Suzuki DF90ATL Troubleshooting
| Engine Model: Suzuki DF90ATL |
| 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 |
____________________________________________________________________________________
| Engine hard to start or will not start |
Empty fuel tank - Add fuel.
Improper fuel grade - Use correct fuel grade.
Air in fuel system - Bleed fuel system.
Defective spark plug wire connection - Inspect the spark plug wire connection, replace or repair.
Defective spark plug - Replace spark plug.
Plugged fuel filter - Install new filter.
Damaged or wear vapor separator needle valve - Change vapor separator needle valve.
Fuel lines are dirty - Fuel lines need to be cleaned.
Fuel tank air vent closed or restricted - Fuel tank air vent need to be opened or cleaned.
Damaged fuel feed pump - Repair or change fuel feed pump.
Improperly adjusted or worn throttle cable - Replace cable or adjust properly.
Incorrect valve clearance - Adjust to proper valve clearance.
Valve timing is wrong - Set the valve timing correctly.
Low fuel pressure - Inspect low pressure fuel pump or inspect fuel system for leaks.
Fuel injector is damaged or dirty - Clean or replace as required.
Fuel regulator failure - Install new fuel regulator.
ECM is faulty - Replace ECM.
| Engine starts but stops suddenly |
Spark plug is faulty - Install new spark plug.
Worn or damaged vapor separator needle valve - Install new needle valve.
Faulty ignition coil - Replace ignition coil as necessary.
Closed or restricted fuel tank air vent - Open or clean air vent.
Faulty fuel pump - Repair or change fuel pump.
Faulty choke system - Inspect and replace choke system components.
Valve clearance is wrong - Check and adjust.
Valve timing is incorrect - Set the valve timing properly.
Damaged or weak valve springs - Replace valve springs.
Valves sticking - Valves need to be cleaned.
Bad compression - Check and repair damaged parts.
Fuel filter is clogged - Replace fuel filter.
Dirty or faulty fuel injector - Clean or install new injector.
Engine oil level low - Checking oil level and add if necessary.
Oil pump is defective - Install new oil pump.
Clogged water intake - Wash or clean as required.
Thermostat failure - Replace thermostat.
Water pump failure - Change water pump.
Defective ignition - Check ignition system and replace faulty parts.
Fuel pump is defective or dirty - Clean or replace fuel pump.
Vapor separator needle valve is damaged or worn - Install new needle valve.
Clogged fuel lines - Fuel lines must be clean.
Fuel tank air vent closed or restricted - Fuel tank air vent need to be opened or cleaned.
Fuel filter is clogged - Change fuel filter.
Intake manifold is air leaking - Replace intake manifold gasket.
Water intake is clogged - Wash or clean as required.
Throttle link and throttle valve are wear or damaged - Replace faulty parts.
Fuel injector is clogged or malfunction - Clean or replace as required.
Engine overloaded - Load reducing required.
Clogged fuel pump or fuel injector - Clean or replace as required.
Ignition timing is improper - Set the ignition timing properly.
Defective thermostat - Thermostat need to be replaced.
Water pump failure - Water pump need to be replaced.
Improper propeller diameter or pitch - Install correct propeller.
Damaged or improper size of propeller - Replace propeller.
Outboard engine is positioned too low or too high - Position the engine correctly.
Engine oil insufficient - Fill up the oil to required level.
Oil pump failure - Change oil pump as required.
Water intake is blocked - Wash or clean as required.
Incorrect valve setting - Set the valves correctly.
Low octane fuel - Use correct fuel.
Excessive engine load - Load reducing is recommended.
Improperly adjusted low idle speed - Adjust as required.
Dirty or faulty fuel pump - Service or change fuel pump.
Main bearings or crankshaft are worn out - Worn parts replacement required.
Damaged cylinder bore or piston rings - Change faulty parts.
Fuel lines are dirty - Fuel lines need to be cleaned.
Defective fuel injector - Replace fuel injector.
Fuel pump is defective or dirty - Clean or install new fuel pump.
Ignition system is defective - Inspect ignition system and change failed components.
Defective cylinder head gasket - Change cylinder head gasket.
Powerhead parts are worn out - Defective components need to be replaced.
Stuck or burned valves - Replace or service valves.
Improper propeller diameter or pitch - Install correct propeller.
Damaged or improper size of propeller - Have propeller repaired or replaced.
Motor mounted at incorrect height on transom - Check the outboard motor mounting height.
Trim angle is incorrect - Make the correct trim angle adjustment.
| Excessive fuel consumption |
Fuel injector is damaged or dirty - Replace or clean if necessary.
Loose or faulty spark plug - Tighten or change the spark plug.
Rings, sleeve, or piston are damaged - Replace defective components.
ECU is faulty - Replace ECU.
| Engine vibrates excessively |
Propeller bent or damaged - Replace propeller.
Propeller shaft damaged - Replace propeller shaft.
Weeds wraped around propeller - Clean the propeller.
Engine mounting bolt is not tightened - Tighten the bolt as required.
Steering pivot is loose or damaged Tighten or replace.
| Starter motor is not working |
Battery capacity is low - Battery is drained, charge it.
Battery runs out quickly - Service or change the battery.
Bad terminals or disconnected battery cables - Check cables and service or change terminals.
Damaged starter motor - Starter needs to be replaced.
| Trim motor is running but trim system cannot move up or down |
Oil level is insufficient - Fill up oil.
Pump assembly faulty - Check pump and change if required.
Manual release valve leaking - Valve need to be closed or changed.
Pump driveshaft or motor damaged - Change worn component.
| Trim does not fully up or down |
Pump assembly is faulty - Change pump as required.
Tilt ram piston ball is displaced - Clean or repair.
Damaged tilt ram piston O-ring - Install new O-ring.
Lack of oil - Fill up oil to required level.
Lower check valve not seating in port side trim ram - Secure valve properly.
____________________________________________________________________________________
| Outboard Engines Technical Specifications |
| Small Engines Technical Specifications |
| Car Engines Technical Specifications |
| Industrial Engines Technical Specifications |
