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Suzuki DF20A Troubleshooting
The Suzuki DF20A is a 4-stroke 2-cylinder OHC (overhead cam) gasoline outboard engine with a rated power of 20 hp (14.7 kW) at 5300-6300 rpm. The engine cylinder bore is 2.38" (60.4 mm) and piston stroke is 2.24" (57 mm). A 20.1 cubic inches (327 cc) outboard motor has a multi-point sequential electronic fuel injection system, integral fuel pump type, pressure lubrication with trochoid pump, starting system with electric or recoil starter, digital CDI ignition system, manual or power tilt, and tiller handle or remote control steering. The fuel tank capacity is 3.2 gal (12 liters). The propeller is made of aluminum and it has three blades.
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| Engine starts hard or won't start |
Empty fuel tank - Fill it up.
Wrong grade of gasoline - Use quality gasoline.
Dirt and debris in fuel system - Remove debris and dirt.
Spark plug wiring connection is damaged - Inspect spark plug wiring connection, change or repair.
Faulty spark plug - Replace spark plug.
Plugged fuel filter - Install new filter.
Vapor separator needle valve is worn or defective - Change vapor separator needle valve.
Fuel lines clogging - Fuel lines must be clean.
Closed or clogged fuel tank air vent - Open or service air vent.
Fuel feed pump is faulty - Repair or change fuel feed pump.
Unadjusted or worn throttle cable - Adjust correctly or replace the cable.
Incorrect valve clearance - Adjustment procedure required.
Valve timing is incorrect - Set the valve timing properly.
Low fuel pressure - Inspect fuel system for leaks or inspect low pressure fuel pump.
Fuel injector is faulty or clogged - Replace or clean as required.
Fuel regulator is defective - Replace fuel regulator.
ECM is faulty - Replace ECM.
| Engine starts and stops suddenly |
Spark plug is defective - Spark plug need to be replaced.
Damaged or wear vapor separator needle valve - Install new needle valve.
Ignition coil is not working - Replace ignition coil as necessary.
Closed or clogged fuel tank air vent - Open or service air vent.
Fuel pump malfunction - Change or rebuild fuel pump.
Damaged choke system - Check and repair choke system.
Valve clearance is improper - Adjust valve clearance according to specifications.
Valve timing is improper - Set the valve timing correctly.
Valve springs are broken or bad - Install new valve springs.
Stuck valves - Clean the valves.
Poor cylinder compression - Check and change damaged parts.
Clogged fuel filter - Fuel filter needs changing.
Fuel injector is dirty or worn - Replace or clean as required.
Engine oil level is low - Need to add engine oil.
Damaged oil pump - Change oil pump.
Water intake screen is dirty - Wash or clean as required.
Thermostat failure - Change thermostat as required.
Faulty water pump - Water pump need to be replaced.
| Engine runs intermittently |
Defective ignition - Check ignition and replace faulty components.
Fuel pump is faulty or clogged - Clean or change fuel pump.
Worn or damaged vapor separator needle valve - Replace needle valve.
Restricted fuel lines - Fuel lines need to be cleaned.
Closed or clogged fuel tank air vent - Open or service air vent.
Plugged fuel filter - Fuel filter needs changing.
Intake manifold is air leaking - Install new gasket.
Clogged water intake - Wash or clean as required.
Throttle valve and throttle link are defective or worn - Replace faulty parts.
Fuel injector is dirty or worn - Clean or replace as required.
| Engine is overheated |
Engine overload - Reduce the load.
Fuel pump or fuel injector is dirty - Clean or replace if necessary.
Ignition timing is incorrect - Set the ignition timing properly.
Faulty thermostat - Change thermostat.
Water pump is defective - Change water pump.
Propeller pitch or diameter incorrect - Install correct propeller.
Propeller bent or damaged - Replace propeller.
Outboard motor is positioned too low or too high - Mount the motor as required.
Lack of engine oil - Add oil to the engine crankcase.
Defective oil pump - Replace oil pump.
Water intake screen is dirty - Clean and wash as required.
Valve setting is wrong - Valves needs to be adjusted properly.
| Engine knocking sound or abnormal noise |
Stale fuel - Use correct gasoline.
Engine overload - Reduce the load.
Incorrect low idle setting - Correct the settings.
Fuel pump is faulty or clogged - Check fuel pump and change if required.
Crankshaft or main bearings wear - Install new parts as as required.
Piston rings or cylinder bore are damaged - Change faulty parts.
| Engine loses power |
Dirt in the fuel lines - Clean fuel lines.
Faulty fuel injector - Replace fuel injector.
Clogged or damaged fuel pump - Inspect fuel pump and change as required.
Ignition system malfunction - Inspect ignition system and change failed components.
Damaged cylinder head gasket - Cylinder-head gasket replacement required.
Powerhead parts are faulty - Replace defective parts.
Valves are stuck or burned - Service or replace valves.
Incorrect propeller selection - Install correct propeller.
Damaged or bent propeller - Replace propeller.
Outboard motor mounting height is set incorrectly - Adjust the outboard motor height correctly.
Incorrect trim angle - Adjust trim angle correctly.
| High fuel consumption |
Clogged or worn fuel injector - Clean or install new injector.
Defective or loose spark plug - Spark plug need to be replaced or tightened.
Worn sleeve, rings, or piston - Change faulty components.
Electronic control unit failure - Change electronic control unit.
| Excessive motor vibration |
Damaged or improper size of propeller - Have propeller repaired or replaced.
Propeller shaft malfunction - Have propeller shaft replaced.
Weeds clogs the propeller - Clean the propeller.
Motor mounting bolt is loose - Tighten bolt.
Steering pivot is loose or damaged Tighten correctly or replace.
| Starter doesn't crank |
Battery capacity is low - Charge the battery.
Battery is not holding charge - Service charging system or change battery.
Wires are disconnected or battery terminals are corroded - Connect wires correctly or change terminals.
Damaged starter motor - Change or repair starter.
| Trim motor is running but trim system cannot move up or down |
Oil insufficient - Check and refill oil.
Defective pump assembly - Inspect pump and change as required.
Leakage of manual drain valve - Close the valve fully or replace it.
Pump driveshaft or motor damaged - Change worn component.
| Trim does not fully up or down |
Pump assembly is defective - Replace pump.
Tilt ram piston ball is not positioned correctly - Service or repair.
Damaged tilt ram piston O-ring - Replace O-ring.
Lack of oil - Fill up oil to required level.
Lower check valve not seating in port side trim ram - Secure valve properly.
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