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Grrr…! Oil leaking from cowl of our brand new DF250

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Grrr…! Oil leaking from cowl of our brand new DF250

Old 11-29-2019, 11:51 PM
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Default Grrr…! Oil leaking from cowl of our brand new DF250

OK, straight up – I’m PO’d!

When performing final walk around after parking the boat in storage lot, I noticed oil all over the lower unit. WTH?? Oil leaking out from cowling.









Popped cowl off, oil fill cap totally missing. Oil about a quart low. Same dealer I bought a brand new Suzuki DF250 from left the oil fill cap off after performing 20-hour oil change!

That was after the first trip out after the 20-hour service. No alarms, ran great. About 45 minutes total, cruising around 4,000rpm/30mph mostly, with a couple of 30-second WOTs to 6,200rpm rev limit/48 mph. After washing the oil out of the cowl, I could see where the oil spray had been sucked up into the air intake. Hopefully this explains the puff of smoke on first start-up I thought was highly concerning on a 20-hour motor…

Anything obvious jumping out at you?

Brand new DF250 oiled down...

Oil sucked into air intake...?

I'm concerned the oil will cause issues with the fiberglass later on down the road...

I'm PO'd at the dealer AND myself... for ignoring my gut and not popping the cowl to give just a quick look/see after dealer service.

I am the guy people roll their eyes at because I’m so anal about maintaining EVERYTHING! And keeping things clean! Things are only new once – the more they are well-maintained, the better they look, longer, etc.

I’m calmer now then a few hours ago. $20K brand new motor oiled down due to installing dealer leaving off the dang oil fill cap. Really? Grrr….

Right now, I’m mostly worried about long-term malfunctions and issues to things like the fiberglass cowl, wiring, electronics, coils, and other things that were never supposed to be soaked in motor oil.

I would greatly appreciate thoughts, etc. from dealers, factory techs, etc. on the possibility of long term issues caused

Happy Thanksgiving and much obliged - gr8ful
Old 11-30-2019, 12:13 AM
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That Sucks, but I wouldn't sweat the Cowl. Old Johnsons used to spit gallons of gas/oil mix out the carbs at the FG Cowls, Dripping down the Pan.

But I would give the Dealer a reaming.

I recall a 4 wheeler I once bought, after about 3 months of running, I Forded some water and it Stopped. I found the Air Cleaner wasn't hooked up to the Carb, and Hydro Locked it.

3 months of Dust then Water to wash it down. I logged Many Miles on that thing without an issue, but I was pissed!
Old 11-30-2019, 12:57 AM
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It will be OK, not a lot of fun for you, but, get the cap, clean the oil off and go boating, then find a good dealer, or get this dealer to do the next service free, then ditch him.
Old 11-30-2019, 03:15 AM
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I feel the same way. Yes unfortunately, you have to insult the mechanics intelligence and look everything over. Looking it over BEFORE you take the boat from the shop is ideal. Rarely do I not find stuff that needs addressing.
Old 11-30-2019, 05:03 AM
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How much oil is left in the motor? Never mind.- Just saw you say it is about a quart low. Hopefully all is well mechanically. See if you can get a free service out of the dealer.
Old 11-30-2019, 05:09 AM
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Zero long term issues.
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Old 11-30-2019, 05:16 AM
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What did the dealer say or offer??
Old 11-30-2019, 05:19 AM
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You need a new dealer. Idiot service department not putting cap on multiple times? I wouldn't trust them to do anything, seriously.
Old 11-30-2019, 05:38 AM
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Annoying? Yes, long term damage to anything? No.

Clean the inside of the cowl up and you're back in business!
Old 11-30-2019, 05:45 AM
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Check your receipt to see if the dealer charged you for the optional "anti-corrosion coating."
Old 11-30-2019, 06:17 AM
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Good time to write a detailed letter with pictures . Copy to dealer and a few to the manufacturer. It documents the goof and will also make you feel better.

sounds like the motor runs great enjoy .

Thanks for the post.
Old 11-30-2019, 07:38 AM
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The dealer really needs to shake up their service department, sooner or later that lack of work ethic is going to cost them on their insurance. Someone buys a brand new DF 250 outboard and the job of an oil change is given to an obviously in-experienced and uncaring clown! Kick that fool to the curb, is what the owner must do.
I've been doing oil changes on my own vehicles since 1972 and have never done that, or left an oil filter loose, or stripped an oil drain plug. These are the simplest jobs that there are, and they can't do it right?
I do it myself, save the receipts and don't really trust anyone, and if there is a job I can't do I always look it over in the lot. I've had to call the mechanic out a few times and have never had a problem, as long as you are nice about it.
This is partly why I hang on to my old school toys. Old school means independence from mechanics and dealerships (most of the time).
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Old 11-30-2019, 08:30 AM
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Consider it additional third world corrosion protection, take off a wrap, add oil and degreaser and go boating.
Old 11-30-2019, 08:44 AM
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Suzuki DF250 is a great engine. We have one, about 2400 hours in close to 4 years. Don't let one bad service experience sour you on the engine. We service ours and routine maintenance is easy and buy our parts through boats.net. Get it cleaned up and enjoy!
Old 11-30-2019, 12:15 PM
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Maybe the oil change guy came from one of those 10 minute oil change places and he tried to make it a 9 minute change.
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Old 11-30-2019, 04:59 PM
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I'd be Pissed also!! But, Humans make mistakes ! Shit happens. Maybe they pulled the Guy off the Job for something after He put Oil in it..He comes back and throws the Cowl on thinking He put the Oil Cap on. Who knows. Dealer should offer Ya' up something for the mess and inconvenience.
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Old 11-30-2019, 06:04 PM
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Seems to be all pitchforks and torches cause nobody in here has ever made a mistake in their lives.
Old 11-30-2019, 06:08 PM
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I agree with the guys that suggest doing your own simple maintenance. The stuff that is overlooked/done poorly at marine service departments is astonishing. I worked in this industry for awhile, and I don’t get it (big topic).
Old 11-30-2019, 07:36 PM
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Document it with your dealer and manufacture like stated above. That intake has a tone off moving parts. Butterflies ,ivac ,tb,etc. The throttle body is right there under the plastic cover. I would pop that cover and see how much oil residue got in. Any residue of oil is gonna collect all the dust -dirt and cause build up. Any build up on the butterflies can't be good. I would pull the ivac to and check it.. more then likely you are ok to go. But let this be there issue and get it documented with a new motor.

as new as that engine is .it looks dry. Spray some corrosion block on it. 656
Old 11-30-2019, 07:44 PM
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Somewhere there's a mechanic wannabee wondering "Gee, wonder where this oil fill cap goes".....but never follows it up, THAT is why he's worthless !!!

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