Suzuki DF115B Troubleshooting
| Engine Model: Suzuki DF115B |
| Engine Type: 4-stroke inline 4-cylinder DOHC 16-valve gasoline outboard engine |
| Total Displacement: 124.8 cu.in (2 L) |
| Rated Engine Power: 115 Hp (84.6 kW) at 5500 rpm |
| Fuel System: Multi point sequential electronic fuel injection |
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| Engine starts up hard or doesn't start |
Empty gas tank - Fill gasoline up.
Improper fuel grade - Use correct fuel grade.
Air in the fuel system - Air bleeding.
Spark plug wiring connection is damaged - Inspect the spark plug wire connection, replace or repair.
Spark plug is faulty - Replace spark plug.
Fuel filter is dirty - Change fuel filter.
Vapor separator needle valve is damaged or worn - Change vapor separator needle valve.
Dirt in the fuel lines - Fuel lines must be clean.
Fuel tank air vent restricted or closed - Open or service air vent.
Defective fuel feed pump - Fuel feed pump need to be replaced.
Incorrectly adjusted or damaged throttle cable - Replace cable or adjust correctly.
Valve clearance is wrong - Check and adjust.
Valve timing is wrong - Adjust valve timing correctly.
Fuel pressure is low - Check low pressure fuel pump or check system for fuel leaks.
Damaged or clogged fuel injector - Clean or install new injector.
Fuel regulator malfunction - Replace fuel regulator.
ECM is faulty - Change electronic control modul.
| Engine starts and then stalls |
Spark plug is damaged - Install new spark plug.
Vapor separator needle valve is worn or defective - Change vapor separator needle valve.
Ignition coil is damaged - Install a new ignition coil.
Closed or restricted fuel tank air vent - Fuel tank air vent need to be opened or cleaned.
Defective fuel pump - Change or rebuild fuel pump.
Choke system is damaged - Change choke system components as required.
Valve clearance is wrong - Adjust to proper valve clearance.
Improper valve timing - Set the valve timing correctly.
Weak or damaged valve springs - Change valve springs.
Valves are stuck - Service the valves.
Bad compression - Check and replace worn parts.
Plugged fuel filter - Change fuel filter.
Fuel injector is faulty or clogged - Clean or replace as required.
Insufficient engine oil - Add oil to the engine crankcase.
Faulty oil pump - Change oil pump as required.
Dirty water intake screen - Need to wash or clean.
Thermostat is defective - Change thermostat.
Water pump is defective - Change water pump as required.
Defective ignition system - Inspect ignition system and change faulty parts.
Fuel pump is dirty or defective - Test fuel pump and change if necessary.
Damaged or wear vapor separator needle valve - Change vapor separator needle valve.
Dirty fuel lines - Service fuel lines.
Closed or clogged fuel tank air vent - Open or service air vent.
Fuel filter is clogged - Replace fuel filter.
Intake manifold air leaks - Replace intake manifold gasket.
Dirty water intake screen - Wash or clean as required.
Throttle link and throttle valve are wear or damaged - Replace faulty parts.
Damaged or clogged fuel injector - Clean or replace if necessary.
Excessive engine load - Load reducing required.
Fuel pump or fuel injector is clogged - Replace or clean as required.
Ignition timing is improper - Set the ignition timing correctly.
Damaged thermostat - Thermostat need to be replaced.
Damaged water pump - Change water pump as required.
Propeller pitch or diameter incorrect - Replace propeller.
Damaged or bent propeller - Have propeller repaired or replaced.
Outboard engine is positioned too low or too high - Position the engine correctly.
Engine oil level low - Need to add engine oil.
Damaged oil pump - Change oil pump as required.
Clogged water intake - Need to clean or wash.
Valve setting is incorrect - Set the valves correctly.
| Engine knocking sound or abnormal noise |
Stale fuel - Change gasoline.
Engine is under excessive load - Reduce load.
Low idle speed set incorrectly - Adjustment required.
Fuel pump is defective or dirty - Check fuel pump and change if required.
Crankshaft or main bearings are worn out - Have bearings or crankshaft replaced.
Damaged piston rings or cylinder bore - Change defective parts.
| Engine power is insufficient |
Fuel lines are dirty - Fuel lines need to be cleaned.
Defective fuel injector - Test fuel injector and change if necessary.
Fuel pump is damaged or dirty - Service or replace fuel pump.
Defective ignition - Check ignition system and replace faulty parts.
Cylinder head gasket is defective - Replace the head gasket.
Powerhead parts are damaged - Replace defective components as required.
Stuck or burned valves - Clean or change valves.
Incorrect propeller selection - Install correct propeller.
Damaged or bent propeller - Replace propeller.
Engine mounted at wrong transom height - Check the outboard engine mounting height.
Trim angle is incorrect - Adjust trim angle.
| Engine uses too much fuel |
Damaged or clogged fuel injector - Clean or replace if necessary.
Loose or defective spark plug - Tighten or change the spark plug.
Piston, sleeve, or rings are damaged - Replace faulty components.
ECU is faulty - Replace ECU.
| Motor vibrates excessively |
Propeller bent or damaged - Have propeller repaired or replaced.
Damaged propeller shaft - Have propeller shaft replaced.
Weeds in the propeller - Clean the propeller.
Motor mounting bolt is loose - Tighten the bolt as required.
Loose or faulty steering pivot Tighten correctly or replace.
Low battery output voltage - Battery is drained, recharge it.
Battery does not hold charge - Service charging system or install new battery.
Wires are disconnected or battery terminals are corroded - Check wire connections and change or service terminals.
Starter motor is damaged - Replace or repair starter.
| Trim motor is running but trim system cannot move up or down |
Lack of oil - Need to add the oil.
Pump assembly is defective - Inspect pump and change as required.
Leakage of manual release valve - Close the valve or change it.
Faulty pump driveshaft or motor - Change worn component.
| Trim cannot be fully up or down |
Pump assembly faulty - Change pump as required.
Tilt ram piston ball is not positioned correctly - Service or repair.
Tilt ram piston O-ring is worn - Install new O-ring.
Low oil level - Need to add the oil.
Lower check valve not seating in port side trim ram - Secure valve properly.
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