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Suzuki DF50A Troubleshooting
The Suzuki DF50A is a 4-stroke 3-cylinder DOHC (double overhead cam) water-cooled gasoline outboard engine with a rated power of 50 hp (36.7 kW) at 5300-6300 rpm. The engine cylinder bore is 2.85" (72.5 mm) and piston stroke is 2.99" (76 mm). A 57.4 cubic inches (941 cc) outboard motor has a multi-point sequential electronic fuel injection, integral fuel pump type, trochoid pump lubrication system, starting system with electric starter, full-transistorized ignition system, power tilt, and tiller handle or remote control steering. The fuel tank capacity is 6.6 gal (25 liters). The propeller is made of aluminum and it has three blades.
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| Engine starts hard or will not start |
Empty fuel tank - Fill it up.
Wrong grade of gasoline - Change gasoline.
Dirt and debris in fuel system - Remove debris and dirt.
Spark plug wire connection are damaged - Inspect spark plug wiring connection, change or repair.
Spark plug is damaged - Spark plug need to be replaced.
Fuel filter is plugged - Fuel filter needs to be replaced.
Damaged or wear vapor separator needle valve - Install new needle valve.
Dirt in the fuel lines - Fuel lines must be clean.
Fuel tank air vent closed or restricted - Open or service air vent.
Faulty fuel feed pump - Repair or change fuel feed pump.
Choke cable is not adjusted properly or worn - Change cable or adjust properly.
Excessive valve clearance - Need to adjust valve clearance.
Incorrect valve timing - Adjust valve timing as required.
Low fuel pressure - Check low pressure fuel pump or check system for fuel leaks.
Fuel injector is dirty or worn - Clean or replace if necessary.
Fuel regulator is not operating - Install new fuel regulator.
Electronic control modul is not operating - Install new ECM.
| Engine starts but then stalls |
Defective spark plug - Install new spark plug.
Damaged or wear vapor separator needle valve - Replace needle valve.
Ignition coil is not working - Ignition coil should be replaced.
Fuel tank air vent restricted or closed - Open or service air vent.
Defective fuel pump - Install new pump or repair it.
Choke system malfunction - Inspect and replace choke system components.
Improper valve clearance - Check and adjust.
Improper valve timing - Adjust valve timing as required.
Valve springs are worn or loose - Install new valve springs.
Valves sticking - Clean the valves.
Low cylinder compression - Check and change damaged parts.
Dirty fuel filter - Replace fuel filter.
Dirty or faulty fuel injector - Clean or replace as required.
Engine oil level is insufficient - Need to add engine oil.
Oil pump is defective - Oil pump need to be replaced.
Water intake screen is dirty - Need to clean or wash.
Damaged thermostat - Install new thermostat.
Faulty water pump - Change water pump as required.
| Engine runs intermittently |
Ignition failure - Test ignition and replace failed parts.
Fuel pump is damaged or dirty - Service or replace fuel pump.
Worn or defective vapor separator needle valve - Install new needle valve.
Clogged fuel lines - Service fuel lines.
Closed or clogged fuel tank air vent - Open or service air vent.
Fuel filter is plugged - Change fuel filter.
Intake manifold is air leaking - Install new gasket.
Water intake is blocked - Wash or clean as required.
Throttle valve and throttle link are damaged or worn - Replace faulty parts.
Fuel injector is faulty or clogged - Clean or replace as required.
| Engine keeps overheating |
Engine is overloaded - Load reducing is recommended.
Clogged fuel pump or fuel injector - Clean or replace as required.
Ignition timing is improper - Adjust ignition timing correctly.
Faulty thermostat - Thermostat need to be replaced.
Damaged water pump - Install new water pump.
Propeller selection improperly - Check the propeller size.
Damaged or improper size of propeller - Have propeller repaired or replaced.
Outboard motor is positioned too low or too high - Mount the motor as required.
Low engine oil level - Fill the crankcase with engine oil.
Damaged oil pump - Replace oil pump.
Water intake screen is dirty - Clean and wash as required.
Valve setting is improper - Adjust valves as required.
| Engine knocks or noises |
Stale fuel - Use correct gasoline.
Engine is running overloaded - Load reducing is recommended.
Too low idle RPM - Adjustment required.
Fuel pump is faulty or clogged - Service or replace fuel pump.
Crankshaft or main bearings failure - Repair or replace defective parts.
Piston rings or cylinder bore are worn - Replace faulty components.
| Engine lacks power |
Clogged fuel lines - Service fuel lines.
Faulty fuel injector - Test fuel injector and replace if necessary.
Fuel pump is dirty or defective - Test fuel pump and replace if necessary.
Defective ignition - Inspect ignition system and change failed components.
Blown cylinder head gasket - Replace the head gasket.
Powerhead parts are worn out - Replace defective components as required.
Stuck or burned valves - Clean or replace valves.
Propeller selection improperly - Replace propeller.
Propeller bent or damaged - Have propeller repaired or replaced.
Outboard engine mounting height improperly - Adjust the outboard motor height correctly.
Trim angle is incorrect - Make the correct trim angle adjustment.
| Excessive fuel consumption |
Dirty or faulty fuel injector - Clean or replace if necessary.
Loose or defective spark plug - Spark plug need to be tightened or replaced.
Worn sleeve, rings, or piston - Change faulty components.
Electronic control unit is not operating - Change electronic control unit.
| Strong engine vibration |
Damaged or improper size of propeller - Replace propeller.
Propeller shaft malfunction - Replace propeller shaft.
Weeds in the propeller - Remove and clean propeller.
Motor mounting bolt is loose - Tighten the bolt as required.
Damaged or loose steering pivot Tighten correctly or replace.
| Starter is not working |
Low battery output - Battery is drained, charge it.
Battery will not hold charge - Service or replace the battery.
Battery terminals are corroded or wires are disconnected - Check wire connections and change or service terminals.
Starter motor is defective - Change or repair starter.
| Trim motor runs but trim system does not move up or down |
Oil insufficient - Check and refill oil.
Pump assembly is damaged - Inspect pump and change as required.
Leakage of manual drain valve - Close the valve fully or replace it.
Broken motor or pump driveshaft - Change defective component.
| Trim cannot be fully up or down |
Pump assembly is faulty - Change pump.
Tilt ram piston ball is displaced - Service or repair.
Worn tilt ram piston O-ring - Change O-ring.
Insufficient oil - Fill up oil to required level.
Lower check valve is not properly secured in port side trim ram - Secure valve properly.
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