be damaged.
  • Page 49 If you notice that water does not spray out of the pilot water hole, stop the engine as soon as possible and consult your authorized Suzuki Marine Dealer. NOTICE Never operate your outboard motor when there is no water coming out of the pilot water hole, or severe damage can result.

  • Page 50: Emergency Start

    3. Make sure lock plate 3 is in position. If equipped with Keyless Start System: EMERGENCY START NOTE: One (1) emergency key is included in the remote control box for the Keyless Start Sys- tem. NOTE: In case of Dual Engine: By carrying out the emergency start operation on either one of the engines, another engine may be started by operating the main switch.
  • Page 51 6. Turn the emergency key to the “ON & OFF” (“ ”) position and hold it until the buzzer sounds. Example: When entering 7 Turn the emergency key back to the “PUSH PUSH PUSH START/STOP” position. The system turns to START START ON &...
  • Page 52 NOTE: To start the engine: (5) Install the lock plate 3 on the emergency • If the passcode input has not been per- stop switch. formed, passcode input for the same digit will start again after the main switch is operated. •...
  • Page 53 NOTE: 4. Turn the emergency key to the “ON & OFF” Starting of another engine of the Dual Engine: (“ ”) position and then release it to the Push the main switch to start the engine. “PUSH START/STOP” position to turn the Keyless Start System to OFF state.

  • Page 54: Shifting And Speed Control

    A detent or notch is present on all Suzuki con- engage the throttle. This can cause the trol boxes to provide a “feel” for positions A, B, boat to move suddenly resulting in per- and neutral.

  • Page 55: Stopping The Engine

    STOPPING THE ENGINE 4. Turn the Keyless Start System to OFF (locked) status by one of the following meth- NOTE: ods. When it is necessary to stop the engine in an • Make sure that the key-fob is within the emergency, pull the emergency stop switch lock communication range of the keyless con- plate out of the emergency stop switch by pull-...
  • Page 56 NOTE: If not equipped with Keyless Start System: Even when the engine is stopped, all lamps in To stop the engine: the monitor-tachometer will continue to light, 1. Shift into “NEUTRAL”. unless the Keyless Start System is turned to 2. After operating at full throttle, cool off the OFF state.

  • Page 57: Mooring

     WARNING NOTICE Unauthorized use of your boat could lead Improperly securing your boat may cause to an accident or damage to your boat. damage to your boat or motor, or other property damage. To prevent unauthorized use of your boat, be sure to remove the key and emergency Do not allow your motor to rub against stop switch lock plate when the boat is...

  • Page 58: Operating The Troll Mode (Optional Item)

    Dealer for more information. NOTE: To monitor engine speed correctly during the troll mode operation, Suzuki recommends the use of the Suzuki 2-scale Monitor Tachometer. Troll mode switch Usual scale NOTE: The troll mode system will not operate if the switch is depressed when the remote control lever is in the neutral position.

  • Page 59: Operation In Salt Water

    If it is necessary to remove the outboard motor when cancelling the troll mode. from your boat, we recommend that you ask your authorized Suzuki Marine Dealer to do the work for you. OPERATION IN SALT WATER After operating the motor in salt water, you...
  • Page 60 Horizontal transport:  WARNING 1. Drain the engine oil. Refer to the ENGINE OIL section. 2. Drain the gasoline from the vapor separator Gasoline is extremely flammable and as follows: toxic. It can cause a fire and can be haz- (1) Remove the motor cover 1.
  • Page 61  WARNING NOTICE Spilled fuel or fuel vapor can cause a fire If you let the lower unit of your outboard and is hazardous to health. sit higher than the power head during transporting or storing, water may trickle Always take the following precautions: into the power head, causing damage to •...

  • Page 62: Trailering

    TRAILERING When trailering your boat with the motor attached, keep the motor in the normal operat- ing position unless there is not enough ground clearance. If you need more ground clearance, trailer the motor in a tilted position using a tran- som saver bar or similar device to support the weight of the motor.

  • Page 63: Inspection And Maintenance

    INSPECTION AND MAINTENANCE NOTICE At each interval, be sure to perform the indi- cated service. Maintenance intervals should be judged by number of hours or number of MAINTENANCE, REPLACEMENT months, whichever comes first. REPAIR EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PER- ...

  • Page 64: Tool Kit

    Suzuki strongly recom- instructions in this section if you have mends that you use genuine Suzuki parts mechanical experience. If you are not or their equivalent. sure whether you can successfully com-...

  • Page 65: Spark Plug

    (usually evidenced by black- ening of the insulator or a wet electrode), per- minum threads of the cylinder head. formance may suffer. Ask your authorized Suzuki Marine dealer to evaluate either of these problems to determine the cause. Insulator Center...

  • Page 66: Breather And Fuel Line

    Remove carbon deposits from the spark plug they must be replaced. Consult your authorized using a small wire brush or spark plug cleaner, Suzuki Marine Dealer if it is necessary to and adjust the gap as follows: replace them. 0.7 – 0.8 mm...

  • Page 67: Engine Oil

    ENGINE OIL 3. Place a drain pan under the engine oil drain screw.  WARNING  CAUTION Never perform any ENGINE OIL proce- dure with the motor running, as serious The engine oil temperature may be high injury can occur. enough to burn your fingers when the drain plug is loosened.

  • Page 68: Gear Oil

    7. Check the engine oil level. NOTE: Recycle or properly dispose of used engine oil. Do not throw it in the trash, or pour it on the ground, down a drain, or into the water. GEAR OIL To check the gear oil level, adjust the engine to UPPER LIMIT an upright position, remove the gear oil level plug 1 and look into the hole.

  • Page 69: Low Pressure Fuel Filter

    LOW PRESSURE FUEL FILTER  WARNING The low pressure fuel filter must be replaced by an authorized Suzuki Marine Dealer periodi- cally. Gear oil can cause injury to people or Replace low pressure fuel filter at every 400 pets. Repeated, prolonged contact with hours (2 years).
  • Page 70 3. Remove the bolt 1 and nut 2 securing the bracket 3 of the fuel filter. 7. Drain the fuel and water in the filter cup into a suitable container. NOTICE NOTICE If spilled gasoline is just left on painted Improperly loosening the filter cup can surface, it may cause a stain or discolora- cause sensor lead wire damage.

  • Page 71: Lubrication

    Before applying grease through the steering bracket grease nipple, lock the motor in the fully tilted up position. Your authorized Suzuki Marine Dealer may also have additional recommendations due to regional climate or operating conditions. Please consult him for advice.

  • Page 72: Corrosion Prevention

    • Do not paint anodes, as this will render sion measures may be helpful under those con- them ineffective. ditions. Consult your authorized Suzuki Marine • Periodically clean anodes with a wire Dealer for details. brush to remove any coating which might decrease their protective ability.

  • Page 73: Bonding Wires

    BATTERY BONDING WIRES If you are using a maintenance-free battery, Bonding wires are used to electrically connect inspect the window area according to the the engine components so they exist in a com- instructions on the battery to make sure the bat- mon ground circuit.

  • Page 74: Engine Oil Filter

    ENGINE RUNNING – Vertical position – procedures. Suzuki recommends that you flush the water passage by using this method. ENGINE OIL FILTER To flush the water passages, you must obtain a The engine oil filter must be changed by autho- commercially available engine flush device.
  • Page 75 NOTICE Severe engine damage can occur in as lit- tle as 15 seconds if the engine is started without supplying water to the cooling system. Never start the motor without supplying water to the cooling system. 1. Make sure that the motor is stopped. 2.

  • Page 76: Submerged Motor

    SUBMERGED MOTOR 3. Install garden hose directly or by using a hose connector matched to flushing point thread B. If your motor has been accidentally submerged Thread B: 0.75 – 11.5 NHR (American stan- in water, it must receive a special repair service dard hose coupling threads for garden hose as soon as possible to prevent corrosion.

  • Page 77: Storage Procedure

    (for example, at the end of the boating sea- son), it is recommended that you take your encounter friction or resistance. motor to your authorized Suzuki Marine Dealer. However, if you choose to prepare the motor for If you encounter friction or resistance...

  • Page 78: Battery Storage

    BATTERY STORAGE 7. Lubricate all other specified parts. Refer to the LUBRICATION section. Spray entire 1. When the outboard motor will not be used powerhead with a rust preventative (not a for a month or longer, remove the battery penetrating oil product). and store it in a cool, dark place.

  • Page 79: After Storage

    IDENTIFICATION NUMBER LOCATION AFTER STORAGE The model and identification numbers of your outboard motor are stamped on a plate When taking your motor out of storage, follow attached to the clamp bracket. Record these the procedure below to return it to operating numbers below for future reference.

  • Page 80: Emission Control Information

    EMISSION CONTROL If not equipped with Keyless Start System: INFORMATION Ignition Key Number: NOTICE • THIS ENGINE IS CERTIFIED TO OPER- ATE ON UNLEADED GASOLINE OF 87 OCTANE ((R+M)/2 METHOD) GREATER. • EXHAUST EMISSION CONTROL SYSTEM: ECM, MFI, HO2S Ignition key number stamped position Spare key...

  • Page 81: Troubleshooting

    • Battery power is lost. action to correct a problem, consult your • Keyless control unit failure. Suzuki marine dealer. • Electric wiring connection is loose. • Remote control box failure. (Side mount type) • Main panel failure. (Top mount type) Starter motor will not operate: •...
  • Page 82 FUSE 4. Inspect the fuse and replace with new fuse if 1. If equipped with Keyless Start System: needed. Turn the Keyless Start System OFF. If not equipped with Keyless Start System: Turn the ignition key to the “off” position. Main fuse (60A) 2.
  • Page 83 Fuel pump fuse: 15 A cal system problem. Spare fuse: 60 A Spare fuse: 30 A Consult your SUZUKI marine dealer. Spare fuse: 10 A NOTE: Spare fuses 8 and 9 are provided for the back of fuse box cover.

  • Page 84: Specifications

    SPECIFICATIONS Item DF115A/115AS DF140A Engine Type 4 Stroke Number of Cylinders Bore and Stroke 86.0 × 88.0 mm (3.39 × 3.46 in) Piston Displacement 2044 cm (124.7 cu. in) Maximum output 84.6 kW (115PS) 103.0 kW (140PS) Full Throttle Operating Range 5000 –...

  • Page 85: Chart Of Total Operating Hours Indication

    CHART OF TOTAL OPERATING HOURS INDICATION MONITOR-TACHOMETER Total Needle 1 operating REV-LIMIT lamp 2 flashing * hours indication 0 h- (49 h) 50 h- 500 r/min 60 h- 600 r/min 540 h- 5400 r/min 550 h- 500 r/min 1 time 560 h- 600 r/min 1 time...
  • Page 86 WIRING DIAGRAM Not equipped with keyless start system DF115A...
  • Page 87 Not equipped with keyless start system DF140A...
  • Page 88 Equipped with keyless start system...
  • Page 89 Equipped with keyless start system DF115A...
  • Page 90 Equipped with keyless start system DF140A...
  • Page 91 Prepared by August, 2019 Part No. 99011-90JA0-03B Printed in Japan © COPYRIGHT SUZUKI MOTOR CORPORATION 2019...

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