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*FIXED* Suzuki Df 140 wont start please help!!

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  • 5 Post By Landingzone10

*FIXED* Suzuki Df 140 wont start please help!!

Old 06-04-2019, 04:35 PM
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Default *FIXED* Suzuki Df 140 wont start please help!!

Ok yíall Iím in dire need of someone who knows what to look at next. Iíve read every Suzuki forum post and canít find anything to help. First of all I have twin 2004 Df 140ís my port side motor is operating fine, last year I developed an oil leak down the drive shaft. So I pulled the power head and replaced all the seals under it for the driveshaft. That was a decent project itself, however, now that everything is put back together she wonít start. Iím going to list all of the things I have done here so yíall can point out if there is something I have missed.

The symptom is: starter engages the flywheel and cranks the motor over and over and over and it will never start. Sometimes it acts like it is going to start and never does. After messing with it for a long time it backfires albeit the backfire is very rare but it has happened 3 times in 2 days.

Turned key to check if vst fuel pump was kicking on, it is

Checked 60a fuse its good

Removed the manifold to remove vst filter to clean, it was clean I didnít do anything to it but open it.

The high pressure fuel filter is brand new.

Swapped the map sensor with the working motor, still nothing

Swapped AIC from working motor, nothing

Flushed fuel out of the whole system and hooked it up to a brand new clean 12 gallon Jon boat tank

Made sure there are no kinks in the hoses

checked battery charge

flipped ecm from working motor, no change

flipped fuel injectors and rail from working motor, nothing

flipped spark plugs from working motor, nothing

checked for spark, has spark

checked low pressure fuel pump, it was clean

swapped the sensor under the flywheel (forgot the acronym) itís on the front of the motor.

Checked the kill switch, itís still good

checked the neutral switch on port side, it is getting contact when it should in neutral. I pushed it in harder to make sure.

Checked compression, 180-180-180-181

can anyone here think of anything else to try/test anything at all. Iím capable of most of the work myself and Iím desperately trying to not take it to a mechanic, I can not afford that right now.

Last edited by Landingzone10; 06-05-2019 at 03:58 PM. Reason: Fixed!
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Old 06-04-2019, 04:55 PM
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I would try two things next. First spray a little starting fluid into the intake while trying to start and see if it tries to run. That could prove a fuel delivery issue. If that doesn't help or makes more backfires I would be checking the ignition timing if that is possible. Not sure if you can mess up the timing, but a backfire is often timing or over lean mixture.
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Old 06-04-2019, 05:55 PM
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I'm stumped. Could it be the dreaded white wire? Someone will come along with a suggestion or 2. Moving it back up!
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Old 06-04-2019, 05:59 PM
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Did you fix the corrosion plug problem?
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Old 06-04-2019, 06:01 PM
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Iíve tried a snort of starter fluid and didnít have any change or response. I donít think this motor has the ďwhite wireĒ but I could be wrong. Thereís no obvious white wire leaving the motor headed towards the battery. Am I looking in the wrong spot?

Keep the recommendations coming gents Iím sure something will stick and solve this!!
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Old 06-04-2019, 06:04 PM
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Mine still has the OG plug rusty as hell but I havenít noticed any holes and Iíve checked it several times. I guess I could hit it with soapy water to be 100% certain before I cross off the plug. When I had the head off it seemed like there was still plenty of meat on that bone. I hit it with a wire brush and some ospho to stop the rust.
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Old 06-04-2019, 07:48 PM
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Anyone else have anything to add? Iím grasping at straws
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Old 06-05-2019, 04:05 PM
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So after today we were going to break down and take it to the shop after changing out the wiring harness off the working motor. It still didnít start. My boat partner said well the only thing we havenít changed from the other motor is the stator..... then it clicked. We pulled the flywheel, pulled the stator, and low and behold we had wire that had melted together, they have protective covering to prevent this however it was dry rotted and broken down. I re soldered the wires and reconnected everything and she started on the first crank. If anyone else runs across this problem donít hesitate to post on here I can walk you through how to remove everything to address the issue.

New stator is on order just re-rigged it to confirm it was the issue!
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Old 06-05-2019, 05:59 PM
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Originally Posted by Landingzone10 View Post
So after today we were going to break down and take it to the shop after changing out the wiring harness off the working motor. It still didnít start. My boat partner said well the only thing we havenít changed from the other motor is the stator..... then it clicked. We pulled the flywheel, pulled the stator, and low and behold we had wire that had melted together, they have protective covering to prevent this however it was dry rotted and broken down. I re soldered the wires and reconnected everything and she started on the first crank. If anyone else runs across this problem donít hesitate to post on here I can walk you through how to remove everything to address the issue.

New stator is on order just re-rigged it to confirm it was the issue!



Nice work!
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Old 06-05-2019, 06:03 PM
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Thanks for update. Glad you got it figured out.
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