1998 Suzuki DT 200 won't start

[Deleted]

Need help troubleshooting.

I have twin 1998 Suzuki DT 200 outboards. This problem started while running 25 kts. Stb motor started to over heat so I shutit off. After it cooled it wouldn't restart. I pulled the cowling and noticed I the starter was smoking (I know better than to let the smoke out). Got home ordered a new starter and water pumps.

Replaced both starter and water pump but the motor still won't start. Since batteries are getting older 3 yrs. I replaced both batteries. Port engine is fine. Starboard motor still won't start and starter is barely turning over like loss of voltage. Before cranking I have 13+ volts at solinoid and while cranking it drops.

Next I replace the battery wires from outboard to battery switch and from battery switch to batteries.

Still won't start. Checked for spark and no spark.


What next? Any advice?

[Simple Man]

Good battery, good wiring from battery to starter, good voltage, start motor and voltage drops to below 11 or so =starter motor bad or main engine locking up.

[Deleted]

I was reading neutral safety switch will cause suzuki motors to not provide spark; does anyone know how to test this?

[Simple Man]

I'm confused. You said you had 13 volts and while cranking the voltage drops but then you say "no spark". I'm no sparkie so explain to me exactly what you mean by that.
Do you have voltage at the non turning over motor or not? What is the voltage before starting and during starting?

Edit: just to clarify, the ignition system and spark plug spark and the cranking system and motor turning over are two separate systems only connected by the key switch and then indirectly. I am confused as to what exactly your problem is?

[Deleted]

So I kept thinking it was bad or corroded wires, bad connection and or batteries since that it the usuals suspect. My brother came over and assisted me - pulled plugs and no spark.

I need to check the neutral safety switch and then....

I can swap power pack side I have a sep parts motor in the shed just want to go down the right path.

[Deleted]

Jul 22, 2014 6:24:40 GMT -6 @poerover said:

2ndwind you seem to know a lot about this, probably way more than me, which will not be a great feat. Anything I would say is just a guess but it could be a whole lot of things and seems you are running down the list. You definitely sound like a handy DIY but you may need to visit a mechanic and get them to hook-up engine to a diagnostic computer, if that is even an option.

My thoughts immediately jumped to solenoid, since maybe it engaged the starter to cause problems to begin with. There could be a short or loose connection to it, or its just bad. I am guessing engine has an electronic ignition system so those power packs can go bad as well. Neutral safety and kill switch could be it but who knows. If something like starter was smoking then you may also need to check fuses or breakers but betting you have looked there as well. Check spark plug wires and caps and see if you see any burn marks where it may have arched. Those wires can wear out, but again all this seems tied to one event that occurred while boat was running.

No spark definitely sounds electrical problem and hopefully it is not as Simple Man suggested a seizing up engine. But if that was the case it would at least still be sparking, I guess.

These are just my thoughts and may not even be anywhere near a target problem.

BTW I just reread your first post.  You shut it down since it was overheating?.  On surface that sounds like a mechanical issue but real issue is/was it actually overheating or was there an electrical short in system to make you think it was overheating.  Dude I am probably not helping you but it could be lots of things. You probably need to take it to a mechanic. 

Thank you but sometimes we forget the easy stuff or rule out the obvious by overlooking! I' need all the help I can get at this point. On Friday if I don't figure it out it goes to the shop for the first time since I owened it. But I leave for two weeks with the Navy so it works out.

[Deleted]

Update

Got home from work travel and swapped the ECM at the advice from a local shop. Same symptom. Sounds the same as if no charge. I think when I get home from this business trip it goes to a shop...

[freezerfiller]

So you are saying that it spins over slowly? or that you are not getting spark at the plugs? or both? If it's spinning over slowly, 1. take a known good battery and run it straight to the starter. 2. you may have gotten a bad starter. I'd swap the starters with the other engine that you know works and see. 3. If it is still not turning over, you may have an engine issue (you did overheat?) pull all the plugs and see how it spins over, if it does fine, get a compression tester and test each cylinder.
For spark, how are you testing that? I like to use a spark plug and ground it to the engine. It's sometimes hard to see in the sunlight so shade is a must. I would think that it would be too coincidental for the Neutral safety switch to go out at the exact same time as the overheat, but you can always temporarily bypass it if you want to eliminate it from the variables. Have you looked for a fuse or a breaker for the ignition system? I don't know how Suzuki does their ignition, so I'm no help there, but I bet there is a Suzuki forum with folks that have had this problem.

[Deleted]

Will post after I get results from a shop- last one I called said 8 weeks to be seen

[obx109r]

I have a 98 dt150 that the local Suzi dealer said had to be the ecm and that it was $1600.00, so I figured why keep throwing money at this old motor. That being said he never mentioned neutral safety switch, how can I check mine?

[cvmarine]

Just wondering if you figured anything out with your motor. I'm having a similar issue with a 98 DT200 no spark. It ran great before it was parked for winter. Checked the neutral switch and its working fine. Lanyard bypassed. But same issue no spark. I hear the fuel system prime up when I turn the key but just no fire. So if you found anything let me know. Thx.

[gtightline]

Replied to this thread before I realized that it was two years old..... 2gunsfiring_v1

[gtightline]

No, nothing definitive.. I had mentioned that if his engine over heated that it could be to a lack of 2 stroke oil, and the fact that he says a piece of the impeller had broken off. I wanted to know if he had to add the oil directly to the gas or if it had one of those 2 stroke oil reservoirs that auto feed the oil to the engine. I thought maybe if the auto feed had stopped working that it would over heat (and possibly) score those pistons, if not lock that engine, I also couldn't understand why the starter was smoking, unless of course it was trying to engage while the motor was running, and overheated, it didn't make any sense to me...just a thought. I also had posted a site he could go on to help trouble shoot the problem..Here is a link to that site, for what it's worth....maybe it could help someone else.

forums.iboats.com/Suzuki-Outboards/Overheat

[fraydknot]

Not hearing what it was is like the old saying " know how to keep a idiot in suspense". --- I WILL TELL YOU TOMORROW ----LMAO

neutral switch is a simple switch put a ohm meter on and look for continuity.. In neutral you should have continuity and should be open in any other position

[boatn25]

ok for starters new account name.

This is what I came up with. NO

1. Motor started had low compression in one cly, not bad but lower so I had a spare power head rebuilt the top half with the help of a friend. Good compression ran it one time stator wires came loose and were burned by flywheel. Back to square one, had stator wires repaired by a shop reconnected and now still won't start. It is currently in the shop for some expert care and handling. Will share when saga is corrected.

In the mean time to ensure I did what I could I got the main wiring updated from batteries to battery switch updated perko switches with the BEP switches by a qualified (I hope) shop for about 1k.

Next if nothing is in my favor - next year will be newer 4 stroke power. Stay Tuned....

[boatn25]

Apr 20, 2016 9:41:01 GMT -6 gtightline said:

No, nothing definitive.. I had mentioned that if his engine over heated that it could be to a lack of 2 stroke oil, and the fact that he says a piece of the impeller had broken off. I wanted to know if he had to add the oil directly to the gas or if it had one of those 2 stroke oil reservoirs that auto feed the oil to the engine. I thought maybe if the auto feed had stopped working that it would over heat (and possibly) score those pistons, if not lock that engine, I also couldn't understand why the starter was smoking, unless of course it was trying to engage while the motor was running, and overheated, it didn't make any sense to me...just a thought. I also had posted a site he could go on to help trouble shoot the problem..Here is a link to that site, for what it's worth....maybe it could help someone else.

forums.iboats.com/Suzuki-Outboards/Overheat

2 Stroke with oil reservoirs.

I think it was a cheap knockoff starter from discount starter who give 100% guarantee that won't stand behind the 100% guarantee.

[boatn25]

Embarrassing update to the saga....

Replaced
Neutral safety switch = bad
Stater relay = bad

And...
Not replaced (yet)
Ignition switch = bad

And she after a fresh set of eyes and brain waves she's up and running

[freezerfiller]

Hooray! at least she's running.

[gtightline]

So this boat has been sitting for near 2 years with that same problem...Glad to hear you finally got her going again. Now it's time to go wet a line or two.

[boatn25]

I started my own business, still in the Navy and younger boys in baseball. I'm happy it only took two years so to speak. I did take her onto the lake We'd evening for about a two hour run with zero issues.