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DF20A cuts out above 3K RPM

S

stickerbush

Member
I was returning to the dock yesterday evening and motor began cutting out above 3K RPM. Warning light would come on and motor would start cutting out. Backing off the throttle completely would turn off the light and the motor could again be brought up to 3K RPM. It felt like the computer was going into a limp home mode. I was able to get back to dock by keeping RPM at 3K or less.

When I removed the engine cover I could smell fuel and there was a fine mist of what appeared to be fuel sprayed on some of the engine components. I didn't see any obvious fuel leaks.

Engine was serviced at the end of last season, new plugs, fuel filter, impeller. Gas is fresh, ethanol free. I have two tank and two fuel hoses, tried both. I've been out two other times in the past week with no issues.

I have Suzuki SDS so will take laptop to the boat today and see if there are any stored codes.
 
I thought you would get a code thrown from the red light. Either on the Suzuki tach or end of the tiller handle. The SDS software will also give you codes plus a history of the engine.
 
There was no code shown on the warning light, it only came on when the condition was detected to cut out the motor. The SDS system showed a low oil pressure warning was causing the problem. Indeed, oil level was at the bottom of the dipstick, took about 600ml to bring it back to full level. There is a significant oil leak somewhere, I was unable to pinpoint the source with the boat in the water so I've pulled the boat out and will be investigating later today. I have about 4 hours on the motor since the last oil change, and yes I did run it then to check for leaks at the oil filter housing and valve cover, there were none.
 
Wonder if it wasn’t filled to the proper level last oil change? One would think if you lost 600ml of oil it would be obvious. Either oil in the engine compartment or a big sheen on the water.
 
The oil leak was due to the low pressure fuel pump coming loose. It bolts to the valve cover so made for a fairly big oil leak when it became loose.

This one's all on me as I did the service last fall and had to remove the oil pump and valve cover to check and set the valve clearance. I didn't have torque specs for the pump so just tightened it to what I felt was enough without risking stripping something. Cleaned everything up and reassembled using blue thread locker.

Yes I should have paid attention to the oil sheen--thought it was from the tiny amount of fuel that was released when I disconnected the fuel line.
 
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