Suzuki DF40ATL Troubleshooting
| Engine Model: Suzuki DF40ATL |
| Engine Type: 4-stroke 3-cylinder long shaft gasoline outboard engine |
| Total Displacement: 57.4 cu.in (941 cc) |
| Rated Engine Power: 40 Hp (29.5 kW) at 6000 rpm |
| Fuel System: Multi-point sequential electronic fuel injection |
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| Engine is not starting or hard starting |
Empty fuel tank - Add gasoline.
Wrong grade of gasoline - Use correct fuel grade.
Air in the fuel system - Air bleeding.
Loose or disconnected spark plug wire - Inspect the spark plug wire connection, replace or repair.
Damaged spark plug - Replace spark plug.
Fuel filter is dirty - Replace or clean fuel filter.
Worn or damaged vapor separator needle valve - Install new needle valve.
Fuel lines are dirty - Fuel lines must be clean.
Fuel tank air vent restricted or closed - Open or clean air vent.
Damaged fuel feed pump - Fuel feed pump need to be replaced.
Choke cable is worn or not adjusted properly - Replace cable or adjust correctly.
Excessive valve clearance - Need to adjust valve clearance.
Valve timing is incorrect - Adjust valve timing correctly.
Low fuel pressure - Inspect low pressure fuel pump or inspect fuel system for leaks.
Fuel injector is dirty or worn - Clean or replace as required.
Fuel regulator is defective - Change fuel regulator.
ECM is faulty - Replace ECM.
| Engine starts and stalls immediately |
Faulty spark plug - Replace spark plug.
Worn or damaged vapor separator needle valve - Change vapor separator needle valve.
Faulty ignition coil - Ignition coil must be replaced.
Fuel tank air vent restricted or closed - Open or clean air vent.
Defective fuel pump - Install new pump or repair it.
Choke system is damaged - Inspect and replace choke system components.
Valve clearance is incorrect - Need to adjust valve clearance.
Valve timing is improper - Set the valve timing properly.
Valve springs are weak or broken - Change valve springs.
Stuck valves - Valves must be cleaned.
Bad compression - Check and repair damaged parts.
Clogged fuel filter - Replace fuel filter.
Fuel injector is damaged or dirty - Clean or replace as required.
Low engine oil level - Check and refill engine oil.
Oil pump failure - Change oil pump.
Water intake is blocked - Need to clean or wash.
Damaged thermostat - Replace thermostat.
Faulty water pump - Change water pump.
| Engine runs intermittently |
Ignition system problems - Inspect ignition system and change failed components.
Clogged or defective fuel pump - Test fuel pump and change if necessary.
Damaged or wear vapor separator needle valve - Replace needle valve.
Restricted fuel lines - Service fuel lines.
Fuel tank air vent restricted or closed - Fuel tank air vent need to be opened or cleaned.
Clogged fuel filter - Replace fuel filter.
Intake manifold is air leaking - Install new gasket.
Dirty water intake screen - Need to clean or wash.
Throttle valve and throttle link are damaged or worn - Replace faulty parts.
Damaged or clogged fuel injector - Clean or install new injector.
Engine is running overloaded - Load reducing is recommended.
Clogged fuel pump or fuel injector - Replace or clean as required.
Ignition timing is incorrect - Adjust ignition timing correctly.
Damaged thermostat - Install new thermostat.
Defective water pump - Replace water pump.
Propeller selection improperly - Replace propeller.
Damaged or improper size of propeller - Replace propeller.
Outboard engine is mounted too high or too low - Mount the motor as required.
Lack of engine oil - Fill the crankcase with engine oil.
Oil pump malfunction - Replace oil pump.
Water intake is clogged - Clean and wash as required.
Valve setting is wrong - Set the valves properly.
Stale or low octane fuel - Use correct fuel.
Engine overload - Load reducing required.
Incorrect low idle setting - Correct idle adjustment.
Fuel pump is defective or dirty - Service or replace fuel pump.
Crankshaft or main bearings wear - Install new parts as as required.
Worn piston rings or cylinder bore - Change faulty components.
Dirt in the fuel lines - Service fuel lines.
Fuel injector failure - Change fuel injector.
Dirty or damaged fuel pump - Inspect fuel pump and change as required.
Defective ignition system - Inspect ignition system and change failed components.
Cylinder head gasket is defective - Change cylinder head gasket.
Powerhead components are worn - Replace defective components.
Valves are stuck or burned - Clean or change valves.
Propeller selection improperly - Install correct propeller.
Propeller bent or damaged - Replace propeller.
Incorrect outboard motor mounting height - Adjust the outboard motor height correctly.
Improper trim angle - Make the correct trim angle adjustment.
Fuel injector is dirty or worn - Clean or replace if necessary.
Loose or faulty spark plug - Replace or tighten spark plug.
Sleeve, rings, or piston are damaged - Change defective components.
ECU failure - Replace ECU.
| Excessive motor vibration |
Damaged or bent propeller - Replace propeller.
Damaged propeller shaft - Replace propeller shaft.
Weeds wraped around propeller - Remove and clean propeller.
Engine mounting bolt is not tightened - Tighten bolt.
Steering pivot is loose or damaged Tighten correctly or replace.
Low battery voltage - Charge the battery.
Battery discharges quickly - Service charging system or install new battery.
Disconnected battery cables or bad terminals - Connect cables properly or replace terminals.
Faulty starter motor - Starter needs to be changed.
| Trim motor runs but trim system does not move up or down |
Oil insufficient - Need to add the oil.
Defective pump assembly - Test pump and change if necessary.
Leakage of manual drain valve - Valve need to be closed or changed.
Pump driveshaft or motor damaged - Change defective component.
| Trim does not fully up or down |
Damaged pump assembly - Replace pump.
Tilt ram piston ball is displaced - Service or repair.
Damaged tilt ram piston O-ring - Change O-ring.
Oil level is low - Fill up oil to required level.
Lower check valve not seating in port side trim ram - Install valve correctly.
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