I’m still trying to sort out my 200EFI Suzi intermittent starting problem.
I’m worried about reminding everyone, in case there is a ‘most public breakdown award’ at the Solent xmas dinner.
To recap – its starts and runs fine from cold but very occasionally won’t start from hot, I can’t get a spark at the plugs, but then suddenly all is well.
I’ve now identified the neutral switch as the most likely culprit.
It’s a micro switch that works off a cam on the gear selector arm mechanism under the hood, and unlike any other outboard I’ve owned its just cuts the ignition rather than disabling the starter motor. So the engine turns over as usual on the starter, but won’t fire.
First thoughts were obviously to junk it, and remember to put it in neutral. But now I’ve realised I can’t do that.
With engine in neutral and not running, the switch is ‘Off’ (presume ignition is not grounded). The engine can be started.
With engine in gear and not running, the switch is ‘On’ (presume ignition is grounded). The engine can’t be started.
Once the engine is running the state of the switch has a different function.
With engine in neutral and running, the switch is ‘Off’ however the engine appears to be limited to @2000RPM. This is what happened when I ran without the switch. Should have thought about it really. – Doh! Obviously stops you revving the nuts off it in neutral.
With the engine in gear and running, the switch is ‘on’ and has allows engine to rev out.
So if I junk it and hard wire it ‘on’ the engine won’t start.
And if I hard wire it ‘off’ the engine will start but only rev to 2000RPM
So looks like I need to pay Suzuki a load of cash for a new switch.
Just like my wife, now it’s a bit old and ‘tired’ I can’t live with it, and can’t live without it!
Anyway, off to Dublin for the weekend, so will sort it out when I get back.
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