Suzuki DT115/DT140 Outboard Motor Service Manual

Repair and service procedures for Suzuki DT115 and DT140 outboard motors. Includes detailed specifications, diagrams, and troubleshooting. Part number: C4256-90954

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Suzuki Models Covered & Key Technical Specifications

Suzuki DT115/DT140 Outboard Motor Service Manual — Comprehensive Maintenance, Diagnostics & Repair Procedures Suzuki DT115 / DT140 (32102-94500) — 1983-1985 Suzuki DT115/DT140 2-Stroke Outboards. Established Specification Data: 115 hp (84.6 kW) is the maximum power output for the DT115 model. Reference Fluid Levels: 1100 ml of gear oil is required for the lower unit lubrication. Essential Operating Range: 5000-5500 rpm defines the optimal operating range for the engine. Baseline Ignition Timing: 6° ATDC at 900 rpm is the specified retard position. Integral Cooling System: Displacement type water pump with thermostat for precise temperature control. Specific Component Data: Standard spark plug gap of 0.8-0.9 mm (0.031-0.035 in).

Technical Specifications
keyboard_arrow_down
Document Number / Seller:
30254 / Mary Scott
File Size:
26.95 MB
File Type:
PDF
Language:
English
Pages:
138
Printable:
Yes
Category:
Outboard Motor
Last updated / verified
Apr 16, 2025

Suzuki Manual Features & Content Preview

Consolidated Repair Overhaul Manual: Suzuki DT115/DT140 Outboard Motor Service Manual - Comprehensive Maintenance, Diagnostics & Repair Procedures Wiring-Compendium

Service-Level: Suzuki DT115 / DT140 (32102-94500) // Specification-Class: Outboard Motor / 2-Stroke Logic // Service-Level: Genuine Factory Workshop Manual

Assessment-Element Parameters Calibration-Spec
Engine Type 4-Cylinder, 2-Stroke -
Displacement 1773 cc (108.20 cu. in.) -
Bore x Stroke 84 mm x 80 mm -
Compression Ratio 5.8:1 - 6.6:1 -

Reference chapters include Engine Removal and Disassembly, Engine Services, Engine Reassembly, Cooling System, Fuel System, Gear Case, and Electrical System diagnostics.

Properly requiring maintenance, this manual outlines the procedures for the engine, fuel, cooling, lubrication, and electrical systems. It also covers the power trim and tilt system, gear case, and troubleshooting.

This manual documents torque specifications for critical engine components to ensure proper cyclic stress resistance.

Manual FAQ, Purchase & Download Details

Are wiring diagrams and electrical connector references included in the Suzuki manual? keyboard_arrow_down

Chapter 12 of the document includes a comprehensive meter wiring diagram for the system. This section also lists the color-coded wire identification and connector pin references for the electrical components.

Does the service data group contain tightening torque values for important engine bolts? keyboard_arrow_down

Service data section provides detailed tables listing tightening torque specifications for various engine fasteners, including cylinder head bolts, crankcase bolts, and flywheel nuts.

Can I find information regarding the optimal gear oil capacity for the lower unit in this manual? keyboard_arrow_down

Service data pages list the required lubricant volume for the lower unit as 1100 ml. This reference value is intended for maintenance and service tasks related to the gear case system.

Is there a reference chart for break-in operation and gasoline mixing ratios? keyboard_arrow_down

General information section contains a specific break-in guide that shows the recommended gasoline to lubricating oil mixing ratios for the engine.

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