Suzuki DF140A Troubleshooting
| Engine Model: Suzuki DF140A |
| Engine Type: 4-stroke inline 4-cylinder DOHC 16-valve gasoline outboard engine |
| Total Displacement: 124.7 cu.in (2 L) |
| Rated Engine Power: 140 Hp (103 kW) at 6000 rpm |
| Fuel System: Multi point sequential electronic fuel injection |
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| Engine starts up hard or won't start |
No fuel in fuel tank - Add gasoline.
Incorrect fuel grade - Change gasoline.
Fuel system clogged - Repair or replace.
Spark plug wire connection are damaged - Inspect the spark plug wire connection, replace or repair.
Spark plug is faulty - Replace spark plug.
Dirty fuel filter - Replace fuel filter.
Vapor separator needle valve is worn or defective - Install new needle valve.
Clogged fuel lines - Clean fuel system lines.
Closed or clogged fuel tank air vent - Open or clean air vent.
Damaged fuel feed pump - Replace or repair fuel pump.
Damaged or not adjusted choke cable - Adjust properly or replace the cable.
Incorrect valve clearance - Check and adjust.
Wrong valve timing - Adjust valve timing correctly.
Low fuel pressure - Check system for fuel leaks or check low pressure fuel pump.
Fuel injector is dirty or worn - Clean or install new injector.
Fuel regulator failure - Install new fuel regulator.
Electronic control modul failure - Change electronic control modul.
| Engine starts and stalls immediately |
Spark plug is faulty - Install new spark plug.
Damaged or wear vapor separator needle valve - Install new needle valve.
Ignition coil is damaged - Replace ignition coil as necessary.
Fuel tank air vent closed or restricted - Open or service air vent.
Faulty fuel pump - Install new pump or repair it.
Faulty choke system - Inspect and replace choke system components.
Valve clearance is incorrect - Adjust to proper valve clearance.
Valve timing is incorrect - Adjust valve timing correctly.
Valve springs are damaged or weak - Valve springs need to be changed.
Stuck valves - Valves must be cleaned.
Weak cylinder compression - Check and replace worn parts.
Fuel filter is plugged - Install new filter.
Dirty or faulty fuel injector - Clean or install new injector.
Lack of engine oil - Add oil to the engine crankcase.
Oil pump malfunction - Install new oil pump.
Water intake screen is dirty - Wash or clean as required.
Damaged thermostat - Change thermostat as required.
Faulty water pump - Change water pump as required.
| Engine runs intermittently |
Defective ignition system - Inspect ignition system and change faulty parts.
Clogged or defective fuel pump - Check fuel pump and replace if necessary.
Vapor separator needle valve is bend or wear - Install new needle valve.
Dirt in the fuel lines - Clean fuel lines.
Fuel tank air vent closed or restricted - Open or service air vent.
Clogged fuel filter - Fuel filter needs changing.
Intake manifold air leaks - Replace intake manifold gasket.
Clogged water intake - Wash or clean as required.
Throttle valve and throttle link are defective or worn - Change faulty components.
Clogged or worn fuel injector - Clean or replace if necessary.
Engine is running overloaded - Reduce the load.
Clogged fuel pump or fuel injector - Replace or clean as required.
Wrong ignition timing - Set the ignition timing properly.
Thermostat failure - Change thermostat.
Defective water pump - Install new water pump.
Incorrect propeller selection - Check the propeller size.
Damaged or bent propeller - Replace propeller.
Outboard engine is positioned too low or too high - Mount the motor as required.
Engine oil insufficient - Add oil to the engine crankcase.
Damaged oil pump - Install new oil pump.
Clogged water intake - Wash or clean as required.
Improper valve setting - Adjust valves as required.
Low octane gasoline - Use proper fuel.
Engine is under excessive load - Reduce the load.
Low idle speed setting is incorrect - Adjust the low idle speed.
Clogged or damaged fuel pump - Inspect fuel pump and change as required.
Worn main bearings or crankshaft - Worn parts replacement required.
Piston rings or cylinder bore are worn - Replace defective parts.
Dirty fuel lines - Clean fuel lines.
Fuel injector is defective - Change fuel injector.
Clogged or defective fuel pump - Clean or change fuel pump.
Defective ignition - Inspect ignition system and change failed components.
Cylinder head gasket is defective - Replace cylinder head gasket.
Powerhead parts are damaged - Change defective components.
Stuck or burned valves - Change or service valves.
Improper propeller diameter or pitch - Replace propeller.
Propeller bent or damaged - Replace propeller.
Incorrect outboard motor mounting height - Have motor adjusted to proper transom height.
Trim angle is incorrect - Make the correct trim angle adjustment.
| Excessive fuel consumption |
Clogged or worn fuel injector - Clean or replace if necessary.
Spark plug is faulty or loose - Replace or tighten spark plug.
Worn rings, piston, or sleeve - Replace defective components as required.
ECU is not functioning - Replace ECU.
| Excessive engine vibration |
Propeller bent or damaged - Have propeller repaired or replaced.
Damaged propeller shaft - Replace propeller shaft.
Weeds in the propeller - Remove and clean propeller.
Engine mounting bolt is not tightened - Tighten bolt.
Damaged or loose steering pivot Tighten correctly or replace.
Battery voltage is low - Low battery charging, charge as required.
Battery will not hold charge - Battery needs to be serviced or replaced.
Wires are disconnected or battery terminals are corroded - Check battery wires and service or replace terminals.
Starter motor failure - Starter needs to be replaced.
| Trim motor is running but trim system cannot move up or down |
Oil insufficient - Fill up oil.
Defective pump assembly - Check pump and change if required.
Manual release valve leaking - Close the valve fully or replace it.
Pump driveshaft or motor damaged - Replace worn component.
| Trim cannot be fully up or down |
Pump assembly faulty - Replace pump.
Tilt ram piston ball is not positioned correctly - Clean or repair.
Damaged tilt ram piston O-ring - Replace O-ring.
Lack of oil - Check oil level and add oil as required.
Lower check valve not seating in port side trim ram - Secure valve properly.
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