Johnson/Suzuki 90hp 4 stroke issue
Hi Guys,
i have a Johnson 4 stroke (suzuki dt90) which failed me yesterday.
we were 20nm off hillarys yesterday, went to start the engine, everything lights up but no ignition, not even a click.
all batteries have full charge, all fuses (external to outboard) ok. im 90% certain its an issue with the key barrel/kill switch. we ripped the whole thing apart trying everything to diagnose but no luck. (not that easy with sea sickness kicking in)
anyway called whitfords sea rescue and got picked up for the long tow home. legends
has anyone else had similar problems? im going to try more diagnostics today and if i cant get it sorted call a marine mechanic/electrician.
does anyone have any marine mechanics/sparkys that they recommend. i want to get the outboard service at the same time
regards
Nick
Gav475
Posts: 397
Date Joined: 16/11/11
elimination
mate that sucks when things break at sea but at least you got home safe. Problem definitely sounds electrical and maybe even a seized starter motor which is what happened to me, in my drive way thankfully. If you are NOR give this bloke a call. He is very good and doesnt rape you on price Mick 0438903945
Stevo81
Posts: 1278
Date Joined: 16/04/12
X2 for Mick at Marine
X2 for Mick at Marine Masters.
He's actually honest too which is rare as rockinghorse shit when it comes to Perth marine mechanics in my experience...
•••••••• Electrical Contractor NOR ••••••••
Perry Home
Posts: 434
Date Joined: 07/10/10
Could be as simple as
The motor being slightly in gear. It's worth moving the fwd control fwd then bringing it back to upright which should put the motor into neutral. Yeah I know it sounds silly but whilst occupied fishing thinking of the next spot etc the simplest matters can catch us out. Give it a test in the driveway. . Can't hurt.
Rob H
Posts: 5797
Date Joined: 18/01/12
Once again, start at the
Once again, start at the simplest stuff.
As Perry says, try the start in gear lockout and also the kill switch (as you have) by bypassing it.
A cheap multimeter ($15 at Bunnings) is worth gold at times like this.
You can go straight to the starter motor and see if it;
A-has 12V at the main terminals
B-is getting a start signal on the smaller control wire.
If it isnt getting a signal to start then it is relatively easy to bridge the main positive terminal to the trigger wire and crank it if (as you say) everything else is lit up.
Give a man a mask, and he'll show you his true face...
The older you get the more you realize that no one has a f++king clue what they're doing.
Everyone's just winging it.
nicksta711
Posts: 56
Date Joined: 07/07/15
its definitely not the start
its definitely not the start in gear lockout.
im about 90% sure its the neutral safety switch. just sourcing a wiring diagram for the ingition barrel to see which cable to bridge out to test it
Rob H
Posts: 5797
Date Joined: 18/01/12
the neutral safety switch is
the neutral safety switch is the start in gear lockout...
Think you mean the dead man switch?
Difference between the 2 electrically is that the neutral cutout switch will allow the engine to run but not start if triggered, the deadman switch will also kill the engine if running
Give a man a mask, and he'll show you his true face...
The older you get the more you realize that no one has a f++king clue what they're doing.
Everyone's just winging it.
cruzy111
Posts: 274
Date Joined: 08/10/13
Is there any plugs or bullet
Is there any plugs or bullet connectors between the controller and the motor. I had a similar problem last year and it turned out to be green corrosion in a sealed bullet connector. Ive been fishing in a boat with a new suzuki the last week and it has a different way of starting. You only briefly turn the key and it starts ,like new cars. So it may be electronically controlled not like an old ignition system. Id turn the key to on and put a wire straight from the battery to the strarter solenoid and see if it starts.
Rob H
Posts: 5797
Date Joined: 18/01/12
shouldnt need to.Just go
shouldnt need to.
Just go straight from the positive terminal on the starter to the solenoid and an inch away.
Give a man a mask, and he'll show you his true face...
The older you get the more you realize that no one has a f++king clue what they're doing.
Everyone's just winging it.
nicksta711
Posts: 56
Date Joined: 07/07/15
as soon as it stops pissing
as soon as it stops pissing down with rain ill try all this.
Rob H: yes i did mean the lanyard switch instead of the start in gear lockout. im assuming there is some sort of contact inside the barrel when you push in the key and lock it in with the lanyard it makes contact.
when we were out there and i tried to start it i knocked the lanyard off. i clipped it back in then after that nothing. that what makes me think its that contact.
ill keep you guys posted.
nicksta711
Posts: 56
Date Joined: 07/07/15
righto had a bit of a look
righto had a bit of a look again on the weekend: my engine is not a DT90 but a DF90 (full electronic ignition and control)
when key switched to on fule pump primes. self diagnostics runs and all warning lights go off like they should
when key switched to start fuel pump primes again, but nothing else
put power direct to starter motor, thats fine
both batteries over 13v
bridged out in gear safety switch
i checked the key barrel and it does whats its meant to do according to this diagram https://www.google.com.au/search?q=brp+outboard+key+barrel+wiring&espv=2&biw=1920&bih=955&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiGmuab9rzMAhVlYKYKHa0lARQQ_AUIBigB#imgrc=eP23yaHwTfgiPM%3A
note: i do have an evinrude/brp key barrel and throttle (suzuki made the outboard, but its rebadged as a johnno.
can anyone tell me with those evinrude/brp key barrel as shown in this pic: https://www.google.com.au/search?q=brp+outboard+key+barrel+wiring&espv=2&biw=1920&bih=955&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiGmuab9rzMAhVlYKYKHa0lARQQ_AUIBigB#tbm=isch&q=evinrude+brp+key+barrel&imgrc=ROg6A-DEDtKR_M%3A
does the outboard turn over when the lanyard is pulled? or is it completely dead?
cheers
Rob H
Posts: 5797
Date Joined: 18/01/12
DT is 2 stroke, DF 4
DT is 2 stroke, DF 4 stroke
just checked mine.
With lanyard pulled is neither primes nor cranks.
When you say "put power direct to starter motor, thats fine" what do you mean?
To the trigger wire or main terminals? it cranked and started, or it just cranked?
Give a man a mask, and he'll show you his true face...
The older you get the more you realize that no one has a f++king clue what they're doing.
Everyone's just winging it.
nicksta711
Posts: 56
Date Joined: 07/07/15
SHE LIVES!ok had a spare
SHE LIVES!
ok had a spare keybarrel to test with no luck.
pulled the cover off the outboard again for another look. pulled out the computer module to retape some wires up. noticed 2 relays with rubber covers that are stuck in behind the computer.
one cover looked slightly crooked. and i mean ever so slightly! turns out it was that harness slightly pulled out of the relay. pushed it back on properly and now fixed them on with cable ties and she fired right up.
just complete bad luck for it to finally loose contact between 2 drifts out there. it must have slightly loosened over a long period of time.
thanks all for your help. always good to learn more about your motor.
Rob H
Posts: 5797
Date Joined: 18/01/12
Handy to know, I might check
Handy to know, I might check my two Suzis!
Thanks for posting up the result
Give a man a mask, and he'll show you his true face...
The older you get the more you realize that no one has a f++king clue what they're doing.
Everyone's just winging it.
Sulo
Posts: 256
Date Joined: 13/08/11
I have the 140's and have
I have the 140's and have replaced the neutral switches as the threaded ends had just reached the end of their life and split away from the casing. it was still in one piece so hard to spot while on the water. It is under the cowling and is in amongst the control cables, it is worth finding and checking as it seems they deteriorate with age and then fall apart and give exactly the symptoms you have described.
I am presuming the 90's have the same system as the 140.
Hopefully you have the issue sorted, but if it happens again check here next as you may have just moved the wires enough to keep it working for a few more starts.