Suzuki DF80A Troubleshooting
| Engine Model: Suzuki DF80A |
| Engine Type: 4-stroke inline 4-cylinder DOHC 16-valve gasoline outboard engine |
| Total Displacement: 91.6 cu.in (1.5 L) |
| Rated Engine Power: 80 Hp (58.8 kW) at 5500 rpm |
| Fuel System: Multi point sequential electronic fuel injection |
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| Engine doesn't start or hard to start |
No gasoline in tank - Add fuel.
Improper fuel grade - Change gasoline.
Air in the fuel lines - Bleed the fuel lines.
Faulty spark plug wire connection - Check the spark plug wire connection, repair or replace.
Spark plug is damaged - Spark plug need to be replaced.
Fuel filter is clogged - Fuel filter needs changing.
Vapor separator needle valve is worn or defective - Install new needle valve.
Dirty fuel lines - Fuel lines must be clean.
Fuel tank air vent clogged or closed - Open or clean air vent.
Faulty fuel feed pump - Change or rebuild fuel feed pump.
Damaged or not adjusted choke cable - Adjust properly or change the cable.
Valve clearance is not correct - Need to adjust valve clearance.
Valve timing is incorrect - Set the valve timing correctly.
Low fuel pressure - Inspect fuel system for leaks or inspect low pressure fuel pump.
Dirty or faulty fuel injector - Clean or install new injector.
Fuel regulator failure - Change fuel regulator.
ECM is faulty - Replace ECM.
| Engine starts but then stalls |
Spark plug is faulty - Replace spark plug.
Worn or defective vapor separator needle valve - Change vapor separator needle valve.
Faulty ignition coil - Replace ignition coil as necessary.
Fuel tank air vent restricted or closed - Fuel tank air vent need to be opened or cleaned.
Fuel pump defective - Install new pump or repair it.
Choke system malfunction - Inspect and replace choke system components.
Excessive valve clearance - Adjust valve clearance according to specifications.
Valve timing is incorrect - Adjust valve timing as required.
Loose or broken valve springs - Install new valve springs.
Stuck valves - Valves must be cleaned.
Weak cylinder compression - Check and change damaged parts.
Fuel filter is clogged - Replace or clean fuel filter.
Damaged or clogged fuel injector - Clean or replace as required.
Lack of engine oil - Checking oil level and add if necessary.
Defective oil pump - Change oil pump.
Dirty water intake screen - Wash or clean as required.
Damaged thermostat - Change thermostat.
Water pump failure - Change water pump.
Ignition system failure - Inspect ignition system and change failed components.
Fuel pump is defective or dirty - Check fuel pump and change if required.
Worn or damaged vapor separator needle valve - Install new needle valve.
Dirt in the fuel lines - Fuel lines need to be cleaned.
Fuel tank air vent restricted or closed - Open or clean air vent.
Fuel filter is plugged - Fuel filter needs changing.
Intake manifold air leaks - Change intake manifold gasket.
Water intake is blocked - Need to clean or wash.
Throttle valve and throttle link are defective or worn - Change faulty parts.
Fuel injector is dirty or worn - Replace or clean if necessary.
Engine overload - Reduce load.
Fuel injector or fuel pump is dirty - Clean or replace if necessary.
Wrong ignition timing - Set the ignition timing properly.
Thermostat is faulty - Change thermostat.
Water pump malfunction - Replace water pump.
Propeller selection improperly - Install correct propeller.
Damaged or bent propeller - Have propeller repaired or replaced.
Outboard motor is positioned too low or too high - Mount the motor as required.
Engine oil level low - Fill up the oil to required level.
Faulty oil pump - Install new oil pump.
Dirty water intake screen - Clean and wash as required.
Valve setting is wrong - Valves needs to be set correctly.
Low octane fuel - Use proper gasoline.
Excessive engine load - Reduce the load.
Wrong adjustment of low idle speed - Adjust idling as required.
Fuel pump is faulty or clogged - Clean or replace fuel pump.
Main bearings or crankshaft are worn out - Install new parts as as required.
Damaged cylinder bore or piston rings - Replace defective parts.
Dirt in the fuel lines - Fuel lines must be clean.
Defective fuel injector - Check fuel injector and change if required.
Clogged or defective fuel pump - Clean or install new fuel pump.
Ignition system problems - Check ignition and replace faulty components.
Blown cylinder head gasket - Replace the gasket as required.
Faulty powerhead parts - Change defective parts.
Valves are burned or stuck - Change or clean valves.
Incorrect propeller selection - Install correct propeller.
Damaged or improper size of propeller - Have propeller repaired or replaced.
Incorrect outboard motor mounting height - Adjust the engine to correct transom height.
Incorrect trim angle - Adjust trim angle correctly.
| Engine using too much gasoline |
Fuel injector is dirty or worn - Clean or replace if necessary.
Spark plug is loose or faulty - Tighten or replace spark plug.
Sleeve, rings, or piston are damaged - Change defective components.
ECU is faulty - Install new ECU.
| Excessive motor vibration |
Damaged or improper size of propeller - Replace propeller.
Propeller shaft malfunction - Replace propeller shaft.
Weeds wraped around propeller - Clean the propeller.
Motor mounting bolt is loose - Tighten the bolt as required.
Damaged or loose steering pivot Tighten or replace.
Battery voltage is low - Charge the battery.
Battery runs out quickly - Battery needs to be serviced or replaced.
Battery cables are disconnected or terminals are faulty - Check cable connections and replace or service terminals.
Damaged starter motor - Starter should be replaced.
| Trim motor runs but trim system does not move up or down |
Not enough oil - Checking oil level and add if necessary.
Pump assembly is damaged - Check pump and replace if necessary.
Manual shut-off valve leaks - Close the valve or change it.
Broken motor or pump driveshaft - Change worn component.
| Trim cannot be fully up or down |
Defective pump assembly - Replace pump.
Tilt ram piston ball is in wrong position - Clean or repair.
Worn tilt ram piston O-ring - Change O-ring.
Oil level is low - Fill up oil.
Lower check valve not seating in port side trim ram - Install valve correctly.
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