Suzuki DF60AV Troubleshooting
| Engine Model: Suzuki DF60AV |
| 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 starts hard or doesn't start |
Fuel tank is empty - Fill it up.
Improper fuel grade - Change fuel.
Air trapped in fuel system - Bleed air.
Defective wiring connection of spark plug - Check spark plug wiring connection, repair or change.
Spark plug is faulty - Replace spark plug.
Fuel filter is dirty - Change fuel filter.
Damaged or wear vapor separator needle valve - Replace needle valve.
Fuel lines are clogged - Fuel lines need to be cleaned.
Fuel tank air vent clogged or closed - Fuel tank air vent need to be opened or cleaned.
Defective fuel feed pump - Repair or change fuel feed pump.
Not adjusted or damaged throttle cable - Replace cable or adjust correctly.
Incorrect valve clearance - Check and adjust.
Wrong valve timing - Adjust valve timing as required.
Fuel pressure is low - Check system for fuel leaks or check low pressure fuel pump.
Clogged or worn fuel injector - Replace or clean as required.
Fuel regulator failure - Change fuel regulator.
Electronic control modul failure - Install new ECM.
| Engine stalls after starting |
Damaged spark plug - Change spark plug as required.
Worn or damaged vapor separator needle valve - Replace needle valve.
Ignition coil is defective - Install a new ignition coil.
Closed or clogged fuel tank air vent - Open or clean air vent.
Defective fuel pump - Replace or rebuild fuel pump.
Choke system is damaged - Check and repair choke system.
Valve clearance is wrong - Adjust valve clearance according to specifications.
Wrong valve timing - Set the valve timing properly.
Broken or loose valve springs - Replace valve springs.
Valves are stuck - Service the valves.
Poor cylinder compression - Inspect and replace defective parts.
Fuel filter is plugged - Replace fuel filter.
Fuel injector is dirty or worn - Replace or clean if necessary.
Engine oil level is insufficient - Add oil to the engine crankcase.
Damaged oil pump - Oil pump need to be replaced.
Water intake is clogged - Wash or clean as required.
Faulty thermostat - Install new thermostat.
Faulty water pump - Install new water pump.
Ignition system failure - Check ignition and replace faulty components.
Dirty or faulty fuel pump - Check fuel pump and change if required.
Damaged or wear vapor separator needle valve - Replace needle valve.
Fuel lines clogging - Fuel lines need to be cleaned.
Closed or clogged fuel tank air vent - Open or service air vent.
Fuel filter is dirty - Change fuel filter.
Intake manifold is air leaking - Change intake manifold gasket.
Clogged water intake - Wash or clean as required.
Throttle link and throttle valve are wear or damaged - Change faulty parts.
Fuel injector is dirty or worn - Clean or replace as required.
Engine is overloaded - Reduce load.
Clogged fuel pump or fuel injector - Clean or replace as required.
Ignition timing is wrong - Adjust ignition timing correctly.
Defective thermostat - Replace thermostat.
Water pump is defective - Water pump need to be replaced.
Incorrect propeller selection - Replace propeller.
Damaged or improper size of propeller - Replace propeller.
Outboard motor is positioned too low or too high - Position the engine correctly.
Low engine oil level - Checking oil level and add if necessary.
Oil pump failure - Change oil pump.
Dirty water intake screen - Wash or clean as required.
Wrong valve setting - Adjust valves as required.
Stale gasoline - Change fuel.
Excessive engine load - Reduce load.
Low idle speed adjustment is incorrect - Adjust idle speed.
Fuel pump is faulty or clogged - Check fuel pump and change if required.
Crankshaft or main bearings failure - Repair or replace defective parts.
Cylinder bore or piston rings are worn - Change faulty components.
Clogged fuel lines - Fuel lines need to be cleaned.
Fuel injector is defective - Check fuel injector and change if required.
Dirty or damaged fuel pump - Check fuel pump and replace if necessary.
Ignition system malfunction - Check ignition and replace faulty components.
Cylinder head gasket is damaged - Cylinder-head gasket replacement required.
Powerhead parts are worn out - Change defective components.
Stuck or burned valves - Replace or clean valves.
Incorrect propeller selection - Check the propeller size.
Propeller bent or damaged - Have propeller repaired or replaced.
Engine mounted at wrong transom height - Check the outboard engine mounting height.
Incorrect trim angle - Adjust trim angle correctly.
Fuel injector is dirty or worn - Clean or replace as required.
Spark plug is loose or defective - Tighten or replace spark plug.
Sleeve, piston, or rings are damaged - Change faulty components.
ECU is not functioning - Change electronic control unit.
| Engine vibrates excessively |
Damaged or bent propeller - Replace propeller.
Propeller shaft damaged - Replace propeller shaft.
Weeds wraped around propeller - Remove weeds from propeller.
Motor mounting bolt is loose - Tighten bolt.
Damaged or loose steering pivot Tighten or replace.
Low battery voltage - Charge the battery.
Battery drains quickly - Battery needs to be serviced or replaced.
Bad terminals or disconnected battery cables - Connect cables properly or replace terminals.
Damaged starter motor - Starter needs to be replaced.
| Trim motor is running but trim system cannot move up or down |
Low oil level - Fill up oil.
Defective pump assembly - Test pump and replace if necessary.
Leakage of manual release valve - Valve need to be closed or changed.
Broken motor or pump driveshaft - Change defective component.
| Trim does not fully up or down |
Pump assembly is damaged - Replace pump.
Tilt ram piston ball is in wrong position - Service or repair.
Damaged tilt ram piston O-ring - Change O-ring.
Oil level is low - Checking oil level and add if necessary.
Lower check valve not seating in port side trim ram - Install valve correctly.
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