Notices

changing DF200AP Suzuki Water Pump Question

Old 06-01-2019, 12:12 AM
  #1  
Senior Member
Thread Starter
 
Join Date: Dec 2016
Posts: 546
Likes: 0
Received 117 Likes on 65 Posts
Default changing DF200AP Suzuki Water Pump Question

I have the fly by wire set up and from what I've been told changing the water pump is a different procedure then a mechanical control engine. The manual says I need to remove the main relay or shift actuator fuse from the fuse box before removing clutch link to avoid shift actuator damage. Does anyone know where this fuse is located and how to tell I'm pulling the right fuse? Or if I disconnected the battery would I still have to pull the fuse?

Last edited by b1gdog83; 06-01-2019 at 12:26 AM.
Old 06-01-2019, 05:13 AM
  #2  
Senior MemberCaptains Club Member
THT sponsor
 
Outboard Specialties's Avatar
 
Join Date: Jan 2007
Location: Pompano Beach, FL
Posts: 2,164
Received 334 Likes on 183 Posts
Default

Nothing is different from those 2 motors regarding changing the water pump. You do not need to remove any fuse or turn power off, the suzuki book will tell you this only out of precaution so nobody starts and shifts the motor while you work on it. Just make sure you are in neutral before dropping lower and in neutral when you put it back up, you can leave the key off to make sure nothing moves.
Likes:
Old 06-01-2019, 11:06 AM
  #3  
Senior Member
Thread Starter
 
Join Date: Dec 2016
Posts: 546
Likes: 0
Received 117 Likes on 65 Posts
Default

Originally Posted by Outboard Specialties View Post
Nothing is different from those 2 motors regarding changing the water pump. You do not need to remove any fuse or turn power off, the suzuki book will tell you this only out of precaution so nobody starts and shifts the motor while you work on it. Just make sure you are in neutral before dropping lower and in neutral when you put it back up, you can leave the key off to make sure nothing moves.
Perfect Thanks! So just so I understand I can leave the batteries connected? I have a dual battery switch that I'll switch to the "OFF" position will that suffice?
Old 06-01-2019, 11:40 AM
  #4  
Senior MemberCaptains Club Member
THT sponsor
 
Outboard Specialties's Avatar
 
Join Date: Jan 2007
Location: Pompano Beach, FL
Posts: 2,164
Received 334 Likes on 183 Posts
Default

Originally Posted by b1gdog83 View Post
Perfect Thanks! So just so I understand I can leave the batteries connected? I have a dual battery switch that I'll switch to the "OFF" position will that suffice?
turning battery switch off is plenty. That’s it.
Old 06-01-2019, 12:54 PM
  #5  
Senior Member
Thread Starter
 
Join Date: Dec 2016
Posts: 546
Likes: 0
Received 117 Likes on 65 Posts
Default

Thanks for the quick response!
Old 06-01-2019, 08:47 PM
  #6  
Senior Member
Thread Starter
 
Join Date: Dec 2016
Posts: 546
Likes: 0
Received 117 Likes on 65 Posts
Default

One last question: The manual says to use a sealant on the mating surfaces of the gearcase and driveshaft housing. It also says to add sealant to the 7 gearcase bolts. Is this necessary? I have the Suzuki grease but no sealant.
Old 06-03-2019, 04:23 AM
  #7  
Senior MemberCaptains Club Member
THT sponsor
 
Outboard Specialties's Avatar
 
Join Date: Jan 2007
Location: Pompano Beach, FL
Posts: 2,164
Received 334 Likes on 183 Posts
Default

Grease all the bolts and driveshaft splines, no sealant needed.
Old 06-27-2019, 08:20 PM
  #8  
Senior Member
 
Join Date: Jul 2010
Location: 32N 064W
Posts: 368
Likes: 0
Received 4 Likes on 3 Posts
Default

Changed my lower unit water pump today and thoroughly enjoyed. As easy as 1-2-3 literally. Old impeller looked a little concerning but swapped out with new seals, key, and impeller and plate. 45 minute job.

Old 06-28-2019, 06:31 AM
  #9  
Senior MemberCaptains Club Member
THT sponsor
 
Outboard Specialties's Avatar
 
Join Date: Jan 2007
Location: Pompano Beach, FL
Posts: 2,164
Received 334 Likes on 183 Posts
Default

Looks unusual but might have twisted when you took it apart. Either way, nice job on doing it yourself, just double check when you run it first time that it is pumping water.
Old 10-03-2019, 12:58 AM
  #10  
Junior Member
 
Join Date: Oct 2019
Location: Slovenia
Posts: 5
Likes: 0
Received 0 Likes on 0 Posts
Default

Hi to all,

Did you remove the clutch link rod when you removing the lover unit?
What they mean with "shift to the neutral position"? step 3
I'm on the same way to change impeller and it is my first time to do this on DF200AP with selective rotation and electronic shift
Old 10-03-2019, 04:05 AM
  #11  
Senior Member
 
Join Date: Jul 2010
Location: 32N 064W
Posts: 368
Likes: 0
Received 4 Likes on 3 Posts
Default

Originally Posted by mika View Post
Hi to all,

Did you remove the clutch link rod when you removing the lover unit?
What they mean with "shift to the neutral position"? step 3
I'm on the same way to change impeller and it is my first time to do this on DF200AP with selective rotation and electronic shift
This means make sure that the control lever is in neutral when removing and replacing the lower unit. Make sure that the motor is trimmed up when doing the job. Cheers and good luck.
Old 10-03-2019, 04:34 AM
  #12  
Junior Member
 
Join Date: Oct 2019
Location: Slovenia
Posts: 5
Likes: 0
Received 0 Likes on 0 Posts
Default

Thanks for the answer,

I always put the engine in neutral when I make some maintenance and switch off the main switch. Who leaves the engine in gear?

But, what is with the clutch link rod?

Must be removed or not?
That is the main question.
Why should I remove that rod? Is something holding the lower unit to drop down?
That link rod is the only solid connection to gear shift in mi case electric powered and under this rod is only one sensor for gear position ( For, Neutral, Back) .
Is that only save measure?
Old 10-04-2019, 08:45 AM
  #13  
Junior Member
 
Join Date: Oct 2019
Location: Slovenia
Posts: 5
Likes: 0
Received 0 Likes on 0 Posts
Default

Nobody ?
Real ?
Old 10-04-2019, 10:36 AM
  #14  
Senior MemberCaptains Club Member
THT sponsor
 
Outboard Specialties's Avatar
 
Join Date: Jan 2007
Location: Pompano Beach, FL
Posts: 2,164
Received 334 Likes on 183 Posts
Default

You do not need to remove the clutch link rod, this is only if you are changing the shift actuator. If you ever need to remove the link rod then you must turn off all power to motor so no damage is done by over extending the actuator.

To drop the lower unit down just unbolt the mounting bolts and it will come down. No shift rod to unscrew.
Old 10-04-2019, 10:50 AM
  #15  
Senior MemberCaptains Club Member
 
Join Date: Jun 2005
Location: Connecticut
Posts: 9,287
Received 3,926 Likes on 1,791 Posts
Default

Originally Posted by Outboard Specialties View Post
Grease all the bolts and driveshaft splines, no sealant needed.
Especially the drive shaft splines, I use spline grease. This is important, the last thing you want is a stuck lower unit next time you drop it, you can read the horror stories if you do a search. Clean any gunk off of the splines and add grease to the sides of the shaft only, if you get too much grease on top of the shaft it will not let the shaft go all the way in.
I use a 12 ga shotgun cleaning kit to clean the splines up in the power head, use the bronze brush and a cotton swab like this

Old 10-04-2019, 11:02 AM
  #16  
Junior Member
 
Join Date: Oct 2019
Location: Slovenia
Posts: 5
Likes: 0
Received 0 Likes on 0 Posts
Default

Thanks for answer and useful hint how to clean and grease shaft splines.
Old 10-04-2019, 12:51 PM
  #17  
Senior MemberCaptains Club Member
 
Join Date: Jun 2005
Location: Connecticut
Posts: 9,287
Received 3,926 Likes on 1,791 Posts
Default

Originally Posted by Outboard Specialties View Post
Nothing is different from those 2 motors regarding changing the water pump. You do not need to remove any fuse or turn power off, the suzuki book will tell you this only out of precaution so nobody starts and shifts the motor while you work on it. Just make sure you are in neutral before dropping lower and in neutral when you put it back up, you can leave the key off to make sure nothing moves.
I am glad you posted that, I have the same motors. The warning in the manual is kind of scary. I just drop my lower units like I normally always did.

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are Off


Thread Tools
Search this Thread

Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service - Do Not Sell My Personal Information

Copyright © 2018 MH Sub I, LLC dba Internet Brands. All rights reserved. Use of this site indicates your consent to the Terms of Use.