Suzuki DF200APX Troubleshooting
| Engine Model: Suzuki DF200APX |
| 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 will not start or hard to start |
No gasoline in tank - Add fuel.
Improper fuel grade - Use correct gasoline grade.
Dirty fuel system - Check and clean.
Defective wiring connection of spark plug - Inspect spark plug wiring connection, change or repair.
Faulty spark plug - Change spark plug as required.
Fuel filter is dirty - Fuel filter needs changing.
Damaged or wear vapor separator needle valve - Change vapor separator needle valve.
Dirt in the fuel lines - Clean fuel lines.
Closed or restricted fuel tank air vent - Open or clean air vent.
Fuel feed pump malfunction - Change or rebuild fuel feed pump.
Unadjusted or worn throttle cable - Change cable or adjust correctly.
Valve clearance is wrong - Adjust valve clearance according to specifications.
Valve timing is incorrect - Set the valve timing correctly.
Fuel pressure is low - Inspect low pressure fuel pump or inspect fuel system for leaks.
Clogged or worn fuel injector - Clean or replace if necessary.
Fuel regulator is defective - Change fuel regulator.
Electronic control modul is not operating - Change electronic control modul.
| Engine starts and stops immediately |
Spark plug is damaged - Install new spark plug.
Worn or damaged vapor separator needle valve - Change vapor separator needle valve.
Faulty ignition coil - Ignition coil should be replaced.
Closed or restricted fuel tank air vent - Fuel tank air vent need to be opened or cleaned.
Fuel pump malfunction - Change or rebuild fuel pump.
Faulty choke system - Check and repair choke system.
Incorrect valve clearance - Adjust valve clearance according to specifications.
Valve timing is improper - Set the valve timing correctly.
Valve springs are broken or bad - Install new valve springs.
Stuck valves - Service the valves.
Weak cylinder compression - Check and replace worn parts.
Fuel filter is dirty - Change fuel filter.
Damaged or clogged fuel injector - Clean or install new injector.
Engine oil insufficient - Checking oil level and add if necessary.
Damaged oil pump - Install new oil pump.
Water intake screen is dirty - Need to clean or wash.
Damaged thermostat - Change thermostat as required.
Water pump is defective - Replace water pump.
| Engine runs intermittently |
Ignition system malfunction - Check ignition and replace faulty components.
Fuel pump is dirty or defective - Check fuel pump and replace if necessary.
Damaged or wear vapor separator needle valve - Install new needle valve.
Fuel lines are clogged - Clean fuel system lines.
Fuel tank air vent clogged or closed - Fuel tank air vent need to be opened or cleaned.
Fuel filter is plugged - Change fuel filter.
Intake manifold air leaks - Change intake manifold gasket.
Water intake is clogged - Need to clean or wash.
Throttle link and throttle valve are wear or damaged - Change faulty components.
Clogged or worn fuel injector - Replace or clean if necessary.
Engine overload - Reduce engine load.
Clogged fuel pump or fuel injector - Clean or replace if necessary.
Ignition timing is wrong - Ignition timing needs to be adjusted correctly.
Thermostat is defective - Change thermostat.
Faulty water pump - Change water pump as required.
Incorrect propeller selection - Check the propeller size.
Propeller bent or damaged - Have propeller repaired or replaced.
Outboard engine is positioned too low or too high - Position the engine correctly.
Engine oil level is low - Fill up the engine oil.
Damaged oil pump - Change oil pump.
Dirty water intake screen - Wash or clean as required.
Valve setting is incorrect - Valves needs to be adjusted properly.
Low octane gasoline - Use proper gasoline.
Engine overloaded - Reduce load.
Incorrectly set low idle speed - Correct the settings.
Dirty or faulty fuel pump - Test fuel pump and replace if necessary.
Crankshaft or main bearings are worn out - Change defective components as required.
Worn cylinder bore or piston rings - Change faulty parts.
Dirty fuel lines - Clean fuel lines.
Fuel injector is defective - Change fuel injector.
Fuel pump is clogged or faulty - Inspect fuel pump and change as required.
Defective ignition system - Check ignition and replace faulty components.
Cylinder head gasket is damaged - Replace cylinder head gasket.
Worn powerhead parts - Replace defective parts.
Valves are stuck or burned - Service or replace valves.
Propeller selection improperly - Install correct propeller.
Propeller bent or damaged - Have propeller repaired or replaced.
Outboard engine mounting height improperly - Check the outboard motor mounting height.
Incorrect trim angle - Make the correct trim angle adjustment.
| Excessive fuel consumption |
Dirty or faulty fuel injector - Replace or clean as required.
Faulty or loose spark plug - Re-tighten or change the spark plug.
Worn piston, rings, or sleeve - Replace defective parts.
ECU is not functioning - Install new ECU.
Propeller bent or damaged - Replace propeller.
Propeller shaft damaged - Have propeller shaft replaced.
Weeds wraped around propeller - Remove and clean propeller.
Engine mounting bolt is not tightened - Tighten the bolt as required.
Steering pivot is loose or damaged Tighten or replace.
Battery power is low - Battery needs to be recharged.
Battery will not hold charge - Service battery or replace it.
Disconnected wires or corroded battery terminals - Connect cables properly or replace terminals.
Starter motor failure - Starter should be replaced.
| Trim motor is running but trim system cannot move up or down |
Lack of oil - Fill up oil to required level.
Defective pump assembly - Inspect pump and change as required.
Leakage of manual drain valve - Valve need to be closed or changed.
Pump driveshaft or motor damaged - Replace worn component.
| Trim cannot be fully up or down |
Pump assembly faulty - Change pump.
Tilt ram piston ball is in wrong position - Clean or repair.
Damaged tilt ram piston O-ring - Replace O-ring.
Not enough 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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