Transcript
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.
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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.
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Offer boaters low fuel consumption, low noise level and low vibration.
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Provide boaters with an outboard that delivers maximum power and performance.
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Incorporate Electronic Fuel Injection for better fuel economy and performance.
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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.
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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.
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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.
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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.
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)
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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.
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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
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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.
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Electric L: 416 X: 427
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L: 410 X: 421
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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
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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
