Suzuki 2.2DT outboard problem

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FairweatherDave

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So my outboard has run beautifully all summer, starting second pull everytime like a dream. On Saturday it didn't. It started like a dream as usual , went a short distance and pretty abruptly died. Wouldn't restart. At home in the dustbin no joy. I have stripped the carb down 3 times now, it's immaculate..... as it was, I never found any gunk and the jets are clear. I've changed the plug and checked for a spark. Spark much the same on both plugs, quite yellow (I thought it was supposed to be blue). The fuel is recently purchased and given the abrupt way the engine cut out (yet started fine) I don't think it is the fuel, and plenty is getting to the bowl. I have had stuck float valve plenty of times in the past and I don't think this fault corresponds. I just managed to start it but again it ran for 10 seconds and then it stopped abruptly. I'm guessing it might be electrical, but that is because I can't think of anything else. Any pointers really welcome
 
ach, the joys of these engines!

The symptoms you describe are very familiar to me. In the end (for us) it always boiled down to fuel issues. When you say "stripped" the carb, did you actually clean it with one of the many products available to clean them? The fuel conduits are so tiny in these engines that the smallest (practically invisible?) bit of gelled ester (formed from oxidized ethanol) can lead to that sort of behaviour.

In the end, I bought an ePropulsion unit. Mostly out of the frustration of dealing with these small ICEs. But this may not help you right now, sorry!
 
Just a couple of things you could try:
Try various combinations of choke and throttle, just in case it is a fuelling issue.
Possibly try easy start or a spray of petrol directly in the carb - if it fires then again the carb is suspect.
Disconnect the kill switch - they can short out intermittently.
Check the HT lead and plug cap, and give it a wiggle.

And depending on the ignition system:
Check the coil, and make sure it's clean and dry.
If it has them - clean and gap the contact breaker points
If you have a multimeter, then in the service manual that's bound to be online somewhere, there will be test procedures for the various ignition components especially the coil

All this is assuming there's decent compression!
 
Yes, took the carb properly apart as per the manual and used carb cleaner. Been thorough and day light is clear through the jets. I have been using this one and servicing it for quite a long time, but never replaced any electrical components other than the plug. Agree it could be a fuel issue and that I might have somehow missed something. But the abrupt stop and total reluctance to restart I hope are clues.
 
FairweatherDave said:
So my outboard has run beautifully all summer, starting second pull everytime like a dream. On Saturday it didn't. It started like a dream as usual , went a short distance and pretty abruptly died. Wouldn't restart. At home in the dustbin no joy. I have stripped the carb down 3 times now, it's immaculate..... as it was, I never found any gunk and the jets are clear. I've changed the plug and checked for a spark. Spark much the same on both plugs, quite yellow (I thought it was supposed to be blue). The fuel is recently purchased and given the abrupt way the engine cut out (yet started fine) I don't think it is the fuel, and plenty is getting to the bowl. I have had stuck float valve plenty of times in the past and I don't think this fault corresponds. I just managed to start it but again it ran for 10 seconds and then it stopped abruptly. I'm guessing it might be electrical, but that is because I can't think of anything else. Any pointers really welcome
Click to expand...
Your spark seems to be very poor.
With CD ignition you should be able to get a spark to jump an air gap of 7/16"
( about 5/16" with points ignition

Check the condition of the HT lead, also disconnect the stop switch and its wiring but very likely the ignition coil assembly is defective ............... The fact that it's not completely dead troubles me a little though.

The ignition coil assembly is NLA as a Suzuki part
 
CM74 said:
Just a couple of things you could try:
Try various combinations of choke and throttle, just in case it is a fuelling issue.
Possibly try easy start or a spray of petrol directly in the carb - if it fires then again the carb is suspect.
Disconnect the kill switch - they can short out intermittently.
Check the HT lead and plug cap, and give it a wiggle.

And depending on the ignition system:
Check the coil, and make sure it's clean and dry.
If it has them - clean and gap the contact breaker points
If you have a multimeter, then in the service manual that's bound to be online somewhere, there will be test procedures for the various ignition components especially the coil

All this is assuming there's decent compression!
Click to expand...

Thanks for that lot. Unfortunately the electric stuff is outside my skill set (at the moment.....). Yes I have played with different combinations on the fuel and wiggled the HT lead and cap. Not sure how to disconnect the kill switch but I did wonder about that.. ..... The HT lead (thanks VicS) I will look at, but not sure what problems I would be looking for. I guess it is a new part of the manual I need to study.
 
FairweatherDave said:
Thanks for that lot. Unfortunately the electric stuff is outside my skill set (at the moment.....). Yes I have played with different combinations on the fuel and wiggled the HT lead and cap. Not sure how to disconnect the kill switch but I did wonder about that.. ..... The HT lead (thanks VicS) I will look at, but not sure what problems I would be looking for. I guess it is a new part of the manual I need to study.
Click to expand...
General condition (of insulation)

Thres a (used) coil assembly on ebay for £29.99 ..... might be worth the risk

Stop switch connection looks like some sort of bullet connector

1634313350473.png
 
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New fuel and a new spark plug fixed that problem for me. Yes, the old plug produced a spark, for six seconds of running, then the insulation broke down, motor stopped until plug cooled.
 
Thanks again Vic
Will try some electrical diagnosis over the next week or so before taking a punt.
RAI.... I tried a new plug and the fuel is only a month old.......previously a new plug has been the solution but not this time
 
BUT HOW WRONG I WAS :)
Yes I tried the new plug at some point in my 3 carb cleans. But I went back to the old plug as the new plug made no difference. ..... Until now.
Just put the new plug in and the engine is running beautifully. (Oh fingers crossed)
Thanks RAI and everyone. The usual suspects have done it again (that's why I love my Suzuki!)
 
Well I'm afraid I'm still not sorted. The basic problem is still there. I can get it to run and idle if I am lucky, and then no more. Had quite a good play about and now I am confident it is a fuel/carb problem, not electrical. So the reason I say that is I got it idling a very solid fast idle. But whatever I did the throttle made no difference at all. I had played with the stop screw a fraction and that acheived a healthy running speed with no choke. But then the throttle made not a jot of difference.
So took the throttle assembly apart and I think I have found a tiny spring clip? (a splodge on the parts diagram above the spring seat (part 4)) that had detached itself. The part looks a bit like the clip that fits round the centere of the throttle rod (which remains in place), but a smaller version. So if anyone has had a similar problem with a duff throttle assembly I'm interested. Will try and reassemble correctly tomorrow.
 
FairweatherDave said:
Well I'm afraid I'm still not sorted.
>
So took the throttle assembly apart and I think I have found a tiny spring clip? (a splodge on the parts diagram above the spring seat (part 4)) that had detached itself. The part looks a bit like the clip that fits round the centere of the throttle rod (which remains in place), but a smaller version. So if anyone has had a similar problem with a duff throttle assembly I'm interested. Will try and reassemble correctly tomorrow.
Click to expand...

What clip are you referring to. Your reference to part 4 make s no sense

Have you found that the throttle valve and jet needle ( #21 and #20) are not lifting when you operate the throttle control lever. A non opening throttle valve would certainly explain the symptoms

fig005.jpg
 
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I am not familiar with that engine, however they all work pretty much the same. A very common cause of fueling issues is a blockage at the small filter/gauze screen at the fuel on/off tap, have you checked this?
 
Well I'm Mr. Happy! Thanks LIB , mrangry, and VicS. I sorted it and it was the throttle assembly. In the meantime I bought a cheapo spark plug tester for a fiver which confirmed I have a spark, however I also learned what VicS meant (in an older thread) by an "air gap" spark plug tester, which would allow you to see a real spark as opposed to a bulb flashing (which is mine). But I had a spark although I wasn't sure it was a good one. Then I followed a good you tube video
At some point I had already put in brand new fuel and another new plug, and had checked the tank switch for possible blockage.
I became more confident it would be something to do with the carb when I tweaked the throttle stop screw, as I said in #11.
So this morning I managed to get the tiny "e clip"? part 15 back on and put the throttle assembly all back together. Fiddly or what and surely a potential repeat problem.
But yes I could see the throttle valve going up and down properly and now all back together running beautifully .
Test is tomorrow going out to my mooring.

My question now is where would one go to buy a supply of these "e clips" as it seems most things for my motor are no longer available from Suzuki. What I am calling an e clip is a sprung clip that fits round the diameter of a rod at a narrow point to hold the rod from slipping out. It is e shaped as you push it on , rather than a complete ring that you would push over the top of the rod and slide it down until it is held at the narrow point. Apologies if the description is lacking. Edit. Just googled e clips and it looks like I wouldn't have a problem, but recommendations of helpful suppliers welcome.
 
FairweatherDave said:
Well I'm Mr. Happy!

My question now is where would one go to buy a supply of these "e clips" as it seems most things for my motor are no longer available from Suzuki. What I am calling an e clip is a sprung clip that fits round the diameter of a rod at a narrow point to hold the rod from slipping out. It is e shaped as you push it on , rather than a complete ring that you would push over the top of the rod and slide it down until it is held at the narrow point. Apologies if the description is lacking. Edit. Just googled e clips and it looks like I wouldn't have a problem, but recommendations of helpful suppliers welcome.
Click to expand...
They are called "E clips"

The two E clips . #15 and #19 in the parts diagram , should be available as spare parts from your Suzuki outboard dealer.

See the official parts list here for the part numbers,
Suzuki Outboard Parts Catalog - Browns Point Marine Service, LLC

.
 
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