Suzuki DF90A Troubleshooting
| Engine Model: Suzuki DF90A |
| Engine Type: 4-stroke inline 4-cylinder DOHC 16-valve gasoline outboard engine |
| Total Displacement: 91.6 cu.in (1.5 L) |
| Rated Engine Power: 90 Hp (66.2 kW) at 6000 rpm |
| Fuel System: Multi point sequential electronic fuel injection |
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| Engine difficult to start or won't start |
Gas tank is empty - Add gasoline.
Improper fuel grade - Change fuel.
Air in fuel tank - Bleed fuel tank.
Spark plug wiring connection is defective - Inspect the spark plug wire connection, replace or repair.
Faulty spark plug - Change spark plug as required.
Fuel filter is dirty - Fuel filter needs changing.
Worn or defective vapor separator needle valve - Install new needle valve.
Clogged fuel lines - Clean fuel system lines.
Closed or restricted fuel tank air vent - Fuel tank air vent need to be opened or cleaned.
Defective fuel feed pump - Install new feed pump or repair it.
Throttle cable is adjusted incorrectly or damaged - Adjust properly or change the cable.
Valve clearance is incorrect - Check and adjust.
Improper valve timing - Set the valve timing properly.
Low fuel pressure - Inspect fuel system for leaks or inspect low pressure fuel pump.
Fuel injector is faulty or clogged - Replace or clean as required.
Fuel regulator failure - Replace fuel regulator.
ECM failure - Change electronic control modul.
| Engine starts but stalls immediately |
Spark plug is faulty - Change spark plug.
Vapor separator needle valve is worn or defective - Change vapor separator needle valve.
Faulty ignition coil - Change ignition coil as required.
Closed or clogged fuel tank air vent - Fuel tank air vent need to be opened or cleaned.
Faulty fuel pump - Install new pump or repair it.
Damaged choke system - Check and repair choke system.
Incorrect valve clearance - Adjust valve clearance.
Valve timing is wrong - Adjust valve timing correctly.
Valve springs are loose or broken - Replace valve springs.
Valves sticking - Valves need to be cleaned.
Poor compression - Check and replace worn parts.
Fuel filter is clogged - Fuel filter needs changing.
Dirty or faulty fuel injector - Clean or install new injector.
Engine oil insufficient - Fill up the engine oil.
Defective oil pump - Change oil pump.
Clogged water intake - Clean and wash as required.
Faulty thermostat - Change thermostat as required.
Damaged water pump - Change water pump as required.
Defective ignition system - Check ignition and replace faulty components.
Fuel pump is defective or dirty - Clean or install new fuel pump.
Damaged or wear vapor separator needle valve - Install new needle valve.
Clogged fuel lines - Fuel lines must be clean.
Closed or restricted fuel tank air vent - Fuel tank air vent need to be opened or cleaned.
Clogged fuel filter - Replace or clean fuel filter.
Intake manifold air leaks - Change intake manifold gasket.
Water intake is clogged - Need to wash or clean.
Throttle valve and throttle link are damaged or worn - Replace faulty components.
Dirty or faulty fuel injector - Clean or install new injector.
Engine is overloaded - Reduce engine load.
Fuel pump or fuel injector is dirty - Clean or replace as required.
Ignition timing is incorrect - Adjust ignition timing as required.
Damaged thermostat - Install new thermostat.
Water pump failure - Replace water pump.
Improper propeller diameter or pitch - Check the propeller size.
Damaged or improper size of propeller - Replace propeller.
Outboard engine is positioned too low or too high - Position the engine correctly.
Low engine oil level - Fill up the oil to required level.
Damaged oil pump - Change oil pump.
Water intake is blocked - Clean and wash as required.
Incorrect valve setting - Valves needs to be adjusted properly.
Low octane gasoline - Use correct fuel.
Engine is under excessive load - Reduce the load.
Incorrectly set low idle speed - Adjust the low idle speed.
Fuel pump is damaged or dirty - Service or change fuel pump.
Main bearings or crankshaft failure - Crankshaft or bearings need to be replaced.
Cylinder bore or piston rings are damaged - Change defective parts.
Fuel lines are clogged - Clean fuel lines.
Damaged fuel injector - Check fuel injector and replace if necessary.
Fuel pump is defective or dirty - Check fuel pump and change if required.
Ignition system failure - Check ignition system and replace faulty parts.
Defective cylinder head gasket - Install new cylinder head gasket.
Powerhead components are worn - Replace defective parts.
Burned or stuck valves - Service or change valves.
Propeller pitch or diameter incorrect - Install correct propeller.
Propeller bent or damaged - Have propeller repaired or replaced.
Engine mounted at wrong transom height - Have motor adjusted to proper transom height.
Improper trim angle - Make the correct trim angle adjustment.
| Excessive fuel consumption |
Fuel injector is faulty or clogged - Clean or install new injector.
Faulty or loose spark plug - Spark plug need to be replaced or tightened.
Rings, sleeve, or piston are damaged - Change faulty components.
Electronic control unit failure - Install new ECU.
| Excessive motor vibration |
Damaged or improper size of propeller - Have propeller repaired or replaced.
Propeller shaft malfunction - Replace propeller shaft.
Weeds wraped around propeller - Clean the propeller.
Engine mounting bolt is not tightened - Tighten the bolt as required.
Steering pivot is faulty or loose Tighten correctly or replace.
Low battery power - Battery is drained, recharge it.
Battery runs out quickly - Service or change the battery.
Bad battery terminals or disconnected wiring - Check wiring connections and replace or clean terminals.
Starter motor is faulty - Starter needs to be replaced.
| Trim motor runs but trim system does not move up or down |
Insufficient oil - Checking oil level and add if necessary.
Pump assembly is defective - Check pump and replace if necessary.
Manual release valve leaking - Close the valve fully or replace it.
Faulty pump driveshaft or motor - Change defective component.
| Trim cannot be fully up or down |
Pump assembly faulty - Change pump.
Tilt ram piston ball is displaced - Service or repair.
Worn tilt ram piston O-ring - Change O-ring.
Insufficient oil - Fill up oil to required level.
Lower check valve not seating in port side trim ram - Install valve correctly.
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