Suzuki DF115BG Troubleshooting
| Engine Model: Suzuki DF115BG |
| 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 is not starting or hard starting |
Empty gas tank - Fill gasoline up.
Low-quality gasoline - Change fuel.
Air in the fuel system - Air bleeding.
Spark plug wire connection are damaged - Check the spark plug wire connection, repair or replace.
Damaged spark plug - Change spark plug as required.
Clogged fuel filter - Fuel filter needs to be replaced.
Vapor separator needle valve is worn or defective - Replace needle valve.
Fuel lines clogging - Clean fuel system lines.
Fuel tank air vent clogged or closed - Open or service air vent.
Damaged fuel feed pump - Install new feed pump or repair it.
Damaged or not adjusted choke cable - Replace cable or adjust correctly.
Excessive valve clearance - Check and adjust.
Valve timing is wrong - Adjust valve timing correctly.
Low fuel pressure - Check system for fuel leaks or check low pressure fuel pump.
Fuel injector is damaged or dirty - Replace or clean as required.
Fuel regulator is defective - Change fuel regulator.
Electronic control modul is not operating - Install new ECM.
| Engine starts but stalls immediately |
Spark plug is faulty - Change spark plug.
Worn or damaged vapor separator needle valve - Replace needle valve.
Faulty ignition coil - Install a new ignition coil.
Closed or clogged fuel tank air vent - Open or service air vent.
Fuel pump malfunction - Change or rebuild fuel pump.
Choke system malfunction - Check and repair choke system.
Valve clearance is incorrect - Adjust to proper valve clearance.
Incorrect valve timing - Set the valve timing properly.
Valve springs are bad or broken - Replace valve springs.
Valves are stuck - Service the valves.
Poor compression - Check and replace worn parts.
Clogged fuel filter - Change fuel filter.
Dirty or faulty fuel injector - Clean or replace as required.
Not enough engine oil - Fill up the oil to required level.
Oil pump malfunction - Change oil pump.
Clogged water intake - Wash or clean as required.
Damaged thermostat - Change thermostat.
Defective water pump - Change water pump.
Defective ignition - Inspect ignition system and change failed components.
Fuel pump is dirty or defective - Clean or replace fuel pump.
Worn or damaged vapor separator needle valve - Change vapor separator needle valve.
Clogged fuel lines - Clean fuel lines.
Closed or clogged fuel tank air vent - Open or clean air vent.
Clogged fuel filter - Replace or clean fuel filter.
Intake manifold air leaks - Install new gasket.
Clogged water intake - Need to clean or wash.
Throttle link and throttle valve are worn or damaged - Change faulty components.
Fuel injector is faulty or clogged - Clean or replace if necessary.
Engine is overloaded - Reduce the load.
Fuel pump or fuel injector is clogged - Clean or replace if necessary.
Ignition timing is wrong - Set the ignition timing correctly.
Faulty thermostat - Replace thermostat.
Faulty water pump - Install new water pump.
Improper propeller diameter or pitch - Check the propeller size.
Propeller bent or damaged - Replace propeller.
Outboard engine is mounted too high or too low - Position the engine correctly.
Engine oil level is low - Check oil level and add oil as required.
Damaged oil pump - Replace oil pump.
Water intake is blocked - Wash or clean as required.
Incorrect valve setting - Adjust valves correctly.
Stale fuel - Change gasoline.
Engine is overloaded - Load reducing required.
Incorrectly set low idle speed - Test and adjust.
Dirty or faulty fuel pump - Inspect fuel pump and change as required.
Crankshaft or main bearings wear - Change defective components as required.
Damaged cylinder bore or piston rings - Change faulty parts.
Dirt in the fuel lines - Clean fuel system lines.
Fuel injector is defective - Change fuel injector.
Fuel pump is dirty or defective - Service or change fuel pump.
Ignition system malfunction - Test ignition and replace failed parts.
Worn cylinder head gasket - Change cylinder head gasket.
Damaged powerhead parts - Replace defective components.
Burned or stuck valves - Replace or clean valves.
Improper propeller diameter or pitch - Replace propeller.
Damaged or improper size of propeller - Have propeller repaired or replaced.
Motor mounted at incorrect height on transom - Have motor adjusted to proper transom height.
Trim angle is incorrect - Make the correct trim angle adjustment.
Fuel injector is damaged or dirty - Clean or replace if necessary.
Defective or loose spark plug - Re-tighten or replace spark plug.
Piston, sleeve, or rings are damaged - Change defective components.
ECU failure - Change electronic control unit.
| Excessive engine vibration |
Propeller bent or damaged - Replace propeller.
Propeller shaft damaged - Have propeller shaft replaced.
Weeds wraped around propeller - Remove weeds from propeller.
Motor mounting bolt is loose - Tighten the bolt as required.
Steering pivot is loose or damaged Tighten or replace.
Battery power is low - Charge the battery.
Battery won’t hold charge - Service battery or change it.
Battery terminals are corroded or wires are disconnected - Check cables and service or change terminals.
Damaged starter motor - Repair or change starter.
| Trim motor is running but trim system cannot move up or down |
Insufficient oil - Check oil level and add oil as required.
Pump assembly is faulty - Check pump and change if required.
Leakage of manual release valve - Valve need to be closed or changed.
Faulty pump driveshaft or motor - Change defective component.
| Trim cannot be fully up or down |
Pump assembly is defective - Replace pump.
Tilt ram piston ball is in wrong position - Clean or repair.
Tilt ram piston O-ring is worn - Install new O-ring.
Low oil level - Check and refill oil.
Lower check valve is not properly secured in port side trim ram - Secure valve properly.
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