Suzuki DF 140 User guide

$ET"UPffiAilUA[

IMPORTANT
..--/ AWARNINGICAUTION/NOTE
Ptease
readthismanual
and
followits
instructions
carefully,
To
emphasize
special
information,thesymbol
A
and
the
words
WARNING,
CAUTION
and
NOTEhave
special
meanings.
Payspecial
attentiontothe
mes-
sages
highlighted
by
these
signal
words.
NOTE:
lndicatesspecialinformation
tomake
maintenance
easier
orinstructiansclearer.
Please
note,however,thatthewarnings
and
cautions
contained
inthismanual
cannot
possibly
cover
all
potential
hazards
relatingto theservicing,
or lackof servicing,
oftheoutboard
motor.
Inaddition
to the
WARNINGSandCAUTIONS
stated,
you
mustuse
good
judgement
andbasic
mechanicalsafety
principles.
Indicatesa potentlal
hazard
thatcouldresultin death
or Iniury.
CAUTION
Indicatesa potential
hazardthatcouldresult
in motor
damage.

FOREWORD
This
outboard
motor
hasbeen
designedand
produced
utilizing
Suzuki's
mostmoderntechnology.
The
finest
product,however,cannot
perform
properly
unless
itis
correctly
assembled
andserviced.
This
set-up
manual
has
been
produced
toaid
you
inproperly
assembling
and
servicing
thisoutboard
motor.
. Thismanual
hasbeen
prepared
on
the
basis
ofthe
latest
specifications
atthetimeofpublication.
lf
modifications
have
beenmadesincethen,
differences
may
exist
between
thecontentofthis
manual
andthe
actualoutboard
motor.
. lllustrations
in
this
manual
areused
toshowthe
basic
principles
of
operation
andwork
procedures
andmay
notrepresent
theactualoutboard
motor
exactly
in
detail.
t This
manual
is
intended
forthosewhohaveenough
knowledge
and
skills
toservice
SUZUKIoutboard
motors.
Without
suchknowledge
andskills,
you
should
not
attempt
servicing
byrelying
onthis
manual
only.lnstead,please
contact
your
nearbyauthorized
SUZUKI
outboard
motor
dealer.
CONTENTS
SYMBOL. ........,.........
I
MATERIALS
REAURED ......,...
1
OUTBOARD
MOTOR
INSTALLATION ......2
HORSEqOWER
SELECTTON............. .......,.......
2
MOTOR
DIMENSIONS ,,...2
MOUNTING
TOTHETRANSOM .,.....
g
TRANSOM
DTMENSIIONS .................
s
CONT4OL
CABLESINSTALLATTON .......4
REMOTE
CONTROLBOXSiDE .......4
ENGTNE
SIDE ......,............
4
WIRE
HARNESS
INSTALLATION ...........,.
8
DRAG
LINK
TNSTALLATTON .........,-..........
g
couNTERROTAnON
MODEL
ORDUALENGINE,
T\E-ROD
KtT(O?T\ONAL?ARTS)
iN9TALLATION........ ..................
11
INSTALLATION
WITH
THE
PRE-RIGGED
ITEMS
FOR
2 CYCLE
MODEL
............,..
14
wtRtNcDTAGRAM .....,...........
16
WIRING
DIAGRAM
FORDUALENGINE .................
17
SUZUKIMOTOR
CORPORATION
Marine
& Power
products
Division
Apprentice
mechanics
or do-it-yourselfmechanicsthatdon't have
the proper
toolsandequlp-
mentrnay
not beableto properlyperform
theservices
described
inthis manual.
lmproperas-
sembly
and/or
servicing
mayresultin injurytothemechanie
and
mayrender
theengineunsafe
fortheboat
operator
andpassengers.
OCOPYRIGHT
SUZUKI
MOTOB
CORPORATION
2OO1

SYMBOL
- Listed
inthe
table
beloware
symbolsindicating
specialinstructions
andother
important
information
neces-
saryfor
proper
servicing.Please
noiethedefinitionforeach
symbol.You
willfind
these
symbols
used
through-
outthis
manual,
Flefer
back
tothis tableif
you
are
not
sureof
any
symbol(s)meanings.
SYMBOL DEFINITION SYMBOL DEFINITION
gTorque
control
required.
Data
beside
it indicates
specified
torque.
.-
1J1E13l
ApplyTHHEADLOCK
"1342".
@Apply
SUZUKI
WATER
FIESISTANT
GREASE. @Usespecialtool,
@ApplySUZUKISILICONESEAL.
MATERIALS
REOUIRED
SUZUKISILICONE
SEAL
99000-31120
(50
g/1.7
oz)

OUTBOARD
MOTORINSTALLATION
HORSEPOWER
SELECTION
NOTE:
' Stafe
themaximum
horsepoweroutboard
motor
that
canbesafely
used
on thatboat.
Thereis severe
product
liability
potential
connectedwith
riggingandselling
aboatwith
anoutboard
motor
exceeding
the
ho
rse
powercapacity
Iimitatian.
' The
rig shouldnotbe underpowered,as thiswillnot
allow
the
performance
balance
youare trying
to
achieve.
Determine
thecustomefsneeds,applicatian
and useof theperspective
rig to makethe best
overal
Iho
rsepower recomme
ndation.
MOTOR
DIMENSIONS
Donot overpower
your boat.
Never
installan outboard
motor
wlth horsepower
exceeding
the
boat
manufacturer's
recommended
maximum.Excessive
horsepower
willhave
anadverse
effect
on hullsafety
andmaycauseoperating/handling
difficulties.
L:998
(39.3)
UL:1116(43.9)
$
J
t
@
F.
J^cY
N(o
FN
:>(O
6(O
6(o
-i5
2

.
MOUNTING
TOTHE
TRANSOM
t--lContainedparts
[l r.rut
O: 55N.m
(5.s
kg-m,40.0tb-ft]
Drill
the
upper
holes
at least
2smn (1.0in)
awayfrom
thetransom
top
surface.
lnstall
the
large
diameter
washer
@onthe
transom
boardside.
To
ensure
a water-tight
engine
installation,sealant
(SUZUKI
STLICONE
SEAL
or equivalent)
shouldbe
applied
toallboltholes.
lf tightening
torque
cannotreachtathe
specifiedtorque
duetoweak
transom
material,it is necessary
to
reinforce
the
transom
boardwith
anattachment
plate.
'\--ITRANSOM
DIMENSIONS
Item Part
name Part
number Q'ty
@
@
@
o
{F)
rF!
v
Bolt(M12)
Washer
(Large)
Washer(Small)
Lockwasher
Nut
cap
09100-12083
091
60-12044
091
60-12066
091
62-12005
09140-12028
41
153-94500
4
4
4
4
4
4
Transom
top
surlace
"l
3

Part
name Partnumber Q'ty
Remote
control
box 67200-99E10-0EP 1
CONTROL
CABLES
INSTALLATION
Contained
parts
For
U.S.A.
model,
remote
control
boxisoptional.
Required
parts
Part
name Part
number Q'ty
Controlcable
7ft
(2.1
m)
Control
cable
8ft
@A
m)
Controlcable
10ft
(3.1
m)
Controlcable
12fi
(8.7
m)
Controlcable
14ft
(a.B
m)
67320-89J00
67320-89J10
67320-89J20
67320-89J30
67320-89J40
2
z
2
2
2
Contained
parts(Remote
controlmodel)
Item Part
name Partnumber Q',ty
@
@
6\
v
@
@
o
Grommet
Cable
stopper
Bolt
Cable
connector
Washer
Lock
pin
61124-90J00
67343-90J01
01550-06257
67467-89J01
091
60-06055
0938s-0601
2
1
1
J
2
I
2
NOTE:
Before
performing
the foltowingprocedures,
be sure that
the
throttle/clutch
controlcables
are instatted
in theremote
control
boxaccording
to the "REMOTE
CONTROL
BOX SET-{JP
tN-
STRUCTION".
(for
Remote
control
modelonty)
Part
name Part
number Q'ty
Controlcable
16ft
(a.9
m)
Controlcable
18ft
(5.5
m)
Controlcable
2oft
(6.1
m)
Control
cable22ft(6.7
m)
67320-89J50
67320-89J60
67320-89J70
67320-89J80
2
2
2
2
Ghoose
one
item
which
ismatched
tothe
boat
in
length.
REMOTECONTROL BOX SIDE
Fortheprocedure
to
connect
thethrottle
control
cable
and
clutch
control
cableto
the
remote
control
box,
refer
tothe
"REMOTE
CONTROL
BOX
SET-UPINSTRUCTION'that
comes
supplied
with
each
unitofremote
controlbox.
(for
Remote
control
model
only)
ENGINE
SIDE
/A\
\E/.V
\b
4

Procedure
. /1) Remove
thenine
(9)
bolts,then
removethe
bothsidelower
covers
from
the
outboardmotor.
'2\ Install
the
clutch
control
cable
O andthrottle
control
cable
,_-,/ @
to
tne
grommet
@.
(3) Secure
the
cable
O and @intnecableholder
@oy
titting
groove
onthe
cable
intoasloton
theholder.
NOTE:
Refertothe
page
I for
installingwireharness
tothe
grommet.
(4) Install
the
cable
stopper
@bythe
bolt
@.
(5) Position
theremotecontrol
handleinto
"NEUTRA|-'.
$: r--.-..-...-
5

I
- Clutchcontrol
cable
-
(6) Make
surethat
theclutchcontrolarm
@isintheneutral
position.
(7) Thread
the
connector
O onto
theclutchcontrolcable
C untiltheconnectorhole
alignswith
the
pivotpin \-:
@on
the
clutch
controlarm
@.
(8) Setthe
connector
@onto
the
pivotpin
@withtheflat
sideof
connector
towards
tne
arm.
(9) Installthe
washer
(pand
lock
pin
@,
then
tightenthe
tocknut
@,
(10)
Make
sure
that
both
forwardandreverse
gearcan
beengaged
withthesame
angleofremotecontrol
handle
travel
from
"NEUTRAH
oosition,
- Throttle
controlcable
-
(11)
Make
surethatthe
throttlelever
@
is
fullyclosed.
(The
CTP
svvitch
@must
bein
"ON
- pushed"position.)
Also
make
sure
that
thestitmark
onthethrottle
controlarm
@aligns
withthe
slitmark
on
the
bracket
@.
(12)
While
pushing
the
throttle
controlcable
@
asshownby
ar-
row,
thread
the
connector
@
ontothe
cableuntiltheconnec-
torhole
aligns
with
the
pivot
pin
@
on
the
throttlecontrol
arm
@.
(13)
Set
the
connector
@
onto
the
pivotpin
@
withtheflat
sideof
connectortowards
thearm.
(14)
lnstall
the
washer
@andlock
pin
@,then
tightenthelock
nut
@,
(15)
Movethe
remotecontrolhandletothefully
opened
position
andreturnit
totheneutral
position
again.
Make
surethat
the
throttle
is
fullyclosed.
CAUTION
Cable
connectors
andturnbacklesmustbethreaded
at
least
8mm
(0.3
in)onto
cable.
NOTE:
After
assembly,
makesurethatthecablesarenotstretched
or
otherwise
sfressedwhenthe
outboardmotor
isturned
allthe
wav
tothe
right
and
left.
After
completing
step
No.15mentionedabove,
perform
thefol-
lowingprocedure
to
verify
thattheCTP
(Closed
ThrottlePosition)
switch
is
correctly
adjusted.
(1) Remove
the
CTPswitchharnesslead
andconnect
aVolt-
Ohm
meter
totheswitchterminal
and
to
engine
ground,
(2) Move
the
remote
control
handteoncemoretotnetuilyopened
position,
thenreturn
itslowlytothe
fullyclosed
throttle,
in
gear
idle
position(lower
unitstill
engaged
infonvard
gear
with
throttle
at
full
close.)
6

'(3) Check
themeter
connectedto
the
CTPswitch.
ltmustindicate
the
switch
has
turned
tothe
"ON"
oosition
-_-/ (meier
will
indicate
continuity).
lfthe
CTPswitchisin
the
"OFF"position
(No
continuity)atthein
gear
idle
position,
loosen
theremote
control
cableconnectorlock
nut
and
readjust
thecable
connector
slightlyuntiltheCTP
switch
isinthe
"ON"
condition
(continuity
indicated).
Afterreadjusting
thecable
connector,tighten
thelocknutand
movetheremote
control
handletothe
fully
opened
position
and
backtotheingear idle
position
toconfirm
thattheCTP
switchisnow
correctly
adjusted
(switch
inthe "ON"
position,
continuity
indicated).
.'-.{6) When
correct
switch
adjustment
hasbeen
confirmed,
remove
thevolt-Ohm
meter
andreconnect
the
CTP
switchharness
lead.
NOTE:
Failure
toproperly
adjusttheCTPswitchmaycause
theengineto stallwhenretrurned
to thein-gear
idle
position.
This
may
occur
tonon-activationof theECMelectric
dash-potfunction
whichis controlted
bythe
CTP
switch's
"ON"
/ "OFF"
position.
(4)
(5)
Neutral
N