suzuki DT65 1990 Rev problems

[upm]

Hi there guys.. i am hoping someone can throw some light on my problem.. when i turn on my ignition i have a green led illuminating by the Rev, thus rendering the engine in limp mode, will not go above 2500rpm.Tsconnected and checked the oil flowhere is no beeping..
I have disconnected the oil flow,oil level and water flow sensors but it didnt make any difference.
I ve checked the ohms on the sensor by the flywheel. and that all seems ok.
The engine runs fine otherwise, could there be a problem with the control unit ?
Appreciate anyones thoughts thanks Ted

[David G]

After disconnecting the sensors have you tried resetting the system using the red button on the side of the outboard near the PTT button?
This needs to be pressed whilst the engine is running.
(Assuming your DT65 is similar to my DT85!)

[upm]

hI THERE.THANKS FOR THAT SUGGESTION BUT I HAVE TRIED THAT AND NO JOY IAM AFRAID... I HAVE CHECKED THAT THE SWITCH IS WORKING OK AND IT IS,,, SO IAM STILL LIMITED TO 2500RPM.. I SPOKE TO BROWNSPOINT MARINE IN USA AND THEY RECKONED IT COULD BE THE CDI, WHICH WOULD MEAN A RIGHTOFF, DUE TO COST......

[DM]

Originally Posted by upm

I have disconnected the oil flow,oil level and water flow sensors but it didnt make any difference.

It's no use just disconnecting the sensors.

The oil level sensor wires need bridging. Red and green to the black. Leave the orange floating.

Remove the oil flow sensor. Dismantle by undoing the four screws/bolts and clean the gauze filter. Ensure the micro switch is open. It should close when the sensor is full of oil. Refit and bleed the oil system by using the bleed screw on the oil pump. Use a fuel/oil mix when doing this as you might be running on neat petrol til you get the air out of the system.

Start engine and press reset button.

If this fails, bridge the water flow sensor wires.

[upm]

i am sure i have tried this but i will give it another go. Have already cleaned out oil flow filter tho....

[upm]

after checking the wiring coming from oil level sensor there are red green orange and black. these go to a multiplug except black which joins a bullet connector.the orange becomes a blue wire thereafter, red and green remain the same colour.... So which wires need bridging ??

[David G]

Can't help with the wire colours etc but one other thing that may be worth looking at, there is a throttle position sensor that advances/retards the timing against mechanical throttle position.
On the DT85 it is on the side of the middle carb; looks like a small 1" square metal plate. There is a silly plastic rotating element inside and when this stuck on mine (or didn't move round and back smoothly) the ignition changed incorrectly and gave me symptoms similar to being on rev-limit-limp-home........
Might be worth taking the screws carefully off the corners of it and cleaning it up a bit.
After two or three 'renovations' it had to be replaced :-(
Might help.
Orve

[upm]

ok thanks orve, i will give the throttle sensor an overhaul, is on the middle carb on the dt 65 too.. i will let you know tomorrow how i got on.......

[upm]

the other reason i feel that this is not one of the normal warning modes( oil flow, oil level, water flow) is iam sure they all have beeping sounds, when this problem doesnt, just a warning light next to REV.
And i have only just cleaned out the oil filter & fitted a new water flow sensor !!

Anyway fingers crossed with this throttle suggestion as iam getting to the end of my tether, and locating a suzuki engineer who would entertain this problem down here in Kent is virtually impossible...

[upm]

I took the throttle sensor apart, and couldnt really see anything wrong with it,there is a little microswitch within that is depressed via a spindle through carb which is operated when the throttle lever has passed halfway position, is there any way of checking the wiring, can i test the cdi unit ???

[David G]

You might gert some advice from here:
The Marine Doctor - Yamaha/Honda/Suzuki