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Suzuki DF250 tilt cylinder seal

Old 07-08-2019, 05:31 PM
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Default Suzuki DF250 tilt cylinder seal

Hoping someone can help me here. The seal around the tilt rod on my PTT assembly went out this weekend. I was figuring this would be a quick fix. I called the local Suzuki dealer today and he told me that they donít sell the seal that goes in the top cap and I would need to buy the entire tilt cylinder assembly. I thought to myself, that canít be right, surely someone has a seal that I can replace in the cap. I called another dealer in Port Richey and they sell a kit, but it appears to be for a different PTT assembly. Looked at boats.net and sure enough, they sell the o rings in the cylinder but nothing for the seal in the cap. Anyone know where I can find this? Is it the same size as one on a different PTT and I can just order a different part number? Below is a picture of what I am looking for and one of the PTT on my motor.




Last edited by Ben W; 07-08-2019 at 05:41 PM.
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Old 07-08-2019, 05:48 PM
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A thought I just had after staring at this more, is the cap (item 6 on the parts diagram) on the trim rod the same cap as the one on the tilt rod? From the picture of my PTT they look similar but not the same.
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Old 07-08-2019, 05:52 PM
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Pull it apart and go visit your local hyd repair shop. Easy fix
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Old 07-08-2019, 06:29 PM
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Thanks Willy. That may be what I have to do. Hoping to find the parts so I can repair it this weekend. Just want to get it fixed and get it in the water right now, plan on doing a full rebuild on both PTTs this winter.
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Old 07-09-2019, 04:41 AM
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The seal, cap and rod are not sold separately, you must buy the whole piston/cylinder assy(part #2) and I would also get parts #17,18, and 19 while you are at it. These other parts are the pin and seals that go underneath the trim cylinder assy and move fluid through it. You can see in pic that your piston(rod) is pitted/chipped and that is what is tearing up the seals causing leaks.
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Old 07-09-2019, 05:14 AM
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^^ I've got to get Mike to do mine this month if I can find the time to pull the boat out of the water.

If you'd like to try to replace the seals, I'm happy to send you my leaking #2 assembly and you can disassemble and see what's what. FWIW my piston actually looks in great shape compared to yours.

There is a shop in the tampa area that claims to rebuild these units for $500. If you walked in with your center cylinder maybe they'd service it alone?
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Old 07-13-2019, 07:13 PM
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So just an update on this, I found a seal that would supposedly replace the one in the tilt cylinder cap. I got the seal, bought the tool to get the cylinder cap off, took the PTT off the boat and could not get the cap off the cylinder. Used a torch to heat it, put it in a vise, used a breaker bar and that thing didnít budge. The local mechanic told me that I wouldnít be able to get it off and he was right. Going to buy a new tilt assembly on Monday. Moral of the story is donít waste your time on this, I think that thing is damn near impossible to get off.
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Old 07-17-2019, 06:47 PM
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Originally Posted by Outboard Specialties View Post
The seal, cap and rod are not sold separately, you must buy the whole piston/cylinder assy(part #2) and I would also get parts #17,18, and 19 while you are at it. These other parts are the pin and seals that go underneath the trim cylinder assy and move fluid through it. You can see in pic that your piston(rod) is pitted/chipped and that is what is tearing up the seals causing leaks.
Wondering if you could help me with my latest issue. I replaced the piston/cylinder assy on my starboard motor and put everything back together. I just put the boat back in the water today and noticed that my port motor trims up faster than my starboard motor so when switching to trim both motors with one switch that creates an issue. Trying to trouble shoot and hoping to get a little advice from an expert. Here are a few things that Iím thinking may be the cause of the issue:
1) I am not sure that I refilled/bled the trim assembly correctly. I completely drained the entire PTT when I removed it from the boat. When I put it back on, I just kept pumping fluid into the reservoir and trimming the motor up until it finally pumped enough fluid into the cylinders to push the motor up. Once I could not get anymore fluid into the reservoir I trimmed the motor up all the way and loosened the manual release screw to allow the motor to drop slowly and push out air. I repeated this process 3 times.
2) I used hydraulic steering fluid in lieu of Dextrol III. The local mechanic told me that is what they use and I just happened to have a bottle sitting in the shop. The manual says to use Dextrol III, not sure if this could be the cause of the difference in trim speed.

I am am concerned that I still have air in the assembly but not sure if I have filled and bled it correctly. I have tried to do some research and have not found much info for when not removing the cylinder caps. Any info would be greatly appreciated. Thank you
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Old 07-21-2019, 05:34 AM
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BTT, hoping someone may be able to give me some advice on this issue.
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Old 07-29-2019, 04:22 PM
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One more try on this, just trying to figure out why my motors trim at different speeds now.
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Old 07-31-2019, 05:13 PM
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When you said you replaced the whole tilt assembly, did you replace the entire cylinder or just the cap and ram? If it's the cylinder, is the new cylinder the same diameter as the old cylinder? Is the diameter different than the cylinder on the other engine? If it's larger it will fill more slowly.
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Old 08-01-2019, 07:59 PM
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Default Tilt speed

I just replaced the tilt cylinder in one of my new-to-me df300s. The motor with the new cylibder was slower to tilt up for the first couple of cycles, but eventually caught up with the other motor. Both motors now tilt at the same speed.

Once mounted on the motor, I see only one difference between what you and I did: you used the manual release to lower yours, whereas I used PTT to move the motor both up and down.

The service manual outlines a procedure for bleeding the cylinder prior to installing it, which I also did. I'm not sure if you did that part or not, or how much of a difference it would make.

Either way, if there's air trapped in the system, you should be able to hear it very clearly.

Good luck!
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Old 08-02-2019, 03:55 PM
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Thanks for the responses. I am going to mess with it more this weekend. I am guessing I still have air in it. I did follow the procedure in the manual. I may not have done it enough cycles or given it enough time for the air bubbles to bleed out. Someone gave me some other input on another thread so Iím going to give that a shot this weekend.
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Old 08-06-2019, 06:49 PM
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I have the same issue currently on a 40hp Evinrude. I called around a lot of marinas and surprised as to how few places actually service the trim cylinders/motors! Best I have found so far is to send the assembly to Florida to a trim and tilt specialists. May go this route anyhow and have them go through entire assembly and have it fixed right.
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