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2007 DF300 - Cranks, no start

Old 11-30-2019, 05:10 PM
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Default 2007 DF300 - Cranks, no start

Well, as the title states Iím having issues with my 2007 DF300ís (twins - fly by wire) on my Intrepid.

The symptoms are the following:

Upon turning the key on the ďONĒ position all the gauges turn on as normal however I get a ďlow voltageĒ alarm. Engines will crank/turn over but I donít hear the fuel pumps kick on and obviously the engines will not start. Trim works fine - engines will go up and down.

So far, Iíve checked all the harness connections, battery voltage, checked the white wire connections and all associated fuses in addition to all fuses on the engines. I also replaced the ignition switch and kill switch with factory parts and still have the same issue.

Prior to this problem I have had no issues whatsoever. Boat has been sitting for maybe three weeks since it was used last.

Im looking for some help as to maybe if Iím missing something. Any feedback is appreciated!

Old 11-30-2019, 05:26 PM
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Does it have safety motor kill switch with lanyard?
Old 11-30-2019, 06:14 PM
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Originally Posted by salbrent View Post
Does it have safety motor kill switch with lanyard?
Yes, switch is new and lanyard is in.
Old 11-30-2019, 07:07 PM
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Is the throttle in neutral?
Old 11-30-2019, 07:40 PM
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Yes, Iíve also checked the neural safety switch.
All is well.
Old 12-01-2019, 10:12 AM
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Fuel pumps are not working with key on? Check fuses under cowling.
Old 12-01-2019, 10:44 AM
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Originally Posted by salbrent View Post
Fuel pumps are not working with key on? Check fuses under cowling.
As my post stated, all has been checked. All fuses on the boat are good.
Old 12-01-2019, 01:53 PM
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Sorry

probably needs to be scanned with diagnostic software.
Old 12-02-2019, 03:52 PM
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Any updates?
Old 12-09-2019, 10:18 AM
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Cranking without starting sounds like a fuel issue, so obviously bad fuel or since you mentioned the pumps do not run it could be coincidentally both bad fuel pumps or electrical. I would consider bringing to a dealer since you tried all the basic things already, you might be looking at internal harness issues or bad wire somewhere in the system.
Old 12-27-2019, 03:19 PM
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Originally Posted by Outboard Specialties View Post
Cranking without starting sounds like a fuel issue, so obviously bad fuel or since you mentioned the pumps do not run it could be coincidentally both bad fuel pumps or electrical. I would consider bringing to a dealer since you tried all the basic things already, you might be looking at internal harness issues or bad wire somewhere in the system.

Thanks for the reply.

Little update:

Had a tech come out to look it over and went through all the common stuff. Also hooked it
up to the computer/Suzuki diagnostics and the engines computers are reading 0 volts. Batteries are at 12.6 volts per multimeter. (Also load tested - all good)

We also checked and powered the fuel pumps from a tester - all is well here - fuel pumps engage when powered. Also, with the fuel pumps powered and cranking the engine it will not start. It seems that itís not getting the message from the engines computer to power the fuel pumps and initiate spark.

Even the tech was at a loss at to whatís going on. At this point Iím starting to think itís the computer under the helm.

Outboard specialities - Any input here?
Old 12-27-2019, 03:53 PM
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No voltage at the ECMs can't be good. You did say you checked the white wire and the fuses under the cowling right?
Also, 12.6 volts at the battery is low. Probably not the issue since the motors are cranking but I would put them on a charger.
Also, as far as the fuel pumps go - you should almost always hear the fuel pump run for a few seconds when the key is turned on.
Good luck.
Old 12-27-2019, 04:01 PM
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Was he able to hook up the Suzuki software and read the ecm at all? If not then you have a harness issue or a possible bad ecm. Any chance of the boat being hit by lightning? That will fry the ecm and bcm and cause these issues without much other damage being seen. Been there multiple times unfortunately.
Old 12-27-2019, 04:10 PM
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Originally Posted by Outboard Specialties View Post
Was he able to hook up the Suzuki software and read the ecm at all? If not then you have a harness issue or a possible bad ecm. Any chance of the boat being hit by lightning? That will fry the ecm and bcm and cause these issues without much other damage being seen. Been there multiple times unfortunately.

Indeed, I can read all the data on the ECMís. States all the typical stuff (hours, warnings, etc) and volt readings at each sensor (which are all low 2-5volts with key on). However the main voltage reading is 0. I cannot test the fuel pumps, etc through the diagnostic program as
when I try I get no response.

I assume anything is possible in reference to lightening however I donít see any points of entry or exit and everything else works as it
should.
Old 01-05-2020, 01:08 PM
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Originally Posted by Outboard Specialties View Post
Was he able to hook up the Suzuki software and read the ecm at all? If not then you have a harness issue or a possible bad ecm. Any chance of the boat being hit by lightning? That will fry the ecm and bcm and cause these issues without much other damage being seen. Been there multiple times unfortunately.

Update:

I had some more time to spend trying to diagnose the issue.

I can read all the data on the ECMís through the Suzuki software in addition to the BCM data.

The ECMís show voltage to all the sensors (which are all under 5v) however the main voltage is 0. Doesnít make sense.

The BCM is showing the identical voltage of the batteries (12.6v). All data can be viewed here as well.

I also had someone crank the engines while I read the voltage on the batteries, while cranking each engine Iím getting a reading of roughly 11.5v. But, since Iím not getting fuel pumps when the key is turned on, I donít think this is an issue.

Iím at the point where I may start throwing parts at it as Iím at a loss.
Old 01-05-2020, 05:23 PM
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Do you have a factory shop manual with wiring diagrams?
Old 01-05-2020, 10:29 PM
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Harness issue - white wire most likely.

Have a read of this sticky post over on the Suzuki forum. Might give you a solution or at least some clues on where to look.


https://www.suzukioutboardforum.com/...-power-failure
Old 01-06-2020, 01:02 PM
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Originally Posted by Moonlighter475 View Post
Harness issue - white wire most likely.

Have a read of this sticky post over on the Suzuki forum. Might give you a solution or at least some clues on where to look.


https://www.suzukioutboardforum.com/...-power-failure
This is what I'm thinking also.
Old 01-07-2020, 03:26 AM
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Guys - thanks for all the help.

I went back to the boat yesterday and started from scratch.

I started at the helm wiring and everything checked out good.

I then went back to where the harness connects to the dual engine harness (Where the two engine harnesses connect to the main harness which leads to the helm).

Behold, a melted wire which looks like was caused by the wire not being supported correctly causing the plug to bounce and wire to get chaffed on a zip tie. This wire being melted was also caused by my white wire being hooked directly to the battery which of course kept constant power to the broken wire. Mix that plus moisture = issues.

I spliced it and boom - fired right up. To be safe, Iíll be replacing the harness from the helm back to the engines.

For anyone chasing a similar problem: CHECK EVERYTHING, unwrap wiring, pull apart connections, check, check, check. I would have never seen this wire break otherwise as it was completely out of sight and being supported under the deck by a zip hanger under a hatch I could barely fit by head into.


Old 01-07-2020, 04:08 AM
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Glad you found it, that would be the wire supplying 12v, the infamous white wire.
Double check the y adapter harness in bilge as well, you may want to just change it while you're in there.

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