Suzuki 300 suddenly dies, needs computer reset to start again

[draymer]

2012 Suzuki DF300 outboard, on a Beneteau Flyer 750 SunDeck. The motor SN is # 3002P-2103.
While cruising at a high power setting, the motor suddenly cuts off instantly. It acts as if the kill lanyard was pulled, but it wasn't. After that, pushing the start button had no effect. The motor readout says Check Engine Code 7-5 which is "Check Control Unit Comm"

The Suzuki mechanic could get it to work again by using his laptop to reset the motor-throttle connection. He also cleaned some corrosion in the throttle-to-motor electrical cabling. I had another mechanic completely redo the boat's wiring as well. But when I took the boat out again, it stopped again, the same way. An electrician friend who happened to be nearby checked that same wiring connector but no new corrosion was seen. He also checked that there was power to the panel and motor, plus other things. All was OK, but the motor won't start.

I'm wondering if maybe that model boat used some sort of cable extension, and it has a hidden connection that may be corroded. Has anybody heard of such cable extensions for the Suz300?

Or does anybody have another idea as to what could be causing this? Boat is running fine then instantly dies! And yes, we checked the kill switch itself!

 

[cyclops222]

Sure sounds like a connection got worse with time. And finally failed completely.

 

[draymer]

Sure sounds like a connection got worse with time. And finally failed

2012 Suzuki DF300 outboard, on a Beneteau Flyer 750 SunDeck. The motor SN is # 3002P-2103.
While cruising at a high power setting, the motor suddenly cuts off instantly. It acts as if the kill lanyard was pulled, but it wasn't. After that, pushing the start button had no effect. The motor readout says Check Engine Code 7-5 which is "Check Control Unit Comm"

The Suzuki mechanic could get it to work again by using his laptop to reset the motor-throttle connection. He also cleaned some corrosion in the throttle-to-motor electrical cabling. I had another mechanic completely redo the boat's wiring as well. But when I took the boat out again, it stopped again, the same way. An electrician friend who happened to be nearby checked that same wiring connector but no new corrosion was seen. He also checked that there was power to the panel and motor, plus other things. All was OK, but the motor won't start.

I'm wondering if maybe that model boat used some sort of cable extension, and it has a hidden connection that may be corroded. Has anybody heard of such cable extensions for the Suz300?

Or does anybody have another idea as to what could be causing this? Boat is running fine then instantly dies! And yes, we checked the kill switch itself!

completely.

 

[draymer]

People - it is still doing it after two years. I've tried everything. Does anybody have another suggestion!! Thanks.

 

[Lou C]

Maybe post this up at The Hull Truth, I recall reading something about a white wire issue with Suzukis, someone there might know.

 

[dingbat]

Hard resets do not clear wire/connection problems.

The code description and the ability to clear the error with a reboot suggests internal communications issue(s).

I suggest digging into the manual to figure out the “start” prerequisites and go from there. This could be something as simple as a partially compromised fuel pump relay, neutral safety switch or a “keep alive” signal failing to respond to the ECM in a timely fashion.