Suzuki DF60A Troubleshooting
| Engine Model: Suzuki DF60A |
| Engine Type: 4-stroke 3-cylinder DOHC gasoline outboard engine |
| Total Displacement: 57.4 cu.in (941 cc) |
| Rated Engine Power: 60 Hp (44.2 kW) at 6300 rpm |
| Fuel System: Multi-point sequential electronic fuel injection |
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| Engine hard to start or doesn't start |
No gasoline in tank - Fill gasoline up.
Incorrect fuel grade - Change fuel.
Clogged fuel system - Remove clogging.
Spark plug wiring connection is damaged - Check the spark plug wire connection, repair or replace.
Spark plug is defective - Install new spark plug.
Clogged fuel filter - Change fuel filter.
Damaged or wear vapor separator needle valve - Replace needle valve.
Dirty fuel lines - Clean fuel system lines.
Fuel tank air vent clogged or closed - Fuel tank air vent need to be opened or cleaned.
Defective fuel feed pump - Replace or rebuild fuel feed pump.
Choke cable is not adjusted properly or worn - Adjust properly or change the cable.
Valve clearance is incorrect - Adjustment procedure required.
Improper valve timing - Set the valve timing properly.
Low fuel pressure - Check system for fuel leaks or check low pressure fuel pump.
Fuel injector is damaged or dirty - Replace or clean as required.
Fuel regulator is defective - Change fuel regulator.
ECM is not functioning - Replace ECM.
| Engine starts and stops immediately |
Faulty spark plug - Install new spark plug.
Vapor separator needle valve is bend or wear - Change vapor separator needle valve.
Ignition coil is faulty - Ignition coil must be replaced.
Fuel tank air vent closed or restricted - Open or clean air vent.
Defective fuel pump - Install new pump or repair it.
Choke system malfunction - Change choke system components as required.
Excessive valve clearance - Adjust valve clearance.
Wrong valve timing - Adjust valve timing as required.
Valve springs are worn or loose - Valve springs need to be changed.
Stuck valves - Valves need to be cleaned.
Poor cylinder compression - Check and repair damaged parts.
Fuel filter is plugged - Fuel filter needs changing.
Fuel injector is clogged or malfunction - Clean or replace as required.
Engine oil level is low - Fill up the oil to required level.
Defective oil pump - Oil pump need to be replaced.
Water intake screen is dirty - Wash or clean as required.
Thermostat is defective - Replace thermostat.
Water pump malfunction - Install new water pump.
Defective ignition system - Check ignition and replace faulty components.
Fuel pump is defective or dirty - Clean or install new fuel pump.
Worn or defective vapor separator needle valve - Install new needle valve.
Fuel lines are dirty - Clean fuel system lines.
Closed or clogged fuel tank air vent - Open or clean air vent.
Clogged fuel filter - Fuel filter needs changing.
Intake manifold is air leaking - Change intake manifold gasket.
Dirty water intake screen - Need to wash or clean.
Throttle valve and throttle link are defective or worn - Replace faulty components.
Clogged or worn fuel injector - Clean or replace as required.
Engine is overloaded - Reduce the load.
Clogged fuel pump or fuel injector - Clean or replace as required.
Wrong ignition timing - Adjust ignition timing correctly.
Thermostat failure - Replace thermostat.
Water pump failure - Water pump need to be replaced.
Incorrect propeller selection - Install correct propeller.
Damaged or bent propeller - Have propeller repaired or replaced.
Outboard motor is mounted too high or too low - Position the engine correctly.
Insufficient engine oil - Check oil level and add oil as required.
Oil pump is defective - Replace oil pump.
Water intake screen is dirty - Clean and wash as required.
Valve setting is improper - Adjust valves as required.
Stale or low octane fuel - Change gasoline.
Engine is overloaded - Reduce the load.
Incorrect low idle setting - Correct idle adjustment.
Fuel pump is clogged or faulty - Clean or replace fuel pump.
Main bearings or crankshaft wear - Replace crankshaft or bearings.
Piston rings or cylinder bore are worn - Replace defective components.
| Engine power is insufficient |
Dirt in the fuel lines - Clean fuel system lines.
Faulty fuel injector - Change fuel injector.
Fuel pump is defective or dirty - Clean or change fuel pump.
Ignition system malfunction - Inspect ignition system and change failed components.
Defective cylinder head gasket - Replace cylinder head gasket.
Powerhead components are worn - Replace defective components.
Burned or stuck valves - Service or change valves.
Incorrect propeller selection - Check the propeller size.
Damaged or bent propeller - Replace propeller.
Motor mounted at incorrect height on transom - Check the outboard motor mounting height.
Incorrect trim angle - Adjust trim angle.
Damaged or clogged fuel injector - Replace or clean as required.
Spark plug is defective or loose - Change or re-tighten spark plug.
Piston, sleeve, or rings are damaged - Replace defective components.
ECU is faulty - Replace ECU.
| Excessive motor vibration |
Propeller bent or damaged - Have propeller repaired or replaced.
Damaged propeller shaft - Replace propeller shaft.
Weeds wraped around propeller - Clean the propeller.
Motor mounting bolt is loose - Tighten bolt.
Steering pivot is faulty or loose Tighten correctly or replace.
Battery power is low - Battery needs to be recharged.
Battery will not hold charge - Service or change the battery.
Disconnected battery cables or bad terminals - Connect wires properly or change terminals.
Faulty starter motor - Repair or install a new starter.
| Trim motor is running but trim system cannot move up or down |
Oil level low - Checking oil level and add if necessary.
Pump assembly faulty - Test pump and change if necessary.
Manual shut-off valve leaks - Close the valve or change it.
Motor or pump driveshaft faulty - Change worn component.
| Trim does not fully up or down |
Defective pump assembly - Replace pump.
Tilt ram piston ball is not positioned correctly - Service or repair.
Damaged tilt ram piston O-ring - Install new O-ring.
Oil level is insufficient - Check oil level and add oil as required.
Lower check valve not seating in port side trim ram - Install valve correctly.
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