Suzuki DF115A Owner'S Manual Download | Manualshive

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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.

NOTICE

If you use the tilt lever to hold the motor
in the fully tilted up position when traile-
ring the boat, towing motion or poor road
surfaces may cause unexpected tilt lock
release, resulting in damage to the motor
and the tilt lock mechanism.

Never use the tilt lever to hold the motor
in the fully tilted up position when traile-
ring the boat. Use a transom saver bar or
similar device to support the weight of
the motor.

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Summary of Contents for DF115A

Page 1: ...1 ENGLISH DF115A DF115AS DF140A OWNER S MANUAL EN ...

Page 2: ...ructions clearer BREAK IN INFORMATION FOR YOUR OUTBOARD MOTOR The first 10 hours are the most important in the life of your engine Proper operation during this break in period is essential to help ensure max imum life and performance Refer to the BREAK IN section of this manual for specific break in recommendations IMPORTANT NOTICE TO OWNERS WARNING Failure to take the proper precautions may incre...

Page 3: ...uipment antennae too close to the engine cowling can cause electrical noise interference Suzuki recommends that antennae be mounted at least one meter 40 inches away from the engine cowling FOREWORD The proper care and maintenance that your outboard motor requires is outlined in this man ual By following these instructions explicitly you will ensure a long trouble free operating life for your outb...

Page 4: ...tate s department of boating and your Suzuki Marine dealer can supply you with addi tional information on boating safety and regula tions or you can call the U S Coast Guard Boating Safety Hotline toll free at 1 800 368 5647 TABLE OF CONTENTS FUEL AND OIL 6 GASOLINE 6 FILLING THE FUEL TANK 7 ENGINE OIL 8 GEAR OIL 8 LOCATION OF SAFETY LABELS 9 LOCATION OF PARTS 11 MOTOR INSTALLATION 12 EMISSION REL...

Page 5: ...ATER 57 OPERATING THE TROLL MODE Optional Item 58 OPERATION IN SALT WATER 59 OPERATION IN FREEZING WEATHER 59 MOTOR REMOVAL AND TRANSPORTING 59 MOTOR REMOVAL 59 MOTOR TRANSPORTING 59 TRAILERING 62 INSPECTION AND MAINTENANCE 63 NOTICE 63 MAINTENANCE SCHEDULE 63 TOOL KIT 64 SPARK PLUG 65 BREATHER AND FUEL LINE 66 ENGINE OIL 67 GEAR OIL 68 LOW PRESSURE FUEL FILTER 69 LUBRICATION 71 CORROSION PREVENTI...

Page 6: ... Do not use fuel having lower than the recommended octane or fuel that may be stale or con taminated by dirt water etc Gasoline Ethanol Blends Blends of unleaded gasoline and ethanol grain alcohol also known as gasohol may be used in your outboard motor if the ethanol content is not greater than 10 Fuel Pump Labeling In some states pumps that dispense oxygen ated fuels are required to be labeled f...

Page 7: ...e top or fuel may overflow when it expands due to heating by the sun Be careful not to spill fuel If you do wipe it up immediately Do not smoke and keep away from open flames and sparks NOTICE Fuels containing alcohol can cause paint damage which is not covered under the New Outboard Motor Limited Warranty Be careful not to spill fuel containing alcohol while refueling If fuel is spilled wipe it u...

Page 8: ...L If SUZUKI MARINE 4 CYCLE ENGINE OIL is not available select a NMMA certified FC W oil or good quality 4 cycle motor oil from the following chart according to the average temperatures in your area NOTE In very cold weather below 5 C 41 F use SAE or NMMA FC W 5W 30 for easier start ing and smooth operation GEAR OIL Suzuki recommends the use of SUZUKI HYPOID GEAR OIL If it is not available use SAE ...

Page 9: ...TISSEMENT 8 Fuel can leak creating a fire hazard if you lay motor on its side Drain fuel completely from vapor separator or carburetor before laying motor on its side See owner s manual for details Le carburent risque de fuir et de présenter un danger d incendie si le moteur est placé sur le côté Vidanger entièrement le carburant du séparateur de vapeurs ou du carburateur avant de procéder Pour pl...

Page 10: ... follows General warning symbol Caution or Warning Read owner s manual carefully Remote control lever gear shift lever operation two direction Forward Neutral Reverse Engine start Hazard caused by fire Hazard caused by laying the motor on its side ...

Page 11: ...UIPPED WITH KEYLESS START SYSTEM PRIMING BULB EMERGENCY PUSH START STOP START Ignition key Emergency stop switch Emergency stop switch Main switch If not equipped with keyless start system If equipped with keyless start system Power trim and tilt P T T switch Remote control handle Free accelerator button Main switch If equipped with Keyless Start System Ignition key If not equipped with Keyless St...

Page 12: ...ongly recommends that you have your outboard motor controls and gauges installed by your authorized Suzuki Marine Dealer He has the tools the facilities and the know how WARNING Overpowering your boat can be hazard ous Excessive horsepower will have an adverse effect on hull safety and may cause operating handling difficulties The boat may also sustain stress and hull damage Never install an outbo...

Page 13: ... the same type capacity manufac turer and of similar age When replacement is necessary they should be replaced as a set Consult your Suzuki dealer for proper battery installation information BATTERY INSTALLATION Secure the battery in a dry area of the boat away from vibration NOTE It is recommended that the battery be installed in an enclosed battery case When connecting batteries hexagon nuts mus...

Page 14: ...injury and can dam age painted surfaces Avoid contact with eyes skin clothing and painted surfaces If battery acid comes in contact with any of these flush immediately with large amounts of water If acid contacts the eyes or skin get immediate medical attention SUB BATTERY CABLE The sub battery cable 1 is used to supply volt age to the engine control system In the midst of the cable a 15 A fuse 2 ...

Page 15: ...ed in the Keyless Start System If the key fob ID is not registered the system prevents the engine from starting using the key fob Key fob Keyless control unit KEY FOB Two 2 key fobs are supplied with the Keyless Start System NOTE The key fob falls under the category of restricted electronic devices for use in flight WARNING Radio waves from the keyless control unit may interfere with the operation...

Page 16: ...gis tered in one keyless control unit The battery life of the key fob is about two 2 years which can vary depending on use The key fob is always in transmission mode in order to communicate with the keyless control unit For this reason the battery may run down quickly if it receives strong radio waves from televisions or personal comput ers etc NOTE The emergency key should be carried sepa rately ...

Page 17: ...y out of reach of children If someone swallows a lithium battery contact a physician imme diately CAUTION There is a danger of explosion if the bat tery is replaced with an incorrect type Only replace the battery with the same or equivalent type If the key fob battery runs low the red CHECK ENGINE lamp will flash To replace the key fob battery 1 Insert a flat blade screwdriver in the slot of the k...

Page 18: ... the O ring is damaged the waterproof performance deteriorates which can cause the key fob to malfunction Be careful not to damage the O ring when removing it 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 5 Reinstall the cover ...

Page 19: ... key fob section 5 Turn the main switch to the ON OFF position and then release it The main switch automatically returns to the PUSH START STOP position The buzzer on the engine control side emits one 1 long sound while the buzzer on the keyless control unit side emits two 2 short sounds simultaneously ON OFF ON OFF PUSH START STOP PUSH START STOP If equipped with side mount type remote control bo...

Page 20: ... by mode for the second passcode digit 3 Repeat Step 2 to enter the second third and fourth passcode digits 4 After entering the fourth pass code digit the buzzer emits one continuous sound within 60 seconds turn the switch ON and hold it for five 5 seconds until the buzzer stops then release it NOTE The buzzer emits one 1 short sound for the 1st digit two 2 short sounds for the 2nd digit three 3 ...

Page 21: ...of key fob blinks LED PASSCODE CONFIRMATION 1 Confirm that the engine is stopped 2 Make sure the emergency switch lock plate is in place 3 Confirm the key fob is within the communi cation range of the Keyless Start System 4 Confirm the key fob is in ON mode Refer to Switching the communication mode of the key fob section 5 Turn the main switch to the ON OFF position and then release it The main sw...

Page 22: ... operate your boat at full throttle depends on the propeller you use Excessive engine speed can seriously damage the motor while low engine speed at full throttle will adversely affect the performance Your operating load will also affect propeller selec tion Smaller loads generally require larger pitch propellers larger loads generally require smaller pitch propellers Your authorized Suzuki Marine...

Page 23: ...the shaft 5 Install the propeller nut 6 and tighten it with a torque wrench to 50 60 N m 5 1 6 1 kgf m 37 44 lbf ft WARNING Failure to take proper precautions when installing or removing the propeller can result in severe personal injury When installing or removing the propeller Always shift into Neutral and remove the emergency stop switch lock plate so that the motor cannot be started accidental...

Page 24: ...roper trim angle WARNING Trim angle greatly affects steering stabil ity If the trim angle is too small the boat may plow or bow steer If the trim angle is too large the boat may chine walk from side to side or porpoise up and down These conditions which result in loss of steering control can cause occupants to be thrown overboard Always maintain proper trim angle based on the combination of your b...

Page 25: ...he maximum trim posi tion the water intake holes may be above the water line causing severe engine damage due to overheating Never operate the boat with the motor trimmed beyond the maximum trim posi tion 2 If the boat tends to veer to port move the 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 board side 3 Ti...

Page 26: ...cannot be set within the specified range contact your authorized Suzuki Marine Dealer Side mount type SETTING OF TILT UPPER LIMIT POSITION If the outboard motor contacts the motor well of the boat during full tilt up operation the upper limit setting should be reset Perform this set up after the current position setting has been canceled as explained in the following procedure CANCELING THE TILT U...

Page 27: ... to the fully closed posi tion SETTING THE TILT UPPER POSITION LIMIT 7 Press the UP side of the PTT switch so that the optimum full tilt up position for the boat can be obtained 8 If equipped with Keyless Start System Turn the Keyless Start System ON If not equipped with Keyless Start System Turn the ignition key to the ON position 9 Pull out the emergency stop switch lock plate 10 Make sure that ...

Page 28: ...upper limit position will not prevent the outboard motor from tilt ing fully up and contacting the motor well if the motor s lower unit hits an object at high speed Such tilting could damage your motor and boat and injure the boat occupants Keep all occupants away from the motor when operating at high speed MOTOR COVER FASTENING ADJUSTMENT If you feel motor cover fastening is loose or too tight wh...

Page 29: ...tion System activates while you are operating your outboard motor stop the motor as soon as possible and cor rect the problem or consult your autho rized Suzuki marine dealer for assistance For the next three seconds the monitor tachometer will indicate the total motor operat ing hours by means of the lamp flashing and needle indicating After this brief check period the monitor tachometer will ret...

Page 30: ...e damage to your out board motor If any of the four lamps does not come on or the buzzer does not sound when the ignition key is turned to the ON posi tion the lamp or buzzer may be broken or a failure may exist in the system circuit Consult your authorized Suzuki marine dealer OVER REVOLUTION CAUTION SYSTEM This system is activated when engine speed exceeds maximum recommended speed for more than...

Page 31: ...cking the oil level stop the engine and remove the motor cover COOLING WATER CAUTION SYSTEM This system is activated when the cylinder wall temperature is too high due to insufficient water cooling NOTE The cooling water caution system will not detect high combustion chamber temperature caused by for example an oil system malfunction poor quality fuel or spark plugs with an incorrect heat range If...

Page 32: ...ses 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 Run engine in NEU TRAL only until the caution systems are can celled NOTE Remember that the cooling water caution sys tem cannot detect overheati...

Page 33: ...ARNING Failure to take proper precautions when inspecting or servicing the battery can be hazardous Do not attempt to inspect or service the battery without first reading the warn ings cautions and instructions in the BATTERY INSTALLATION section of this manual KEYLESS START SYSTEM CAUTION SYSTEM IF EQUIPPED WITH KEYLESS START SYSTEM KEY FOB CAUTION SYSTEM The caution system is activated when key ...

Page 34: ... REPLACEMENT section KEYLESS CONTROL UNIT CAUTION SYSTEM This system is activated when the 12 volt bat tery voltage to the keyless control unit drops to a point which could impair the keyless control unit performance If this system activates the red CHECK ENGINE lamp will flash NOTE If this system activates check the following The 12 volt battery is in sound condition Contact failure of the batter...

Page 35: ...0 seconds when the Diagnostic System is activated then it stops automatically This diagnostic code is designed to appear while the Keyless Start System is in ON state NOTE If not equipped with Keyless Start System The CHECK ENGINE lamp will light briefly when the ignition key is turned to the ON position The failed system can be identified by the mode of the red CHECK ENGINE lamp flash ing and buz...

Page 36: ...one of the main switch In case system activation cancellation is per formed on the Twin Switch Panel the operat ing time of the two outboard motors will be reset simultaneously 1 If equipped with Keyless Start System Turn the Keyless Start System to ON state by turn the main switch to the ON OFF position and then release it The main switch automatically returns to the PUSH START STOP position NOTE...

Page 37: ...PUSH START STOP PUSH START STOP If equipped with top mount type remote control box Main switch panel ON OFF ENGINE STALLING CAUTION SYSTEM This system informs the operator when the motor stalls while it is operating When the engine stalls for any reason the cau tion buzzer sounds three times WATER IN FUEL ALERT SYSTEM This engine is equipped with an integral fuel fil ter water separator and associ...

Page 38: ...ip Each engine can be operated by the switches 2 at the cover separately If equipped with Keyless Start System If not equipped with Keyless Start System WARNING The power trim and tilt PTT switch on the side cover can be accidentally acti vated when the Keyless Start System is in OFF state resulting in injury Keep all persons away from the outboard motor to help prevent accidental activa tion of t...

Page 39: ...y When you tilt the motor manually ensure that your grip and footing are secure and that you are able to support the weight of the engine TILT LEVER The Tilt Lever is provided so you can support the motor in a tilted position for non moving engine support To set the Tilt Lever 1 Tilt the motor all the way up by pressing the Power Trim and Tilt UP switch 2 Pull down the Tilt Lever as shown in the i...

Page 40: ...s otherwise stationary The tilt lever relieves pressure from the power trim and tilt and should only be used when the boat is stationary Do not use the tilt lever when trailering your boat and motor Refer to the TRAILERING sec tion of this manual If not equipped with Keyless Start System CAUTION The remote Power Trim and Tilt switch will work when the ignition switch is off If someone activates th...

Page 41: ...your boat and motor before beginning a trip can be hazardous Before boating always perform the inspections described in this section NOTICE Running the engine with an insufficient amount of oil can cause serious engine damage Always check the oil level before each trip and add oil if necessary 1 Place the motor in a vertical position then remove the motor cover 1 by unlocking the lever 2 and 3 2 P...

Page 42: ...level The level should be kept between the MAX and the MIN level lines at all times If the level drops below the MIN level line refer to MAINTENANCE section Make sure that the battery leads are securely connected to the battery termi nals Visually check the propeller to make sure it is not damaged Make sure the motor is securely mounted to the transom Check for proper operation of the Power Trim a...

Page 43: ...can result in severe engine damage Be sure to follow the engine break in pro cedures described below NOTICE Running at high speed without sufficient warm up may cause severe engine dam age such as piston seizure Always allow sufficient idling time 5 min utes for the engine to warm up before running at high speed 2 For the next 1 hour Safe boating conditions permitting operate the engine in gear at...

Page 44: ...side mount type remote control box PUSH START STOP If equipped with top mount type remote control box Main switch panel NOTE If the operation in the above step 2 is per formed continuously it is regarded as a theft or tampering and the main switch operation will not be accepted until a certain period has elapsed BEFORE ATTEMPTING TO START THE ENGINE 1 Lower the motor into the water 2 If there is a...

Page 45: ... and clamped 4 Direct the pilot water hole to the position you intend 5 Make sure the motor is in NEUTRAL Fuel hose Side mount type Top mount type 6 Make sure the lock plate is in place and the emergency stop switch cord is fastened securely to your wrist or appropriate clothing area such as your belt ...

Page 46: ...bruptly and the loss of forward motion may unexpectedly throw occu pants forward WARNING Exhaust gas contains carbon monoxide a dangerous gas that is difficult to detect because it is colorless and odorless Breathing carbon monoxide can cause death or severe injury Never start the engine or let it run indoors or where there is little or no ventilation If equipped with Keyless Start System 1 Squeez...

Page 47: ...his 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 5 Warm up the engine for about 5 minutes NOTICE 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 en...

Page 48: ... start NOTE The continuous operating time of the starter 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 4 Warm up the engine for about 5 minutes NOTICE If you hold the ignition key at the START position to start the engine the starter system can be damaged Turn the ...

Page 49: ...tely after starting the engine without allowing the engine to warm up may cause engine fail ure Always allow the engine to warm up suffi ciently before operating it at high speeds NOTICE Never operate your outboard motor when there is no water coming out of the pilot water hole or severe damage can result After starting the engine check to make sure that there is water coming out of the pilot wate...

Page 50: ...art System OFF locked state can be released by using the emergency key and entering the 4 digit passcode 1 Turn the main switch 1 to the right about 15 and pull it out 2 Insert the emergency key 2 into the key cyl inder 15 3 Make sure lock plate 3 is in position 4 Turn the emergency key to ON OFF position and then release it to the PUSH START STOP position The buzzer emits one 1 long sound and fiv...

Page 51: ...H START STOP PUSH START STOP If equipped with top mount type remote control box Main switch panel ON OFF ON OFF ON OFF PUSH START STOP PUSH START STOP If equipped with top mount type remote control box Main switch panel ON OFF 3 After an 11th long sound repeat steps 1 and 2 to enter the second third and fourth pass code digits NOTE The buzzer emits one 1 short sound for the 1st digit two 2 short s...

Page 52: ...gency key to the counterclock wise within 10 seconds after entering the 4th digit of the passcode The buzzer emits two 2 short sounds when the passcode input is successful and the engine can then be started If the emergency key is not operated within 10 seconds the buzzer sounds five 5 times followed by another beep and the input operation is cancelled In this case repeat the procedure beginning a...

Page 53: ... ON OFF position and then release it to the PUSH START STOP position to turn the Keyless Start System to OFF state And then pull out the emergency key from the key cylinder NOTE The passcode authentication state is main tained for 15 seconds after turning the emer gency key to the PUSH START STOP position In this state the engine can be started by turning the emergency key to the left and pressing...

Page 54: ... operating the boat in reverse Always allow the engine speed to return to idle before shifting Exercise caution and use minimal speed when operating the boat in reverse Be sure the handle shift lever is in the desired position before accelerating NOTICE If you shift gears when the engine is not running the shifting mechanism can be damaged Avoid shifting gears when the engine is not running NOTE T...

Page 55: ... is within the communication range of the keyless con trol unit Turn the main switch to the ON OFF position and then release it The main switch automatically returns to the PUSH START STOP position The buzzer sounds once to notify that the Keyless Start System has been turned to OFF locked state NOTE If equipped with Dual Engine When either one of the engines of Keyless Start System is turned OFF ...

Page 56: ...ead to an accident or damage to your boat To prevent unauthorized use of your boat be sure to remove the key and emergency stop switch lock plate when the boat is unattended WARNING If you leave the motor stopped for a long period of time with the fuel line connected fuel can leak out Disconnect the fuel line from fuel tank if there is a fuel connector whenever you leave the motor stopped for a lo...

Page 57: ... is a fuel connector whenever you leave the motor stopped for a long period of time OPERATION IN SHALLOW WATER When operating your boat in shallow water it may be necessary to tilt the motor higher than the normal trim angle When you tilt the motor beyond the normal trim angle however you should only operate the boat at slow speeds After returning to deep water be sure to lower the motor to the no...

Page 58: ...t into forward or reverse gear and make sure that the throttle is fully closed in gear idle speed 2 Press the UP or DN position of the troll mode switch until you hear one beep The REV TRL or REV lamp on the monitor gauge will flash indicating that the motor has been set to the troll mode The REV TRL or REV lamp will continue to flash while the motor is in the troll mode NOTE The troll mode system...

Page 59: ... cooling system drains completely NOTICE If you leave your outboard motor out of the water in freezing temperatures with water still in the cooling system the water can freeze and expand causing severe damage to the motor When your outboard is in the water in freezing temperatures keep the lower unit submerged in the water at all times When the motor is stored out of the water in freezing temperat...

Page 60: ...draining retighten the drain screw and reinstall the all items back in place 3 Rest the motor on a case protector with the starboard side downwards as shown WARNING Gasoline is extremely flammable and toxic It can cause a fire and can be haz ardous to people and pets Use a proper safe container to store any gasoline drained from the outboard motor Keep gasoline away from sparks flames people and p...

Page 61: ...oling water com pletely damage can occur Engine oil may enter the cylinder from the sump water may enter the cylinder through the exhaust port or the outer casings may be damaged Always drain the engine oil and cooling water completely before laying the motor on its side and be careful laying the motor down NOTE When horizontal transportation is performed the matte finish paint may be damaged For ...

Page 62: ...ar device to support the weight of the motor NOTICE If you use the tilt lever to hold the motor in the fully tilted up position when traile ring the boat towing motion or poor road surfaces may cause unexpected tilt lock release resulting in damage to the motor and the tilt lock mechanism Never use the tilt lever to hold the motor in the fully tilted up position when traile ring the boat Use a tra...

Page 63: ...PART WHICH HAS BEEN CERTIFIED UNDER THE PROVISIONS IN THE CLEAN AIR ACT Sec 207 a 2 WARNING Exhaust gas contains carbon monoxide a dangerous gas that is difficult to detect because it is colorless and odorless Breathing carbon monoxide can cause death or severe injury Never start the engine or let it run indoors or where there is little or no ventilation Interval Item to be serviced Initial 20 hrs...

Page 64: ...e motor NOTICE The maintenance intervals in the chart are designed for normal usage of your outboard motor If your outboard motor is used under severe conditions as outlined below you may need to perform mainte nance more often than indicated in the chart Frequent full throttle operation TOOL KIT A tool kit is provided with your outboard motor Keep the kit on board your boat and make sure that all...

Page 65: ...ion of the elec tronic ignition causing misfiring or causing problems with other electronic boat equipment and accessories Use ONLY resistor type spark plugs in your outboard motor Center electrode Insulator Ground electrode Gap NOTICE Use of improper spark plugs or improp erly tightening spark plugs can cause severe engine damage Do not experiment with other spark plug brands unless you can deter...

Page 66: ...placed Spark plug gap 0 7 0 8 mm 0 028 0 031 in BREATHER AND FUEL LINE Inspect the breather and fuel line for leaks cracks swelling or other damage If the breather and fuel line are damaged in any way they must be replaced Consult your authorized Suzuki Marine Dealer if it is necessary to replace them WARNING Fuel leakage can contribute to an explo sion or fire resulting in serious personal injury...

Page 67: ...equently if your engine is used for extended trolling 3 Place a drain pan under the engine oil drain screw 4 Remove the engine oil drain screw 1 and gasket 2 then let the engine oil drain 5 After draining secure the engine oil drain screw with a new gasket NOTE There are spare gaskets in the tool bag 6 Fill with recommended engine oil to the upper level Oil capacity 5 5 L 5 8 4 8 US Imp qt Engine ...

Page 68: ...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 Then reinstall and tighten the plug Periodic gear oil replacement is essential for long life of your outboard motor To change the gear oil 1 Make sure the motor is in an upright posi tion Place a drain pan under the lower c...

Page 69: ...until the oil is changed and the cause of the contamination is corrected LOW PRESSURE FUEL FILTER The low pressure fuel filter must be replaced by an authorized Suzuki Marine Dealer periodi cally Replace low pressure fuel filter at every 400 hours 2 years Inspect and clean the fuel filter as follows 1 Turn the engine off and allow it to cool 2 If equipped with Keyless Start System Make sure that t...

Page 70: ... before removing the filter cup a 7 Drain the fuel and water in the filter cup into a suitable container 8 Pull out the filter element 7 Inspect the filter element 7 O ring 8 and seal ring 9 for damage If they are damaged replace them 9 Wash the filter element with clean solvent and dry it 10 Reinstall the seal ring and filter element in their original positions 11 Verify that the O ring is in pla...

Page 71: ...each working part of your outboard motor The following chart shows the lubrication points of your motor and the recommended lubricant LOCATION LUBRICANT Throttle Shift linkage Marine grade water resistant grease Propeller shaft Trim ram pad DF140A DF115AS NOTE Before applying grease through the steering bracket grease nipple lock the motor in the fully tilted up position Your authorized Suzuki Mar...

Page 72: ...ro sion measures may be helpful under those con ditions Consult your authorized Suzuki Marine Dealer for details NOTE Consult your authorized Suzuki Marine Dealer for inspection and replacement of internal anodes attached to the powerhead NOTICE If anodes are not properly maintained underwater aluminum surfaces such as the lower unit will suffer galvanic corro sion damage Periodically inspect anod...

Page 73: ...s below the MIN level line add DIS TILLED WATER ONLY until the battery solution level reaches the MAX level line WARNING Battery acid is poisonous and corrosive and can cause severe injury Avoid contact with eyes skin clothing and painted surfaces If battery acid comes in contact with any of these flush immediately with large amounts of water If acid contacts the eyes or skin get immediate medical...

Page 74: ...brackish or salt water you should flush the water passages and motor surface with clean fresh water If you do not flush the water passages salt can corrode the motor and shorten its life Flush the water passages as follows ENGINE RUNNING Vertical position Suzuki recommends that you flush the water passage by using this method To flush the water passages you must obtain a commercially available eng...

Page 75: ...gine 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 5 Allow the engine to run only at idle speed while flushing Readjust the water flow if necessary so that there is still plenty of excess water flowing out from around the rubber cups 6 Allow the water to continu...

Page 76: ...ossible to prevent corrosion If pos sible have a qualified marine dealer service the engine If immediate servicing is not available take the following steps to help protect your motor In the event that your motor is acciden tally submerged take the following steps 1 Get the motor out of the water as soon as possible 2 Remove the motor cover and immediately wash the engine thoroughly with fresh wat...

Page 77: ...or a long period of time for example at the end of the boating sea son it is recommended that you take your motor to your authorized Suzuki Marine Dealer However if you choose to prepare the motor for storage yourself follow the procedure outlined below 1 Change the gear oil as outlined in the GEAR OIL section 2 Change the engine oil as outlined in the ENGINE OIL section 3 Fill a high quality fuel...

Page 78: ... the engine 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 BATTERY STORAGE 1 When the outboard motor will not be used for a month or longer remove the battery and store it in a cool dark place Do not set battery on concrete or earth as this w...

Page 79: ...ave a matte finish 6 Recharge the battery before installing it GENERAL INFORMATION WARRANTIES For U S A The warranties covering your outboard motor are explained in a separate Limited Warranty booklet given to you at the time of sale Please read this booklet carefully so you can under stand your rights and responsibilities IDENTIFICATION NUMBER LOCATION The model and identification numbers of your...

Page 80: ...m Ignition Key Number Ignition key number stamped position Spare key EMISSION CONTROL INFORMATION NOTICE THIS ENGINE IS CERTIFIED TO OPER ATE ON UNLEADED GASOLINE OF 87 OCTANE R M 2 METHOD OR GREATER EXHAUST EMISSION CONTROL SYSTEM ECM MFI HO2S ...

Page 81: ...ngine is overloaded Propeller is not properly matched to loads The Keyless Start System does not turn ON even when the main switch is oper ated The error sound five short buzzer beeps is NOT heard If equipped with Keyless Start System Emergency stop switch lock plate is not in position The main switch has been operated continu ously while the communication with the key fob is disabled Battery term...

Page 82: ...TARTER RELAY SPARE 15A 30A 30A 60A LOAD 60A MAIN PLUG Fuse puller 4 Inspect the fuse and replace with new fuse if needed NOTE If a fuse is blown try to determine the root cause and correct it If the cause is not corrected the fuse may be blown again WARNING If you replace a blown fuse with a fuse having a different amperage rating or with a substitute such as aluminum foil or a wire extensive elec...

Page 83: ...IN RELAY STARTER RELAY SPARE 15A 30A 30A 60A LOAD 60A MAIN PLUG Fuse box cover 1 Main fuse 60 A 2 Load fuse 60 A 3 PTT switch fuse 15 A 4 Ignition coil Injector ECM IAC fuse 30 A 5 Starter motor relay fuse 30 A 6 Fuel pump fuse 15 A 7 Spare fuse 60 A 8 Spare fuse 30 A 9 Spare fuse 10 A NOTE Spare fuses 8 and 9 are provided for the back of fuse box cover ...

Page 84: ... Throttle Operating Range 5000 6000 r min min 1 5600 6200 r min min 1 Idle speed in Neutral 700 50 r min min 1 Ignition System Full transistor Engine Lubrication Trochoid pump pressure lubrication Engine Oil Capacity 5 5 L 5 8 4 8 US Imp qt Spark Plug NGK BKR6E Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in Valve Lash IN 0 23 0 27 mm 0 009 0 011 in EX 0 23 0 27 mm 0 009 0 011 in Fuel Type Alcohol free u...

Page 85: ...ting hours MONITOR TACHOMETER Needle 1 indication REV LIMIT lamp 2 flashing 0 h 49 h No No 50 h 500 r min No 60 h 600 r min No 540 h 5400 r min No 550 h 500 r min 1 time 560 h 600 r min 1 time 1040 h 5400 r min 1 time 1050 h 500 r min 2 times 1540 h 5400 r min 2 times 1550 h 500 r min 3 times 2030 h 5300 r min 3 times 2040 h or over 5400 r min 3 times Action Starting operation Cancellation Indicat...

Page 86: ...R G R G R G B R G B B B B B B B B B B Y Y O Y O Y B B B Bl B Bl Y O Y B B Bl W W R B R B W W W W G G R R R R Gr Gr R R R R W W W W W W W W W R W R W W Y G Y G Y G Y G W R B W W G R R R R W W W W W R W Y G Y G W W W W W W W W W W W W B R B R B B G B G R W R W B W B W R B B G B W B B W W W R R R R R R R R R R R R W W W G W G W P W P W Bl B Bl B G W P W Bl B G W G W P W P W Bl B Bl B G W P W Bl B G W...

Page 87: ... G B B B B B B B B B B Y Y O Y O Y B B B Bl B Bl Y O Y B B Bl W W R B R B W W W W G G R R R R Gr Gr R R R R W W W W W W W W W R W R W W Y G Y G Y G Y G W R B W W G R R R R W W W W W R W Y G Y G W W W W W W W W W W W W B R B R B B G B G R W R W B W B W R B B G B W B B W W W R R R R R R R R R R R R W W W G W G W P W P W Bl B Bl B G W P W Bl B G W G W P W P W Bl B Bl B G W P W Bl B G W G W P W P W Bl...

Page 88: ...OX MAIN SWITCH KEYLESS BUZZER KEYLESS CONTROL UNIT KEYLESS BUZZER MAIN SWITCH KEYLESS CONTROL UNIT KEYLESS BUZZER W TUBE NEUTRAL SWITCH FUSE 15A Side mount remote control model METER BUZZER NEUTRAL SWITCH ECM PWR RELAY DUMMY SELECT PTT SWITCH TRIM METER SHIFT POSITION SENSOR NEUTRAL SWITCH N ON F R OFF Y G Y B Br Bl B Bl P Bl B W Y G R W W G W R W R P B Lg Lbl W R P Lbl B Lg B Lg R W Y Bl B Bl W B...

Page 89: ... B Bl B G W P W Bl B G W G W P W P W Bl B Bl B G W P W Bl B G W G W P W P W Bl B Bl B G W P W Bl B Y O Y O Y B B Bl B Bl Y O Y B B Bl Gr O B B Bl Gr R W B B Lg W B W B Bl Bl Gr Gr O B O B Gr Gr R W R W Lg W Lg W B W B W Gr Gr O Gr O Gr Gr Bl Bl Gr Bl B Bl Gr O B Gr Gr B Br B Br Gr B Br Gr R W B B Lg W B W Y Bl Y Bl B W B W B Bl B Bl Y Bl B W B Bl W R W R P Lbl Lbl W R P Lbl W R W R P Lbl Lbl W R P...

Page 90: ...W Bl B Bl B G W P W Bl B G W G W P W P W Bl B Bl B G W P W Bl B G W G W P W P W Bl B Bl B G W P W Bl B Y O Y O Y B B Bl B Bl Y O Y B B Bl Gr O B B Bl Gr R W B B Lg W B W B Bl Bl Gr Gr O B O B Gr Gr R W R W Lg W Lg W B W B W Gr Gr O Gr O Gr Gr Bl Bl Gr Bl B Bl Gr O B Gr Gr B Br B Br Gr B Br Gr R W B B Lg W B W Y Bl Y Bl B W B W B Bl B Bl Y Bl B W B Bl W R W R P Lbl Lbl W R P Lbl W R W R P Lbl Lbl W...

Page 91: ...Prepared by August 2019 Part No 99011 90JA0 03B Printed in Japan COPYRIGHT SUZUKI MOTOR CORPORATION 2019 ...

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