Suzuki 115 Possible Oil Injection Problem

[Knightgang]

Okay, I have read alot of information on this site, and I think I have my problem and trouble shooting figured out. But a little more experience never hurts if you do not mind taking the time. I have a '85 or '87 (not sure) Suzuki DT115 2 Stroke with Oil Injection. Was out running one after noon, and the engine died. No warning or anything. Fired right back up. Plained out and ran about 300 yards same thing, died again. Fired back up, 300 yards died again. This time I checked the oil reservor, even though it did not buzz at me. It was down about 1/2 way, maybe a little more. Anyway I filled it up, no more problem that day, or other two times out. I made sure the reservoir was full on each subsequent outing.<br /><br />This past Sunday, we went to the lake. After running about 1 hour, the engine hickuped. It acted as though it was going to shut off, but before it died completely, it picked back up like it never missed a beat. While it was trying to die, an alarm buzzer went off for about a second. Finished the ride with no problem, reservoir still 7/8 full. A couple of hours later, about 20 minutes into the ride, same thing, but no buzzer and the hickup was only a fraction of a second. <br /><br />Brought it home. Checked the low oil indicator and it works well. Cannot find an oil filter or oil flow sensor even though the gage has a light for it. Could this probably be gummed (jellied)up oil in the bottom of the tank. If so, I imagine that a good cleaning of the lines and the tank will take care of it. But I am not sure the problem is the oil. What else should I check? Water seperator, fuel flow, electrical??? I have only had the boat about a month, and this is the only intermiten problem I have had. Previous owner said that every thing had been rebuilt and he never had a problem. Should I disconnect the oil injection and premix?<br /><br />He moved up to a 22' Angler with Evinrude 275, nice!!<br /><br />By the way, looking for a manual for this motor now.<br /><br />Thanks for any advice.<br />Eric

 

[jim dozier]

Re: Suzuki 115 Possible Oil Injection Problem

You should have a oil filter and/or a oil sensor in the oil line underneath the oil tank. You may need to loosen or remove the tank to see it. The oil screen if there is no sensor is a puck like round thing in the oil line. The oil flow sensor would be similar and a little bigger with a wire coming out of it and also in the oil line. The oil screen can get clogged with jellied oil and should be replaced. When you get your manual you can check the output of the oil pump for the spec rate with a large syringe (temp replacement for oil tank to measure oil use over specified time at different throttle settings). Thats a good idea with a used engine of uncertain history, I would probably replace the oil hoses too. Suzuki invented oil injection. I would keep it if its operating properly, thats just my opinion, I'm sure there are others with more experience than me. Besides the convenience, using less oil and fouling plugs less, if your carb jet gets clogged (do a search and see how often that happens ) the oil keeps flowing. If you're on premix and the carb jet cloggs so does your oil and you are up a stinky creek with no paddle. If the Suzuki oil injection system is properly maintained they work well.

 

[Knightgang]

Re: Suzuki 115 Possible Oil Injection Problem

I will take a look (after I get the manual) for the oil screen. Is it in the bottom of the tank? The oil gage has an oil flow light. I have never seen it come on. I can trace the line form the oil tank to the pump, and I see the five lines that lead out to each carb and the crankcase. I do not see any wires on any of them to indicate an oil flow sensor. I would like to keep the oil injection going for all of the reasons that you mentioned. I will keep you updated.

 

[jim dozier]

Re: Suzuki 115 Possible Oil Injection Problem

I checked the exploded parts diagrams at www.brownspoint.com and it looks like the oil screen and/or sensor started in 1986. If yours is pre-1986 it may not have one.<br /><br />You should probably start investigating fuel flow and connections in your ignition as the possible causes for your intermittent cutouts. Try pumping the fuel bulb next time it cuts out. It could be either something simple like a closed or clogged gas tank vent or something more complex like a fuel pump diaphragm leaking. If pumping the fuel bulb has no effect try squirting some premix in the carb throats when it cuts out. If that has no effect start checking all the connections in your ignition system, you may have a loose connection or a frayed insulation on a wire that is occaisionally grounding itself momentarily. Good luck.

 

[Knightgang]

Re: Suzuki 115 Possible Oil Injection Problem

THe serial number starts with a 7, indicating by what I have read here that it is an '87 model. Back in the Drive Way, I did notice a short in the wires under the console. It was only by looking around that I found it because I want to put in a new ignition switch. When they were giggled, the dash lights went out for a moment, and so did the oil gage. I am going to trace this short and repair it before the next outing. Don't want to have to di it in the river with electrical tape.<br /><br />By the way, I picked up a Clymer Manual yesterday, and it says to use TC-W2 2 cycle oil. What is the difference in that and TC-W3??<br /><br />Thanks again for the advice.

 

[jim dozier]

Re: Suzuki 115 Possible Oil Injection Problem

That's an old recommendation probably from an old edition of the manual. TCW3 came out after your motor (and your edition of the manual). Use the TCW3 which supercedes TCW2. I believe TCW3 has additives to prevent jelling which is important for the oil injection. I don't think you can find TCW2 anyway.<br /><br />Your engine is a 1987 DT115 and should therefore have an oil filter screen and/or a oil flow sensor.

 

[DjPro]

Re: Suzuki 115 Possible Oil Injection Problem

JIMD<br /><br />Are you a Suzuki mech.?

 

[jim dozier]

Re: Suzuki 115 Possible Oil Injection Problem

Negative. I don't present myself as one either. All my comments are my opinions and should be taken as such. Anybody who finds a factual error in my comments should alert me and the rest of the forums to it.

 

[Knightgang]

Re: Suzuki 115 Possible Oil Injection Problem

Jim,<br /><br />Thanks for the advice. I will be going through the oil system and the under dash electrical next week before we go back to the water. I will let everyone know what I find and how the problem was resolved.<br /><br />Until next time.

 

[Knightgang]

Re: Suzuki 115 Possible Oil Injection Problem

Pretty sure that I have found the problem. Pulled out the oil tank and drained it so that it could be cleaned out. I found a previous Oil Cap Keeper spring and the small pivoting ball chain in the bottom of the tank. Went ahead and washed it out with gasoline to get that out of the tank, and noticed that there seemed to be a blockage in the oil pickup tube in the bottom of the tank. about 1 & 1/2 of those little balls from the keeper chain had come apart and gotten lodged in the tube restricting the oil flow. Used compressed air to clear the tube, and I have replaced the oil line from the tank to the pump. It seems to make sense now. The few times that the engine hickuped, it was after extended smooth running. Quite possibly there was enough sucktion at the end of the pickup tube to pull the remining chain to the end of the tube, and further restrict the oil flow beyond what is acceptable for high RPM running. It explains the alarm that I got the one time as well. When the engine either hichuped or shut down, it produced enough slosh in the tank to move the chain from the end of the tube. I am planning to go out in a few days, I will keep you posted.

 

[rodbolt]

Re: Suzuki 115 Possible Oil Injection Problem

hello<br /> this is out of the suzuki electrical trouble shooting manual 1986-1992page 8-5 oil flow warning system. 87 and up dt115/140 model years had an oil flow sensor. in 86 just a level sensor in the tank.if the level sesor was at fault it will trigger the rev limiter if rpm is above 3000 and set the red light on the monitor.<br />if you are above 3000 rpm and the low oil swicth is on you will get a buzzer,a red oil lamp and a red rev-limit light. you should have a cooling water indicator at start up then when the head is filled is should go out. if not test the wiring.if the water level drops then you will get a rev red lightif above 3000 and a red water indicator and the rev limiter will turn on. if your motor is an 87 then it should have a oil flow switch between the tank and the pump.I know it gets confusing but its a lot of what was then high tech stuff<br /> good luck and keep posting

 

[Knightgang]

Re: Suzuki 115 Possible Oil Injection Problem

Well, after doing some research in the manual, and the Browns Point Marina parts listing, I have discovered that I have an '87 bracket and foot, with an '85 powerhead. No problem though, everything runs fine. <br /><br />The tank and line cleanout seemed to work fine, however, I saw one of the oil fittings on the oil pump looked like the nipple was crimped and bent over. I got concerened about oil flow throught that nipple, si I tried to straighten it,.... oops, broke it off. I will be checking every Suzuki anything and other outboard repair shops tomorrow to see if I can find one. Once that is replaced, I should be good to go. Should have left it alone, oil flow was fine before I messed around. Hind sight, sometimes better than 20/20, just to late.<br /><br />Thanks everyone.