2007 df90 fuel issue

[wblack]

Hello All,

Brand new here, first post. Lucky for me I suppose! Any rate, I bought the subject motor new and haven’t had any issues to speak of other than common ethanol issues ruining fuel lines, etc which leads to my current problem I think.

Recently I took the 27 gal. gas tank out of my skiff to thoroughly clean it. Afterwards, the motor wouldn’t start. Turns out the primer bulb and fuel line to the motor was completely stopped up with what looks like black bubble gum or crude oil. So replaced the hose, primer bulb and Racor water filter including the pick-up inside the tank, all is good from the tank to the motor. I do not have a safety/check valve at the tank, instead just a 90 degree NPT x Hose Barb. I also performed maintenance including new plugs.
Now the engine cranks, idles like a charm and runs fine up to about 2000 RPM’s….. beyond that it simply is not getting the gas it needs. The primer bulb will pump hard but will not stay hard. I can pump it while at 2000 RPMs and the engine will catch up. Is this a tale-tale the Low Pressure Fuel pump is bad?

I do not know where to go from here. I don’t mind replacing anything but I would like to have a good idea that it’s a problem or potential anyway. Can you guys please help!!!???

Thanks, Wes

[Seaduck]

I went through this with my 07 115. I ended up changing all fuel lines including those under cowling. Then I replaced low pressure fuel filter and then the fun part. Removed vst tank and high pressure filter. High pressure filter had goop and fuel hose particles inside. The small filter inside the vst was clogged. Once I cleaned everything and put it back together she has run like a scalded dog. If you already found trash in fuel line in sure its in vst tank and high pressure filter. Taking manifold off is a job but doable with the service manual. Good luck bud.

[wblack]

I ended up changing all fuel lines including those under cowling. Then I replaced low pressure fuel filter and then the fun part. Removed vst tank and high pressure filter. High pressure filter had goop and fuel hose particles inside. The small filter inside the vst was clogged...........found trash in fuel line in sure its in vst tank and high pressure filter.

Thanks Seaduck! You are describing what a local certified service manager told me today. He basically said, "most likely it is a stopped up injector or the pickup filter inside the vst tank". I did replace all the hoses under the cowl a couple years ago with Teflon lined hose. I should have used it on the outside but didn’t have the extra doe.

I do have a question for you though. What I see as the low pressure filter isn't actually a filter at all is it? Just a small reservoir to catch "heavy" trash? I mean its doesn't have filter media inside of it? However, I did drain it out when I went through every thing else and looked in it closely, it was clean as it could be. That's what led me to believe it couldn't be inside. Oh well...... I'll get to tear it down this weekend and let you know what happens. Thanks again!

[Seaduck]

Yeah bud its not a great filter but I changed it since it was 12 bucks or so. I would bet vst or debri in high pressure filter. Good luck on tear down. I will be getting ready for hurricane if it does come in through va.

[wblack]

I will be getting ready for hurricane if it does come in through va.

Lets hope not!!! Button down the hatches anyway!

[wblack]

OK, I got the manifold off tonite and will disassemble everything else tomorrow. I'm thinking about leaving that dumb thing Suzuki calls a fuel filter completely out or replacing it with a real in-line filter. Don't mean to sound condescending about the filter...... but son-of-a-gun: can somebody explain the theory behind the design? My guess would be it just allows heavy solids to settle in the bottom?

Any rate, I have a Racor filter/water separator with 10 micron filter: RACOR 10 Micron Spin-On Series Fuel Filter/Water Separator - I/O 320R | West Marine

I am trying to convince myself I need to keep that Suzuki one. I sure would appreciate you guys opinions or experiences. Thanks in advance for your help.

[Moonlighter]

You really need both filters. The Racor style filter should be considered compulsory for all EFI engines. It will keep the majority of dirt etc out of the other one.

Change Racor element every year or 100hrs, whichever comes first.

[Seaduck]

I cant give you a good reason bud but I would keep it. Good job on the manifold. Its not that hard just time consuming. I will be interested to see what you find out inside that vst tank and the screen inside there as well. Good luck.

[wblack]

...........I will be interested to see what you find out inside that vst tank and the screen inside there as well. Good luck.

Hey Seaduck! Glad to hear from you. Hope you guys fared well this weekend?

OK, here's the report: it was worse than I expected although didn't seem really bad but it did look like the culprit. The high pressure pump filter was covered with small particles, nothing gooey. The inside of the tank had some small sediment but nothing major in my view; put some purple stuff in there and brushed it out with a tooth brush. Someone who sees them all the time may say different and that wouldn't surprise me. The regulator was terrible, really scrubbed it to get it clean and sprayed it out with WD-40. So we have the tank put back together and bolted on the manifold. We hope to put everything back together tomorrow and crank it (fingers crossed)

Oh, I bought a Wix fuel filter I will replace the Suzuki one with. It's clear to me now that I did need to keep the old one in place at the very least but feel very good about a quality "in-line" being there. Thanks to you guys who reinforced that.

Just realized I need to check the float, test the regulator and seal the tank joint.... what a goofball! Oh well.. wanna get it done right. So we'll take the tank back apart tomorrow and I'll report back. Thanks again guys!

[Seaduck]

Sounds good bud. we just had some heavy rain but really got lucky. How was the little white screen/filter in the vst tank. Sounds to me you might be on the right track. Hope see purrs like a kitten when your done.

[wblack]

Update:

I took the vst tank back off today and checked the regulator which blew at 38 psi.

Set the float to 43mm. Maaan was it way out. It was like 6mm too low. Not sure if I bent it when I was taking it out or not, don't think I did but could have I guess. Anyway, now it's right.

Put the two tank pieces back together with sealant, which I missed in the manual before.

Bolted the tank back to the manifold.

Checked the injectors for the correct resistance: 16 Ohms on each one. Cleaned them with some mineral spirits and blew them out. They didn't look bad but did have some dirt of the outlet side, all clean now.

Hope to get everything put back on the motor tomorrow including the inline low pressure filter and a new high pressure that should be delivered tomorrow.

[wblack]

Got everything put back together tonite without issue..... thank goodness. Crunk it a couple times and everything seems fine. It was too late to hook water to it, so we'll put it in the water tomorrow for the real test.

Fingers crossed!!!

Thanks for your input Seaduck and Moonlighter! Maybe we'll get lucky and hook a catfish or two...... maybe even a few stripers!

[Seaduck]

good stuff. hope it works out for sure. we are looking for some stripers as well. just another shot of rain saturday. sunny all work week and of course rain on the weekend. Good luck.

[wblack]

Got the boat in the water yesterday morning and to use the words of Seaduck; "she ran like a scalded dog!".... I was so relieved, it ran like it was brand new.

There is just one thing that wasn't right; it seemed to take gradually a little longer to start each time. Last time after all day it turned over maybe five or six times. I am used to it cranking the first time over. Any ideas?

Finally, we (me and my 70 yr old Dad) did have a very welcome surprise during the last 100 yards of our final drift for catfish, 42lbs-8ozs!

[Seaduck]

Man that is great news!! I always squeeze my primer bulb before each start. I know they say you shouldn't need to but the fuel traveling from my tank all the way back to the filter then into the motor I just give it a couple squeezes. I noticed my motor would turn over a little longer until I did this. Anyways glad to hear yours is working.