engine stalling

[jeffstevens763@g]

Up date
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

[neil.mccrirrick]

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

[Fenlander]

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.

[jeffstevens763@g]

Originally Posted by neil.mccrirrick

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

[jeffstevens763@g]

Originally Posted by Fenlander

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

[DeltaTango]

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

[jeffstevens763@g]

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.

[jeffstevens763@g]

so after a successful trip in loch feochan i thought i had the engine sorted [wrong]
had a trip with gurnard out of resipole all ok engine ticked over for 10-15 we set off on the plane no probs until we stopped for coffee then the problem returned.
i booked the engine in and wrang suzuki technical up lucky to get hold of them spoke to gary porter told him the symptoms straight away he said it's the high pressure filter it gets overlooked because its a 1000 hour replacement & a problem on the 25 & 30's. well i can tell you if you open one up you will change it every service the mesh is minute [ see pics] there was more crap than you can see in the pics and the mesh was black when wet.
my guess is that when stood all the crap settled which allowed fuel flow until you slow from high revs it then sticks to the mesh blocking flow at low revs.
no i have a fuel separator a course inline filter and the low pressure filter before this so where its come from i have no idea
high pressure filter £15.45
low pressure filter £9.48 not big money but its ruined two seasons got to trial it yet but ive had it tested/ explored right through pumps, IAC valve, SDS no faults, fuel rail cleaned, compression test. ran up for a week with no issues.

[jeffstevens763@g]

a few pics

[jeffstevens763@g]

last one tried a macro shot of the mesh but it wont download but if you zoom in its clear how much shite is in there ive no idea where it all came from my tanks have been clean and cleaned which i am going to do again to make sure.

lastly if dealing with suzuki dont bother contacting them by email they dont respond i was given garry porters number years ago and told to use it only if desperate to be fair he was great knows his stuff and i hope its sorted now.

cheers