2003 Suzuki DF-50 No Spark

[Rocketman1098]

My 2003 Suzuki outboard let me down for the fist time! The engine will not fire up. I have checked all fuses. The engine will turn over, but not fire. I pulled a plug and check for spark by holding the base of the plug against the intake manifold- nothing! I jumped out the safety switch- nothing. I have oredered a repair manual, but it waill take several days before I get it. Any ideas on trouble shooting? Rectifier?, ECU? Relays?

When I turn the key I do get the 2 second beep. I get no warning lights, and no further beeps. The starter will turn the engine over, but will not fire up. Batteries are good. How to tell if you have a bad ECU?
Appreciate any ideas as to how to proceed with trouble shooting.

[Russ]

I'm not a mechanic by a long shot.

100% of my Suzi problems have been fuel. Specifically, fuel line.

Are you sure the intake manifold is grounded and that is a fair test?

I do have a Seloc manual, but haven't taken it out of the wrapper (I'll do that). I would check connectors. Maybe a fuse you didn't see. If I recall, there is a harness that goes through the cover with lots of connectors.

What led up to this? Was it running, stopped? First time this year?
Can you give more background about it?

[Rocketman1098]

Thanks for the reply. I had cleaned up the boat from winter strorage. As part of this process I always test the motor to be sure it runs. The motor strated up and ran fine. I took the boat out the following weekend to the bay and after putting her in the water I couln not get the egine started. I checked for loose wires in the steering console, etc. She will turn over, but not fire. I know we had a significant thunderstorm ealier that week and I did get water in the bilge, I checked all fuses, etc..all good.??? I am afraid it may be the ECU??

[Québec 1]

kill switch?

[Rocketman1098]

Shorted out the kill switch..no luck

[Mark J]

Cycle from Neutral to Forward and back for the Neutral-Only start switch?
Obvious, perhaps, but I've killed the engine in-gear, and it would not start until I cycled the throttle in to gear and back to Neutral. Symptom sounded similar (engine would turnover, but not fire).

Mark

[socalmacer]

I would eliminate the fuel issue by squirting some carb cleaner or WD40 into the intake. If it starts up, you likely have a carb issue....stuck floar or clogged injector, etc. If it doesn't turn over, than it's an ignition issue. Check for corroded, loose connections. Good luck...

[sbods]

Hi guys...

There must be something more fundemental that we are missing beacause I have exactly the same problem with my Yam 50 (see post http://www.macgregorsailors.com/forum/v ... =9&t=16003)

What is the link?

Steve

[K9Kampers]

Did youze no-spark guys check the nut behind the wheel?

sowwy!

[Rocketman1098]

Verified the forward-neutral-reverse position. I verified that the engine will not even turn over if out of neutral. Once back in neutral it turns over fine..so switch is working correctly. Everything that I can check without the repair manual looks good. It must be one of the solid state components or the relay. I hope the repair manual will show me how to tcheck these!

[Bleakco]

shorting out the kill switch only makes sure it will not start,,,,the little red clip opens the circuit to the kill operation,,,common mistake on outboards...

[Catigale]

I don't think that's right. Kill switch is a normally closed and is opened to kill the motor on my Mercury, he says with 85% confidence

[Russ]

Okay... Suzi shop manual says:
Observe the meter (multimeter) reading while pulling the lanyard switch connector from the lanyard switch. Continuity should be noted with the connector detached from the lanyard switch.

Therefore, it would seem shorting the switch will kill the engine. Seems counter intuitive, but that's what it says.

The next troubleshooting section in the manual is regarding the System Relay.
The system relay supplies electrical current to the ignition coils and fuel injection system. A fault with the system relay generally prevents the engine from starting. The system relay is mounted on the upper starboard side of the power head near the engine control module. Removal of the electrical component cover is required to access the relay.

There is a fuse indicated in a diagram right next to the diagnostic connector on the upper part of the powerhead. I wish I could scan this and post it. I would also disconnect and check every connector to make sure there is no moisture or corrosion in there.



--Russ

[Rocketman1098]

Russ- Many thanks! I suspect it certainly could be the system relay. I did check that fuse it's OK. Does it tell you how to check the system relay???

Everyone- thanks for the infor on the kill switch. I have tried it both ways ( shorted and open). I suspect their is nothing wrong with my wiring I think it has to be an electrical component in the ignition system..the relay is a high probability.

[Russ]

Does it tell you how to check the system relay???

Check your Private Messages.


--Russ