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Old 15 April 2014, 06:43   #1
Country: Other
Town: Matosinhos - Portugal
Boat name: Game Club
Make: Valiant PT-520
Length: 5m +
Engine: Suzuki DF90
Join Date: Nov 2013
Posts: 23
Suzuki DF 90 electrical problem

Last weekend, I had some unexpected electrical problems with my DF 90 Suzuki (2006).
The engine ran smoothly for a few hours but, when I stopped it and a few minutes later tried to restart it, nothing happened. The battery was ok since the tilt could move the engine up and down, but, there was no reaction when I turned the key: no lights in the rpm meter, no buzzer sound, nothing at all.
After a few movements of the control lever (forward, backward, clutch), removal and insertion of the kill switch and a few retries on turning the key, the lights in the rpm meter finally lit and the usual buzzer sounded. The engine started normally and ran smoothly. The next time I stopped the engine, it restarted normally.
A similar situation happened 4 or 5 times during that day and the following 2 days and there was even one situation where the engine stopped suddenly while cruising at 4000 rpm.
Any hints about what may be causing this?


Antonio Carrapatoso

Valiant Knight is offline   Reply With Quote
Old 15 April 2014, 10:55   #2
Country: USA
Town: Seattle
Boat name: Water Dog
Make: Polaris
Length: 4m +
Engine: Yamaha 60hp
Join Date: Apr 2007
Posts: 1,152
1) The in-gear start protection is staying on even though its in neutral. (mostly likely)
2) Bad ignition switch.

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Old 26 April 2014, 14:15   #3
freespirit3's Avatar
Country: UK - England
Town: West Midlands
Boat name: Freespirit
Make: Redbay
Length: 6m +
Engine: Suzuki DF 140
Join Date: Apr 2013
Posts: 359
I agree

Had a similar problem myself with another boat.

The gear selector may think the engine is in gear and hence cuts the electrics, mine was a tired switch that kept sticking, shouldn't be too bad to replace.

Changed my switch and never did it again


Check all the connections to the ignition switch, look for the green colouring on the wiring,
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Old 26 April 2014, 16:30   #4
dnkarran's Avatar
Join Date: Jun 2013
Posts: 2
Had a similar experience myself last weekend, try the battery contacts, strop , clean & refit with Vaseline on to prevent further problems.
Worked a treat, just a bad contact. Hope yours is as simple
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