Suzuki 2.5 T4 Outboard

[Stingo]

This morning I pulled the Suzuki 2.5 T4 out of a locker on my wreck for the first time, put it on the transom of my dinghy and fired it up. All nice and smokey, but no water coming out the piss-pipes. A Google search for a service manual turned up nothing useful.

Help, I have no idea where to start poking around inside the engine cover?

TIA

 

[Stingo]

Youtube to the rescue. It's looks like an easy enough job.

 

[Halo]

Are you sure there is no water?? The amount that comes out of mine is tiny but it keeps on running.
A few years ago I cleared a load of salt out of the waterways in mine but the increase in water output was negligible.
Suggest you take a close look before doing anything drastic

 

[Stingo]

Yep. This is all that is left of the impellor

 

[Dellquay13]

Yep. This is all that is left of the impellor View attachment 179466

Hopefully you found all the missing pieces of blades in the housing and not lost inside the waterways round the head

 

[Stingo]

That's one of today's jobs to clean out all the waterways and heads.

 

[shanemax]

Strange, but I have had several 2hp engines over the last 50 years and have never changed an impeller. I do on my bigger engines but never on a two, perhaps I am just lucky. Also if the gear oil is a bit milky, I top up and just ignore it and they just seem to keep running with no complaint.
Marvelous little engines.

 

[Stingo]

Update. I now have water pissing out of all three holes (as per photo), but I suspect that the upper and offset hole should actually be plugged. A question for other Suzuki outboards: is the upper hole plugged or not?

 

[VicS]

Update. I now have water pissing out of all three holes (as per photo), but I suspect that the upper and offset hole should actually be plugged. A question for other Suzuki outboards: is the upper hole plugged or not?

The upper hole is the telltale . The other two are the exhaust back pressure relief ports ....... See the video you posted at just over 17 minutes

 

[Stingo]

But, but, but, via Telegram, another Suzuki owner sent this photo to me, showing that the upper hole is blocked. Time to try find a reliable Suzuki service agent within 100 NM

 

[AMOREST]

It’s not blocked. It has a pilot hole through the middle of the screwed in plastic plug. As a tell tale.

 

[VicS]

It’s not blocked. It has a pilot hole through the middle of the screwed in plastic plug. As a tell tale.

The parts lists show item #7, part number 61155-97J01

 

[Stingo]

Perfect! Thank you @VicS

 

[ss2016]

I am getting ready to change the impeller on my 2.5, the video was useful, thanks! It's 7 or 8 years old but little used, so for the price of an impeller I would rather renew and make sure the bolts are not seized also.
A QUESTION. Is there no fuel filter? I was expecting to replace that but can neither find it or mention of it.

 

[VicS]

I am getting ready to change the impeller on my 2.5, the video was useful, thanks! It's 7 or 8 years old but little used, so for the price of an impeller I would rather renew and make sure the bolts are not seized also.
A QUESTION. Is there no fuel filter? I was expecting to replace that but can neither find it or mention of it.

ITYWF it is part of the fuel cock assembly. Detach the tap from the tank and you will find it . Fairly normal position for small engines, including my Seagulls and my vintage lawnmower ( By appointment to HM King George VI )

The original part is replaced by 66100 97JL1 but you should be able to carefully clean it and reuse it.

 

[ss2016]

Vic, thanks. Curious it's not mentioned (I think) in the service docs. Perhaps a fuel filter is not really necessary.
Thanks again, Steve.

 

[VicS]

Vic, thanks. Curious it's not mentioned (I think) in the service docs. Perhaps a fuel filter is not really necessary.
Thanks again, Steve.

It's on the service schedule in the 2017 edition of the Owner's Manual

 

[ss2016]

So finally I got around to actually doing the Suzuki 2.5 service. It's close to 8 years old but probably not done 100hrs. I do change the oils and run fresh water through it each year. This year my particular goal was to change the impeller which I have done. I wonder why in retrospect since it was very hard to see the difference from a new one.
While the leg was disconnected from the top end I changed first the gear oil and then the impeller. When I came to reassemble it I briefly held the leg upside down and oil started running out through the hole where the gear engage rod goes. My QUESTION, is this normal? Am I missing something? A secondary question. While the leg was disconnected, with the new impeller in place, turning the propeller by hand had a 'grainy' feeling to it. I can't see why since the blades do not actually have to compress. Again, normal?

 

[VicS]

So finally I got around to actually doing the Suzuki 2.5 service. It's close to 8 years old but probably not done 100hrs. I do change the oils and run fresh water through it each year. This year my particular goal was to change the impeller which I have done. I wonder why in retrospect since it was very hard to see the difference from a new one.
While the leg was disconnected from the top end I changed first the gear oil and then the impeller. When I came to reassemble it I briefly held the leg upside down and oil started running out through the hole where the gear engage rod goes. My QUESTION, is this normal? Am I missing something? A secondary question. While the leg was disconnected, with the new impeller in place, turning the propeller by hand had a 'grainy' feeling to it. I can't see why since the blades do not actually have to compress. Again, normal?

There should be an O ring seal around the shift rod where it enters the gearcase.

The propeller should turn smoothly. The grainy feeling is probably due to a rough bearing. Perhaps water has entered the gearcase and caused corrosion of the bearing.. Maybe new seals are needed.

You can see exploded parts diagrams at Browns Point Marine Service, LLC - Suzuki Parts Lookup

 

[ss2016]

Vic, thanks. How is that o-ring retained? I presume it is part #09280-06004. Without the shift rod in place does it make sense the oil falls out if inverted? Also can the o-ring fall out? I will have to disassemble to see if it is there. I don't believe I have lost it. Could it be the shift rod slides smoothly past it on reassembly?
The old oil looked clean and it's little used so I am surprised if it's a bearing issue giving rise to the grainy feeling. Thanks again.