Suzuki DF100C Owner's Manual
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Suzuki DF100C Owner's Manual

Suzuki DF100C Owner's Manual

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DF100C
DF115B
DF140B
OWNER'S MANUAL
EN
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ENGLISH
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Summary of Contents for Suzuki DF100C

  • Page 1 DF100C 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..........5 INFORMATION REGARDING FUEL AND OIL........5 EC – DIRECTIVE ......... 88 LOCATION OF SAFETY LABELS ..8 LOCATION OF PARTS......9 SUZUKI KEYLESS START SYSTEM (IF EQUIPPED WITH ....11 KEYLESS START SYSTEM) OPERATION OF TILTING SYSTEMS..........15 METER (OPTION) MULTI-FUNCTION GAUGE .....

  • Page 5: Identification Number

    IDENTIFICATION Suzuki highly recommends that you use alco- hol-free unleaded gasoline whenever possible, NUMBER LOCATION with a minimum octane rating of 91 (Research method). However, blends of unleaded gasoline The model and identification numbers of your and alcohol with equivalent octane content may...
  • Page 6 Use the recommended gasoline which NOTICE conforms to the following labels. Gasoline kept in the fuel tank for long periods of time will produce varnish and gum, which can damage the engine. Always use fresh gasoline. 78RB0900* NOTICE Pump Labeling for Gasoline/Alcohol Blends Fuels containing alcohol can cause paint In some states, pumps that dispense gasoline/...

  • Page 7: 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 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 MULTI-FUNCTION GAUGE MONITOR-TACHOMETER Priming bulb (Option) FUEL LINE Power trim and tilt (PTT) switch Power trim and tilt (PTT) switch Lock-out Remote control handle lever Warm-up lever Remote control handle Ignition switch Emergency stop switch Free accelerator button Throttle tension adjuster SIDE MOUNT TYPE REMOTE CONTROL BOX TOP MOUNT TYPE REMOTE CONTROL BOX...

  • Page 11: Suzuki Keyless Start System (If Equipped With Keyless Start System)

    Keyless fob from accidently being pressed. NOTE: The keyless fob falls under the category of restricted electronic devices for use in flight. Keyless control unit NOTE: Please consult with a Suzuki Marine Dealer for the installation of the Keyless Start System.
  • Page 12 • 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 13 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 less fob for more than one second to switch is replaced with an incorrect type. between ON mode and OFF mode.
  • Page 14 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 15: 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 16: Tilt Lock Lever

    TILT LOCK LEVER To release the Tilt Lock Lever, tilt the motor all The Tilt Lock Lever is provided so you can sup- the way up using the Power Trim and Tilt “UP” port the motor in a tilted position for non-moving switch, and pull up the Tilt Lock Lever.

  • Page 17: Meter (Option) Multi-Function Gauge

    NOTE: There is information that cannot be displayed depending on the model and equipment. NOTE: Consult your authorized Suzuki marine dealer for setting up the multi-function gauge. NOTE: For details the proper handling of the multi- function gauge, refer “OPERATION...

  • Page 18: Button Functions

    BUTTON FUNCTIONS SCREEN SELECTION The multi-function gauge has four buttons: The multi-function gauge can select the display [MENU], [ ], [ ], and [SET]. screen from the following choices. • Engine Speed • Ground Speed/Fuel Information • Fuel Information • All Items Display Screen (Full Item) To select the display screen: Press the [SET] button and select the desired display screen.
  • Page 19 1. Engine Speed Display Screen 3. Fuel Information Display Screen The engine speed 1, shift position 2, trim This screen indicates the remaining fuel lev- position 3, time 4, engine position 5 and els of each tank installed, along with sub sub information 6 are displayed.
  • Page 20 NOTE: Digital Press and hold either the [ ] or [ ] button to reset the trip time, trip distance, average fuel consumption, and total fuel consumption in the sub information simultaneously. All other items are also reset simultaneously, in addition to the displayed item.
  • Page 21 4. Battery Voltage/Cooling Water Tempera- 8. Average fuel economy ture This screen indicates the total average fuel The cooling water temperature and battery economy of all outboard motors installed. voltage are displayed. 9. Total fuel used 5. Instantaneous fuel flow This screen indicates the total fuel used of This screen indicates the instantaneous fuel all outboard motors installed.
  • Page 22 MENU INFORMATION SELECTION Day or Night The menu screen is displayed when the MENU Press the [ ] or [ ] button to select “Day or button is pressed while any screen is displayed. Night”. Next, select “Day” or “Night” using the While the menu screen is displayed, press the [SET] button.
  • Page 23 2. Auto Trim NOTE: • “ A” is not displayed if the trim position does Sets the Auto Trim mode. Set the outboard motor to the full trim down not appear on the multi-function gauge position. Use the [ ] or [ ] buttons to select screen.
  • Page 24 Data Output NOTE: Display For details the proper handling of the multi- Tacho function gauge, refer “OPERATION INSTRUCTION MANUAL” packed in the gauge. Speed & Fuel Fuel ON OFF Press the [ ] or [ ] button to select “Data Output”...
  • Page 25 6. Keyless You can display the Keyless Start System pass- Device List CAN 2 code. You can also change the passcode. (1) If you have the keyless fob 34200-96L41 • Confirm the keyless fob is within the com- 33920-98L20 munication range of the Keyless Start 33920-98L20 System.
  • Page 26 Passcode appears once the [SET] button is pressed after you have entered all 6 digits. Language (2) If you do not have the keyless fob When the keyless start system starts up, English enter your passcode, and you can change it Français within 1 minute after unlocking.
  • Page 27 Quantity: set the unit for fuel quantity. Time Press the [SET] button to select the unit. Setting for the time indication. Clock: setting for display/non-display of the clock. Press the [SET] button to select “ON” or “OFF.” G ( US ) G ( IMP ) Quantity Speed Scale HIGH...
  • Page 28 The buzzer sound also stops when the cause is eliminated. Position Setting for the gauge and engine position. Consult your authorized Suzuki marine dealer for setting change of “Position”. Caution message Caution alarm icon Component Setting Settings for component.

  • Page 29: Caution System

    Suzuki For the next three seconds, the monitor- marine dealer for assistance. tachometer will indicate the total motor operat- ing hours by means of the lamp flashing and needle indicating.

  • Page 30: Over-Revolution Caution System

    “ON” position, the lamp or restore full engine operation. buzzer may be broken or a failure may exist in the system circuit. Consult your authorized Suzuki marine dealer.

  • Page 31: Oil Pressure Caution System

    “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- The “Low Oil Pressure” indication clears when vates for no apparent reason.

  • Page 32: Overheat Caution System

    Check the oil level and add oil if necessary. If the oil level is correct, consult your authorized Suzuki Marine Dealer. V WARNING The “Overheat” indication clears when any of the button is pressed in the gauge. However,...
  • Page 33 If the Overheat Caution System activates, stop In order to cancel this ALERT SYSTEM, quickly the engine as soon as possible, wind and stop the engine and consult with SUZUKI water conditions permitting, and inspect the marine dealer. engine according to the above instructions.

  • Page 34: Battery Voltage Caution System

    This system will be canceled automatically boat accessories, contact your authorized when the battery voltage restores to the proper Suzuki Marine Dealer. voltage level. Refrain from using any electrical equipment such as PTT system, hydraulic trim tabs, hydraulic jack plate, etc.
  • Page 35 NOTICE If this system activates for no apparent rea- son, there may be a problem with the system. Consult your authorized Suzuki marine dealer. The “Check Troll System” indication clears when any of the button is pressed in the gauge.

  • Page 36: Keyless Start System Caution System (If Equipped With Keyless Start System)

    – The keyless fob battery has sufficient capacity. – 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.

  • Page 37: Diagnostic System

    If this system activates, the red CHECK • If this caution system activates continuously, ENGINE lamp will flash and a buzzer will consult your authorized Suzuki Maine Dealer. sound. The failed system can be identified by the mode of the lamp flashing and buzzer sounding.

  • Page 38: Oil Change Reminder System

    Repeat nals of the control system. *1: Lapse of initial 20 hour’s operation Consult your authorized Suzuki marine dealer *2: Lapse of 80 hour’s operation for repair of the control system. *3: Lapse of 100 hour’s operation...

  • Page 39: System Activation

    SYSTEM ACTIVATION If equipped with multi-function gauge: When the total operating hours have reached the preprogrammed hours, the “Change Oil” is displayed on screen, and the buzzer sounds. This indication will repeat until you cancel the system activation. If not equipped with Keyless Start System: Turn the ignition key to the “ON”...

  • Page 40: Engine Stalling Caution System

    • Canceling of the system activation is possible regardless of whether or not the engine oil has been replaced. Once the system has operated, however, Suzuki strongly recom- mends that the engine oil be replaced before canceling the system activation.

  • Page 41: Motor Mounting

    “Certification Plate”. Contact your do so, and check the fuel filter/water separator authorized Suzuki marine dealer if you are for water. Or consult your authorized Suzuki unable to locate the hull “Certificate Plate”.

  • Page 42: Battery Installation

    To avoid creating a spark when is necessary, they should be replaced as a charging the battery, connect the battery char- set. Consult your Suzuki dealer for proper ger cables to the proper terminals before turn- battery installation information.

  • Page 43: Sub Battery Cable

    To remove the battery, first disconnect the black lead from the negative terminal, then discon- nect the red lead from the positive terminal. Suzuki recommends that you install the termi- nal cap on the positive battery terminal to pre- vent an accidental short circuit of battery terminals.

  • Page 44: Use Of Electrical Accessories

    Ask your authorized Suzuki marine dealer to assist you in selecting a suitable propeller for your boat. You can determine if your propeller is appropri-...

  • Page 45: Propeller Installation

    Always check the oil level before each trip and add oil if necessary. 1. Coat the propeller shaft splines 1 liberally with Suzuki water resistant grease to help To check the oil level: prevent corrosion. 2. Place the stopper 2 on the shaft.
  • Page 46 2. Pull out the oil dipstick and wipe oil off with a NOTICE clean cloth. Running the engine with an excessive amount of oil can damage the engine. Do not overfill the engine with oil. 3. Tighten the oil filler cap securely. •...

  • Page 47: Break-In

    BREAK-IN NOTE: You may throttle up beyond the recommended operating range to plane your boat, then imme- Proper operation during this break-in period will diately reduce the throttle to the recommended help ensure maximum life and performance operating range. from your engine. The following guidelines will explain proper break-in procedures.

  • Page 48: Operation

    BEFORE ATTEMPTING TO START THE OPERATION ENGINE 1. The motor has been lowered into the water. ENGINE SWITCH (OPTION) 2. The fuel hose is securely connected to the Use this switch if equipped with Keyless Start fuel tank and the motor. System.

  • Page 49: Starting The Engine

    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 50 NOTE: NOTE: If the emergency stop switch lock plate is not in The continuous operating time of the starter position, the starter motor cannot operate. motor is set at four seconds. When this time is exceeded, the starter motor If equipped with Keyless Start System: will automatically stop.
  • Page 51 START 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 52: Emergency Start

    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 53: Shifting And Speed Control

    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 shifting from “FORWARD”...

  • Page 54: Stopping The Engine

    STOPPING THE ENGINE A detent or notch is present on all Suzuki con- trol boxes to provide a “feel” for positions A, B, NOTE: and neutral. Always shift quickly and firmly from When it is necessary to stop the engine in an...
  • Page 55 4. After stopping the engine, disconnect the 3. Turn the ignition key to the “OFF” position. fuel line from the outboard motor if there is a Always leave the ignition key in the “OFF” fuel connector. position when the motor is not running, or the battery can discharge.
  • Page 56 NOTE: low tide or corrosion from salt water. Please contact your authorized Suzuki Marine Refer to the TILT LOCK LEVER section for Dealer for more information. details on how to tilt up the motor.
  • Page 57 3. When “YES” is selected: Example of the troll mode display on the When “YES” is selected and the [SET] but- Mmulti-function gauge that can operate the troll ton is pressed, one beep sounds to show mode. that it is now in TROLL Mode. At the same time, the screen will change and display the specific TROLL Mode screen, and is displayed on the gauge screen.
  • Page 58 700 r/min to 1200 r/min using the • When pressing the [ ] button, one short “UP” button or “DN” switch. beep sounds engine speed decreases by 50 r/min. “UP” switch TROLL MODE “DN” switch NOTE: Please contact your authorized Suzuki Marine Dealer for more information.
  • Page 59 NOTE: To monitor engine speed correctly during the troll mode operation, Suzuki recommends the use of the Suzuki 2-scale Monitor Tachometer. Usual scale NOTE: • This system will not function properly until engine is at normal operating temperature.

  • Page 60: Operation In Shallow Water

    OPERATION IN SHALLOW WATER NOTE: When operating your boat in shallow water, it • When pressing the “DN” switch at the lower may be necessary to tilt the motor higher than limit of trolling speed of all engines, the the normal trim angle. When you tilt the motor engine speed will not change and three long beyond the normal trim angle, however, you beeps will sound.

  • Page 61: Operation In Freezing Weather

    OPERATION IN FREEZING WEATHER ADJUSTMENT When operating your outboard motor in freez- ing temperatures, you should keep the lower TRIM ANGLE ADJUSTMENT unit submerged in the water at all times. When taking motor out of the water, stand it up V WARNING in a vertical position until the cooling system drains completely.
  • Page 62 To help maintain steering stability and good NOTICE performance, always maintain the proper trim angle as shown in the illustration. The appropri- If you operate the boat with the motor trimmed ate trim angle varies depending on the combi- beyond the maximum trim position, the water nation of the boat, engine, and propeller, as well intake holes may be above the water line, as operating conditions.

  • Page 63: Trim Tab 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. 3. Tighten the bolt that holds the trim tab in place.
  • Page 64 CANCELING THE TILT UPPER POSITION 3. Make sure that remote control handle is in LIMIT SETTING “NEUTRAL”. 1. If equipped with Keyless Start System: 4. Using the throttle only function of the remote Press and hold the engine switch 1 for more control box, move the lever until the caution than two seconds to turn on the power.

  • Page 65: Motor Cover Fastening Adjustment

    If not equipped with Keyless Start System: from your boat, we recommend that you ask Turn the ignition key to the “ON” position. your authorized Suzuki Marine Dealer to do the 3. Pull out the emergency stop switch lock work for you.
  • Page 66 (3) Pull the drain hose end 2 out. V WARNING (4) Loosen the vapor separator drain screw 3 and drain the gasoline into a suitable con- Spilled fuel or fuel vapor can cause a fire and tainer. is hazardous to health. Always take the following precautions: •...

  • Page 67: 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 68: 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 69 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 70: Spark Plug

    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 71: Breather And Fuel Line

    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 72 ENGINE OIL Engine oil change The oil should be changed when engine is V WARNING warm so that the oil will drain thoroughly from the engine. Never perform any ENGINE OIL procedure To change the engine oil: with the motor running, as serious injury can 1.
  • Page 73 GEAR OIL 5. After draining, secure the engine oil drain screw with a new gasket. V WARNING NOTICE Gear oil can cause injury to people or pets. Repeated, prolonged contact with used gear A previously-used gasket may leak, resulting oil may cause skin cancer. Even brief contact in engine damage.

  • Page 74: Low Pressure Fuel Filter

    NOTE: The low pressure fuel filter must be replaced by To avoid insufficient injection of gear oil, check an authorized Suzuki Marine Dealer periodi- the gear oil level 10 minutes after doing the pro- cally. cedure in the step 4. If the oil level is low, slowly Replace low pressure fuel filter at every 400 inject the gear oil up to the correct level.
  • Page 75 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 76 Inspect the MPC filter for dust and clogged ele- lower case 2 by turning the filter case cap ments. clockwise. Have your authorized Suzuki marine dealer replace the MPC filter if there is any evidence of clogging. MPC filter 5. Remove the filter 3.
  • Page 77 : Marine-grade water resistant grease (Use a grease gun to lubricate the grease nip- ple) Throttle/Shift linkage Swivel bracket Trim ram pad Swivel bracket (DF140B) DF100C/115B transom “L” only Propeller shaft Steering bracket IMP311020023-02 NOTE: Before applying grease through the steering bracket grease nipple, lock the motor in the fully tilted...

  • Page 78: Anodes And Bonding Wires

    ANODES AND BONDING WIRES NOTE: Anodes Consult your authorized Suzuki Marine Dealer The motor is protected from exterior corrosion for inspection and replacement of internal by anodes. These pieces of anodes control anodes attached to the cylinder block/cylinder electrolysis and prevent corrosion. The anodes head.

  • Page 79: Engine Oil Filter

    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 80: 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 81 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 82: 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 83: Table Of Contents Troubleshooting

    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 84 Engine idles unstably or stalls: The Keyless Start System does not turn ON even when the engine switch is oper- • Spark plug is fouled. • Fuel hose is kinked or pinched. ated. The error sound (three short buzzer • Fuel hose is not properly connected to beeps) is NOT heard: engine.
  • Page 85 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 86 If a new fuse blows in a short time after instal- Spare fuses 9 and 0 are provided for the back lation, you may have a major electrical system of fuse box cover. problem. Consult your SUZUKI marine dealer. Fuse box cover...

  • Page 87: 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 88: Specifications

    SPECIFICATIONS Item DF100C DF115B DF140B 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 73.6 kW (100PS) 84.6 kW (115PS) 103.0 kW (140PS) Full Throttle Operating Range 5000 –...
  • Page 89 Prepared by June, 2022 Printed in Japan © COPYRIGHT SUZUKI MOTOR CORPORATION 2022...

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