________________________________________________________________________________________
| Home / Outboard Engines / Suzuki Engines / Suzuki DF60ATL |
Suzuki DF60ATL Troubleshooting
The Suzuki DF60ATL is a 4-stroke 3-cylinder DOHC (overhead cam) water-cooled gasoline long shaft outboard engine with a rated power of 60 hp (44.2 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.
____________________________________________________________________________________
| Engine will not start or starts up hard |
Empty gas tank - Fill gasoline up.
Incorrect fuel grade - Use quality gasoline.
Air in fuel system - Bleed fuel system.
Faulty spark plug wire connection - Check the spark plug wire connection, repair or replace.
Faulty spark plug - Replace spark plug.
Fuel filter is plugged - Install new filter.
Vapor separator needle valve is worn or defective - Change vapor separator needle valve.
Clogged fuel lines - Fuel lines must be clean.
Fuel tank air vent closed or restricted - Open or service air vent.
Fuel feed pump malfunction - Repair or change fuel feed pump.
Choke cable is not adjusted properly or worn - Replace cable or adjust correctly.
Incorrect valve clearance - Need to adjust valve clearance.
Improper valve timing - Adjust valve timing correctly.
Low fuel pressure - Check low pressure fuel pump or check system for fuel leaks.
Fuel injector is faulty or clogged - Replace or clean as required.
Fuel regulator is defective - Replace fuel regulator.
ECM failure - Install new ECM.
| Engine starts but stalls suddenly |
Spark plug is defective - Change spark plug.
Worn or damaged vapor separator needle valve - Install new needle valve.
Damaged ignition coil - Change ignition coil as required.
Fuel tank air vent clogged or closed - Open or service air vent.
Fuel pump is faulty - Install new fuel pump or rebuild it.
Damaged choke system - Check and repair choke system.
Valve clearance is not correct - Adjust valve clearance according to specifications.
Valve timing is incorrect - Adjust valve timing correctly.
Loose or worn valve springs - Replace valve springs.
Stuck valves - Valves must be cleaned.
Bad cylinder compression - Check and change damaged parts.
Fuel filter is clogged - Fuel filter needs to be replaced.
Fuel injector is faulty or clogged - Clean or replace if necessary.
Low engine oil level - Fill up the oil to required level.
Oil pump is defective - Change oil pump as required.
Water intake is clogged - Need to clean or wash.
Defective thermostat - Change thermostat.
Water pump is defective - Replace water pump.
| Irregular engine running |
Ignition system is defective - Inspect ignition system and change failed components.
Dirty or faulty fuel pump - Service or replace fuel pump.
Vapor separator needle valve is bend or wear - Replace needle valve.
Dirty fuel lines - Service fuel lines.
Closed or clogged fuel tank air vent - Open or service air vent.
Plugged fuel filter - Install new filter.
Intake manifold air leaks - Install new gasket.
Clogged water intake - Need to clean or wash.
Throttle valve and throttle link are defective or worn - Replace faulty components.
Damaged or clogged fuel injector - Replace or clean if necessary.
| Engine overheats |
Excessive engine load - Reduce engine load.
Fuel pump or fuel injector is dirty - Replace or clean if necessary.
Improper ignition timing - Ignition timing needs to be adjusted correctly.
Damaged thermostat - Thermostat need to be replaced.
Water pump failure - Replace water pump.
Propeller selection improperly - Replace propeller.
Damaged or bent propeller - Replace propeller.
Outboard engine is positioned too low or too high - Position the engine correctly.
Engine oil level low - Check and refill engine oil.
Oil pump is defective - Change oil pump.
Clogged water intake - Need to clean or wash.
Wrong valve setting - Set the valves correctly.
| Engine noises or knocks |
Stale gasoline - Change fuel.
Engine overload - Reduce engine load.
Too low idle RPM - Correct idle adjustment.
Fuel pump is defective or dirty - Test fuel pump and change if necessary.
Crankshaft or main bearings failure - Have bearings or crankshaft replaced.
Cylinder bore or piston rings are damaged - Replace faulty parts.
| Engine power loss |
Dirty fuel lines - Fuel lines need to be cleaned.
Fuel injector failure - Inspect fuel injector and change as required.
Clogged or damaged fuel pump - Inspect fuel pump and change as required.
Ignition system malfunction - Check ignition and replace faulty components.
Cylinder head gasket is blown - Install new head gasket.
Worn powerhead components - Replace defective parts as required.
Valves are stuck or burned - Change or clean valves.
Propeller selection improperly - Replace propeller.
Propeller bent or damaged - Have propeller repaired or replaced.
Engine mounted at wrong transom height - Have motor adjusted to proper transom height.
Trim angle is incorrect - Adjust trim angle correctly.
| Engine uses too much fuel |
Dirty or faulty fuel injector - Clean or install new injector.
Spark plug is loose or faulty - Spark plug need to be tightened or replaced.
Worn sleeve, piston, or rings - Replace faulty parts as required.
ECU is faulty - Install new ECU.
| Excessive motor vibration |
Propeller bent or damaged - Have propeller repaired or replaced.
Damaged propeller shaft - Have propeller shaft replaced.
Weeds in the propeller - Remove and clean propeller.
Engine mounting bolt is not tightened - Tighten the bolt as required.
Damaged or loose steering pivot Tighten or replace.
| Starter will not crank |
Low battery capacity - Charge the battery.
Battery will not hold charge - Service or change the battery.
Wires are disconnected or battery terminals are corroded - Connect cables properly or replace terminals.
Faulty starter motor - Repair or install a new starter.
| Trim motor is running but trim system cannot move up or down |
Oil insufficient - Fill up oil to required level.
Pump assembly is faulty - Test pump and change if necessary.
Manual release valve leaking - Valve need to be closed or changed.
Faulty pump driveshaft or motor - Change defective component.
| Trim does not fully up or down |
Pump assembly is damaged - Change pump as required.
Tilt ram piston ball is not positioned correctly - Clean or repair.
Tilt ram piston O-ring damaged - Change O-ring.
Oil insufficient - Check and refill oil.
Lower check valve is not properly secured in port side trim ram - Secure valve properly.
________________________________________________________________________________________
________________________________________________________________________________________
| Engines Technical Specifications |