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Old 21 December 2018, 11:06   #21
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Got the engine back the mechanic had it 3 weeks, it appears that the fuel pump can be inspected but you need screwdriver bits hex with a hole in the middle all was good and pumped ok. Rocker box off checked the cam all ok,all hoses checked all ok, now this is where the problem lies I had some sort of residue in the tank and filters when serviced so I cleaned everything out but what wasn't looked at because it's a thousand hour replacement is a small metal filter below the side pannel pre the plastic filter just before the pump, that was blown out to clean a new bulb fitted she fires up now first pull and runs right through the full Rev range. Result. Now the original bulb which was a quicksilver one brand new fitted when all the trouble started I decided to strip down what I found is on the outlet side to the engine was the end cap which holds non return ball in was only pushed part way in on the pi$$ and the spring not being able to keep the ball on its seat to prevent fuel draining back.so with the steel filter partially blocked the fuel bulb allowing the fuel to drain back we think at low revs we got fuel starvation.

Just to add I am mertickulas with keeping fuel clean I guess I have had some contamination from the fuel station I also think if I had only one of the problems I might have got away with it. Hope this helps for others
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Old 21 December 2018, 11:32   #22
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Glad it's sorted, does sound like a very well buried problem on top of another problem. These things are sent to test us, not sure what for but they do test lol
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Old 21 December 2018, 11:52   #23
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Good to hear it looks like you have a result Jeff. When I had the fuel contamination issue on this year's holiday with the 20hp the dealer said the main Suzuki filter doesn't take all the minute particles out and there are some super fine filters just before the injectors on the 20 and it was those they flushed out.
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Old 21 December 2018, 13:19   #24
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Glad it's sorted, does sound like a very well buried problem on top of another problem. These things are sent to test us, not sure what for but they do test lol
You're right Neil it does show contamination can ruin the day we.ve had three garage upgrades in our town was it from them who knows
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Old 21 December 2018, 13:30   #25
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Good to hear it looks like you have a result Jeff. When I had the fuel contamination issue on this year's holiday with the 20hp the dealer said the main Suzuki filter doesn't take all the minute particles out and there are some super fine filters just before the injectors on the 20 and it was those they flushed out.
That's good to know David.
I have a fuel separator in circuit plus the engine filters but the residue got as far as the plastic engine filter, in there it was like a very fine chalk film.
The thing that bothers me is no proof of what was in the steel filter time is money to a mechanic as you know and probably didn't think to blow onto paper to try and capture. Anyway not bothered if it's sorted I've got some other work to do for next season so I'll leave it a few days and run it again to prove it, it was failing every few minutes before time will tell
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Old 24 December 2018, 12:31   #26
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Suzuki diagnostics don't give you a fuel pressure reading but gives you fuel pump duty cycle.

Should normally run around 60% duty when warm and off choke.
If its up towards the 100% mark then the high pressure pump is not being supplied enough by the low pressure pump
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Old 21 January 2019, 07:51   #27
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finished job

just to finish this off ive left the engine until today since i got it back she fired up first pull and ran on tick over as sweet as a nut
pic below shows the outlet non return valve as it came out of the bulb the spring wasn't able to keep the ball on its seat so allowing fuel to siphon back, just shows brand new can give problems.
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