Suzuki DF115BG DF140BG Owner's Manual
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Suzuki DF115BG DF140BG Owner's Manual

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DF115BG
DF140BG
OWNER'S MANUAL
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ENGLISH
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Summary of Contents for Suzuki DF115BG DF140BG

  • Page 1 DF115BG DF140BG OWNER’S MANUAL ENGLISH...
  • Page 2 • Do not hold onto the motor cover or any This symbol appears in various locations on other parts of your outboard motor while your Suzuki product to refer you to important getting on or off your boat. information in the owner’s manual.
  • Page 3 FOREWORD • Never remove the flywheel cover (except for when emergency starting). Thank you for choosing a Suzuki outboard motor. Please read this manual carefully and NOTE: review it from time to time. It contains important Mounting radio transceiver or navigational...

  • Page 4: Table Of Contents

    EC – DIRECTIVE ......... 91 MOTOR MOUNTING......12 FLOWCHART OF OIL CHANGE REMINDER SYSTEM......92 BATTERY INSTALLATION ....12 USE OF ELECTRICAL ACCESSORIES ........14 SUZUKI KEYLESS START SYSTEM (IF EQUIPPED WITH KEYLESS ........15 START SYSTEM) PROPELLER SELECTION AND INSTALLATION........19 ADJUSTMENT........20 METER (OPTION) MULTI-FUNCTION GAUGE .....

  • Page 5: Identification Number Location

    IDENTIFICATION Suzuki recommends that you install a water- separating fuel filter assembly between your NUMBER LOCATION boat’s fuel tank(s) and outboard motor(s). Fuel filtration systems of this type will help prevent The model and identification numbers of your water that may be present in your boat’s fuel outboard motor are stamped on a plate tank(s) from contaminating your motor’s elec-...
  • Page 6 NOTE: NOTICE If you are not satisfied with the operation or fuel economy of your outboard motor when you are Gasoline kept in the fuel tank for long periods using gasoline/alcohol blends, you should of time will produce varnish and gum, which switch back to unleaded gasoline containing no can damage the engine.
  • Page 7 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 8: 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: Location Of Parts

    LOCATION OF PARTS Motor cover Power trim and tilt (P.T.T.) switch Clamp bracket Flush plug Manual release screw Anti-cavitation Pilot water hole plate Engine oil drain plug Anode Anode Gear oil level plug Trim tab Gear oil drain plug Water intake hole Flush plug (No.2)
  • Page 11 MULTI-FUNCTION GAUGE KEYLESS FOB (Option) (IF EQUIPPED WITH KEYLESS START SYSTEM) Power trim and tilt (P.T.T.) switch Shift lock button Remote control handle Throttle only switch Throttle only switch Select switch Select switch THROTTLE SELECT ONLY Emergency stop switch Type A Type B REMOTE CONTROL BOX (Option) Priming bulb...

  • Page 12: Motor Mounting

    NOTE: boat’s “Certification Plate”. Contact your • The specifications listed above are the mini- authorized Suzuki marine dealer if you are mum battery rating requirements for starting unable to locate the hull “Certificate Plate”. the engine.
  • Page 13 Suzuki recommends that you install the termi- • Be sure to attach battery leads correctly. nal cap on the positive battery terminal to pre- •...

  • Page 14: Use Of Electrical Accessories

    For getting a detailed nected to the battery, engine cannot be started. information, please inquire of your authorized Suzuki Marine Dealer. NOTE: Use of too much power for electrical accesso- ries under certain operating conditions can...

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

    Keyless fob Keyless control unit V WARNING NOTE: Please consult with a Suzuki Marine Dealer for the installation of the Keyless Start System. The keyless fob emits radio waves that may interfere with aircraft operations. Also refer to the “Keyless Start System Instruc- tion Manual”...
  • Page 16 • If the keyless fob is lost, immediately contact may cause ignition, electric shock, or injury. your authorized Suzuki Marine Dealer. Do NOT attempt to disassemble (except for • The keyless fob uses a weak radio wave that...
  • Page 17 V CAUTION Switching the communication mode of the keyless fob Press and hold the lock button 1 on the key- There is a danger of explosion if the battery is less fob for more than one second to switch replaced with an incorrect type. between ON mode and OFF mode.
  • Page 18 To replace the keyless fob battery: 3. Insert a flat blade screwdriver into the slot at 1. Insert a flat blade screwdriver in the slot of mark on the cover to remove the bat- the keyless fob and remove the cover. tery.

  • Page 19: Propeller Selection And Installation

    Ask your authorized Suzuki marine dealer to assist you in selecting a suitable propeller for your boat. 1. Coat the propeller shaft splines 1 liberally...

  • Page 20: Adjustment

    ADJUSTMENT V WARNING TRIM ANGLE ADJUSTMENT Trim angle greatly affects steering stability. If To help maintain steering stability and good the trim angle is too small, the boat may performance, always maintain the proper trim “plow” or “bow steer”. If the trim angle is too angle as shown in the illustration.
  • Page 21 3. Tighten the bolt that holds the trim tab in If idle speed cannot be set within the specified place. range, contact your authorized Suzuki Marine Dealer. After adjusting the trim tab, check to see if the boat still tends to veer to one side. If necessary,...
  • Page 22 SETTING OF TILT UPPER LIMIT POSITION 3. Make sure that remote control handle is in If the outboard motor contacts the motor well of “NEUTRAL”. the boat during full tilt up operation, the upper 4. Confirm the select LED lights, if not, depress limit setting should be reset.
  • Page 23 MOTOR COVER FASTENING 4. Make sure that remote control handle is in ADJUSTMENT “NEUTRAL”. 5. Confirm the select LED lights, if not, depress If you feel motor cover fastening is loose or too the select switch on the remote control box. tight when locking the levers, adjust as follows: Depress the “THROTTLE ONLY”...

  • Page 24: Meter (Option) Multi-Function Gauge

    ] and [ ] buttons to move the selection cursor, select sub information, and NOTE: adjust information input. Consult your authorized Suzuki marine dealer for setting up the multi-function gauge. NOTE: Press and hold either the [ ] or [...
  • Page 25 SCREEN SELECTION 1. Engine Speed Display Screen The multi-function gauge can select the display The engine speed 1, shift position 2, trim screen from the following choices. position 3, time 4, engine position 5 and sub information 6 are displayed. •...
  • Page 26 3. Fuel Information Display Screen Digital This screen indicates the remaining fuel lev- els of each tank installed, along with sub information. The sub information display can be switched by pressing the [ ] or [ ] buttons. This screen indicates only in digital mode. Analog1 Analog2 SUB INFORMATION SELECTION...
  • Page 27 NOTE: 4. Battery Voltage/Cooling Water Tempera- Press and hold either the [ ] or [ ] button to ture reset the trip time, trip distance, average fuel The cooling water temperature and battery consumption, and total fuel consumption in the voltage are displayed.
  • Page 28 MENU INFORMATION SELECTION 8. Average fuel economy The menu screen is displayed when the MENU This screen indicates the total average fuel button is pressed while any screen is displayed. economy of all outboard motors installed. While the menu screen is displayed, press the MENU button to return to the previous screen.
  • Page 29 Day or Night 2. Auto Trim Press the [ ] or [ ] button to select “Day or Sets the Auto Trim mode. Night”. Next, select “Day” or “Night” using the Set the outboard motor to the full trim down [SET] button.
  • Page 30 NOTE: Data Output • “ A” is not displayed if the trim position does NOTE: not appear on the multifunction gauge For details the proper handling of the multi- screen. function gauge, refer “OPERATION • The PTT switch operations take priority, even INSTRUCTION MANUAL”...
  • Page 31 Device List CAN 2 Display 34200-96L41 Tacho Speed & Fuel 33920-98L20 33920-98L20 Fuel ON OFF 34200-96L40 34200-96L40 When the indication is set to “OFF”, the display Use the [ ] or [ ] buttons to select “EXTER- screen for that item is skipped and the next NAL”...
  • Page 32 6. Keyless Passcode appears once the [SET] button is You can display the Keyless Start System pass- pressed after you have entered all 6 digits. code. You can also change the passcode. (2) If you do not have the keyless fob (1) If you have the keyless fob When the keyless start system starts up, •...
  • Page 33 Quantity: set the unit for fuel quantity. Press the [SET] button to select the unit. Language English Français Español Deutsch G ( US ) G ( IMP ) Quantity Italiano Speed Scale HIGH Econ Q/D I/100km The confirmation message appears. To change the display language, use the [ ] or ] button to select “YES”, and press the...
  • Page 34 12h or 24h: select 12-hour or 24-hour display. Setting for the gauge and engine position. Press the [SET] button to select “12h” or “24h.” Consult your authorized Suzuki marine dealer for setting change of “Position”. Component Setting Settings for component.

  • Page 35: Caution System

    If the Caution System activates while you are operating your outboard motor, stop the motor as soon as possible and correct the problem or consult your authorized Suzuki marine dealer for assistance. INDICATOR CHECK If equipped with Keyless Start System:...
  • Page 36 Consult your authorized problem with the Over-Revolution Caution Suzuki marine dealer. System. Consult your authorized Suzuki marine dealer if the Over-Revolution Caution System acti- OVER-REVOLUTION CAUTION SYSTEM vates for no apparent reason. This system is activated when engine speed exceeds maximum recommended speed for more than 10 seconds.
  • Page 37 Check the oil level and add oil if necessary. If NOTE: the oil level is correct, consult your authorized In case that the engine is automatically stopped Suzuki Marine Dealer. due to the CAUTION system, the engine can be started again. NOTICE However the CAUTION system will repeatedly activate until eliminating the cause.
  • Page 38 Be aware that “Overheat” is displayed on screen again if engine temperature rises abnor- mally. If either of the above situations arises, your authorized Suzuki Marine Dealer must be consulted as soon as possible. NOTE: If pilot hole water discharge is sufficient, buzzer If this system activates, the “Check Thermostat”...
  • Page 39 However, the caution alarm icon is displayed Suzuki Marine Dealer. until eliminating the cause. This system will be canceled automatically when the battery voltage restores to the proper voltage level.

  • Page 40: Electronic Throttle And Shift Control Caution System

    However, the caution alarm icon is displayed son, there may be a problem with the system. until eliminating the cause. Consult your authorized Suzuki marine dealer. NOTICE If this system activates for no apparent rea- son, there may be a problem with the system.
  • Page 41 2000 r/ NOTICE min. with the remote control lever. If this system activates for no apparent rea- son, there may be a problem with the system. Consult your authorized Suzuki marine dealer. THROTTLE SELECT ONLY NOTE: While the message, “Check Shift Control”, is...
  • Page 42 TROLL Mode operation is not available. Consult your authorized Suzuki marine dealer. If this system activates, the “Check Station Set- ting” is displayed on screen. GAUGE COMMUNICATION CAUTION...

  • Page 43: Keyless Start System Caution System (If Equipped With Keyless Start System)

    – The correct keyless fob has been authenti- cated by the Keyless Start System. • If this caution system activates continuously, contact your authorized Suzuki Maine Dealer. The “Check Troll System” indication clears when any of the button is pressed in the gauge.
  • Page 44 • If the message “Keyless Unit Battery Low” is TERY REPLACEMENT section.) displayed, check the following: – 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 45: Diagnostic System

    If the diagnostic system activates while you are operating your outboard motor, there is an abnormal condition in one of the sensor sig- nals of the control system. Consult your authorized Suzuki marine dealer for repair of the control system.
  • Page 46 CANCELLATION 4. If equipped with Keyless Start System: For the single engine: Press and hold the engine switch 1 for more 1. If equipped with Keyless Start System: than two seconds to turn off the power. Press and hold the engine switch 1 for more than two seconds to turn on the power.
  • Page 47 Once the system has operated, however, Suzuki strongly recom- mends that the engine oil be replaced before canceling the system activation. • Even if the engine oil has been replaced with the system not operating, it is still necessary to perform the cancellation.

  • Page 48: Engine Stalling Caution System

    If this system activates, stop the engine imme- diately, if wind and water conditions are safe to do so, and check the fuel filter/water separator for water. Or consult your authorized Suzuki marine dealer. For inspection and cleaning of the fuel filter,...
  • Page 49 V CAUTION If not equipped with Keyless Start System: V WARNING The motor is very heavy. When you tilt it man- ually, you could injure your back or slip and The power trim and tilt (PTT) switch on the fall causing injury. side cover can be accidentally activated when the ignition key is off, resulting in injury.
  • Page 50 If not equipped with Keyless Start System: NOTICE V CAUTION If you do not retract the trim rams completely when mooring, they may become deteriorated The remote Power Trim and Tilt switch will or corroded. work when the ignition key is off. If someone activates the switch while you are moving the Be sure to retract the trim rams completely tilt lock lever, your hand could be injured.

  • Page 51: Inspection Before Boating

    INSPECTION BEFORE 2. Pull out the oil dipstick and wipe oil off with a clean cloth. BOATING V WARNING Failure to inspect your boat and motor before beginning a trip can be hazardous. Before boating, always perform the inspec- tions described in this section. It is important to make sure that your boat and motor are in good condition and that you are NOTE:...

  • Page 52: Break-In

    BREAK-IN NOTICE Proper operation during this break-in period will Running the engine with an excessive amount help ensure maximum life and performance of oil can damage the engine. from your engine. The following guidelines will explain proper break-in procedures. Do not overfill the engine with oil. NOTICE 3.

  • Page 53: Operation

    OPERATION NOTE: You may throttle up beyond the recommended operating range to plane your boat, then imme- ENGINE SWITCH (OPTION) diately reduce the throttle to the recommended Use this switch if equipped with Keyless Start operating range. System. • Quickly press the engine switch to start and 2.
  • Page 54 CONTROL PANEL (OPTION) Start & Stop Switch This is a switch to start and stop the engine. The engine can be started with the remote con- trol handle at the neutral position. For dual engine For triple engine ] (UP) & [ ] (DOWN) The “Power Trim and Tilt”...
  • Page 55 • If the THROTTLE ONLY mode cannot be selected, turn off the power and wait for 20 seconds, and then turn on the power again. • Consult your authorized Suzuki marine dealer if the THROTTLE ONLY mode can not be selected.
  • Page 56 • If failed to switch from the 2nd station to the 1st station, turn off the power and wait for 20 seconds, and then turn on the power again. • Consult your authorized Suzuki marine dealer if the station can not be selected. Fuel hose SELECT 3.
  • Page 57 V WARNING 5. Make sure that the motor is in “NEUTRAL”. Failure to properly attach the emergency stop switch cord or to take proper precautions to help ensure that the emergency stop switch works as intended may result in serious injury or death to the operator or passengers.
  • Page 58 STARTING THE ENGINE (3) To start each engine individually, press and hold the engine switch for at least 2 seconds V WARNING to set Keyless Start System to ON state (buzzer sounds once). Then press the con- trol panel start/stop switch to start each Exhaust gas contains carbon monoxide, a engine individually.
  • Page 59 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. NOTE: If equipped with Keyless Start System: The communication range is a distance of 1 m (40 in) between the keyless fob and the keyless control unit.
  • Page 60 If equipped with Keyless Start System: 3. Enter a 6-digit passcode. Use the [ ] or [ ] buttons to select a num- EMERGENCY START ber for each digit. If the keyless fob cannot be used due to a dead Press the [SET] button to move to the next keyless fob battery or other issue, you can start digit.
  • Page 61 SHIFTING AND SPEED CONTROL To start the engine: 5. Make sure the motor is in “NEUTRAL”. NOTICE • Severe engine damage may occur if (a) engine speed is not allowed to return to idle and boat speed is not reduced when shift- ing from “FORWARD”...
  • Page 62 NOTE: A detent or notch is present on all Suzuki con- trol boxes to provide a “feel” for positions A, B, • When the engine stops, the clutch moves to and neutral. Always shift quickly and firmly from the neutral position irrespective of the posi- neutral to position A or B to prevent abnormal tion of the remote control lever.
  • Page 63 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 keyless fob is within emergency, pull the emergency stop switch lock the communication range of the keyless plate by pulling the emergency stop switch...
  • Page 64 If not equipped with Keyless Start System: NOTICE To stop the engine: 1. Shift into “NEUTRAL”. If the Keyless Start System is in ON state 2. After operating at full throttle, cool off the while the engine is not running, the battery engine a few minutes by allowing it to idle or will be discharged.
  • Page 65 NOTICE NOTICE If the ignition key is left ON when the engine is Improperly securing your boat may cause not running, the battery will discharge. damage to your boat or motor, or other prop- erty damage. Always turn the ignition key OFF when the engine is not running.
  • Page 66 ] or [ ] button. an analog to a digital display. NOTE: Please contact your authorized Suzuki Marine Dealer for more information. Setting the Troll Mode 1. Shift into forward or reverse gear and make sure that the throttle is fully closed (in-gear idle speed).
  • Page 67 Example of the troll mode display on the Multi- NOTE: Function Gauge that can operate the troll • This system will not function properly until mode. engine is at normal operating temperature. • If the [MENU] button is pressed and held while the remote control lever is in neutral, the mode will not switch to TROLL Mode.
  • Page 68 (in-gear idle speed) before pressing the NOTE: Please contact your authorized Suzuki Marine troll mode switch. Dealer for more information. In-gear idle speed of all engines is con- –...
  • Page 69 OPERATION IN FREEZING WEATHER Adjusting Trolling Speed When operating your outboard motor in freez- • When pressing the “UP” switch, one short ing temperatures, you should keep the lower beep sounds engine speed unit submerged in the water at all times. increases by 50 r/min.

  • Page 70: Motor Removal And Transporting

    MOTOR REMOVAL If it is necessary to remove the outboard motor from your boat, we recommend that you ask your authorized Suzuki Marine Dealer to do the work for you. MOTOR TRANSPORTING When transporting the motor, place the motor either vertically or horizontally.

  • Page 71: Trailering

    TRAILERING V WARNING When trailering your boat with the motor Spilled fuel or fuel vapor can cause a fire and attached, keep the motor in the normal operat- is hazardous to health. ing position unless there is not enough ground clearance.

  • Page 72: Inspection And Maintenance

    INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE V WARNING It is important to inspect and maintain your out- board motor regularly. Follow the chart below. At each interval, be sure to perform the indi- Exhaust gas contains carbon monoxide, a cated service. Maintenance intervals should be dangerous gas that is difficult to detect judged by number of hours or number of because it is colorless and odorless.
  • Page 73 When replacing Be sure to have maintenance performed parts on your outboard motor, Suzuki strongly according to the schedule in the above chart. recommends that you use genuine Suzuki Suzuki recommends that only your authorized parts or their equivalent.
  • Page 74 If the standard plug is not suit- 1. Remove the fuel hose guard 1. able for your operating, consult your authorized Suzuki Marine Dealer. 2. Remove the bolt securing the ignition coil. 3. Pull out the ignition coil.
  • Page 75 Consult your authorized brush or spark plug cleaner, and adjust the gap Suzuki Marine Dealer if it is necessary to according to the following chart: replace them. 0.8 – 0.9 mm...
  • Page 76 ENGINE OIL 3. Place a drain pan under the engine oil drain screw. V WARNING V CAUTION Never perform any ENGINE OIL procedure with the motor running, as serious injury can The engine oil temperature may be high occur. enough to burn your fingers when the drain plug is loosened.
  • Page 77 GEAR OIL 7. Check the engine oil level. To check the gear oil level, remove the upper oil level plug and look into the hole. The oil level should be at the bottom edge of the hole. If the oil level is low, add the specified gear oil until the level reaches the bottom edge of the hole.
  • Page 78 LOW PRESSURE FUEL FILTER V WARNING The low pressure fuel filter must be replaced by an authorized Suzuki Marine Dealer periodi- Gear oil can cause injury to people or pets. cally. Repeated, prolonged contact with used gear Replace low pressure fuel filter at every 400 oil may cause skin cancer.
  • Page 79 14. Restart the engine and check that there are no leaks around the fuel filter. NOTE: If any water exists in the fuel filter cup, remove the cup and drain the water. Always dispose of excess fuel safely. For questions, consult your authorized Suzuki Marine Dealer.
  • Page 80 LUBRICATION Proper lubrication is important for the safe, smooth operation and long life of each working part of your outboard motor. The following chart shows the lubrication points of your motor and the recommended lubricant: LOCATION LUBRICANT Clutch lever Shift link Marine-grade Marine-grade water resistant...
  • Page 81 • Periodically clean anodes with a wire brush to remove any coating which might decrease their protective ability. NOTE: Consult your authorized Suzuki Marine Dealer for inspection and replacement of internal anodes attached to the cylinder block/cylinder head.
  • Page 82 The battery solution level must be kept between The engine oil filter must be changed by autho- the MAX and the MIN level lines at all times. If rized Suzuki Marine Dealer periodically. the level drops below the MIN level line, add...

  • Page 83: Flushing The Water Passages

    2. Install the flushing attachment 1 so that the ENGINE RUNNING – Vertical position – water intake holes are covered by the rubber Suzuki recommends that you flush the water cups on the attachment. passages by using this method. 3. Connect a garden hose to the flushing...
  • Page 84 ENGINE NOT RUNNING 4. Turn on the water to obtain a good water – Vertical position – flow. Flush the engine for about five minutes. 1. Make sure that the motor is stopped. 5. Turn off the water. 2. Remove the plug A or C from the flushing 6.

  • Page 85: Submerged Motor

    SUBMERGED MOTOR 7. Take the motor to your authorized Suzuki Marine Dealer as soon as possible to be overhauled. A motor that has been accidentally submerged in water must be overhauled as soon as possi- NOTICE ble to prevent corrosion. In the event that your...

  • Page 86: Storage Procedure

    (for example, at the end of the boating sea- supplying water to the cooling system. son), it is recommended that you take your motor to your authorized Suzuki Marine Dealer. Never start the motor without supplying water However, if you choose to prepare the motor for to the cooling system.

  • Page 87: After Storage

    5. Clean the motor and wax the painted sur- If you are not sure about the proper action to faces. correct a problem, consult your Suzuki marine 6. Recharge the battery before installing it. dealer. Starter motor will not operate: •...
  • Page 88 Engine idles unstably or stalls: Engine vibrates excessively: • Spark plug is fouled. • Propeller is damaged. • Fuel hose is kinked or pinched. • Engine mounting bolts or clamp screws are • Fuel hose is not properly connected to loose.
  • Page 89 FUSE 4. Remove the sub battery cable fuse. 1. If equipped with Keyless Start System: Turn the Keyless Start System OFF. If not equipped with Keyless Start System: Turn the ignition key to the “off” position. 2. Remove the motor cover. 3.
  • Page 90 Shift actuator fuse: 15 A problem. PTT switch fuse: 10 A Fuel pump fuse: 15 A Consult your SUZUKI marine dealer. Load fuse: 60 A Main fuse: 60 A Spare fuse: 60 A Spare fuse: 30 A...

  • Page 91: Specifications

    SPECIFICATIONS Item DF115BG DF140BG Engine Type 4 Stroke Number of Cylinders Bore and Stroke 86.0 × 88.0 mm (3.39 × 3.46 in) Piston Displacement 2045 cm (124.8 cu. in) Maximum output 84.6 kW (115PS) 103.0 kW (140PS) Full Throttle Operating Range 5000 –...

  • Page 92: Flowchart Of Oil Change Reminder System

    FLOWCHART OF OIL CHANGE REMINDER SYSTEM Action Starting operation (*1) (*4) Indication Cancellation (*2) (*4) Indication Cancellation (*3) (*4) Indication Cancellation (*3) (*4) Indication Cancellation *1: Lapse of initial 20 hour’s operation *2: Lapse of 80 hour’s operation *3: Lapse of 100 hour’s operation Repeat *4: When performing cancellation before system activation...

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