Most Common Problems With Suzuki 200 HP Outboard

Suzuki Marine has been manufacturing outboards since 1965. This was just 56 years after they were established by Michio Suzuki. 

Suzuki Marine produces lightweight outboards that deliver 12% more efficiency. The outboards deliver good acceleration with low-end torque.

The engine has an off-set system of the transmission shaft that comes with a two-stage reduction. This produces compacted outboard dimensions. Moreover, it maintains a 2.50:1 propeller ratio. This ratio like the patrol: air ratio, is unique and groundbreaking!

In this article, I will talk about the most common problems with Suzuki 200 HP Outboard. Each problem will be discussed with the best possible solutions! Give it a read till the end to find all that out! 

A Quick Overview to Suzuki 200 HP Outboard Issues and The Reasons Behind Them:

IAC valve failure Idle clogging.
It turns a high pitch propeller slowly.Prop and engine capacity not matching

1. IAC Valve Failures

IAC stands for Idle Air Control. This valve controls an engine’s idling rotational speed. In Suzuki 4-stroke models DF200,225,250,300 etc, one or more IAC valves reportedly fail. 

Customers have complained regarding replacing valves at least once a year. This is way too frequent! The valves are pretty expensive too! Original parts made by Mitsubishi cost around $300. 

Common symptoms of AIC Valve failures:

  • The engine fails to start.
  • Rough idle.
  • Engine fails at idle.
  • Stalls in idle.
  • The engine requires throttling during warm-up to overcome stalling.

Reason for the Problem:

Idle gets clogged when accumulation occurs. As IAC valves control the idling rotational speed, idle health is related to them. The carbon build-up causes an issue. Fuel residue or oily residue is also the reason. It messes with the electromagnetic functions. 

Most carbon buildup is on the exhaust side. So, unfortunately, cleaning carburetors or dirt off the AIC doesn’t solve the problem often. 

Possible Solution:

Many people reported solving the issue by cleaning the valve. Here is the process to clean the valve:

To fix this, things You’ll Need

  1. Screwdriver.
  2. Throttle Body Cleaner.
  3. Rags.
  4. Plastic Wire Brushes.

Step 1: Remove the Connector Wire and Screws on the Side

Two screws are holding a cap on the mouth of the valve. Below the cap is the connector. Disconnect the connector. Then unscrew the screws with a screwdriver.

Step 2: Spray Throttle Body Cleaner

Spray the throttle body cleaner inside the IAC valve. A carburetor cleaner can also work. But it is not preferred. 

Step 3: Rub Off the Dirt

Clean the insert valve with a rag. On the exhaust side, use a plastic wire brush. 

If the idle problem still does not go away, check the carburetor. Check the spark plugs as well. If everything seems okay, change the AIC valve. Replacing the valve is the last resort here.

2. A High Pitch Propeller Gets Reduced Acceleration

A propeller is a part attached to an outboard engine. It is designed with a combination of blades. These blades propel or push water. 

The propeller pitch is the distance the propeller would move in one revolution. The direction of the distance it moves is towards the direction of your boat. 

The most attractive feature of this motor is that it can push efficiently from low RPMs. The huge capacity of the engine (2,867 cc.) allows you powerful accelerations. The engine can be described as a mid-range engine. But it delivers top-of-the-range engine performances. Similar to the DF300, the DF350A, etc.

The propeller blades are rotated by the power from the outboard. The Suzuki DF200AP outboard has got an additional reduction gear. This provides extra gear. Enables spinning of a bigger propeller. 

However, this causes problem sometimes. It converts the torque of the engine to have an effective grip in the water. Especially when the propeller is rotating. 

Reason for the Problem:

The engine is undoubtedly very powerful. But larger props take more power to turn a certain RPM. A big prop diameter with no change in the pitch results in lower RPMs. 

Moreover, there can exist a mismatch between the prop and the engine. There may be too much pitch at a time. At other times, the prop may be too big. While at other times the diameter of the prop may be small. This causes slips, frequently!

You need a good ratio of power, hull, and gear ratio. A higher gear ratio doesn’t necessarily give you higher acceleration. It is all in the balance of everything. 

Possible Solution:

Changing the prop can prevent slipping. Experts should be consulted to get the best prop size for optimum performance. One can change the prop by themselves too. 

Things You’ll Need:

  1. Needle-Nose Pliers
  2. Prop Wrench

Step 1: Remove the Cotter Pin

With the needle-nose pliers, take out the cotter pin. It is a narrow clip-like pin. It holds the retaining ring and the prop nut in place. 

Step 2: Remove the Retaining Ring

Unscrew the retaining ring with your fingers.

Step 3: Remove the Prop Nut

Remove the prop nut with the prop wrench. Fix the Hollow end of the wrench on the nut so it fits. Then twist out the prop nut. 

Step 4: Remove the Propeller

Hold the propeller carefully with both hands. Then gently slide out the propeller.

Step 5: Remove the Splined Insert and Plastic Insert

The splined insert is embedded in the middle of the propeller body. It can be gently taken out at this point. 

Step 6: Reverse the Above Steps with New Propeller and Inserts

Gently grease the propeller shaft. Also, make sure it is clean from any fishing net. Then reverse the steps respectively in backward order. Finally, make sure to bend the cotter pin with the pliers.

What Majority of the Users Feel About this Suzuki 200 HP Outboard?

Majority of people feel pretty okay with this outboard. Customers have reported it being reliable. They reported the customer service to be clean too!

The outboard performs really well especially at greater RPMs. Not to mention it’s great fuel saving capabilities at those high speeds!

Most owners have said that the engine runs smoothly. In an average it has been reported to run 300+ hours smoothly. 

Spare parts of the outboard are also cheap. And can be found easily. 


Suzuki 200 HP outboards deliver really good performance. Most users report it to be a smooth runner. They hardly face any issues with the outboard.

The core of the engine contains all the bests of Suzuki technology. A Suzuki Lean Burn system in the core continuously fixes the air to petrol ratio for combustion. Even at the highest speeds, the engine can save up to 16% fuel. Because it mixes more oxygen with less fuel. Harmful emissions are also intelligently controlled.

Moreover, it’s difficult to find a budget-friendly, high-power yet lightweight 4-stroke engine. Suzuki delivers it all! 

So, it is a very good choice as your outboard engine!

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