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Suzuki DF60A Troubleshooting
The Suzuki DF60A is a four-stroke three-cylinder overhead camshaft gasoline outboard engine. This engine has a wet sump lubrication, multi-point sequential electronic fuel injection, integral fuel pump, water cooled with thermostat, and full-transistorized ignition system. A 57.4 cu.in (941 cc) outboard motor has a cylinder bore of 2.85" (72.5 mm), piston stroke of 2.99" (76 mm), and maximum power of 60 hp (44.2 kW) at 5300-6300 rpm. The boat motor is equipped with an electric starting system, 3-blades aluminum standard propeller, power trim and tilt, and tiller handle or remote control steering system. The fuel tank has a capacity of 6.6 gal (25 liters).
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| Engine won't start or starts hard |
No gasoline in tank - Fill it up.
Improper fuel grade - Use quality fuel.
Dirt and debris in fuel system - Remove debris and dirt.
Faulty spark plug wire connection - Check the spark plug wire connection, repair or replace.
Defective spark plug - Change spark plug.
Clogged fuel filter - Replace or clean fuel filter.
Damaged or wear vapor separator needle valve - Install new needle valve.
Dirt in the fuel lines - Clean fuel lines.
Closed or clogged fuel tank air vent - Open or service air vent.
Defective fuel feed pump - Replace or rebuild fuel feed pump.
Choke cable is worn or not adjusted properly - Adjust properly or replace the cable.
Incorrect valve clearance - Adjust valve clearance according to specifications.
Improper valve timing - Set the valve timing properly.
Fuel pressure is low - Inspect fuel system for leaks or inspect low pressure fuel pump.
Damaged or clogged fuel injector - Replace or clean if necessary.
Fuel regulator malfunction - Change fuel regulator.
ECM failure - Install new ECM.
| Engine starts and then stalls |
Spark plug is damaged - Install new spark plug.
Damaged or wear vapor separator needle valve - Install new needle valve.
Ignition coil is faulty - Ignition coil should be replaced.
Closed or clogged fuel tank air vent - Open or clean air vent.
Fuel pump is faulty - Replace or rebuild fuel pump.
Damaged choke system - Inspect and replace choke system components.
Valve clearance is wrong - Adjustment procedure required.
Improper valve timing - Adjust valve timing correctly.
Valve springs are loose or broken - Change valve springs.
Stuck valves - Clean the valves.
Poor cylinder compression - Check and change damaged parts.
Fuel filter is clogged - Fuel filter needs to be replaced.
Clogged or worn fuel injector - Clean or replace if necessary.
Low engine oil level - Check and refill engine oil.
Defective oil pump - Oil pump need to be replaced.
Dirty water intake screen - Need to wash or clean.
Defective thermostat - Change thermostat.
Water pump malfunction - Install new water pump.
| Engine runs irregularly |
Ignition failure - Inspect ignition system and change failed components.
Dirty or faulty fuel pump - Check fuel pump and change if required.
Vapor separator needle valve is worn or defective - Install new needle valve.
Dirt in the fuel lines - Fuel lines must be clean.
Closed or clogged fuel tank air vent - Open or service air vent.
Clogged fuel filter - Install new filter.
Intake manifold air leaks - Install new gasket.
Water intake screen is dirty - Need to wash or clean.
Throttle link and throttle valve are wear or damaged - Replace faulty parts.
Clogged or worn fuel injector - Replace or clean as required.
| Engine keeps overheating |
Engine is under excessive load - Reduce engine load.
Fuel pump or fuel injector is dirty - Clean or replace if necessary.
Bad ignition timing - Set the ignition timing correctly.
Defective thermostat - Change thermostat as required.
Faulty water pump - Replace water pump.
Incorrect propeller selection - 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 is insufficient - Check and refill engine oil.
Oil pump is defective - Replace oil pump.
Water intake is clogged - Need to clean or wash.
Improper valve setting - Adjust valves correctly.
| Abnormal engine noise or knocking |
Stale fuel - Use proper fuel.
Engine is running overloaded - Load reducing required.
Incorrectly adjusted low idle speed - Adjust the low idle speed.
Fuel pump is faulty or clogged - Check fuel pump and change if required.
Main bearings or crankshaft wear - Worn parts replacement required.
Piston rings or cylinder bore are worn - Replace faulty parts.
| Lack of engine power |
Dirty fuel lines - Clean fuel system lines.
Faulty fuel injector - Test fuel injector and replace if necessary.
Clogged or damaged fuel pump - Check fuel pump and change if required.
Defective ignition - Inspect ignition system and change faulty parts.
Cylinder head gasket is damaged - Change cylinder head gasket.
Powerhead parts are faulty - Replace defective parts.
Valves are stuck or burned - Service or replace valves.
Incorrect propeller selection - Check the propeller size.
Damaged or improper size of propeller - Replace propeller.
Motor mounted at incorrect height on transom - Adjust the engine to correct transom height.
Incorrect trim angle - Adjust trim angle.
| Engine uses too much fuel |
Clogged or worn fuel injector - Clean or replace if necessary.
Spark plug is defective or loose - Re-tighten or replace spark plug.
Worn rings, piston, or sleeve - Change faulty parts.
Electronic control unit failure - Install new ECU.
| Excessive engine vibration |
Damaged or improper size of propeller - Have propeller repaired or replaced.
Propeller shaft malfunction - Propeller shaft needs to be replaced.
Weeds in the propeller - Remove and clean propeller.
Engine mounting bolt is not tightened - Tighten bolt.
Steering pivot is loose or damaged Tighten or replace.
| Starter is not cranking |
Battery capacity is low - Battery is drained, charge it.
Battery is not holding charge - Service battery or change it.
Bad battery terminals or disconnected wiring - Connect wires properly or change terminals.
Starter motor failure - Repair or install a new starter.
| Trim motor is running but trim system cannot move up or down |
Not enough oil - Checking oil level and add if necessary.
Pump assembly is faulty - Check pump and change if required.
Leakage of manual drain valve - Close the valve fully or replace it.
Broken motor or pump driveshaft - Replace worn component.
| Trim cannot be fully up or down |
Defective pump assembly - Change pump as required.
Tilt ram piston ball is displaced - Service or repair.
Tilt ram piston O-ring damaged - Replace O-ring.
Oil level is insufficient - Fill up oil to required level.
Lower check valve not seating in port side trim ram - Install valve correctly.
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