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Suzuki DF 140 2005 Surging Sputtering at 2500 rpm

C

Chip17

New member
I bought a used pioneer 197 sportfish with a 2005 Suzuki DF 140. The motor ran really well from May to September of 2023. I had the marina put gas in and then took the boat out later that day. I had issues with the motor surging and sputtering around 2500 rpms. It would then stall. I've had 2 different mechanics look at it, they've gone through the VST, checked fuel pressure, voltage, etc. The issue went away for 3 trips out and came back again on my last outing. I did notice that I was able to throttle through the sputtering and get to WOT where the motor ran fine.

I've been chasing this problem since Oct of 2023 and no one can seem to find a glaring issue.

Any help would be appreciated.
 
Did they look at the NEUTRAL switch on the motor shift linkages ?----This switch ( if stuck / defective ) tells ECU that motor is in NEUTRAL and RPM is then limited.----Easy to check out.---Costs no beer tokens to check that out.
 
I will look that up and give it a go. The issue has been intermittent, so it has been tough to chase. Sometimes the engine pushes through the 2500 rpm sputter and other times it doesn't. Once it does stall it is tougher to start. The engine sounds like it is not getting gas when it happens since it makes a revving sound as the tach jumps up and down. The gas in the tank looked a little off-color to me as well, but I couldn't see separation and i know they dumped a bunch of stabilizer in it before the season. I will see if I can add the video of the gas and the motor sputtering when I'm home.
 
racerone said:
Cleaning the vapor separator tank may help as well.
Click to expand...
Thanks! They actually did that and showed me the VST while I was there and the filter screen. I also did the water separator and low pressure fuel filter.

The previous owner had taken care of the exhaust issue that is common with these motors where they were going to put an O2 sensor but ended up using a metal plug which was a dissimilar metal. He had that corrected years ago and there was no corrosion there.

Feels like I’ve been chasing a ghost.
 
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