Suzuki DF115 / DF140 – Outboard
Photo: Tokumeigakarinoaoshima, CC BY-SA 4.0, via Wikimedia Commons (cropped)

Suzuki · Outboard

Suzuki DF115 / DF140

Suzuki’s 2-litre four-cylinder for 115 and 140 hp, in three generations: the first DF115 (from 2001) and DF140 (from 2002), the DF115A and DF140A (2013 to 2021), and the current DF115B and DF140B, launched in October 2020 as the drive-by-wire DF115BG/DF140BG and built with mechanical controls since the 2022 model year. Since the A, both outputs use the same 86 × 88 mm block of 2044–2045 cm³ with a chain-driven double overhead camshaft and Suzuki’s offset driveshaft with two-stage reduction; the DF100A and DF100C are the same engine at 100 hp. The impeller has not changed since 2001, and the A and B share water pump kit, fuel filter, oil filter, gearcase seal kit and propeller hardware, but not spark plugs, thermostat or maintenance kit; the first generation has its own fuel filter (the DF140 also its own oil filter), and the first DF115 even its own pistons and gearcase. It is a common engine on 6 to 8 m motorboats and RIBs; check the engine number (see the table) before ordering parts.

Manuals & documents

The links go straight to Suzuki. We host no manuals or drawings — the manufacturer’s copy is the current one.

Wear parts & part numbers

PartOEM numberAlso fitsNote
Service kit16500-99L001,2,3—B generation and DF100C, including the BG models: water pump kit 17400-92J23, oil filter, low-pressure fuel filter 15412-92J00, four LKR6E plugs, five anodes with two cover gaskets, drain plug gaskets, cotter pin and O-rings. Suzuki USA sells the same contents as 99100-99L01, Suzuki New Zealand as 99100-99L00.
Service kit17400-928241,2,3—Maintenance kit for the DF100A, DF115A and DF140A from 2013, as in Suzuki’s global 2026 kit list; Suzuki USA and Suzuki New Zealand list it as 17400-92823.
Service kit17400-928431,2,3—First-generation DF100 and DF115 of 2010–2012 (engine number 11502…); Suzuki New Zealand lists 17400-92842.
Service kit17400-928531,2,3—First-generation DF140 of 2010–2012 (engine number 14002…); the model table in Suzuki USA’s catalogue gives 17400-92852.
Raw water pump impeller17461-90J014,5,6,7,8,9,10—The same impeller in every DF115 and DF140 parts list from 2001 to 2025, first generation, A and B; it also comes in the pump kits below.
Water pump repair kit17400-92J232,1,4,6,8,10,11—Water pump repair kit with impeller, for every DF115 and DF140 from 2009 (from engine number 11501F-983179 and 14001F-983646), so all A and B models; it is also part of the B maintenance kit.
Water pump repair kit17400-92J002,10,11—First-generation engines from 2006 to early 2009 (up to engine number 11501F-983178 and 14001F-983645); Suzuki USA lists 17400-90J20 for 2001–2005 engines.
Engine oil filter16510-61A332,1,12,13,14,15,3,16replaces 16510-61A32—Spin-on filter for every DF115A, DF140A, DF115B and DF140B, and for the 2010–2012 DF115; on the B it is reached from the top under the cover, with a tray that catches the oil. Dealers name it as successor of 16510-61A32, which Suzuki New Zealand still lists in its B kit.
Engine oil filter16510-827032—First-generation DF140, 2002–2012.
Engine oil filter16510-61A212,17—First-generation DF90 and DF115, 2001–2008 (catalogue number 16510-61A21-MHL).
Fuel filter (engine)15412-92J002,1,18,19,20,21—Low-pressure fuel filter element in the clear cup on the engine, A and B; on the B the cup carries the water-in-fuel sensor. Replace every 400 h or 2 years.
Fuel filter (engine)15410-87J302,22,23,24,25,26—First generation from 2006 (engine number …681518 on the DF115, …682149 on the DF140) to 2012: in-line filter in the hose to the fuel pump. Older engines use 15410-87J10 with a different bracket.
Spark plug09482-006492,1,27,21NGK LKR6E21,2B generation and DF100C: four per engine, gap 0.8–0.9 mm, 15–19 N·m. Do not swap it for the BKR6E of the older engines; each manual names its own plug.
Spark plug09482-004272,29,30,31,32,28NGK BKR6E28,2A and first generation: four per engine; the A manual gives a gap of 0.7–0.8 mm and 25–29 N·m.
Thermostat17670-90J0133,34,35,36—60 °C thermostat, standard on the first generation and on the B; a 71 °C version, 17670-90J11, is listed as an option.
Thermostat17670-90J2137,38—50 °C thermostat, standard on the DF115A and DF140A.
Anode (engine)55321-87J012,1,27,39,40,41,29—Aluminium anode used all over the engine: on the A and B two in the cylinder head, one in the block and two under the rectifier covers (cover gasket 11265-87E10), plus one on the trim cylinder of the DF115A/B. Five come in the B maintenance kit.
Anode (clamp bracket)55320-9491042,43,44,45,46—Anode set on the clamp brackets, the same on all three generations.
Anode (lower unit)55321-90J0147,48,49,50,46—Anode on the gearcase, all generations; Suzuki’s 2026 accessory list calls it a zinc anode.
Anode (lower unit)55125-90J01 · 55125-92J002,47,51,49,52—Trim tab above the propeller, which also works as an anode: 55125-90J01 on standard-rotation engines, 55125-92J00 on the counter-rotating Z models (on the B with a colour suffix, -YAY black or -QTN white).
Lower unit seal kit25700-92J002,47,48,53—Gearcase seal kit for every DF140 and for the DF115A and DF115B.
Lower unit seal kit25700-90J012,50,54—First-generation DF90 and DF115: the old DF115 has a different gearcase from the DF140 (Suzuki USA: 2001–2011; the 2012 DF115 parts list shows it too).
Drain plug gasket09168-120122,1,55,21—Engine oil drain plug gasket, 12.5 × 20 × 2.5 mm, all generations; fit a new one at every oil change (spares come in the tool bag). Drain plug 10–15 N·m on the B.
Drain plug09248-120092,55,56—Engine oil drain plug, all engines from 2004.
Gear oil plug gaskets09168-100222,1,47,21—Two per gear oil change, under the drain and level screws (09248-10008), 9–11 N·m; all generations.
Propeller hardware kit57630-90J102,3,47,53,21—Spacer, washer, nut and cotter pin, listed for the DF115 and DF140 gearcases of all generations. Tighten the propeller nut to 50–60 N·m and lock it with a new cotter pin, 09204-03003.
Fuel pre-filter65910-98J0146,3,21—Element for Suzuki’s water-separating filter 65900-98J11, which the manual recommends between tank and engine; change the element every 12 months.
Flushing attachment17917-87L0046,2,21—Garden-hose adapter for the flushing port, listed for these engines; according to its manual the B comes with a hose connector.
Gear oil990A0-01E81-01Q2,21—Suzuki ECSTAR hypoid gear oil, 1 US quart (0.95 l); a change takes 1.05 l, so buy two. Suzuki’s gear lube pump 990C0-99002 fits the bottle.
Propeller58100-90JA0-01957,3—3-blade aluminium, 14 × 17 in. Suzuki lists this aluminium range (13-1/2 × 15 to 14 × 23 in) for the DF100C, DF115B/BG and DF140B/BG.
Propeller58100-90JB0-01957,3—3-blade aluminium, 14 × 19 in.
Propeller58100-90JC0-01957,3—3-blade aluminium, 14 × 21 in.
Propeller58200-92J60-000 · 58200-92JB0-00057—3-blade stainless steel, 13-7/8 × 19 in: 58200-92J60-000 for regular rotation, 58200-92JB0-000 for counter rotation. Suzuki’s stainless range runs from 15 to 25 in pitch (counter rotation 17 to 23 in).

Numbers checked against the sources below on 23 October 2026. Always confirm against your serial number and exact type before ordering.

Service intervals

TaskInterval
First serviceBreak-in over the first 10 h: 5 min warm-up, the first 2 h at idle or below half throttle (3000 rpm), the next hour up to 4000 rpm, then no more than 5 min at a time at full throttle. First service after 20 h or 1 month: engine oil, oil filter and gear oil; check idle speed, anodes, lines, propeller and bolts21
Engine oil changeEvery 100 h or yearly, first time after 20 h21,28
Oil filterFirst after 20 h or 1 month, then every 200 h or yearly (dealer job in the manual)21,28
Gear oil changeEvery 100 h or yearly, first time after 20 h21,28
Spark plugCheck, clean and gap every 100 h or yearly; replace when worn21,28
Fuel filterLow-pressure filter: check at 20 h, then every 100 h or yearly; replace every 400 h or 2 years21,28
Fuel pre-filterWater-separating filter between tank and engine: replace the element every 12 months21,28
Raw water impellerWater pump and impeller: check every 200 h or yearly; replace the impeller every 300 h or 3 years (dealer)21,28
ThermostatCheck every 100 h or yearly (dealer)21,28
AnodeExternal anodes: check at 20 h, then every 100 h or yearly; anodes inside the powerhead: every 100 h or yearly (dealer)21,28
Valve clearanceCheck every 300 h or 3 years (dealer)21,28
Idle speed checkCheck at 20 h, then every 200 h or yearly (dealer)21,28
LubricationEvery 100 h or yearly, first time after 20 h21,28
PropellerPropeller nut and cotter pin: check at 20 h, then every 100 h or yearly, and retighten all bolts and nuts (dealer)21,28
Hoses & clampsFuel and breather lines: check at 20 h, then every 100 h or yearly21,28
BatteryBattery and bonding wires: check at 20 h, then every 100 h or yearly21,28
Fresh-water washAfter running in salt, brackish or muddy water: flush through the flushing port with fresh water for about 5 minutes, engine off21
WinterisingBefore laying up: add fuel stabiliser and run 5 min at about 1500 rpm in neutral, flush, change gear oil and engine oil, grease all points and spray the powerhead with rust preventive21

Hours or months, whichever comes first, from Suzuki’s English owner’s manual 99011-99L60-054 for the DF100C/DF115B/DF140B (June 2023); the 2027 German edition keeps the intervals and adds an off-season column, and the DF100A/115A/140A manuals of 2012 and 2021 give the same intervals (the 2012 edition also asks for an ignition timing check every 200 h). The timing chain has no replacement interval. Suzuki asks for shorter intervals under hard use: frequent full throttle, long trolling or idling, muddy or shallow water, no warm-up, frequent hard acceleration or shifting. No manual for the 2001–2012 engines was online to compare.

Specifications

TypeFour-stroke in-line four, DOHC 16 valves, timing chain with automatic tensioner; offset driveshaft with two-stage reduction58,15
Displacement2044 cm³ in the A manuals, 2045 cm³ in the B manuals: the same 86 × 88 mm block28,21
Bore × stroke86 × 88 mm21,28
Compression ratio10.6:1 on the B generation, raised from the A15,59
PowerDF140: 103.0 kW (140 PS); DF115: 84.6 kW (115 PS); sister models DF100A and DF100C: 73.6 kW (100 PS)21,28
Full-throttle rangeDF140A 5600–6200 rpm; DF140B, DF140BG and DF115BS 5700–6300 rpm; DF115A, DF115B, DF115BG and the DF100 models 5000–6000 rpm21,28,58
Idle speed650–750 rpm in neutral (factory setting on the B)21
InjectionMulti-point sequential electronic fuel injection; Lean Burn control on the B15,58
IgnitionFully transistorised; on the B the ignition coils sit directly on the plugs21,15
Engine oil capacity5.5 l; Suzuki USA gives 5.7 l with a filter change21,28,2
Engine oil gradeSAE 10W-40 or 10W-30, Suzuki ECSTAR marine oil or another NMMA FC-W or API SG (or higher) four-stroke oil; 5W-30 below 5 °C21
Gear oil capacity1.05 l21,28,2
Gear oil gradeHypoid gear oil SAE 90, API GL-5, or Suzuki outboard gear oil21
Gear ratio2.59:1 (B generation)15,58
Spark plugB: NGK LKR6E, gap 0.8–0.9 mm, 15–19 N·m. A and first generation: NGK BKR6E (A manual: gap 0.7–0.8 mm, 25–29 N·m); 4 per engine21,28,2
Valve clearance (cold)Intake 0.23–0.27 mm; exhaust 0.33–0.37 mm on the B, 0.23–0.27 mm on the A21,28
Alternator12 V, 40 A on the B (20 A at 700 rpm)15
FuelUnleaded petrol, at least RON 91 (AKI 87), no more than 10 % ethanol21
Dry weightWith battery cable, without propeller and oil: DF140B 186 kg (L) / 190 kg (X); DF115B and DF100C 188 / 192 kg; DF140BG 188 / 192 kg; DF115BG 190 / 194 kg58,15
Shaft lengthL 20 in (508 mm), X 25 in (635 mm)15,60
Propeller sizesB: pitch 15–25 in (regular rotation) or 17–23 in (counter rotation); aluminium 13-1/2 to 14 in diameter, stainless 13-7/8 in15,57
VersionsT = power trim and tilt, L or X = 20 or 25 in shaft (e.g. DF140BTL, DF140BTX); Z = counter-rotating version for twin installations (DF140BTZX, engine number with Z); G = drive-by-wire Suzuki Precision Control (DF140BG); DF115BS = DF115 with the 5700–6300 rpm range of the DF14060,15,21,61
Serial number prefixesDF115: 11501 (2001–2009), 11502 (2010–2012), 11503 (DF115A), 11504 (DF115A SS), 11505 (DF115BG), 11506 (DF115B). DF140: 14001 (2002–2009), 14002 (2010–2012), 14003 (DF140A), 14004 (DF140BG), 14005 (DF140B). Then F for standard, Z for counter rotation62,61,63
Years builtDF115 from 2001, DF140 from 2002; A generation 2013–2021; DF115BG/DF140BG from October 2020 (2021 model year), DF115B/DF140B with mechanical controls from the 2022 model year; still in production62,61,59,64

Good to know

  • Check the first five digits of the engine number before you order: 11501/11502 and 14001/14002 are the first generation, 11503/11504 and 14003 the A, 11505/11506 and 14004/14005 the B. The impeller 17461-90J01 fits all of them and the pump kit 17400-92J23 every engine from 2009, but plugs, thermostat and maintenance kits differ between A and B, and the first generation also has its own fuel filter (the DF140 its own oil filter too).62,61,10,4,2
  • The A and B take different spark plugs: BKR6E (gap 0.7–0.8 mm, 25–29 N·m) on the A and the first generation, LKR6E (0.8–0.9 mm, 15–19 N·m) on the B. The B maintenance kit contains LKR6E, so an A owner needs the A kit 17400-92824 or BKR6E plugs bought separately.28,21,1,2
  • On DF115 and DF140 built up to 2007 a steel exhaust plug (09248-18010, gasket 09160-18031) sits in the aluminium engine holder between powerhead and oil pan; Suzuki’s parts lists show it only up to 2007. Steel in aluminium corrodes in salt water, so on a used early engine have the holder around this plug checked before you buy.65,66,67
  • Both outputs drive their camshafts with a self-adjusting timing chain lubricated by the engine oil, so there is no belt to change, but clean oil matters: change it every 100 h or yearly, and sooner after long trolling, as the manual warns. The oil change reminder counts the running hours (first 20 h, then every 100 h) and has to be reset after each change.21,58
  • The B has a water sensor in the low-pressure fuel filter cup and sounds an alarm when water collects; stop, drain the cup and clean the element as the manual describes. Suzuki also recommends a water-separating filter between tank and engine (65900-98J11, element 65910-98J01, changed yearly).21,46
  • Gear oil goes in from the bottom: drain, fill 1.05 l through the lower hole until it comes out at the upper one, refit both screws with new gaskets 09168-10022 and check the level again after 10 minutes. Milky oil means water in the gearcase; Suzuki says not to run the engine until the cause is found.21,2

Videos & how-tos

Links to YouTube, nothing embedded. The maker’s own channel comes first; the rest are channels we found clear and correct for this model.

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Sources

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