Suzuki DF4 fuel overflow

[R.F.Price]

My Suzuki DF4 (2005) outboard motor jets out fuel from one of the plastic pipes attached to the top of the carb. The overflow is not constant so I assume it occurs when the float drops & the chamber fills then over fills with fuel.

I have cleaned the float chamber & needle valve with carb cleaner but the problem persists. If I blow thru the carb petrol input pipe, I can feel when the needle valve closes as I lift the float, so I assume the needle & seating is correct. My assumption then is that the float setting is incorrect, & the fuel level in the chamber is too high.

Can anyone with a workshop manual or knowledge of this engine for this engine please explain how to check & adjust the float setting, or give any other ideas how to stop the overflow.

Apart from this the engine starts & runs reasonably well.

 

[RichardS]

Adjusting the level of fuel in the chamber is usually a matter of slightly bending a tang of metal which presses on the valve such that the valve closes when the level is a little lower.

Blowing through the fuel line is a good test but you need to be careful to only close the valve very gently as the float does not exert much force.

There might well be a fuel level spec in the manual but getting it right tends to be trial and error.

Welcome to the forum by the way.

Richard

 

[VicS]

My Suzuki DF4 (2005) outboard motor jets out fuel from one of the plastic pipes attached to the top of the carb. The overflow is not constant so I assume it occurs when the float drops & the chamber fills then over fills with fuel.

I have cleaned the float chamber & needle valve with carb cleaner but the problem persists. If I blow thru the carb petrol input pipe, I can feel when the needle valve closes as I lift the float, so I assume the needle & seating is correct. My assumption then is that the float setting is incorrect, & the fuel level in the chamber is too high.

Can anyone with a workshop manual or knowledge of this engine for this engine please explain how to check & adjust the float setting, or give any other ideas how to stop the overflow.

Apart from this the engine starts & runs reasonably well.

Almost certainly due to the carb flooding due to the float needle valve not closing properly

Your engine is covered by one of the manuals at Boat Info
This link should take you straight to section dealing with the DF4 carbs:
http://boatinfo.no/lib/suzuki/manuals/suzuki_1996-2007.html#/142 The float height setting and adjustement is described in section 3-21

Note the carb type changed in mid 2004 so you should have the later Keihin type ( note also the little clip between the float arm and the needle valve)

If the float height setting appears to be correct when checked as described in the manual I would change the needle valve , not attempt to alter the setting.