89 DT65 full revs in neutral, bogs when put in gear.

[motoman125yztb]

I picked this motor up and ran it on muffs with zero issues. Now it still runs great on muffs and even in a barrel filled up to the hydrofoil. But on the lake, full revs in neutral, but I can only give it 1/4 throttle while in gear before it bogs and wants to die.

I have fresh 93 octane fuel and full synthetic 2 stroke oil. I have 105 psi on all 3 cylinders. I have the gap type spark tester. I get spark from all 3 coils. But not a heavy spark when gap tested. The primer bulb never gets rock hard, seems the air fuel separator keeps that from happening but it gets firm. The plugs after running are lightly showing signs that its running rich but all plugs show signs that they are firing. I ran some decarbonizer sat it for a few hours and let it run bumped up in neutral till the smoke stopped or lessened.

I'm going to order a fuel pump diaphragm not sure where else to try. No dealers around here work on Suzuki, only the backyard mechanics that I'm no to fond of going to. Anybody know what length to test the spark jump? Anything else I can try before I haul my boat an hour away to get serviced? Thanks for any input, Don.

 

[99yam40]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

monitor fuel pressures at problem RPM/load to make sure in spec
Motors needs more fuel to run under a load,

but once everything is full of fuel there should be no where for the fuel to go unless there is a leak and the primer should firm up solid


it is always good to make sure you have local dealer before buying a brand of motor

 

[motoman125yztb]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

I have a dt40 that I can barrow the fuel water separator and the fuel pump. I get no fuel leaking inside the cowl. I have new seasense line and primer new Moeller tank. I will inspect the fuel path and make sure everything is good and sealed try to get a solid primer bulb. Thanks for the help.

I picked this motor up because I am so impressed with the dt40. They are larger than other motors in the same power range but they are quiet and have all the safety bells and whistles. I assumed any yamaha dealer would be able to do basic tune ups but no luck.

 

[mphelle8vld]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

I would thoroughly clean, and then adjust and synch the carbs, paying attention to the transition ports drilled into the throat of the carbs near the top of the throttle plate. Then adjust the throttle position sensor. Since the motor is new to you, a fuel pump diapram and water pump ikit would be a good idea. I would recommend purchasing the Suzuki factory manual.

 

[motoman125yztb]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

I had some fuel coming out of the tank connector on the hose. I borrowed the connector from the dt40 and I tightened everything down I could find in the fuel line. And now my primer gets rock hard and I can hear a flow in the carbs. I am eager to get out tomorrow and give it another shot on the lake.

I won this motor on an ebay auction. The guy I bought it from had receipt from his local marina where they rebuilt and resynchronized the carbs. Put on a new/used lower unit that he had resealed and new water pump put on last spring. Said nothing about the fuel pump so I am going put a new diaphragm in. It came with a Seloc repair manual, and I don't like it's layout. Doesn't seem as in order as the Clymer manuals. I ordered a carb cleaning tool with the different diameter wires for clearing passage ways. So I will probably take the carbs off and go through them just to be sure. Thanks for the valuable input.

 

[99yam40]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

you should never run hard wires through the jets and passages on gas motors

but they will sell anything

 

[motoman125yztb]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

I have used copper wire before but saw this online. Probably not the last time I'll need it. Reviews say the fingers are malleable.

K&L Supply Carb Cleaner Kit 35-3498:Amazon:Automotive

 

[motoman125yztb]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

I removed the carbs and cleaned them removing all jets poking with a fine wire and spraying them out. They all looked beautiful before I got to them but wanted to be sure. I took the opportunity to check the reeds for function and they were all free moving. I replaced the fuel pump diaphragm.

I put the boat on the water and it did the same thing running in neutral and dying in gear. I was able to slowly walk the throttle up and one time it revved up and took off. I thought something shook free and it was gonna be good to go but no luck. I fussed with it for 20 minutes pulling plug wires one at a time and noticing no difference from one to another. I tried covering the carb openings one at a time, nothing. The fuel bulb feels tight through all revs even when bogging down.

I did notice that when I adjust the electronic idle control knob nothing changes. And when I was cleaning the carbs on the top carb the main jet black tube was a 1/4 of an inch longer than the bottom 2 when looking down the throat. Anybody have anything else to be checked?

 

[mphelle8vld]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

What is the serial number of your motor?

The black plastic nozzles are held in place by the emulsion tube that holds the main jet. They should be the same length (should extend to just under the choke shaft when looking in the bore), also make sure the small holes in the emulsion tube are clear.

If the carbs are clean, use an inductive timing light to check that the timing is advancing. Pulling plug wires while running can damage the CDI.

 

[motoman125yztb]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

I took the carbs off and pulled the emulsion tubes out and they are good and clean. The top carb with the longer black tube had a different emulsion tube making me think the carb may be different but everything else is the same. Put it on the water and the same problem. I read you can block off the carb inlets one at a time while running to spot the problem carbs. And it looks like my top and bottom carbs only function at idle. The middle carb is doing all the work when in gear. I have some shops to call tomorrow hopefully one of them knows suzuki so I can haul it off to be diagnosed.

 

[mphelle8vld]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

Check your serial number to verify the year, this motor reminds me of a 88 on ebay that was titled as an 89. I have a set of carbs if you need to compare jet sizes/tubes, sounds like someone has been playing with the carbs.

 

[motoman125yztb]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

06502-807485

 

[motoman125yztb]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

what manual do you have for the motor? I am thinking of ordering the clymer manual since that's what I'm used to. Is there a special system of priming the carbs. When I test the motor I choke it till it starts than let it idle for a minute or so than shift it into gear. Sounds like it idles low and adjusting the switch to fast does nothing. I read the motor should Idle between 650-700 to shift properly.

 

[mphelle8vld]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

It's a 1988, makes a big difference when ordering electrical and some carb parts. Highly recommend the Suzuki factory manual. It's not unusual for the idle adjustment switch to go bad, look for a cheap one on ebay but make sure it has a return policy.

 

[mphelle8vld]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

I may have seen this before in a 85-88, do you know what the rpm is when the motor bogs?

 

[motoman125yztb]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

I dont have a tachometer but could order one of those pulse ones for testing.

 

[mphelle8vld]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

That would help to isolate the problem, in the mean time I'll look for the notes I made on one a few years ago. Do you have the monitor gauge hooked up?

PM sent

 

[motoman125yztb]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

I Have the standard multi warning gauge. It wasn't lighting up the way I hooked it up so unhooked it for now. I picked up a tach tester. Will be a couple days before we get good enough weather to get back on the water.

PM replied

 

[mphelle8vld]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

Since it appears the PO mixed parts on the two sets of carbs, I would go through them one more time to verify the proper jets. The 88 uses the shorter black plastic nozzle, 150 main, 77.5 pilot

 

[motoman125yztb]

Re: 89 DT65 full revs in neutral, bogs when put in gear.

I took the boat back to the water. Changed and gapped the plugs just for fun. First I let it idle for a minute and pressed the red button to reset any codes. Put it in reverse, and she bogged like normal. I putted away from the dock and shut it down. I unplugged the warning switch to cdi plug. Fired it up and it felt like it had a little more push in gear, but still bogged down. I did the rag over the carb test with the same results only getting push from the center cylinder. When I got home the top and bottom plugs are wet with fuel, and no significant signs of burn. I am going to haul it away to the service shop tomorrow morning for diagnosis. I will post up what they tell me when they get to it.