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1991 Suziki DT 85

nos3665

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"Hi, This is a 1991 DT 85 Suzi

"Hi, This is a 1991 DT 85 Suziki Problem is as Follows: Suziki DT85-8501-Ser.-131061
Neighbors Boat, He had to be towed in, quit running. I checked his Fuel and Fuel System and found the Fuel pump had quit. Installed new Fuel Pump, Engine runs again.

But at IDLE or at any speed above it has a Mis-Fire at times on Test Tank. I have checked at the Carbs intakes it does not spit back thru the Carbs when it misfires theres a "Churp" with it and engine dies. but will start right back up. This problem seems worse on a cold start and gets a little better in run time as the engine warms up, 2-3 mins of run.

In talking with my Neighbor He has had the carbs gone thru 2 times in 14 months from his Local Repair Center for the tune of 1200 bucks for both times. The Misfire/Churp was there after this Shop Built the carbs both times and when he asked about it they said it was the lower carb causing the Churp. I find that the dead miss on exhaust side /churp stops Engine. I did pull the upper drain and lower drain on the bowls, looking for water in carbs the middle bowl drain was broken off from earlier service. Any Ideas? I will list the things I have checked below. I have no problem going thru the Carbs for my neighbor, but before I go thru the effort of the Carbs I would like some feed back as to the misfire/churp. I am NOT a boat mechanic or a outboard expert by any means and not putting down the shops work. I have built and tuned many 2 strokes, mainly Rotax and Hirth engines and a Rebuilder of Automatic Transmissions for 30 Years Retired.

I did not get to see and read the old Plugs. All Plug Wires look good and read good on Meter. Spark on all plugs strong and no visibe problems on Wiring and all connectors opened and cleaned treated and checked. No "green connectors found" Compression Test -Good I was suspect of Fuel, so I used a Fresh 2 gallon Tank of good Fuel to run this Engine. I did find water in Fuel in the Boats Tank and sumped the Tank and treated the fuel But all Tests so far done on New Fresh Temp-Fuel Tank. I know I have to find the source of the Misfire It may be Fuel Related But looking for Advice Before I start. thanks in advance, Steve Email is [email protected]"
 
Maybe the lower crankshaft oil

Maybe the lower crankshaft oil seal is shot.....my DT115 did the same thing.
 
Can I vac-test for that failur

Can I vac-test for that failure? on crankcase
it should show up if seal has failed correct?
 
yes u can pressure test the cr

yes u can pressure test the crankcase
you will need to plug the exhaust and intake
 
"Ok I started Pulling the Carb

"Ok I started Pulling the Carbs and found the Lowest #3 Carb Gasket installed backwards, That Leaves A bare spot on ons side of the Throat and covers Quite a Bit of the other side of the Throat Body Its also the Suspect cylinder I thought was Misfiring at times due to the Carbs.
These Guys did a Very poor Job, Missing Bolts, Cut wires ob the Choke sol, etc. All Hardware Looks Like it was removed with a hammer and a chisel.
The Carbs need to be Cleaned, so I will do that next.
I think his guy got a real BUM job on the Carbs Overhauls Or whatever they did.
Remember this (Churp spit) Came in only after the Carbs where done and They had told Him ONE main jet would not come out Etc and that was causing his problem. I had NO issues removing all the Jets, Needles Etc. I will let you know what I find."
 
"Ok, Just to let you Folks Kno

"Ok, Just to let you Folks Know, I went thru the Carbs,Fresh Gaskets. Installed new Plugs so I could get a good read on this Motor. It Cranks and Runs Perfect in the 30 Gal. Test Bucket for 20 mins, with a fresh water hose also running in Bucket.
Motor cold cranked and fast Idle kicked off, and Idled just fine will take Throtte Just after( normal I did not want to cold shock ) Once warmed it's Throtte Response seems to be Very Good. I will get a (ICW) Waterway Run on the Boat Monday, But it seems to be ok, I could not find anyone to be a Chase Boat because the wind was Kicking up today.
JUST-IN-TIME I Pulled the Plugs and its Burning a GOOD read on the plugs now and theres NO Churp Misfire anymore, As for Listing that Shops Name since I did not have Direct Contact with them and Not 100% sure of what or when they did the work, (I did not the the bills) I am gonna elect not to say there Name. But I will say IF You need
Repairs in the 28462 area code Be carful and ask around First. There's Only 3 Shops In this Small Town under This Zip Code.
A Big Thanks for the Input in helping me find the problem,---- Nos3665
Service I performed:
New fuel Pump, and Decarb with Seafoam, Pulled Lower Unit New w-Impeller Pulled T-Stat and Flow tested, Replaced with new, Drained Gearlube and Fresh Back in, Greased all Fittings, Cleaned Engine.I found JUST-IN-TIMES drawing of his DVA and made one up and Tested,Purged all Fuel Lines and Fiters, Before Carbs Gone Thru."
 
"I did in test tank,But it blo

"I did in test tank,But it blows alot of water out so will fine tune in the water, Thanks agains"
 
"Finally got to run this Motor

"Finally got to run this Motor in Open water today
did the Idle adj-in gear and AShe Runs Sweet Thanks for the Help, BuT the chase boat broke down and I had to tow it back, , Guess it will be next."
 
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