PRODUCT INFORMATION

Way of Life!

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, award-

winning 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 fi rst 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 effi ciency 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, effi cient

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

Fully Committed to the Future

DF115/140 PRODUCT INFORMATION

3

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.

Off set Drive Shaft

DF115 DF140

Compact Outboards Along with creating clean-running outboards,

another important goal that Suzuki engineers

set for the DF series was to create a compact

outboard. With the DF115 and DF140 they have

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

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.

DF115

Brand A 115HP

Brand B 100HP DF140

Brand A 130PS

Four Stroke Engine Size / Profi le Comparison

4

Suzuki’s Advanced Engineering 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.

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.

Cylinder Head Assy

Cylinder Block Cylinder Head

Reduction Gear & Cam Drive System

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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 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.

The ventilation system is designed to force air from within the upper cover to the outside. Fan blades on the magneto flywheel ventilate air out through the mag cover and upper cover reducing the air temperature within the engine cover. This provides a cooler intake air temperature, which in turn improves engine performance while enhancing reliability and durability of the outboard’s electronics, etc. and keeps air temperature under control.

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.

Outstanding Fuel Effi ciency 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.

Multi Point Sequential Electronic Fuel InjectionThe 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, better drivability and outstanding throttle response.

DF115/140 PRODUCT INFORMATION

Intake Manifold

2-STROKE EFI VS. 4-STROKE EFIPERFORMANCE CURVES

2000

20

0

10

30

10

20

30

40

50

40

50

60

70

80

90

100

110

120

130

140

3000 4000

ENGINE SPEED (rpm)

DT115SDF115

OU

TP

UT

PO

WE

R (

PS

)OUTPUT POWER

SPECIFIC FUEL CONSUMPTION

5000 6000

10

12

14

16

18

20

TOR

QU

E (

kgf.

m)

FU

EL

CO

NS

UM

PT

ION

(l/

h)

TORQUE

60

2-Stroke EFI vs. 4-Stroke EFIPerformance Curves

E.C.M. (Engine Control Module)

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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.

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.

The Idle Speed Control uses a linear solenoid system and is programmed to let the engine idle at a very low 620 rpm’s.

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.

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.

OFF

IG

ST

Battery

Cylinder Block

Manifold Absolute Pressure Sensor (MAP Sensor)

Cylinder Head

Camshaft Position Sensor (CMP Sensor)

Cylinder Head Cover

IntakeManifold

ThrottleBody

Silencer

Ignition Coil

Injector

Oxygen Sensor(Service tool only)

Cylinder Wall Temp Sensor

Spark Plug

Idle Air Control Valve (IAC Valve)

Blow-by Hose

Pilot AirAdjust Screw

Closed ThrottlePosition Switch(CTP Switch)

Intake Air Temperature Sensor (IAT Sensor)

Evaporation Hose

FlywheelMagneto

E.C.M.

Crankshaft Position Sensor (CKP Sensor)

Exhaust JacketTemp Sensor

Fuel Tank

Squeeze Pump

Fuel Connector

Low Pressure Fuel Filter

Low Pressure Fuel Pump

Vapor Separator

HighPressure

Fuel Pump

Pressure Regulator

Float

High PressureFuel Filter

Fuel Cooler

Starter Relay

Main Relay

IgnitionSW

Fuse

Neutral SW

Multi Point Sequential Electronic Fuel Injection

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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 water-cooled regulator makes use of a large capacity power generator.

Also the DF115 and DF140 are the fi rst Suzuki outboards to utilize a 1.4kw dust-proof starter motor.

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, fl owing lines present a refi ned 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.

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 fi lter is utilized and the oil fi ller 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.

Keeping the Outboard CoolThe 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.

Multi-Function TachometerThe 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.

Flywheel magneto

Alternator

0

5

10

15

20

25

30

35

40

1000 2000 3000 4000 5000 (rpm)

(A)

Alternator OutputBLOCK COMP. CYLINDER

OIL GALLERY

WATER GALLERY

Oil Cooler

DF115/140 SPECIFICATIONS DF115/140 FEATURES

DF115/140 Product Information 0307 99953-11540-010

■ 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

AMERICAN SUZUKI MOTOR CORPORATIONP.O. BOX 1100 BREA, CA 92822-1100

http://www.suzukimarine.com

* 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, specifi cations, 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 LABELThe three-star label identifi es 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.

EPA 2006 LABELSuzuki’s four-stroke technology ensure compliance with EPA 2006 exhaust emission standards set by the U.S. Environmental Protection Agency.

Suzuki AutomobilesProducing 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 effi cient vehicles, known globally as being sporty, user friendly, fun to drive and respected for their excellent quality and value.

Suzuki MotorcyclesSuzuki 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 OutboardsRanging from the world’s fi rst 300 HP four-stroke outboard to the portable DF2.5, Suzuki offers a comprehensive lineup that represents state-of-the-art engine design and technology. The also offer great fuel effi ciency and environmentally responsible operation that meets many of the toughest emission standards – world wide. In 2008 Suzuki introduced the fi rst 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 effi cient, deliver low fuel consumption and high power output while placing less stress on the environment.

Suzuki MotorsportsOn 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, effi ciency, ease-of-use, and value. It’s why Champions Choose Suzuki. So, what are you gonna ride?

To learn more about Suzuki, visit your local Suzuki dealer or go to

www.suzuki.com

Suzuki Motor CorporationA tradition of InnovationSuzuki 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, diversifi ed, 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.

MODEL DF115 DF140

ENGINE TYPE 4-Stroke DOHC 16 ValvesFUEL DELIVERY SYSTEM Multi Point Sequential Electronic Fuel InjectionTRANSOM HEIGHT L: 20 X: 25STARTING SYSTEM ElectricWEIGHT kg (Ibs.) L: 416 X: 427 L: 410 X: 421

NO. OF CYLINDERS In Line 4DISPLACEMENT 119.0 cu. in. (1950cc) 124.7 cu. in. (2044cc)BORE × STROKE mm (in.) 3.30 x 3.50 in. (84 x 88) 3.40 x 3.50 in. (86 x 88)MAXIMUM OUTPUT /rpm 115 / 5500 140 / 6000 FULL THROTTLE OPERATING RANGE rpm 5000-6000 5600-6200

STEERING RemoteOIL PAN CAPACITY l quart (liter) 5.8 (5.5)IGNITION SYSTEM Fully transistorizedALTERNATOR 12V 40AENGINE MOUNTING Shear MountTRIM METHOD Power Trim and TiltGEAR RATIO 2:59:1GEAR SHIFT F-N-REXHAUST Through Prop Hub ExhaustDRIVE PROTECTION Rubber HubPROPELLER SIZE (in.) Aluminum Stainless SteelOPTIONAL 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