Suzuki 200HP 4 stroke stalling issue

Hey folks

 

I've had a stalling issue on a relatively new engine (approx 60 hrs) for quite some time. It will stall at varying speeds. It will happen maybe once or multiple times going from A to B and then it may not occur again. Sometimes it may not stall at all. Anyway, during this investigation period, various items were replaced but it did not fix the issue e.g. fuel filter, ignition switch, bateery terminals etc etc
 
I've had 2 mechanics look it over and cannot find the fault. On 1 of the ocassions there was even a Suzuki dealer on board when it happened and nothing turned up on his diagnostics program on his laptop.
 
My gut feeling is it's an electrical issue as opposed to a fuel problem. Would someone recommend a marine electrician or have a suggestion on who to go to to get this resolved.

 

 

 


Feral's picture

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 also check to make sure

Wed, 2017-11-15 09:54

 also check to make sure there is nothing rolling around in your fuel tank that might cover the pickup tube then roll away after the vacuum is removed .. my fork lift at work had a plastic fuel tank nossel in the tank and would at times block it up and do the same sort of thing (and no i wasnt the dickhead that dropped it in there) :)

Posts: 419

Date Joined: 30/12/09

 Hah the leading hand did

Wed, 2017-11-15 10:31

 Hah the leading hand did this yesterday filling up the genset. He couldn’t get it out. 

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wangler's picture

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Fuel vapor separator

Wed, 2017-11-15 11:30

Inside is the fuel pump filter - check/clean/replace - $15 part

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bleicester's picture

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Brett Ward

Wed, 2017-11-15 11:47

Have you already tried Brett Ward from West Coast Suzuki?

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The mechanic called on a

Wed, 2017-11-15 14:12

The mechanic called on a midland suzuki dealer when he took it for a test run and he couldnt figure out what was wrong. 

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Date Joined: 22/07/15

The best description I can

Wed, 2017-11-15 14:13

The best description I can provide of when it stalls is like when someone pulls out the kill switch.

 

Scotte's picture

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 On that  note did u look at

Wed, 2017-11-15 20:04

 On that  note did u look at the kill switch etc

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Yup kill switch was inspected

Thu, 2017-11-16 04:44

Yup kill switch was inspected and nothing wrong with it. 

VaSSagO's picture

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Date Joined: 09/12/09

Does it throw weird fault

Wed, 2017-11-15 14:39

Does it throw weird fault codes?

Had similar happen on my 2015 DF200A, a wire was exposed on the wiring harness between the motor and throttle and corroded through (barely making contact causing the motor to stop dead).

Can send a pic by sms or email if that helps.

Posts: 129

Date Joined: 22/07/15

When it stalls no faults

Wed, 2017-11-15 14:56

When it stalls no faults codes are logged on the computer and neither are there any engine warning light flashes. 

sea-kem's picture

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 I'm hearing Vassago on this

Wed, 2017-11-15 16:18

 I'm hearing Vassago on this one Jerry, had a very similar fault in a car of mine years ago. A live wire was exposed and every time I braked hard it would stall the whole car cutting everything out as it earthed to the body. Might be worth doing a behind the dash check, could be something very simple.

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OK will check this out. 

Wed, 2017-11-15 17:51

OK will check this out. 

Rob H's picture

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 So is it as you say take it

Wed, 2017-11-15 14:41

 So is it as you say take it out of gear it just conks out?

Often with that it is either idle air control valve (IAC) or TPS throttle position sensor (common on Yam F115)

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Date Joined: 22/07/15

Not sure if I understand what

Wed, 2017-11-15 14:58

Not sure if I understand what you're saying.

But it conks out in gear when underway. Almost as if I pulled out the kill switch.

It will restart each and everytime.

Rob H's picture

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 Yeah its not what I listed

Wed, 2017-11-15 17:04

 Yeah its not what I listed then as the above issues cause stalling when you take it out of gear and the idle doesnt pick up.

Id be certainly looking for a power supply wire fault, and I think those may have a seperate wire to the main power/start cable, which runs the ECU.

A momentary power cut on that will stop it dead with no alarm, I believe it may be a white wire?

Get it idling, then go around tugging and pulling on the wiring all over, behind the dash etc

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 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.

 

Adam Gallash's picture

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Tps

Wed, 2017-11-15 20:14

 Have the tps as an issue on my 115. 1300 rpm is my nightmare dropping doen to nuetral coming into the ramp.

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Rob H's picture

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 Its usually just an

Thu, 2017-11-16 11:47

 Its usually just an adjustment adam, using the multimeter
Cant eremember the correct setting but its on the workshop manual

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 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.

 

dowders's picture

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Date Joined: 23/01/11

 Yep i had mine done, took to

Thu, 2017-11-16 12:41

 Yep i had mine done, took to a Yamaha dealer they just hooked it up the computer and adjusted, been good ever since.

Scotte's picture

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 It says at top that  is

Wed, 2017-11-15 19:59

 It says at top that  is stalling  at various speeds so throttle partially  open??

Walfootrot's picture

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Its the flux

Wed, 2017-11-15 15:10

Its the flux capacitor.....
Only 60hrs on the clock, take it back and tell em to fix it or replace it, warranty yes?

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Unfortunately its out of

Wed, 2017-11-15 18:01

Unfortunately its out of warranty. Bought the boat from the previous owner who had it new but only used 60 hours over 5 years. 

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yep

Wed, 2017-11-15 16:38

I've heard bad things about those flux capacitors too.
definitely take it back....or was it forward ????

....sorry couldn't help it.

z00m's picture

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Process of elimination

Wed, 2017-11-15 20:10

To rule out the tank, get a 25 litre portable tank and plumb it up with new lines and connectors and run it with that. If it doesn't conk out then you know it is your tank and lines. Otherwise need to move under the cowl and work from there. 

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Flux capacitor

Thu, 2017-11-16 06:27

 To find out if that’s the problem , get her out on the water open her up and see what happens when you hit 88 knots. Maybe you will end up in bygone years prior to demersal ban and bag limits !!. If nothing happens I’d try jiggling some wires

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ranmar850's picture

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I don't know if a TPS would do that.

Thu, 2017-11-16 10:30

 I've just been through this myself. Motor would hunt and surge badly at a particular rev band if you tried to make a small adjustment to speed. Was right in the billfish trolling band so very annoying, but it never looked like cutting out. When checked, motor threw a TPS error code. mechanic said it looked like the security -type screw head used to adjust and secure it ( F115a) had been previously tampered with, with the wrong tool. He reset to the correct voltage value, and hey presto, problem had shifted to just above idle. Looks like the previous owner of the motor had the problem, and just pushed it to a rev rang he never stayed in, saving himself $300. 

I also had a problem last year with random cut-outs at sea, but it wouldnt  just stop, always started to lug and drop revs first. The fuel filter under the cowling would always be low--it was sucking air. I checked and tightened every single component I could find nothing worked. So I gave it to the people who had installed the motor--turns out there was a hidden connection inside the flex conduit that hides all the controls and wirnig in the well. It was loose, their bad, fixed it for free. Complimented me on my instal job for the inline external filter, asked me if I wanted a job.  Bu the cut-out wasn't instantaneous, and you had to pump the bulb up to get it going, doesn't sound like your problem?

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Date Joined: 22/07/15

Doesn't sound like the same

Thu, 2017-11-16 10:49

Doesn't sound like the same symptoms. Mine wouldnt surge or drop revs at all before stalling. Like mentioned above, it's almost as if someone pull out the kill switch.

Coastrunner's picture

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Date Joined: 25/10/14

THT info

Thu, 2017-11-16 18:54