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Suzuki DF60AV Troubleshooting
The Suzuki DF60AV is a 4-stroke 3-cylinder 12-valve overhead camshaft gasoline outboard engine. This engine has a wet sump lubrication, 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 hard to start or won't start |
Fuel tank is empty - Add gasoline.
Incorrect fuel grade - Change gasoline.
Dirty fuel system - Check and clean.
Spark plug wiring connection is defective - Check spark plug wiring connection, repair or change.
Spark plug is defective - Change spark plug.
Fuel filter is plugged - Replace or clean fuel filter.
Vapor separator needle valve is damaged or worn - Change vapor separator needle valve.
Dirt in the fuel lines - Clean fuel system lines.
Fuel tank air vent closed or restricted - Open or clean air vent.
Defective fuel feed pump - Fuel feed pump need to be replaced.
Worn or unadjusted choke cable - Replace cable or adjust correctly.
Excessive valve clearance - Adjustment procedure required.
Valve timing is improper - Set the valve timing properly.
Low fuel pressure - Inspect low pressure fuel pump or inspect fuel system for leaks.
Clogged or worn fuel injector - Replace or clean if necessary.
Fuel regulator is not operating - Install new fuel regulator.
Electronic control modul failure - Replace ECM.
| Engine stalls after starting |
Spark plug is defective - Change spark plug.
Damaged or wear vapor separator needle valve - Change vapor separator needle valve.
Defective ignition coil - Install a new ignition coil.
Fuel tank air vent restricted or closed - Open or service air vent.
Fuel pump is faulty - Repair or change fuel pump.
Choke system malfunction - Inspect and replace choke system components.
Valve clearance is incorrect - Adjust valve clearance according to specifications.
Incorrect valve timing - Adjust valve timing as required.
Bad or broken valve springs - New valve springs need to be installed.
Valves are stuck - Clean the valves.
Poor cylinder compression - Check and change damaged parts.
Dirty fuel filter - Replace fuel filter.
Clogged or worn fuel injector - Replace or clean if necessary.
Engine oil level low - Check oil level and add oil as required.
Defective oil pump - Replace oil pump.
Water intake is clogged - Need to wash or clean.
Thermostat failure - Change thermostat.
Water pump failure - Replace water pump.
| Engine runs roughly |
Defective ignition - Inspect ignition system and change faulty parts.
Clogged or defective fuel pump - Service or replace fuel pump.
Damaged or wear vapor separator needle valve - Change vapor separator needle valve.
Restricted fuel lines - Fuel lines must be clean.
Fuel tank air vent restricted or closed - Open or service air vent.
Fuel filter is plugged - Install new filter.
Intake manifold is air leaking - Install new gasket.
Clogged water intake - Clean and wash as required.
Throttle link and throttle valve are wear or damaged - Change faulty components.
Fuel injector is damaged or dirty - Replace or clean if necessary.
| Engine overheated |
Engine is under excessive load - Reduce load.
Fuel injector or fuel pump is clogged - Replace or clean if necessary.
Improper ignition timing - Ignition timing needs to be adjusted correctly.
Thermostat is faulty - Replace thermostat.
Water pump malfunction - Water pump need to be replaced.
Propeller pitch or diameter incorrect - Install correct propeller.
Damaged or bent propeller - Replace propeller.
Outboard engine is mounted too high or too low - Mount the motor as required.
Engine oil level is insufficient - Need to add engine oil.
Damaged oil pump - Oil pump need to be replaced.
Dirty water intake screen - Wash or clean as required.
Valve setting is incorrect - Set the valves properly.
| Abnormal engine noise or knocking |
Low octane gasoline - Use proper fuel.
Engine is under excessive load - Reduce the load.
Incorrectly set low idle speed - Correct idle settings.
Fuel pump is clogged or faulty - Test fuel pump and replace if necessary.
Worn crankshaft or main bearings - Repair or replace defective parts.
Cylinder bore or piston rings are worn - Replace faulty components.
| Low engine power |
Fuel lines clogging - Fuel lines must be clean.
Fuel injector is damaged - Replace fuel injector.
Dirty or faulty fuel pump - Clean or install new fuel pump.
Ignition system failure - Inspect ignition system and change faulty parts.
Blown cylinder head gasket - Install new head gasket.
Powerhead parts are worn out - Defective components need to be replaced.
Valves are stuck or burned - Change or clean valves.
Improper propeller diameter or pitch - Check the propeller size.
Propeller bent or damaged - Have propeller repaired or replaced.
Incorrect outboard motor mounting height - Have motor adjusted to proper transom height.
Incorrect trim angle - Adjust trim angle correctly.
| Excessive fuel consumption |
Damaged or clogged fuel injector - Clean or replace if necessary.
Faulty or loose spark plug - Re-tighten or replace spark plug.
Piston, sleeve, or rings are damaged - Change faulty parts.
ECU failure - Install new ECU.
| Strong engine vibration |
Damaged or bent propeller - Have propeller repaired or replaced.
Damaged propeller shaft - Replace propeller shaft.
Weeds wraped around propeller - Remove weeds from propeller.
Motor mounting bolt is loose - Tighten bolt.
Loose or faulty steering pivot Tighten or replace.
| Starter is not working |
Low battery capacity - Battery needs to be recharged.
Battery drains quickly - Battery needs service or replacement.
Battery terminals are corroded or wires are disconnected - Connect wiring properly or install new terminals.
Starter motor is damaged - Repair or replace starter.
| Trim motor runs but trim system does not move up or down |
Not enough oil - Check and refill oil.
Defective pump assembly - Test pump and replace if necessary.
Leakage of manual release valve - Valve need to be closed or changed.
Faulty pump driveshaft or motor - 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.
Damaged tilt ram piston O-ring - Replace O-ring.
Not enough oil - Fill up oil to required level.
Lower check valve not seating in port side trim ram - Secure valve properly.
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