Rev limiter DT 225 1998

[Igonefishn]

Got an interesting one. I have a 1998 DT 225. I have replaced the following: Throttle position sensor, air temp sensor, port and starboard temp sensor, ignition control unit, CDI, oil flow sensor, rectifier, oil level sensor, new plugs,
in line resistor for false heat reading. Having said that, I am still getting the rev limiter at about 3200 rpm and motor will shut down. Put the thing in neutral and it will settle down and here we go again. Took to the local Suzuki dealer and gave him the list of things replaced and the relayed the problem to him. He has no idea. All sensors were set according to specs. Any suggestions

[seaox230c]

I assume the only light you get is the rev limiter. Does this happen at different engine speeds or the same speed each time. Are all your lights functioning? I have the 2003 dt225 but I have the false overheat that send the rev limit signal..shut the engine off and right back on and it good for 10 min or a week. Your computer should store those faults and possibly the causes...have you had your computer read

[FourWinns91]

Hey Guys,

I'm new to the forum but have been reading all of your posts for a few months now. I bought a 1998 DT225 back in February and I am having rev limit issues.

The engine runs and sounds great for the first 8-12 miles or so at WOT and then suddenly loses power, the rev limit light comes on and alarm buzzes until throttle is reduced. It is only the rev limit light that comes on and not the temp light, etc...

I have already taken it to the local Suzuki dealer / repair center and they couldn't find any issues after running it on the dyno. They said it was bad gas, so we drained the tank. They also mentioned that my left cylinder head bank was running at 190 degrees. Thus, I removed the heads, took them to the machine shop to have cleaned and reinstalled with new thermostats, hoses, etc... It stays below 140 degrees now. However still having the same issue with the rev limiter.

I have already changed out every inch of fuel line, water seperator, fuel bulb, under cowling fuel filter, fuel vapor separator, throttle and shift cables, and spark plugs.

A different Suzuki shop mentioned that it could ONLY be the CDI unit. I looked through the owners manual and it appears that the only way to check if the CDI unit is bad is with Suzuki's CDI tester. I hate to start throwing parts at this old motor unless i know for sure what the issue is.

Do you guys have any idea? Seaox230c - I appreciate you taking the time to write up that post on your issues with the DT225.

Any help is greatly appreciated.

[seaox230c]

The rev limiter is entirely a computer controlled function and it should limit your rpm's to exactly 3000. try unplugging your oil flow sensor and see if it fixes anything are you sure nothing else lights up except the rev limit...sometimes they are hard to see. Hit the low oil reset button....do you have at least 2 greens on your oil level sensor

[FourWinns91]

I will unplug the flow sensor and see if that fixes it. If so, i'll go ahead and replace. Hopefully that's it...

I'm sure it's just the rev limit sensor lighting up.

I've currently got 2 greens on the sensor, however it's happened with 3 greens as well. I'll fill the tank before next time i go out.

Thanks for the fast reply, Seaox230c!

[seaox230c]

Unless your tach is showing 6000+ rpm's you should have some other light illuminated..I am going to my boat on fri...I will see what lights up when I turn the key on. I would take BOTH overheat sensors out of the mounting pads but still connected and see if the same thing happens...high rpm...overheat...low oil quantity and low oil flow all trip the rev limiter and should illuminate the respective lights unless burnt out...no other mechanical or electrical failure should trip the rev limiter. A previous low oil quantity may have tripped the rev limit and it was not reset even though you have enough oil now...just a possibility