Suzuki DF225 mystery

[BadfishToo]

Hi gang, I’m chasing a gremlin. I have a 2004 Suzuki four stroke. It cuts out at idle periodically. When I try to start it, it cranks but won’t turn. I crack fuel lines and try and prime. Eventually I can get it running again. The mystery. I ran it it, it cut out at idle. Crank but no turn . I switched to an auxiliary tank. No joy. I fussed with it and finally pulled the kill switch in and out and it cranked and I motored home just fine. I know mystery solved, but... when the kill switch is tripped it should not crank or make any noise at all. It cranked the whole time. Thoughts? I’ve been fighting this menace for two weeks. Actions I have took:
— Replaced idle air control x2
— replaces fuel bulb
— ran from auxiliary tank. (Hasn’t cut out on me on the auxiliary, but wouldn’t crank turn for me either until the kill switch).
Any insight? Much appreciated from a very frustrated guy.

[Ed]

On those Suzuki's there is a neutral safety switch on the lower right side of the powerhead I believe. We have replaced 3 or 4 over the last couple of years. I would look there. It is roughly a $35 part.

https://www.brownspoint.com/store/pc...il.asp?ID=3002

[kmoose]

I agree with Ed that it may be the neutral switch but you can also have worn or out of adjustment linkage. Not sure how many hours are on yours but the elaborate cable and rod system does wear and adjustment has a pretty tight spec.

Also, don't forget the dreaded white wire hooked to the battery from the harness. If the connector is compromised by corrosion it will give you just as many issues as a bad IAC servo.

[BadfishToo]

Appreciate the insight. I’ll conitinue to troubleshoot. I decided to fix the engine and sell it. Repowering with a Suzuki 300 🤙🏽