Suzuki DF115B Owner's Manual
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Suzuki DF115B Owner's Manual

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DF115B
DF140B
OWNER'S MANUAL
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ENGLISH
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Summary of Contents for Suzuki DF115B

  • Page 1 DF115B DF140B 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

    LOCATION OF SAFETY LABELS ..8 LOCATION OF PARTS......9 MOTOR MOUNTING......11 BATTERY INSTALLATION ....11 USE OF ELECTRICAL ACCESSORIES ........13 SUZUKI KEYLESS START SYSTEM (IF EQUIPPED WITH ....14 KEYLESS START SYSTEM) PROPELLER SELECTION AND INSTALLATION........21 ADJUSTMENT........

  • 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 9: Location Of Parts

    LOCATION OF PARTS Motor cover Power trim and tilt (PTT) 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 10 Power trim and tilt (PTT) switch Lock-out Remote control handle lever Warm-up lever Main switch (If equipped with Keyless Start System) Ignition key (If not equipped with Keyless Start System) Emergency stop switch KEYLESS FOB Throttle tension adjuster (IF EQUIPPED WITH KEYLESS START SYSTEM) REMOTE CONTROL BOX Priming bulb...

  • Page 11: 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 12 Suzuki recommends that you install the termi- • Be sure to attach battery leads correctly. nal cap on the positive battery terminal to pre- •...

  • Page 13: 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 14: Suzuki Keyless Start System (If Equipped With Keyless Start System)

    Two (2) keyless fobs are supplied with the Key- less 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 15 • If the keyless fob and the emergency key are keyless fob. lost, immediately contact your authorized Suzuki Marine Dealer. NOTICE • The keyless fob uses a weak radio wave that is susceptible to external influences when it communicates with the keyless control unit.
  • Page 16 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 17 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 18 SETTING AND/OR CHANGING THE PASS- 6. Pull out the emergency stop switch lock CODE plate. By setting a 4-digit passcode, the engine can be started by entering the passcode even if the keyless fob battery has run down or the keyless fob is lost.
  • Page 19 NOTE: NOTE: If the operation in Step (2) is not performed • If a passcode is not entered during the 10 within 60 seconds after performing Step (1), the sounds, the process will start over again after passcode input operation will be cancelled and briefly turning the switch.
  • Page 20 (6) Install the lock plate on the emergency stop 6. Within eight (8) seconds after performing switch. Step 5, start the following operation. (7) Turn the main switch to the “ON & OFF” (1) Turn the main switch to the “ON & OFF” position and then release it to the “PUSH position and hold it for five (5) seconds or START/STOP”...

  • Page 21: 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 22: 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 23 TRIM TAB ADJUSTMENT Make a test run in the boat to determine if the This adjustment is used to compensate for the trim angle needs to be adjusted. Adjust the trim possible tendency of your boat to veer slightly angle using the Power Trim and Tilt system. If to port or starboard.
  • Page 24 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. 3. Make sure that remote control handle is in SETTING OF TILT UPPER LIMIT POSITION “NEUTRAL”.
  • Page 25 V WARNING 5. Press the “UP” side of the PTT switch for three seconds and the buzzer will sound twice briefly indicating the setting has been Setting of the tilt upper limit position will not canceled. prevent the outboard motor from tilting fully up and contacting the motor well if the motor’s lower unit hits an object at high speed.

  • Page 26: Caution System

    If the Caution System activates while you are operating your outboard motor, stop the motor as soon as possible and correct the NOTE: problem or consult your authorized Suzuki For checking the total motor operating hours, marine dealer for assistance. refer to the CHART OF TOTAL OPERATING HOURS INDICATION on the last page.
  • Page 27 “over-trim- ming” or “ventilation”, there may be a problem with the Over-Revolution Caution System. Consult your authorized Suzuki marine dealer if the Over-Revolution Caution System acti- NOTICE vates for no apparent reason. If the Caution System is not working properly,...
  • Page 28 If either of the above situations arises, your OVERHEAT CAUTION SYSTEM authorized Suzuki Marine Dealer must be con- This system is activated when the cylinder wall sulted as soon as possible. temperature is too high due to insufficient water cooling.

  • Page 29: Keyless Start System Caution System (If Equipped With Keyless Start System)

    NOTE: • If this caution system activates continuously, • A marginal battery may have enough power contact your authorized Suzuki Maine Dealer. to start your engine, yet may still cause this caution system to activate whenever engine or boat accessory use places a high current demand on the battery.
  • Page 30 • If this system activates, check the following: TERY 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 31: 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 32: Oil Change Reminder System

    OIL CHANGE REMINDER If not equipped with Keyless Start System: Turn the Ignition key to the “ON” position. SYSTEM NOTE: This system informs the operator of the time for When the ignition key is ON and the engine replacing engine oil on the basis of the mainte- inactivated, buzzer continues sounding.

  • Page 33: 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 34: Operation Of Tilting Systems

    OPERATION OF TILTING If not equipped with Keyless Start System: SYSTEMS V WARNING POWER TRIM AND TILT The power trim and tilt (PTT) switch can be The “Power Trim and Tilt” is operated by press- accidentally activated when the ignition key is ing the switch.
  • Page 35 TILT LOCK LEVER If equipped with Keyless Start System: The Tilt Lock Lever is provided so you can sup- V CAUTION port the motor in a tilted position for non-moving engine support. The remote Power Trim and Tilt switch will To set the Tilt Lock Lever: work when the Keyless start system is off.

  • Page 36: 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 37: 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 38: Operation

    OPERATION NOTE: You may throttle up beyond the recommended operating range to plane your boat, then imme- MAIN SWITCH (OPTION) diately reduce the throttle to the recommended If equipped with Keyless Start System: operating range. Turn the Keyless Start System to ON or OFF state by as follows.
  • Page 39 BEFORE ATTEMPTING TO START THE 5. Make sure that the motor is in “NEUTRAL”. ENGINE 1. The motor has been lowered into the water. 2. The fuel hose is securely connected to the fuel tank and the motor. 6. Make sure the lock plate is in place and attach the emergency stop switch cord to a part of your body.
  • Page 40 V WARNING If equipped with Keyless Start System: 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 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 41 NOTE: PUSH PUSH The continuous operating time of the starter START START ON & OFF ON & OFF STOP STOP motor is set at five seconds. When this time is exceeded, the starter motor will automatically stop. If the motor stops, wait about ten seconds for the motor to cool down and try again.
  • Page 42 If you notice that water does not spray out of the pilot water hole, stop the engine as soon as possible and consult your Suzuki Marine Dealer. NOTICE If you hold the ignition key at the “START” position to start the engine, the starter system can be damaged.
  • Page 43 V WARNING If equipped with Keyless Start System: EMERGENCY START Operating the boat when the emergency stop NOTE: switch is not operating properly can be haz- One (1) emergency key is included in the ardous. remote control box for the Keyless Start Sys- tem.
  • Page 44 3. Make sure lock plate 3 is in position. 6. Turn the emergency key to the “ON & OFF” position and hold it until the buzzer sounds. Turn the emergency key back to the “PUSH START/STOP” position. The system turns to stand-by state for passcode input.
  • Page 45 (3) After an 11th long sound, repeat steps 1 and (4) Turn the emergency key to the counterclock- 2 to enter the second, third and fourth pass- wise within 10 seconds after entering the 4th code digits. digit of the passcode. The buzzer emits two (2) short sounds when the passcode input is NOTE: successful, and the engine can then be...
  • Page 46 To start the engine: NOTE: (5) Install the lock plate 3 on the emergency Starting of another engine of the Dual Engine: stop switch. Push the main switch to start the engine. (6) Make sure the motor is in “NEUTRAL”. To stop the engine: 1.
  • Page 47 SHIFTING AND SPEED CONTROL 4. Turn the emergency key to the “ON & OFF” position and then release it to the “PUSH NOTICE START/STOP” position to turn the Keyless Start System to OFF state. And then, pull out the emergency key from the key cylinder. Severe engine damage may occur if (a) engine speed is not allowed to return to idle and boat speed is not reduced when shifting from...
  • Page 48 STOPPING THE ENGINE Shifting To shift into “FORWARD”, squeeze the lock-out NOTE: lever on the control handle and move the con- When it is necessary to stop the engine in an trol handle forward to approximately position A, emergency, pull the emergency stop switch lock as shown in the illustration.
  • Page 49 5. After stopping the engine, disconnect the PUSH PUSH fuel line from the outboard motor if there is a START START ON & OFF ON & OFF STOP STOP fuel connector. V WARNING If you leave the motor stopped for a long period of time with the fuel line connected, fuel can leak out.
  • Page 50 3. Turn the ignition key to the “OFF” position. NOTE: Always leave the ignition key in the “OFF” To make sure that the emergency stop switch position when the motor is not running, or operates properly, stop the engine occasionally the battery can discharge.
  • Page 51 Please contact your authorized Suzuki Marine 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. “DN” 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 52 OPERATION IN SHALLOW WATER OPERATION IN FREEZING WEATHER When operating your boat in shallow water, it When operating your outboard motor in freez- may be necessary to tilt the motor higher than ing temperatures, you should keep the lower the normal trim angle. When you tilt the motor unit submerged in the water at all times.

  • Page 53: 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 54: 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 55: 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 56 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 57 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 58 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 59 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 60 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 61 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 62 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 63 Swivel bracket water resistant grease (Grease Gun) Marine-grade water resistant grease Propeller shaft DF115B transom “L” Trim ram pad (DF140B) Steering bracket NOTE: Before applying grease through the steering bracket grease nipple, lock the motor in the fully tilted up position.
  • Page 64 • 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 65 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 66: 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 67 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 68: 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 69: 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 70: 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 71 FUSE The Keyless Start System does not turn 1. If equipped with Keyless Start System: ON even when the main switch is oper- Turn the Keyless Start System OFF. ated. The error sound (five short buzzer beeps) is NOT heard: If not equipped with Keyless Start System: (If equipped with Keyless Start System) Turn the ignition key to the “off”...
  • Page 72 If a new fuse blows in a short time after instal- lation, you may have a major electrical system Main fuse (60 A)/ problem. Load fuse (60 A) Consult your SUZUKI marine dealer. Normal fuse Blown fuse Normal fuse Blown fuse...

  • Page 73: Specifications

    Sub battery cable fuse: 15 A NOTE: Spare fuses 9 and 0 are provided for the back of fuse box cover. SPECIFICATIONS Item DF115B DF140B Engine Type 4 Stroke Number of Cylinders Bore and Stroke 86.0 × 88.0 mm (3.39 × 3.46 in)

  • Page 74: Information Regarding Ec - Directive

    INFORMATION REGARDING EC – DIRECTIVE (For European countries) Sound Pressure Level Regulation Sound pressure level limit 2013 / 53 / EU 75 dB(A) Sound pressure level is measured according to ISO 14509-1:2018. CHART OF TOTAL OPERATING HOURS INDICATION MONITOR-TACHOMETER Total Needle 1 operating REV-LIMIT...

  • Page 75: 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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