Suzuki Outboard - NO COMPRESSION ON 3 CYLINDERS - 900h - 5 years old

[marctrevenen]

Not quite, it was on a mates 2406 z craft.

[rcoliveira84]

I just got this reply from the Engineer:

Upon inspection of the above mentioned cyl-heads, we found the exhaust guides to be severely and abnormally worn, resulting in damage to the valve faces and seats. As this type of failure is usually the result of either insufficient valve to guide lubrication or excessive combustion and exhaust temperatures, we thus recommend a detailed inspection of the entire fuel/ignition system be carried out in order to pinpoint the cause.

Tomorrow he's going to send me the pictures.

[FishStyx]

I just got this reply from the Engineer:

Upon inspection of the above mentioned cyl-heads, we found the exhaust guides to be severely and abnormally worn, resulting in damage to the valve faces and seats. As this type of failure is usually the result of either insufficient valve to guide lubrication or excessive combustion and exhaust temperatures, we thus recommend a detailed inspection of the entire fuel/ignition system be carried out in order to pinpoint the cause.

Tomorrow he's going to send me the pictures.

Sounds like the possibility that too much alcohol was added to the fuel... Also sounds like a big expense.

[dugong]

I just got this reply from the Engineer:

Upon inspection of the above mentioned cyl-heads, we found the exhaust guides to be severely and abnormally worn, resulting in damage to the valve faces and seats. As this type of failure is usually the result of either insufficient valve to guide lubrication or excessive combustion and exhaust temperatures, we thus recommend a detailed inspection of the entire fuel/ignition system be carried out in order to pinpoint the cause.

Tomorrow he's going to send me the pictures.

I am no 4str outboard mechanic but could this have possibly been as a result of the exhaust jackets I mentioned??

[rcoliveira84]

This is what Suzuki replied this morning:


This type of damage to the exhaust valves  is typically the result of them being exposed to very high combustion temperatures, which can be from a number of factors. Bad or contaminated fuel, cooling system blockages, worn water pumps. In  the photos sent by Laurens the water jackets appear to have some build up in them of sand/salt, this would affect the amount of cooling as well. Valve clearances need to be inspected every 200 hours and if this is not done, there is a possibility for the valves to “ride” if there is insufficient clearance and this would also have an effect on the exhaust valves as they are the most exposed to combustion gases

[rcoliveira84]

I am no 4str outboard mechanic but could this have possibly been as a result of the exhaust jackets I mentioned??

Not sure mate. I dont even know what exhaust jackets are 

[rcoliveira84]

Here goes some pictures as promised.
Sent by the mechanic.

[rcoliveira84]

Some more.

[HooknCook]

What was the final outcome of the inspection of the fuel system?

[dugong]

Those valves are seriously kaput and lots of crud in the water sleeve

[rcoliveira84]

What was the final outcome of the inspection of the fuel system?

Still waiting for parts to rebuild Power Head.
Fuel system hasn't been inspected just yet, they will do that when they come to mount the powerhead.

[Johnny Earing]

The valves don't look good. Looks like a fuel problem that caused excessive combustion temperatures which is why the exhaust valves burnt away.

Does your boat have a built in fuel tank?

[rcoliveira84]

No, I use 25lt jerrycans.

[HooknCook]

Something to be very careful with is storing fuel in Cans, never leave them Half full or with just a bit of fuel in as this cause condensation.

[rcoliveira84]

BTW
If anyone needs a Suzuki Outboard Service Manual for DF60A 2010-2015 models.
Suzuki Outboard Parts Catalogue Df40, 50, 60 2011 - 2016
& Suzuki Outboard Service Manual Download - DF60 DF70 - 2003

Check The link:
https://www.youtube.com/watch?v=Xh_Al0n7qWs

[rcoliveira84]

Hi guys
Been a while.
Just managed to finish quickly the video with the final outcome. Includes mechanic videos, emails and all.
Basically Suzuki blamed all on the petrol quality.


And here's the video:


https://youtu.be/AFXQHPEl_ZQ


Enjoy.. Because I didn't 

[John F]

Not being a mechanic and at the risk of sounding completely  .... and also because I own a pair of zukes, use the same fuel as you and operate in the same area with rivers, sand/mud banks, etc....


Suzuki was wrong: it is/was not a fuel problem.


You mechanic was right: it was a sludge problem! The valves overheated because there was a lot of SLUDGE in the cooling system (which you showed yourself).


So, sludge in the cooling system, means nothing to do with the quality of the valves.

My take home message: stop bad-mouthing Suzuki and flush your motors properly! 

[rcoliveira84]

I think if it was that sludge in the cooling system and the water wasn't enough it would sound the heat alarm. So the sludge was there blocking but it wasn't blocking anything major. All the engines in this bay will have the same problem even if you clean them.

Time to fish now 

[rcoliveira84]

This was a reply in another Forum that I think its interesting.




______
I had a look. 
yohh, those valves are done!!!!
what is quite strange is that they are worn away quite badly. one would expect that a lean run cycle, holes/ pitted areas would be present. 


I tend to agree that substandard metal could have been used. to wear a valve away like that is not normal. 


look, they served you well, 900 hours and 5 years. so a good overhaul and you are set. 
at least they are running again and that spare parts were available. 
so time to fish. 
the best is for others to take notice of this tread.
 it can happen to anyone!!!!  all the best!!

by willem wikkel spies