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Suzuki DF140 User Manual

Suzuki DF140
21 pages
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Suzuki DF140 Specifications

General IconGeneral
Engine Type4-Stroke DOHC 16-Valve
Fuel Delivery SystemMulti-Point Sequential Electronic Fuel Injection
Ignition SystemFully-transistorized
Starting SystemElectric
SteeringRemote
Gear Ratio2.59:1
Trim MethodPower Trim and Tilt
Cylinder4
Alternator Output12V 40A
Warranty3 years
Displacement2044 cc
Bore x Stroke86 x 88 mm
Maximum Output103 kW (140 PS)
Full Throttle RPM Range5600 - 6200 RPM
Shaft LengthL: 508 mm, X: 635 mm

Summary

Important Safety Definitions

Warning Definition

Defines WARNING as a potential hazard resulting in death or injury.

Caution Definition

Defines CAUTION as a potential hazard resulting in motor damage.

Note Definition

Defines NOTE as special information for easier maintenance or clearer instructions.

Foreword

Symbols and Definitions

Torque Control Symbol

Indicates torque control is required, specifying the torque value.

Water Resistant Grease Symbol

Indicates the application of SUZUKI WATER RESISTANT GREASE.

Silicone Seal Symbol

Indicates the application of SUZUKI SILICONE SEAL.

Thread Lock Symbol

Indicates the application of THREAD LOCK '1342'.

Special Tool Symbol

Indicates the use of a special tool.

Materials Required

Outboard Motor Installation

Horsepower Selection

Guidance on selecting the correct horsepower for the boat, avoiding overpowering.

Motor Dimensions

Provides detailed physical dimensions of the outboard motor.

Mounting to the Transom

Contained Parts for Transom Mounting

Lists the specific parts included for mounting the outboard motor to the transom.

Transom Mounting Notes

Provides important notes for correct transom mounting procedures.

Transom Dimensions

Details the required dimensions for the boat's transom.

Control Cables Installation

Contained Parts for Control Cables

Lists parts included for control cable installation.

Required Parts for Control Cables

Lists additional parts needed for control cable installation.

Remote Control Box Side Connection

Instructions for connecting control cables to the remote control box.

Engine Side Connection

Instructions for connecting control cables to the engine.

Contained Parts for Engine Side Connection

Lists parts included for engine side connection.

Engine Side Notes

Important notes before performing engine side control cable procedures.

Wire Harness Installation

Contained Parts for Wire Harness

Lists the parts included for wire harness installation.

Wire Harness Installation Procedure

Steps for routing and connecting wire harnesses.

Wire Harness Notes

Notes regarding optional parts and wiring diagram references.

Drag Link Installation

Drag Link Installation Warning

Warns of loss of steering control if drag link is not installed correctly.

Drag Link Installation Notes

Notes on specifications for mechanical push-pull steering systems.

Contained Parts for Drag Link

Lists the specific parts included for drag link installation.

Drag Link Installation Caution

Caution against reusing safety nuts after torquing.

Tie-Rod Kit Installation

Tie-Rod Kit Contained Parts

Lists the parts included in the tie-rod kit for dual engines.

Tie-Rod Kit Installation Warning

Advises authorized mechanics for kit installation.

Tie-Rod Kit Parts Installation Procedure

Step-by-step procedure for installing the tie-rod kit components.

Tie-Rod Length Adjustment Procedure

Details the procedure for adjusting tie-rod length for optimal results.

Recommended Rigging Procedure

Steps for checking rigging using tape for proper alignment.

Tie-Rod Adjustment Caution

Caution regarding degreasing and handling tape during adjustment.

Tie-Rod Kit Double-Check Procedures

Procedures for double-checking bolt tightness and tape contact after installation.

Tie-Rod Kit Tape Caution

Caution about damaged aluminum tapes and replacement.

Tie-Rod Kit Final Warnings

Warnings about toe-in/toe-out variation and periodic checks.

Installation with Pre-Rigged Items for 2 Cycle Model

Required Parts for Pre-Rigged Installation

Lists adapter wire harnesses and link plate for pre-rigged models.

Pre-Rigged Installation Procedure

Steps for connecting wire harnesses and meters for pre-rigged boats.

Pre-Rigged Installation Notes

Notes on specific pre-rigged configurations and wiring diagrams.

Remote Control Box Disassembly and Reassembly

Steps for disassembling and reassembling the remote control box for connection.

Remote Control Box Connection Notes

Notes on control cable connection and checking smooth operation.

Wiring Diagram

Wiring Diagram for Control Box/Meter/Wire Harness

Illustrates the wiring connections for control boxes, meters, and harnesses.

Wire Color Code

Provides a key to the wire colors used in the diagrams.

Wiring Diagram for Dual Engine

Dual Engine Wiring Diagram Components

Details wiring for dual engines, including meters, switches, and ECUs.

Dual Engine Wiring Diagram Notes

Illustrates connections for dual engines with top mount remote control box.

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