The Suzuki DF140 and its smaller siblings, the DF90, DF100 and DF115, are common outboards on centre consoles and RIBs. Suzuki's own campaign notices name two faults by serial number. Corrosion is the other thing to look at, as on any outboard used in salt water.
Water pump sleeve: overheating at idle
What happens. Suzuki's service campaign notice says a water pump case sleeve of the wrong size got into some engines. At idle, or when the engine was put back in neutral under way, the pump couldn't deliver enough water and the overheat warning could sound. The fix was a new water pump case assembly.
Which engines. DF90, DF100, DF115 and DF140 engines built from 30 January to 29 May 2008, 156 in all, listed by serial number in the notice. Suzuki reported all of them serviced.
Where to look. Run the engine at idle on the trailer or in the water: steady tell-tale flow, no overheat alarm, and the temperature settling. Check the serial number against the notice, and the date of the last impeller change; see outboard water pump impeller.
Engine control module: water in fuel alarm silent
What happens. A second campaign covered a fault in the engine control module's fuel filter water detection program: the water in fuel alarm didn't sound. Suzuki warned that water in the fuel could then cause the engine to run badly. The control module was replaced free of charge.
Which engines. DF100A, DF115A and DF140A engines built from 22 May 2013 to 31 March 2015, 641 in all. For the DF140A the serial ranges are 14003F-410004 to 14003F-414459 and 14003F-510005 to 14003F-513293. Suzuki notes that not every engine in the ranges is affected.
Where to look. Check the serial number, ask a dealer whether the campaign was done, and drain the fuel filter bowl to see what's in it.
Corrosion
Outboards in salt water corrode at the lower unit and bracket, and where the engine meets its mount. Suzuki has since added its Edge eCoat, an anodizing treatment of the cooling water passages in the block, head and crankcase, first on the DF140B, according to IBI's report. Older engines don't have it. See outboard corrosion.
Where to look. Bubbling paint and white powder on the lower unit, bracket and engine holder; the anodes; and the flushing records.
What to check on a Suzuki DF140
| Area | What to look for | Source of the concern |
|---|---|---|
| Serial number | Against both campaign lists; dealer confirmation | Suzuki campaigns |
| Cooling at idle | Tell-tale flow, overheat alarm, impeller age | Suzuki water pump campaign |
| Water in fuel alarm | Works; fuel filter bowl clear | Suzuki ECM campaign |
| Corrosion | Lower unit, bracket, engine holder, anodes | Suzuki eCoat report |
Writing it up
"Outboard, Suzuki DF140A, serial 14003F-41xxxx: serial falls within Suzuki's engine control module service campaign range; no record that the campaign was carried out. Recommend a Suzuki dealer confirms and completes the campaign before the vessel is next used. Paint bubbling with white corrosion on the lower unit leading edge." Note the serial number and hours in the particulars.