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Johnson/Suzuki 90 problem
TransFueler
#1 Print Post
Posted on 11/25/17 - 4:52 PM
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My boat has a 2003 Johnson made by Suzuki 90 four stroke outboard. I have only run it a couple times since I bought it. After not running it for a couple months, we took it out today.
Topped off the tank with fresh fuel, but it had about half a tank of months old gas already in the tank.
Started right up at the ramp. We headed out on Lake Sammamish, and after a few minutes it quit. The fuel had unplugged itself. So I plugged it back in, and it started right up.
Planing along for a couple minutes, and the power just slowly backed off, until it dies altogether.

Fuel line plugged in. It tried to run a couple times, but eventually nothing so we had to get towed in.

Battery is fine, it turns over normally, but acts like no fuel.

Very frustrating... My son and I had spent a lot of time cleaning the boat. Installing a new rub rail, new Chartplotter / fishfinder, etc. Then first time out; failure.

Seeking input on why it stalled, and how do we get her going again...

Ed


Smirk is a 1987 Super Sport Limited 17 w/Johnson/Suzuki 90 EFI four-stroke
 
tedious
#2 Print Post
Posted on 11/26/17 - 2:36 AM
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It looks like this is a fuel injected motor, so the best guess is gummed up fuel injectors and / or filters from letting it sit for two months, possibly combined with the old fuel. If you let the boat sit for that long, you really need to winterize it before you put it away - at a minimum, use a fuel stabilizer. Add the stabilizer your last time out so it gets all through the fuel system - just dumping it into the tank won't help much.

At this point, if you want to tackle it yourself, I would do the following:

- change all fuel filters and test
- clean or replace fuel injectors and test
- test fuel pump(s)

No offense, but from your post it does not sound like you have a lot of experience working on motors, so finding a good mechanic may be your best bet. Good luck!

 
Phil T
#3 Print Post
Posted on 11/26/17 - 12:42 PM
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First off, explain what you did to prep the engine and fuel for storage.


1992 Outrage 17, 1992 Evinrude 115
 
TransFueler
#4 Print Post
Posted on 11/26/17 - 5:07 PM
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Phil T wrote:
First off, explain what you did to prep the engine and fuel for storage.



Well, I backed the boat into our barn. I've never really thought that a couple months required "winterization" or prep.

We've got a diesel trawler that sometimes doesn't get run for a few months, and cranks right up. Got a Wooldridge jet sled with a Suzuki outboard that sits most of the winter and fires right up as well, though I try to remember to toss some Stabil in it's tank.

With three boats, two motorcycles & eight cars, plus a tractor, couple of mowers, golf cart, it's a lot to keep track of!


Admittedly, I'm a hack mechanic...

I'm pretty good at rebuilding & tuning old British engines (MG & Triumph) I can set up SU carbs, and occasionally get a Weber right... I can rebuild a two stroke motorcycle engine, no prob. I can even adjust the valves on my wife's vintage Formula V race car with it's ancient VW motor...
Currently rebuilding the mechanical fuel injection on my '73 450SL. But by no means would I attempt to rebuild or even do much diagnosis on a four stroke, EFI outboard.

I guess I'll change the fuel filter, maybe a couple of lines, & try it with some fresh fuel. Otherwise, unless someone here has some other good ideas, off to the outboard mechanic it goes.


Smirk is a 1987 Super Sport Limited 17 w/Johnson/Suzuki 90 EFI four-stroke
 
Phil T
#5 Print Post
Posted on 11/27/17 - 4:01 AM
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Any idea as to the conditon of the engine and fuel when you bought it?

I would start with new fuel supply.

Could be:

a) clogged VST or injectors due to bad gas
b) hose degraded and caused A above
c) Closed vent on tank
d) electrical fault/loose ground



1992 Outrage 17, 1992 Evinrude 115
 
TransFueler
#6 Print Post
Posted on 11/27/17 - 8:59 AM
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Agreed. Good places to start.
Tank vents are clear & open. I'll start with a new fuel filter...


Smirk is a 1987 Super Sport Limited 17 w/Johnson/Suzuki 90 EFI four-stroke
 
TransFueler
#7 Print Post
Posted on 11/28/17 - 4:05 PM
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Took a pretty good size fuel sample from the Fuel Vapor Separator. About 60% gas, 40% water.
Drained both fuel tanks. Bought low & high pressure fuel filters. Will replace filters tomorrow, drain fuel rail and try it with fresh gas...


Smirk is a 1987 Super Sport Limited 17 w/Johnson/Suzuki 90 EFI four-stroke
 
tedious
#8 Print Post
Posted on 11/29/17 - 12:58 PM
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Sounds like you have found the problem! You fooled me with your first post - based on your experience, I'd say you're well able to do pretty much any diagnosis and repair on this motor! Grab the factory service manual and have at it.

 
TransFueler
#9 Print Post
Posted on 11/29/17 - 5:04 PM
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Thank you. While I'm a pretty decent wrench on vintage cars, I'm not as confident working on a modern EFI motor.
But as we all know, they're simply nuts & bolts. Pieces of metal. Wiring, etc. Nothing to be afraid of, eh!


Smirk is a 1987 Super Sport Limited 17 w/Johnson/Suzuki 90 EFI four-stroke
 
steelhead55
#10 Print Post
Posted on 11/29/17 - 6:37 PM
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I have some experience with these motors, having owned a 225 and a 70. These motors are extremely susceptible to bad gas, and water in the gas. Based on your symptoms, if your lucky it is just the high pressure fuel filter. If you are unlucky, it is the high pressure fuel pump, and or the low pressure fuel pump.

To test for the high pressure fuel pump, unplug the low pressure fuel pump and take a stethoscope to the motor and listen for the whirr of the high pressure fuel pump. If you do not hear it, thats your problem. Bad news, these pumps are all stupid expensive.

 
Weatherly
#11 Print Post
Posted on 01/12/18 - 6:10 AM
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TransFueler: Good job fixing your main outboard. I hope you do not now think you need a kicker motor as back-up because of your on-the-water breakdown. You really do not need more weight added to your boat. Have faith in your good diagnostics and repair work and skip the notion that you now need a kicker as back-up security.

 
Sharky1
#12 Print Post
Posted on 01/12/18 - 1:59 PM
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While you're at it, you should either test your fuel injectors or send them out to be cleaned. Makes a world of difference. There are a few youtube videos on how to clean them yourself or at least test them using a 9 volt battery. Once you have the fuel system all clean and water free you'll never let it go bad again trust me. It could cost hundreds of dollars for a new VST tank not to mention the high pressure fuel pump. Rec 90 is the only way to go and really all you need to do is put some Sta-Bil in the gas and you should be good to go.

 
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