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Problem Solved: Engine Overheating, tried everything I could think of....please help

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Problem Solved: Engine Overheating, tried everything I could think of....please help

Old 05-21-2018, 08:02 AM
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Default Problem Solved: Engine Overheating, tried everything I could think of....please help

My 2009 Suzuki DF 225 keeps overheating at idle or running while in the water. No water coming from the tell-tale. I tried hooking it up to run it on the earmuffs and no flow coming out the tell tale or prop exhaust. The engine will overheat in a matter of minutes on or off the water.


So far Ive tried .....
-flushing from the top two hose ports
-running it on earmuffs
-taking out the thermostats, cleaning them, blackflushing through the thermostats, and running without them.
-cleaned poppet valve
-checked for clogged suction or discharge ports.
-water pump new and inspected


-when I hookup the muffs to the engine and run it, the water doesn't come out anywhere except around the seals of the muffs (with other suction ports tape up)


-When I flush past the thermostats water will come out of prop. When I backflush upstream of thermostats, water will come out of the bottom suction strainers and tell tale.


-When I flush the engine using the top two hose ports the water will come out of the suctions ports (but should be coming out of tell-tale too I think)


Anyone have a clue what the problem might be?
Old 05-21-2018, 08:31 AM
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Who did the water pump.
i would check that again
Old 05-21-2018, 08:45 AM
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And orientation of impeller
Old 05-21-2018, 08:46 AM
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Originally Posted by fish46 View Post
Who did the water pump.
i would check that again

David Wade marine, they've been good to me so far.


I figure if the water pump was the problem the upper engine flush would work just fine/ come out of the tell tale with water hose pressure, and the engine shouldn't be running when flushing this way.
Old 05-21-2018, 10:46 AM
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Unless they didn't line up the water tube....
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Old 05-21-2018, 10:50 AM
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2nd on making sure the water pump tube is lined up correctly

Also make sure tell tale hole is not clogged up
Old 05-21-2018, 11:54 AM
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I'll check on the water tube when I get home, and I made sure the tell tale wasn't clogged.
Old 05-21-2018, 12:30 PM
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Did they replace the stainless steel cup over the water pump? Did it have any cracks in it? Did they test it prior to returning it to you?

Originally Posted by CaptainNemo225 View Post
David Wade marine, they've been good to me so far.


I figure if the water pump was the problem the upper engine flush would work just fine/ come out of the tell tale with water hose pressure, and the engine shouldn't be running when flushing this way.
Old 05-21-2018, 12:37 PM
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Old 05-21-2018, 12:50 PM
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If a professional shop did the work why are you trying to fix? Why wouldn’t you simply take back to them ?

not casting any stones at any shop btw
Old 05-21-2018, 01:37 PM
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because I don't know if this is a result of the routine maintenance I had done prior to finding this problem, or the problem existed before the routine maintenance (although I did run the engine about a month prior with no issues)


the shop did say they test all engines on the earmuffs before they get returned. The owner double checked the water pump line up when I brought it back, and he did the check up work for free. somehow he got a stream coming from the tell tale on the earmuffs (even sent me a pic) but when I tried at home.....nothing. almost like something keeps getting clogged but not sure.


I suspect that if the water hose connection was loose around the water pump discharge it would be spraying somewhere around the lower unit when I start up the engine


I wish I knew the answer......might be clogged hoses in between water pump and engine block
Old 05-21-2018, 01:44 PM
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I had similar problems on a used motor. Had to take off the heads & water jackets and scrape the salt buildup out.
previous owner didn't flush engine regularly. It was a big PIA.. but no more overheats after that...
Good Luck!
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Old 05-21-2018, 02:01 PM
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Not sure if you have square or round muffs , but I’ve had to squeeze the muffs when the engine first starts to get a good stream going . Can you fill a large barrel and run the engine in that ?

You say overheating , alarm going off ?

You didnt have shop diagnose when
you took it back for them to check water pump ?

Im lost !
Old 05-21-2018, 04:10 PM
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First question I would have was did it overheat before you brought it to them? I have only had good luck with the round muffs. If you change your title thread to opinion on Merc vs any other motor he will be on this thread in minutes.
Old 05-21-2018, 04:26 PM
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Run it in the water. Some engines don't like muffs.
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Old 05-22-2018, 03:37 AM
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Getting closer to the answer, I dropped the lower unit yesterday after I got back home, connected a hose directly to the tube that connects to the impeller discharge. Almost immediately had flow coming out of the tell tale. That led me to believe the problem is the impeller or connection to that tube. I took out the impeller, inspected it, and put it back in the right orientation. Still no flow while idling, but if I throttle up Ill get some flow. I believe the problem might be the wrong size impeller, maybe its not a perfect match to the OEM Suzuki impeller for my engine. So ill be picking one up later today if I can find one in stock.


-I also realized that my water hose connection was too small for the amount of water flow that my engine needs. I realized this when I swapped to a new hose with no restrictions and had flow coming out of tell tale while flushing from top hose connection.


Long story short: I don't think I have any blockages, just thinking something is wrong with the impeller and ill replace it with Suzuki OEM impeller and get back to yall.
Old 05-22-2018, 05:11 AM
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Just wondering who (if it is the impeller) fitted the wrong size? Also check the woodruff key is there - without it the impeller wont spin at low revs but friction with the shaft may be enough to make it pump some water at higher revs.
Old 05-22-2018, 05:18 AM
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You need more water pressure from your hose.
How far away are you from putting it in the water.
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Old 06-01-2018, 01:16 AM
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PROBLEM SOLVED: they installed the wrong size impeller.

I ordered a new impeller. When it came in I took the old one out and put it side by side with the new OEM impeller. Diameter was the same but height was about 1/4” taller....Big difference! Now to see how they handle it
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Old 06-01-2018, 02:15 AM
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Recommend that you use the small round muffs, the old style ones originally for OMC motors.

The Suzukis work best with these, my dealer put me onto them, they are all he uses in all hp Suzukis. Tested several shape muffs myself and the round ones are always reliable.

Also recommend that whenever you change the impeller, you also change the stainless housing as well, because a slight even invisible bend in that housing and the impeller will not seal up and you wont get good water pressure. So, we always replace both parts.

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