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Ok guys and gals...first time posting so please bear with me. I have a 2006 DF175 outboard on a 21 foot robalo bay boat. I started seeing issues with my outboard about 2 months ago. The motor would die suddenly while underway... immediately after shutting off, the motor would crank and but not start the first 3-4 times i would turn the key and then would crank and start. I started troubleshooting with the "white wire", battery terminal connections and loose wires with no luck until i checked the fuse panel under the cowling. NO fuses were blown however when i removed and re-inserted the main relay and the starter relay the motor cranked and started fine. I tested the boat the next day and it ran fine for about 10 minutes before it died suddenly. While in the water i again removed and reinserted the main relay and starter relay and the motor cranked and started immediately. On my way back to the dock this happened 3-4 times and eventually removing and re-inserting the relays did not fix the problem. The short term fix was cutting up a foam coozie and inserting the coozie into the fuze panel cover to apply downward pressure on the relays which i assume provided a better connection. Made it back to safe harbor and replaced the relays with Suzuki replacement parts and tested again....same problem...the engine would run for a short period of time and then i would have to insert coozie pieces under the fuze cover to apply downward pressure which i can only assume provided a better connection. Now with the background provided here are my issues and potential solutions:
Issues: Engine will not run reliably...will shut off randomly at all speeds.
Source of Issue: I believe the source of the issue is the Main Relay and not the starter relay. The motor will turn over but not start unless downward pressure is applied to the relay(s). One way i can tell i have an issue before starting the engine is whether or not the fuel pump primer kicks on when i turn the key one click. If the fuel pump primer does not engage then the engine will crank but not start. if i apply pressure on the relays then the fuel pump will prime and the engine will start.
Potential Fixes (this is where i need your help): my options are...purchase a new fuse box and associated wiring for $600 + labor or implement a solution suggested by someone on this site!!!
All comments and suggestions are appreciated. Thank you for your help.
Issues: Engine will not run reliably...will shut off randomly at all speeds.
Source of Issue: I believe the source of the issue is the Main Relay and not the starter relay. The motor will turn over but not start unless downward pressure is applied to the relay(s). One way i can tell i have an issue before starting the engine is whether or not the fuel pump primer kicks on when i turn the key one click. If the fuel pump primer does not engage then the engine will crank but not start. if i apply pressure on the relays then the fuel pump will prime and the engine will start.
Potential Fixes (this is where i need your help): my options are...purchase a new fuse box and associated wiring for $600 + labor or implement a solution suggested by someone on this site!!!
All comments and suggestions are appreciated. Thank you for your help.
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