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DF200 max rpm limited to 4000

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  • DF200 max rpm limited to 4000

    Motor is a 2005 DF200Z. 320 hours. On a 20 foot catamaran.
    Normal max rpm is about 6000 for me.
    My last 2 trips I have had a hard time getting up to 4000 rpm.
    Boat starts fine. Does not sputter or spit. Just maxes out at 4000.

    What I have done so far: Changed low pressure fuel filter, changed water separator filter, and changed external fuel lines and primer squeeze bulb. Internal lines look and feel fine, no flaking or collapsing.

    I pumped fuel into glass and saw no debris, no water. Low pressure filter bowl fills with no problem. Primer bulb pumps up tight and is in proper orientation according to instructions. Fuel pumped directly from tank has no flow issues and looks clear. No sediment in glass jar.

    Boat is a cat and draws off both tanks by design to maintain level attitude. I gave the faulty anti-siphon valve a thought but that would mean both tanks are having same problem at same time. Seems unlikely.

    Anything else I should look into before I take it to service tech? I am really not sure I want to tackle the high pressure side of the fuel delivery system.

    Merritt Marine in Hillsboro, NC is closest to me by 50 miles. Any experience with them that you could share would be appreciated as well.

    This is my first 4 stroke outboard. I have had several I/O and about 40 years of experience with working on boats.

    Any advice would be greatly appreciated. I am missing out on a lot of striper right now. Plus my kids want me to take them skiing.
    Last edited by Striperk9; 07-13-2017, 12:56 PM. Reason: sp
    2005 ProKat 20 with Suzuki DF200. Tight lines and screaming drags!!

  • #2
    Make sure you're getting full travel out of your throttle cable. Check and confirm the butterfly is opening fully. Also check the condition of your power cables, I've had engines do strange things when the battery cables were old and corroded internally. Use an ohm meter and see if you're getting much resistance through them. I'm not familiar with that engine so that's about all I can offer. If you want mechanic references, Bob Dumong at Buckhorn Boat Doc. He's a little further than your guy but he's the best in NC/SC and he's reasonable.

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    • #3
      Thanks, Lunchmoney. I will look into those items. And I am willing to travel a little further for good honest service.
      2005 ProKat 20 with Suzuki DF200. Tight lines and screaming drags!!

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