Suzuki Tale of Woe

R

rogerar

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C Dory Year
1999
C Dory Model
22 Cruiser
Vessel Name
Duck
My last Suzi exploded in a ball of fire at 800 hrs.
Now my replacement 90a won't run at 675 hrs., got the best mechanic I can find(Suzuki Dealer), can't figure it out, even with SDS, compression is good, please read my tale of woe at Suzuki Parts Forum if you can help.
Roger

http://www.suzukioutboardforum.com/foru ... iew=stream
 
rogerar":1l2equ8l said:
My last Suzi exploded in a ball of fire at 800 hrs.
Now my replacement 90a won't run at 675 hrs., got the best mechanic I can find(Suzuki Dealer), can't figure it out, even with SDS, compression is good, please read my tale of woe at Suzuki Parts Forum if you can help.
Roger

http://www.suzukioutboardforum.com/foru ... iew=stream
Click to expand...

& the compression test says?? :wink:

start at battery & check all grounds inc. on engine. :beer
 
Can the mechanic swap out the IAC valve? That is where I would start. This seems to have been a problem with some.

Sure bad "luck" with the Suzuki...I have had 3 and no problems....
 
Thanks, the dealer was very sarcastic when I suggested it could be the IAC, go ahead, he said. it's a 300.00 gamble. THe compression was 210 psi in all cylinders, cold, since it won!t even start.
I put a shot of starting fluid in yesterday and it ran perfect till it burned it off.
The injectors are currently at the dealer for cleaning and testing.
I have taken top care of this motor and used it lightly, thanks for input, will keep you posted.
THanks
Roger
 
That...sucks.
 
rogerar":3b7kw0le said:
Thanks, the dealer was very sarcastic when I suggested it could be the IAC, go ahead, he said. it's a 300.00 gamble. THe compression was 210 psi in all cylinders, cold, since it won!t even start.
I put a shot of starting fluid in yesterday and it ran perfect till it burned it off.
 The injectors are currently at the dealer for cleaning and testing.
I have taken top care of this motor and used it lightly, thanks for input, will keep you posted.
THanks
Roger
Click to expand...

Bad fuel? Have you drained the reservoir at the H/P fuel pump?
Fuel pressure at the rail?
 
I am totally sure the fuel is clean and fresh and just to prove it I am now running off a fresh separate 6gallon tank of non ethanol.
I have always been really picky, I do use 10% ethanol fuel normally, with blue stabil, and I pump it off the boat and burn it in the car if it sits 3 months!
Thanks Roger
 
rogerar":309uzj6v said:
I am totally sure the fuel is clean and fresh and just to prove it I am now running off a fresh separate 6gallon tank of non ethanol.
I have always been really picky, I do use 10% ethanol fuel normally, with blue stabil, and I pump it off the boat and burn it in the car if it sits 3 months!
Thanks Roger
Click to expand...

What did you ever find out?
Thanks & have a good one!! :beer
 
My last Suzi exploded in a ball of fire at 800 hrs.
Click to expand...

Sorry about your trouble.

If you don't mind me asking: why did you buy another one?
 
We just bought a 90a and are hoping for better luck. Sorry you didn't have enough with yours.

Greg
 
rogerar":3kz0qbee said:
My last Suzi exploded in a ball of fire at 800 hrs.
Now my replacement 90a won't run at 675 hrs., got the best mechanic I can find(Suzuki Dealer), can't figure it out, even with SDS, compression is good, please read my tale of woe at Suzuki Parts Forum if you can help.
Roger

http://www.suzukioutboardforum.com/foru ... iew=stream
Click to expand...

Ever find out what was up?? :beer
Hope it all worked out!!!
Have a good one. :mrgreen:
 
Hi all, thanks and sorry to take so long, but the dealer just now got the part he figured was out of spec-the MAP sensor. I just paid 225.00 for one (non returnable).I just installed it and it did not help. This is a respected dealer w/ an excellent trouble shooter(30 yrs. experience) who ran the SDS and later after we did the compression test and cleaned the injectors(takes a special machine, only 2 in the county) after numerous delays including the mechanic's bill, I'm out 500.00 with NO IMPROVEMENT! And no boating.
Thanks
Roger
 
Well, it finally quit starting or running right at my dock. I checked the fuel pump as per manual procedure and heard it run. I then checked the fuel pressure as per the manual and there is 12 psi, should be 36 psi. So there is the problem. I still have lines in my display indicating(to me) an electronic problem.
The dealer's SDS indicated a 68% duty cycle on the high pressure pump, but it was running then(roughly). There is no way to check fuel pump operation that I can find other than duty cycle, looks like another SDS before I haul out and replace the pump, regulator or whatever is wrong.
It seems unbelievable to me that there is no way to test the pump other than SDS, but I cannot find in the manual or anywhere.
Is it the pump, regulator or ECM?? Something is dying right at my dock without use other than testing. Engine runs fine on starting fluid!!
Thanks
Roger
 
Does it have 2 fuel pumps - a low and high pressure?

Yamaha keeps the high pressure pump inside the vapor separator tank and the pump has a small snap on filter on the bottom of the pump. The filter over time clogs and I replace it instead of cleaning. It is a 3 hour job for me

Have you replaced all fuel lines to the OB. I just replaced a rigging hose on a Yamaha F225 and replaced the fuel hose inside the tube going from the Racor fuel filter to under cowling filter. . I looked at the old hose and found the inner hose was pinched or clinked badly at the 90 deg bend going from hose to the under cowling fuel filter. The outer hose looked brand new but the inner hose was loose inside of it and could moved it around. New hose had the inner hose held firmly in price.

I am thinking of a fuel restriction somewhere
 
"I then checked the fuel pressure"


Are you checking the pressure on the fuel rail that is after the pump to rail to injectors?
 
Here is the diagram
https://www.brownspoint.com/store/pc/suzuki/df90/01.asp

Yes it has avapor separator tank with fuel pump inside with a filter.

Thinking the VST should be pulled, cleaned and replace filter if needed. VST might be dirty (doubtful) but more likely the pump filter might be clogged and impending fuel flow. This pump powers the fuel rail to injectors and a fuel pressure reading on the rail is important

Most likely the injectors have a filter inside them. When they are serviced, a machine is used and tests them before and after cleaning including a full printout of the details for each injectors. So factor in injectors into the equation. I have Flag Ship marine in Punta Gorda, Fl serviced my injectors. About $40 each plus shipping. Fast turn around times too again m2cw




again m2cw
 
Yes, just as described in the service manual, I get 12 psi (key on) and there should be 36 when starting for sure, but the pressure did not come up when I hit the starter.
The procedure is to disconnect the return line and place the pressure gage on a "tee" in the line between the pump/filter and the injector rail.
I was just reading more of the manual and the pump is controlled by the ECM giving it .8msec. bursts to ground, followed by .1 msec. off. this amounts to one "duty cycle" I can't think of any way to test maybe an oscilloscope that I don't have, nor know how to use.
Thanks
Roger
 
Yeah, I already had some of the bad fuel hose in another place, bad business. All fuel lines are OEM Suzuki changed out 4 yrs. ago.
Thanks
Roger
 
I am still thinking electronic problem-remember how it started and it has completely deteriorated just sitting at the dock.
Roger
 
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