Suzuki DF200AP Troubleshooting
| Engine Model: Suzuki DF200AP |
| Engine Type: 4-stroke inline 4-cylinder DOHC 16-valve gasoline outboard engine |
| Total Displacement: 175 cu.in (2.9 L) |
| Rated Engine Power: 200 Hp (147 kW) at 6000 rpm |
| Fuel System: Multi point sequential electronic fuel injection |
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| Engine won't start or hard to start |
Gas tank is empty - Add fuel.
Incorrect fuel grade - Use correct fuel grade.
Air in fuel tank - Bleed fuel tank.
Faulty spark plug wire connection - Inspect the spark plug wire connection, replace or repair.
Defective spark plug - Change spark plug as required.
Dirty fuel filter - Fuel filter needs changing.
Worn or damaged vapor separator needle valve - Change vapor separator needle valve.
Restricted fuel lines - Clean fuel system lines.
Fuel tank air vent clogged or closed - Open or clean air vent.
Defective fuel feed pump - Replace or repair fuel pump.
Throttle cable is worn or adjusted improperly - Adjust correctly or replace the cable.
Incorrect valve clearance - Adjust to proper valve clearance.
Valve timing is wrong - Adjust valve timing correctly.
Fuel pressure is low - Inspect low pressure fuel pump or inspect fuel system for leaks.
Damaged or clogged fuel injector - Replace or clean as required.
Fuel regulator is defective - Change fuel regulator.
ECM failure - Replace ECM.
| Engine starts and stops immediately |
Spark plug is defective - Replace spark plug.
Vapor separator needle valve is bend or wear - Replace needle valve.
Ignition coil is damaged - Ignition coil must be replaced.
Closed or restricted fuel tank air vent - Fuel tank air vent need to be opened or cleaned.
Defective fuel pump - Replace or repair fuel pump.
Choke system is damaged - Inspect and replace choke system components.
Incorrect valve clearance - Need to adjust valve clearance.
Valve timing is wrong - Adjust valve timing correctly.
Loose or broken valve springs - Change valve springs.
Stuck valves - Clean the valves.
Poor compression - Check and change damaged parts.
Fuel filter is clogged - Change fuel filter.
Damaged or clogged fuel injector - Clean or install new injector.
Engine oil level low - Fill the crankcase with engine oil.
Damaged oil pump - Change oil pump.
Water intake is blocked - Need to wash or clean.
Thermostat failure - Change thermostat as required.
Damaged water pump - Install new water pump.
Defective ignition system - Test ignition and replace failed parts.
Dirty or faulty fuel pump - Service or change fuel pump.
Vapor separator needle valve is bend or wear - Change vapor separator needle valve.
Fuel lines are clogged - Fuel lines must be clean.
Fuel tank air vent clogged or closed - Open or clean air vent.
Plugged fuel filter - Change fuel filter.
Intake manifold is air leaking - Change intake manifold gasket.
Water intake is clogged - Need to clean or wash.
Throttle link and throttle valve are wear or damaged - Replace faulty components.
Dirty or faulty fuel injector - Clean or replace as required.
Engine overloaded - Reduce the load.
Fuel pump or fuel injector is clogged - Clean or replace if necessary.
Wrong ignition timing - Set the ignition timing properly.
Defective thermostat - Install new thermostat.
Defective water pump - Install new water pump.
Incorrect propeller selection - Replace propeller.
Propeller bent or damaged - Replace propeller.
Outboard motor is positioned too low or too high - Position the engine correctly.
Engine oil level is low - Fill the crankcase with engine oil.
Oil pump is defective - Change oil pump.
Clogged water intake - Need to wash or clean.
Improper valve setting - Set the valves correctly.
Stale gasoline - Use correct fuel.
Engine is overloaded - Load reducing is recommended.
Low idle speed setting is incorrect - Adjustment required.
Fuel pump is dirty or defective - Clean or replace fuel pump.
Worn main bearings or crankshaft - Have bearings or crankshaft replaced.
Cylinder bore or piston rings are damaged - Replace faulty components.
Fuel lines are dirty - Clean fuel system lines.
Faulty fuel injector - Change fuel injector.
Dirty or faulty fuel pump - Test fuel pump and replace if necessary.
Ignition system malfunction - Inspect ignition system and change failed components.
Cylinder head gasket is damaged - Cylinder-head gasket replacement required.
Faulty powerhead components - Change defective components.
Stuck or burned valves - Service or replace valves.
Incorrect propeller selection - Install correct propeller.
Damaged or bent propeller - Replace propeller.
Motor mounted at incorrect height on transom - Have motor adjusted to proper transom height.
Incorrect trim angle - Adjust trim angle.
Clogged or worn fuel injector - Clean or replace if necessary.
Spark plug is loose or defective - Change or re-tighten spark plug.
Worn sleeve, piston, or rings - Change defective parts.
Electronic control unit is not operating - Install new ECU.
Propeller bent or damaged - Replace propeller.
Damaged propeller shaft - Have propeller shaft replaced.
Weeds in the propeller - Clean the propeller.
Engine mounting bolt is not tightened - Tighten bolt.
Loose or faulty steering pivot Tighten or replace.
Low battery capacity - Low battery charging, charge as required.
Battery discharges quickly - Service or replace the battery.
Disconnected wires or corroded battery terminals - Check cable connections and replace or service terminals.
Damaged starter motor - Repair or change starter.
| Trim motor is running but trim system cannot move up or down |
Lack of oil - Checking oil level and add if necessary.
Pump assembly is damaged - Check pump and change if required.
Leakage of manual drain valve - Valve need to be closed or changed.
Motor or pump driveshaft faulty - Change defective component.
| Trim does not fully up or down |
Damaged pump assembly - Replace pump.
Tilt ram piston ball is not positioned correctly - Service or repair.
Damaged tilt ram piston O-ring - Replace O-ring.
Oil level is low - Checking oil level and add if necessary.
Lower check valve is not properly secured in port side trim ram - Install valve correctly.
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