55509-Suzuki DF115-140 Brochure-v3
PRODUCT INFORMATION
Way of Life!
Fully Committed to the Future
Suzuki’s four-stroke outboards, the DF115 and DF140, are
the product of years of experience in the design, development and
manufacturing of motorcycle, automotive and outboard engines.
Experience that has resulted in environmentally friendly, awardwinning designs.
Suzuki engineers have gone to great lengths to keep both
engines as compact as possible. The utilization of an offset drive
shaft, combined with a two-stage mixed cam drive—a first for any
outboard—offers overall compactness as well as increased
performance. Suzuki engineers also worked hard to make
these outboards as quiet as possible. A larger silencer,
a very low 620 rpm idle speed and stiffer crankshaft,
crankcase, engine holder and cowling all work
together to reduce engine noise and vibration.
Performance is delivered with the engine’s
superior power and enhanced prop efficiency due to
the use of a 2.59 gear ratio, large pitch and diameter
prop.
These motors not only meet the 2006 EPA*
exhaust emission standards, their clean, efficient
operation has allowed them to comply with the 2008
CARB** which represents a 65% reduction from the
2006 EPA emission standards.
Committed to the future, Suzuki has and will continue
to provide boaters with the best in performance, reliability and
durability it has to offer.
* Exhaust emission standards set by the U.S. Environmental Protection Agency.
** Exhaust emission standards set by the California Air Resources Board.
2
DF115/140 PRODUCT INFORMATION
The following points have been kept in
mind in the design of the DF115 and
DF140 outboard motors.
■
Create an overall design that is compact.
■
Offer boaters low fuel consumption, low noise level and low
vibration.
■
Provide boaters with an outboard that delivers maximum
power and performance.
■
Incorporate Electronic Fuel Injection for better fuel economy
and performance.
■
Ensure Compliance with CARB (California Air Resources
Board) exhaust emission standards set to take effect in the
year 2008 and EPA 2006 exhaust emission standards.
Compact Outboards
Offset Drive Shaft
DF115
DF140
Four Stroke Engine Size / Profile Comparison
Along with creating clean-running outboards,
Brand A 115HP
another important goal that Suzuki engineers
set for the DF series was to create a compact
outboard. With the DF115 and DF140 they have
DF115
Brand B 100HP
DF140
surpassed their goal. The overall design has the
same sleek, flowing lines that have been found
throughout the entire DF series.
But it is underneath the body where Suzuki’s
Brand A 130PS
engineers have been hard at work. In order to
create a compact outboard, they incorporated an
offset drive shaft into the system. The use of the
offset drive shaft allowed for other size-reducing
measures such as the utilization of two-stage
mixed cam system, which in turn has allowed the
use of a smaller cam sprocket, smaller cylinder head and cover.
After so much size reduction, what’s left are two outboards that are compact yet deliver the power and performance users demand.
3
Suzuki’s Advanced Engineering
Cylinder Head Assy
A long history in the design and manufacture of motorcycle,
automotive and marine engines gives Suzuki an unrivaled ability to
blend the best of its advanced technology and know-how into the
creation of the D115 and DF140 outboard engines. Based on proven
automotive designs, engines for both outboards have been specifically
redesigned for use in marine applications.
The DOHC, 4-valve cylinder head is designed to keep overall size to
a minimum. The engineers utilized an offset drive shaft system with a
reduction gear incorporated at the bottom of the power head to transfer
power from the crankshaft to the drive shaft.
The utilization of a two-stage mixed cam drive system, the first time
this system has been used in outboards, incorporates both gears and a
chain. The first stage gears transfer power between the crankshaft and
the drive shaft while the second stage utilizes a chain to deliver power
from the drive shaft to the camshaft.
As gear reduction allows for the use of a smaller diameter cam
sprocket as well as a smaller cylinder head and cylinder head cover, the
greatest merit of this system is the significant reduction in the overall
size of the engine. Valve angles are also reduced to offer a more compact
combustion chamber for increased combustion efficiency.
The Cam Drive System utilizes a highly durable timing chain. The
timing chain is equipped with an automatic hydraulic tensioner to keep
the chain properly tensioned. The system will provide users with years of
maintenance-free operation.
Cylinder Block
Both models also feature a two-stage reduction gear that delivers
a larger gear ratio of 2.59. On the drive shaft, the first stage reduction
delivers a ratio of 1.25 while the second stage, in the gear case itself,
delivers a further reduction of 2.08. The biggest gain this system
delivers is in its capability to use a highly efficient, large pitch, large
diameter propeller.
A group exhaust system utilized in the cylinder head and cylinder
block increases power output by reducing drag in the exhaust system
with better exhaust flow through its 4-2-1 design.
Compared to previous outboards, the offset drive shaft system puts
the center of gravity closer to the front of the outboard allowing the
upper mount to be positioned above the torque roll. Also, increasing the
mounts capacity—by 1.8 times on the upper mount and 1.6 times on the
lower compared to our 2-stroke V6 outboards—has lead to an effective
reduction in engine vibration.
4
Reduction Gear & Cam Drive System
Cylinder Head
DF115/140 PRODUCT INFORMATION
Fuel Delivery System
The DF115 and DF140 use a high-volume diaphragm type fuel pump that runs off
the cam drive. Upstream of the pressure regulator, a Fuel Cooler is incorporated in place
of a water jacket to cool the fuel. All fuel-related components are located on the intake
manifold.
Intake Manifold
Intake Manifold
Outstanding Fuel Efficiency
The graph shows a comparison in the performance of the DF115 engine with the
2-stroke DT115S. At idle, fuel consumption of the DF115 is 75% less than the DT115S.
Even at maximum performance levels, the DF115 consumes over 31% less fuel than
its 2-stroke counterpart. A relatively flat torque curve also provides plenty of power
throughout the entire speed range from low to high speeds and increases its overall
drivability.
When comparing the DF140 4-stroke vs. the DT140 2-stroke, the fuel consumption
follows the same line. At idle, fuel consumption of the DF140 is 60% less than the DT140.
Even when comparing at WOT, the DF140 consumes over 30% less fuel than its 2-stroke
counterpart. The DF140 has a great hole shot to get a boat up on plane quickly. And with
a wide power band, the 4 stroke 140 is 2 seconds faster 0-30 mph than the 2-stroke.
18
16
14
12
10
100
OUTPUT POWER (PS)
Fresh air is channeled through intake ducts to the silencer. The large capacity
silencer is equipped with a baffle plate inside for further noise reduction.
20
TORQUE (kgf.m)
2-Stroke EFI vs. 4-Stroke EFI
The ventilation system is designed to force air from within the upper cover to the 2-STROKE EFI VS. 4-STROKE EFI
Performance Curves
outside. Fan blades on the magneto flywheel ventilate air out through the mag cover and PERFORMANCE CURVES
upper cover reducing the air temperature within the engine cover. This provides a cooler
140
intake air temperature, which in turn improves engine performance while enhancing
130
TORQUE
reliability and durability of the outboard’s electronics, etc. and keeps air temperature
120
under control.
110
90
DT115S
80
DF115
OUTPUT POWER
70
60
50
40
SPECIFIC FUEL CONSUMPTION
30
60
50
40
20
30
10
20
10
0
2000
3000
4000
5000
FUEL CONSUMPTION (l /h)
The aluminum-cast intake manifold is designed with a comparatively long branch
to boost the engine’s mid range torque. The intake manifold consists of the IAC (Idle Air
Control), a Fuel Cooler, Vapor Separator, two types of Fuel Filters, the Throttle Body and
related fuel system components. The entire system is assembled into a compact, easy to
maintain module.
6000
ENGINE SPEED (rpm)
Multi Point Sequential Electronic Fuel Injection
The DF115 and DF140 both utilize the same Multi Point Sequential Electronic Fuel
Injection of the Speed Density type that is found in the every Suzuki 4-stroke fuel injected
model. The use of this particular system enables these outboards to pass future emission
standards while providing lower fuel consumption, smoother starting, stable idling,
E.C.M. (Engine Control Module)
better drivability and outstanding throttle response.
5
The E.C.M. (Engine Control Module) system controls the
engine’s ignition system and provides an ideal fuel supply under
all running conditions. The E.C.M. constantly monitors crucial
data, in real time, from a series of sensors placed in critical
areas in the engine. The sensor system is made up of the Manifold
Absolute Pressure Sensor, Crankshaft Position Sensor, Intake
Air Temperature Sensor, Cylinder Wall Temp Sensor, Camshaft
Position Sensor, and Exhaust Jacket Temp Sensor. The data from
these sensors is conveyed to a computer that instantly calculates
(Speed-Density type) the optimum amount of fuel to be injected at
high pressure into each of the cylinders.
Regulating intake air under different running conditions, intake
air is increased when the engine’s rpm’s are low, and decreased
when rpm’s are high.
A Fast Idle Function provides smooth, quick starts and stable
engine warm-ups. When the engine is started, the IAC valve fully
opens to let an increased flow of air into the cylinder.
Suzuki’s Dash Pot System is electronic. Other manufacturers
generally use mechanical systems. The Electronic Dash Pot
System only functions when there is a sudden throttle transition
from open to closed, smoothly reducing rpm’s to lessen stress on
the engine.
The DF115 and DF140 also incorporate an IAC (Idle Air
Control) which consists of an Idle Speed Control, Fast Idle
Function, and a Dash Pot System to further enhance engine
performance with stable operation at all times.
Blow-by gas generated inside the crankcase is separated
into liquid and gas components inside the breather chamber. Only
the resulting gas component is sent via the breather hose to the
silencer. After this, it is mixed with fresh air, and the resulting
mixture is drawn into the combustion chamber and burnt instead
of being released as pollution into the atmosphere.
The Idle Speed Control uses a linear solenoid system and
is programmed to let the engine idle at a very low 620 rpm’s.
Multi Point Sequential Electronic Fuel Injection
Fuel Tank
Low Pressure Fuel Filter
Evaporation Hose
Squeeze Pump
High
Pressure
Fuel Pump
Fuel Connector
High
Pressure
Fuel Filter
Low Pressure Fuel Pump
Battery
Crankshaft
Position Sensor
(CKP Sensor)
Float
Vapor Separator
Flywheel
Magneto
Fuel Cooler
Neutral SW
E.C.M.
Pressure Regulator
Ignition Coil
Cylinder Head Cover
Blow-by Hose
Idle Air Control Intake
Manifold
Valve (IAC Valve)
Starter Relay
IG
ST
Camshaft
Position Sensor
(CMP Sensor)
Injector
Cylinder Head
Cylinder Block
Throttle
Body
Ignition
SW
Main Relay
Silencer
OFF
Cylinder Wall
Temp Sensor
Fuse
Pilot Air
Adjust Screw
Intake Air Temperature
Sensor (IAT Sensor)
6
Closed Throttle
Position Switch
(CTP Switch)
Manifold Absolute
Pressure Sensor
(MAP Sensor)
Exhaust Jacket
Temp Sensor
Oxygen Sensor
(Service tool only)
Spark Plug
DF115/140 PRODUCT INFORMATION
High Output Alternator
Both the DF115 and
DF140 are equipped with
high output alternators
that deliver a total of
40A(12V) for increased
electrical power. Fan
blades incorporated
on the large diameter
flywheel magneto
circulate air out of the
engine cover to reduce air
temperature. A watercooled regulator makes
use of a large capacity
power generator.
Flywheel magneto
Oil changes are easy with
the drain plug located on the
front of the oil pan making
draining of the oil possible
with the engine in the tilt up
position. A spin on oil filter is
utilized and the oil filler cap
is attached to the top of the
cylinder head to provide easy
access from the boat.
The water pressure valve is attached to the oil pan with its
cover attached from the exterior of the oil pan for easy cleaning and
replacement without having to remove the power head.
Alternator
Also the DF115 and
DF140 are the first Suzuki outboards to utilize a 1.4kw dust-proof
starter motor.
Alternator Output
WATER GALLERY
Oil Cooler
(A)
Keeping the
Outboard Cool
40
35
30
OIL GALLERY
BLOCK COMP. CYLINDER
The DF140 utilizes a comprehensive cooling system that circulates
water not only through the block but also cools the crankcase,
intake manifold, fuel line and a specially designed oil cooler (see
above). Its compact and simple design is efficient at keeping oil
temperature under control while providing ease of maintenance.
25
20
15
10
5
0
1000
2000
3000
4000
5000 (rpm)
Distinctive Styling With Easy Engine
Access for Maintenance
The distinctive styling found throughout Suzuki’s DF series is
evident in the DF115 and DF140 as well. Smooth, flowing lines present
a refined image that promotes their clean running characteristics. The
lower covers are held in place with fasteners at three locations, one
in front and the other two on either side at the rear of the engine. The
lower cover separates into two sections, the port and starboard, to allow
easier access to the 4-stroke engine.
Multi-Function Tachometer
The DF115 and DF140 are designed to operate with a Multi-Function
Tachometer that includes a comprehensive
monitoring system to provide you with an
excellent backup to the performance of the
outboard engine. Using data supplied from
each sensor to the E.C.M., this system detects
abnormalities in the running of the outboard,
giving you the needed information and alerts
before problems arise, so that appropriate measures can be taken
before the problem becomes serious.
7
Suzuki Motor Corporation
A tradition of Innovation
Suzuki history begins with the founding of Suzuki Loom Works by Michio Suzuki in October 1909. Realizing that weaver wanted to produce cloth both vertical and
horizontal patterns, he developed an automated loom capable of weaving patterned cloth from space dyed yarn. His commitment to innovative engineering was the
start of an uncompromising focus on creating products that meet people’s needs and offer new life style possibilities.
While the company has evolved, diversified, and expanded since then, we have always honored our founder’s commitment to innovative engineering. His philosophy
lives on in the “Way of Life!” brand slogan and our dedication to provide our customers with value packed products that bring satisfaction and meet their needs.
Suzuki Automobiles
Producing over two million cars per year, Suzuki offers an automotive lineup
that ranges from Performance Sport Sedan, the Kizashi to an economical
compact SX4. Not to mention the “4x4 of the year” Equator pick up truck and the
outstanding SUV, the Grand Vitara. Suzuki is one of the leading manufactures
of dependable, fuel efficient vehicles, known globally as being sporty, user
friendly, fun to drive and respected for their excellent quality and value.
Suzuki Motorcycles
Suzuki offers a comprehensive lineup of motorcycles that includes super-sport,
street, cruisers, dual purpose, scooters, off-road, motocross, and all terrain
vehicles. Suzuki motorcycles and ATVs are well known and highly respected for
their race-proven cutting edge technologies, functional features, quality, and
dependability all tailored to meet the demands of our customers.
Suzuki Outboards
DF115/140 SPECIFICATIONS
MODEL
STARTING SYSTEM
WEIGHT kg (Ibs.)
NO. OF CYLINDERS
DISPLACEMENT
BORE × STROKE mm (in.)
MAXIMUM OUTPUT /rpm
FULL THROTTLE
OPERATING RANGE rpm
STEERING
OIL PAN CAPACITY l quart (liter)
IGNITION SYSTEM
ALTERNATOR
ENGINE MOUNTING
TRIM METHOD
GEAR RATIO
GEAR SHIFT
EXHAUST
DRIVE PROTECTION
PROPELLER SIZE (in.)
OPTIONAL
DF140
To learn more about Suzuki,
visit your local Suzuki dealer or go to
www.suzuki.com
■
4-Stroke DOHC 16 Valves
Multi Point Sequential
Electronic Fuel Injection
L: 20 X: 25
TRANSOM HEIGHT
On the track, Suzuki has captured major championships around the world. The
experience, knowledge and expertise gained on the track produces race proven,
leading edge technologies that are utilized in every vehicle we make. Suzuki
supplies you with the best combination of performance, durability, reliability,
efficiency, ease-of-use, and value. It’s why Champions Choose Suzuki. So, what
are you gonna ride?
DF115/140 FEATURES
DF115
ENGINE TYPE
FUEL DELIVERY SYSTEM
Suzuki Motorsports
Ranging from the world’s first 300 HP four-stroke outboard to the portable
DF2.5, Suzuki offers a comprehensive lineup that represents state-of-theart engine design and technology. The also offer great fuel efficiency and
environmentally responsible operation that meets many of the toughest
emission standards – world wide. In 2008 Suzuki introduced the first of its
new generation four-stokes, the DF90A and DF70A, followed by the DF60A in
2009. 2010 was another big year with the introduction of the DF50A and DF40A
and the redesigned DF300A. These outboards deliver clean running economical
operation with Suzuki’s Lean Burn Technology. At Suzuki, it is our goal to build
outboards that are highly efficient, deliver low fuel consumption and high power
output while placing less stress on the environment.
■
■
■
Electric
L: 416 X: 427
■
L: 410 X: 421
■
In Line 4
119.0 cu. in. (1950cc)
3.30 x 3.50 in. (84 x 88)
115 / 5500
124.7 cu. in. (2044cc)
3.40 x 3.50 in. (86 x 88)
140 / 6000
5000-6000
5600-6200
Remote
5.8 (5.5)
Fully transistorized
12V 40A
Shear Mount
Power Trim and Tilt
2:59:1
F-N-R
Through Prop Hub Exhaust
Rubber Hub
Aluminum
Stainless Steel
3 × 13 1/2 × 15
3 × 14 × 16
3 × 14 × 17
3 × 14 × 18
3 × 14 × 19
3 × 14 × 20
3 × 14 × 21
3 × 14 × 22
3 × 14 × 23
3 × 14 × 24
3 × 14 × 26
3 × 14 × 28
■
■
■
■
■
■
■
■
■
■
■
■
■
Electronic Fuel Injection
Oil Change Reminder System
Over-Rev Limiter
Low Oil Pressure Caution
Emergency Stop Switch
Fully Transistorized Ignition
Through Tube Bracket
Spiral Bevel Gear
Temp Activated Fast Idle
Full Shifting F-N-R
Neutral rpm Limiter
Start-in-Gear Protection
Tilt Stopper
S.S. Water Pump Housing
Anti-Corrosion System
Fishing Line Cutter
Freshwater Engine Flush Port
Throttle Tension Adjuster
Multi-Function Tachometer (optional)
Check Engine Indicator
Rev-Limit Indicator
Overheat Warning Indicator
Oil Pressure Indicator
* Boats and motors come in a large variety of combinations. See your authorized dealer for correct
propeller selection to meet recommended RPM range at W.O.T.
Please read your owner’s manual carefully. Remember, boating and alcohol or other drugs don’t
mix. Always use a USCG-approved life jacket. Please operate your outboard safely and responsibly.
Suzuki encourages you to operate your boat safely and with respect for the marine environment.
SUZUKI MOTOR CORPORATION reserves the right to change, without notice or obligation, equipment,
specifications, colors, materials and other items to apply to local conditions. Each model may be
discontinued without notice. Please inquire at your local dealer for details of any such changes.
Actual body colors may differ slightly from the colors in this brochure.
CARB THREE-STAR LABEL
EPA 2006 LABEL
The three-star label identifies
engines that meet the California Air
Resources Board’s 2008 exhaust
emission standards. Engines
meeting these standards have 65%
lower emissions than EPA 2006
exhaust emission standards.
Suzuki’s four-stroke technology
ensure compliance with EPA
2006 exhaust emission standards
set by the U.S. Environmental
Protection Agency.
AMERICAN SUZUKI MOTOR CORPORATION
P.O. BOX 1100 BREA, CA 92822-1100
http://www.suzukimarine.com
DF115/140 Product Information 0307
99953-11540-010
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