Expert: Jeff Grigg - 1/25/2008

Question
Hi Jeff,
      I have a Suzuki DT65 outboard (serial 06502 501488)which was running fine when last used .
It sat for about 2 years since.
I have pulled the carbies apart and cleaned them and attempted not to alter the previous settings in the process.
The motor cranks easily but will not start. It seems to not pull the fuel through .
IF I fully choke it and crank it a lot it will pull enough fuel to kick but not start. If I squirt fuel into the carbies it will start and run nicely until this fuel is gone (about 30- to 60 seconds).
I have checked fuel is being delivered to the fuel bowl and the pump is pumping on each stroke .
Delivery pressure is about 3.5 pounds to 4 pounds while running and seems to adequately fill the bowls .
I have cleaned the long tube up the cente of the fuel bowl (I expect this is the idle tube) I have cleaned the jet under this tube on the outside of the fuel bowl and I have cleaned the jet above this on the top of the carby.
I have blown through and checked the operation of the needle and seat .
Even when primed and having a full fuel bowl it will not start unless fuel is injected straight into the carby .
There must still be something I have not cleared .
Can you tell me what it is ?
Thanks Jeff

Answer
Greg, you will need to pull the carb back apart. Get a complete carb rebuild kit and replace all of the gaskets, seals, o rings etc. There are a number of small aluminum port seals or covers, you will need to remove these as well. Make sure they are in the kit before you remove them. A punch will remove them. To reinstall put the disk in place concave side down and using a small socket or punch tap them into place.
All of the passages need to be absolutely clean.
The idle circuits are very small and easily gummed up. Use a fine wire along with spray carb cleaner to clean these passages. Be careful not to enlarge or change the shape.
Always use now gaskets.
Do this and see if the engine doesn't start. Post back if you need further help.
Jeff