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Another Stuckzuki lower unit thread

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Another Stuckzuki lower unit thread

Old 07-27-2020, 06:42 PM
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Default Another Stuckzuki lower unit thread

I repowered in 2016 with a DF300. Been singing their praise for 4 years up thru Saturday with only some very trivial issues to date. I have done all the book maintenance at the owners manual service intervals. Oil, oil filter, LU oil, anodes, plugs, fuel filters, impellers. And of course, dropping the LU yearly to grease. This was my 900 hour service so an impeller was due. Looking back at my maintenance records, I replaced the impeller at 608 hours in May 2019, so its been 14 months since my LU was dropped. The LU literally just fell out as I backed out the last bolt like it was falling out of butter in May 2019. This was 14 months ago!!!! I greased it up nice with Pink Flamingo and a little Aquashield like normal when I last installed in May 2019.

I drop all 7 bolts Saturday and it is not budging at all. Beat on it with a mallet. Nada. Bolted all back up and ran it Sunday and tried immediately to drop it (while it was hot) in the ramp parking lot...nada. I dont have the wedges and feel I want to leave this to someone that has done DOZENS if not HUNDREDS and that would be any local Suzuki shop. I drop it off next Monday and am sick to think the rest of this week that I may be looking at the dreaded powerhead pull and/or cut the driveshaft. I am hoping since I have really maintained it by the book that the guys can get it with the wedges.

My motor is into the second half of the "3+3" warranty, but if this ends up being a major ordeal I am going to be raising holy hell with Suzuki to kick in some warranty. The guy at the local shop that I am taking it to that are authorized Suzuki service providers said Suzuki sucks for this type of customer service. I actually stopped by tonight (Boathouse Marine) to talk to one of the mechanics and I kid you not, he was putting the cowling back on a pair of 2018 zuk's on a Bluewater that he just had finished the powerhead job on!!! Are you kidding me? He showed me the big gears that were replaced and said they corrode and rust. This is total BULLSHIT. This is a MAJOR issue for Suzuki. There is not another motor brand that has this much consistency with these stuck lower units. yes I know it happens with all of them for various reasons, but when you have people dropping their LU yearly to lube and STILL having this issue commonly, that is just total BULLSHIT. I am so pissed and dissapointed. So just know that b/c you are dropping and greasing every year, you are not immune to having this problem (I thought I was until Saturday). I guess us Suzuki owners will now need to drop every 6 friggin months.

I will keep updated and any advice/info is welcomed.

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07-27-2020, 08:32 PM
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Suzuki's are known to be cheaper than other brands. Is this a case of one getting what one pays for?
Old 07-27-2020, 06:45 PM
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That sucks...

Never heard of this problem before. So Zukes require the lower to be dropped every year??? That requirement alone would be a deal breaker for me I were considering repower options.
Old 07-27-2020, 06:51 PM
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Does your engine have the zerk for greasing the top of the drive shaft?
Old 07-27-2020, 06:51 PM
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My neighbors both have suzuki 300s, one has a single, the other twins and they've both had this same very problem recently. In addition, they have both also had the same lower drive gear shear off.
Old 07-27-2020, 07:03 PM
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Originally Posted by Patton222 View Post
Does your engine have the zerk for greasing the top of the drive shaft?
The zerk doesn't grease the top of the drive shaft. (Try to imagine how a zerk would manage to do that)

The zerk greases the seal which otherwise is prone to failure and when it fails, water gets to the top of the driveshaft and bad things happen.
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Old 07-27-2020, 07:32 PM
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Neighbors two Zuki 300’s got stuck last year. It was costly to fix. He no longer runs Zukis!
Old 07-27-2020, 07:46 PM
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Zuks are kinda weird.
Old 07-27-2020, 08:32 PM
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Suzuki's are known to be cheaper than other brands. Is this a case of one getting what one pays for?
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Old 07-27-2020, 09:51 PM
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Read this. Suzuki stuck lower unit. Dodged a bullet!
Old 07-28-2020, 04:51 AM
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Maybe take it somewhere else sounds like they are setting you up for disappointment already? I know it would be a haul but you might consider Pirates marine in the port or somewhere else Boathouse sells everything under the sun so not sure what to expect from them.


Originally Posted by chad.sfds View Post
I repowered in 2016 with a DF300. Been singing their praise for 4 years up thru Saturday with only some very trivial issues to date. I have done all the book maintenance at the owners manual service intervals. Oil, oil filter, LU oil, anodes, plugs, fuel filters, impellers. And of course, dropping the LU yearly to grease. This was my 900 hour service so an impeller was due. Looking back at my maintenance records, I replaced the impeller at 608 hours in May 2019, so its been 14 months since my LU was dropped. The LU literally just fell out as I backed out the last bolt like it was falling out of butter in May 2019. This was 14 months ago!!!! I greased it up nice with Pink Flamingo and a little Aquashield like normal when I last installed in May 2019.

I drop all 7 bolts Saturday and it is not budging at all. Beat on it with a mallet. Nada. Bolted all back up and ran it Sunday and tried immediately to drop it (while it was hot) in the ramp parking lot...nada. I dont have the wedges and feel I want to leave this to someone that has done DOZENS if not HUNDREDS and that would be any local Suzuki shop. I drop it off next Monday and am sick to think the rest of this week that I may be looking at the dreaded powerhead pull and/or cut the driveshaft. I am hoping since I have really maintained it by the book that the guys can get it with the wedges.

My motor is into the second half of the "3+3" warranty, but if this ends up being a major ordeal I am going to be raising holy hell with Suzuki to kick in some warranty. The guy at the local shop that I am taking it to that are authorized Suzuki service providers said Suzuki sucks for this type of customer service. I actually stopped by tonight (Boathouse Marine) to talk to one of the mechanics and I kid you not, he was putting the cowling back on a pair of 2018 zuk's on a Bluewater that he just had finished the powerhead job on!!! Are you kidding me? He showed me the big gears that were replaced and said they corrode and rust. This is total BULLSHIT. This is a MAJOR issue for Suzuki. There is not another motor brand that has this much consistency with these stuck lower units. yes I know it happens with all of them for various reasons, but when you have people dropping their LU yearly to lube and STILL having this issue commonly, that is just total BULLSHIT. I am so pissed and dissapointed. So just know that b/c you are dropping and greasing every year, you are not immune to having this problem (I thought I was until Saturday). I guess us Suzuki owners will now need to drop every 6 friggin months.

I will keep updated and any advice/info is welcomed.
Old 07-28-2020, 04:53 AM
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Bullshite, and I will take my chances haven't let me down in 14 years of use....and not 1 stuck lower.

Originally Posted by alloyboy View Post
Suzuki's are known to be cheaper than other brands. Is this a case of one getting what one pays for?
Old 07-28-2020, 04:56 AM
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Suzuki owes you a brand new motor, i would accept nothing less.
Old 07-28-2020, 05:31 AM
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OP, hopefully it works out for you and they can get it off without an issue.

In another sense, this is a very common and known problem. I dont understand why people dont just drop the lower every 6 months or so and apply some grease and be on their way? Literally takes 15 mins. They saved thousands by buying a suzuki over another brand. Whats the big deal with spending an extra 15 mins a year for some preventative maintenance?
Old 07-28-2020, 05:38 AM
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Hope it works out.. my 4.2 yam made oil i was worried.. it seems to have stopped now . Hate the feeling of impending outboard trouble doom !
Old 07-28-2020, 06:47 AM
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Originally Posted by ktroyer2265 View Post
OP, hopefully it works out for you and they can get it off without an issue.

In another sense, this is a very common and known problem. I dont understand why people dont just drop the lower every 6 months or so and apply some grease and be on their way? Literally takes 15 mins. They saved thousands by buying a suzuki over another brand. Whats the big deal with spending an extra 15 mins a year for some preventative maintenance?

Thank you. My feeling is that this went from a quiet problem to a pretty common knowledge problem with the perception that dropping and greasing yearly prevents this (which was mine). If you read what i wrote, you will see that I have done exactly as you suggest. I dont believe this perception of dropping and greasing is a end all be all preventative maintenance fix (obviously or I would not have a stuck LU). There's several threads on here you can dig up where folks have dropped and greased yearly like I have and still have encountered this.

HighSpeed - I am glad for you. As I said, been singing their praise and love my Suzuki. However, I think its pretty clear there is a design issue. All you have to do is look at this thread below and its the root cause of the problem. It seems somewhat random if you get unlucky or not (part tolerance stackup?.?). A friend has twin 250 and he does maintenance on both, same time side by side. 3 months ago, one was stuck (shop got it loose) and one he dropped just fine on his own. There is some kind of design issue with the interface in the picture below where fly186 documents this in detail. I grabbed this pic from his very detailed thread b/c its the crux of the issue for why they are "stuck". Rhetorically speaking, tell me how/why saltwater is getting that high up into the engine and tell me what kind of stainless steel looks like THAT after what should be minor salt water exposure at best.

From fly186 thread

fly186 picture


Thanks for that insight. I am going to call around some, the place you mentioned being one. I am still going to stay positive and hold out hope since mine was just out 14 months ago no prob, that the shop can drop it.

Tell me why I shouldn't pull the powerhead on my DF225 myself and save $$$$
Old 07-28-2020, 07:02 AM
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Originally Posted by chad.sfds View Post


. I am still going to stay positive and hold out hope since mine was just out 14 months ago no prob, that the shop can drop it.

l
haha, if this is positive would hate to see stressed out. Hopefully they drop without problems and this is just an inconvenience for you. Guess I will be the one to ask the dumb question, are you sure the bolt under the trim tab was removed when you tried to drop them?
Old 07-28-2020, 07:33 AM
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This is why I love THT because you learn things you didn't know. Oddly, I've been thinking a lot lately about going to Suzuki for my repower, as I'm sure a lot of folks do simply because of the cost. I will add this; I've always changed my LU fluid every 100 hours, and every other fluid change I drop the LU just to take a look. 95% of the time, I'm in saltwater so it doesn't take a lot of hours to go from "everythings great" to "what the hell is that?", lol. Sounds like it wouldn't be a bad habit for Suzuki owner's to adopt.
Old 07-28-2020, 11:52 AM
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Originally Posted by Drako View Post
The zerk doesn't grease the top of the drive shaft. (Try to imagine how a zerk would manage to do that)

The zerk greases the seal which otherwise is prone to failure and when it fails, water gets to the top of the driveshaft and bad things happen.
Ya know I haven’t done mine yet(will in the next few weeks) but I thought I read from a reputable source that the zerk was added in the newer engines(16/17/18 not sure which year first got them) to address this exact issue. How and why it works I’ll have to get back to you. I grease my hubs and bearings through a zerk all the time, what would be so different about the top gears in a drive shaft?
Old 07-28-2020, 11:56 AM
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sub'd!
Old 07-28-2020, 03:02 PM
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So you all know lowers are getting stuck. Why not to pull them more frequently on older motors working in harsh environment?

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