New Suzuki 2.5 hp O/B failure

scross

scross

Well-known member
Joined
Jan 30, 2015
Messages
2,092
Fluid Motion Model
C-28
Hull Identification Number
FMLC2831A717
Vessel Name
R-25 Classic - Sold
MMSI Number
367719470
Has anyone had to deal with Suzuki Customer Service regarding one of their 2.5 HP outboards? Purchased our mid-February and this was its first use. It completely locked up after about 1 hour of use. Feels like the starting rope is jammed - it doesn’t move even 1/4”. The engine was running great until the second it wasn’t.
Any helpful insights into dealing with the Suzuki folks?
 
Does the 2.5hp have a manual gear lever? Or is it just a forward-motion centrifugal clutch?

I upgraded from 2.5hp Yamaha with a centrifugal clutch to a 5hp Tohatsu (yay propane) with a gear lever a few months ago. I now need to make sure the gear lever is in neutral before starting, or it feels like it is broken. I've forgotten several times and freaked out. If it does have a gear lever, see if it isn't disengaging for some reason.

Good luck
 
The “transmission” on the Suzuki 2.5HP is a neutral or forward manual lever. The engine was running great and we were cruising in our dinghy at about 3 mph when it stopped within a second or two. Prop spins normally in neutral. Not the gas cap vent causing fuel starvation - it was wide open. I’m 90% sure the failure has something to do with the starting rope.
We were lucky to be within 100 yards of the boat in calm waters when it failed.
We owned our last Suzuki 2.5 HP O/B for 7 years and never had any issues with it. I am pretty familiar with all the controls on that O/B.
 
To confirm it is a starter recoil and not a locked up power head. Remove the spark plug, put the engine in gear turn the prop to turn the engine over. If the engine turns over freely then you know the engine did not lock up. Based on you failure description it sounds like the engine was running and locked up. Is the oil level correct ? I know when I purchased my 6 hp Suzuki it had the oil drained for shipment. There was oil in the pan from the factory but then drained. I had to purchase oil and fill the crank case. If it is a new motor take it to a Suzuki dealer for warranty assistance.
 
Thanks Brian!
Literally on the water in Sucia Island tonight. Yes, there was exactly the right amount of oil in the engine. Overtons filled it with oil prior to shipment and test ran it. I spoke with their customer about this when the engine was delivered. I checked the levels twice before use. Little window on the engine makes that easy.
The engine started on the first full pull 3 different times this week before failure. I’ll pull the spark plug tomorrow and try your test. We have less than 1 hour and 1 mile of usage on it.

UPDATE: I pulled the spark plug, put the engine in forward and tried to turn the prop. No movement. Rechecked the oil. It’s not showing in the window. No signs of oil leaking anywhere. Spark plug looks normal, not oil fouled.
 
Sounds like the power head is locked up. When I purchased my Suzuki it was test run then oil drained for shipment. I was told they could not ship the motor with oil in it. The window is deceiving. The dip stick is the go to way to check the oil level with the engine in the running position.
 
Bummer to hear this. Thankfully you're close enough to Friday Harbor, Roche, or any of the other bigger marinas where someone can help you out with it. They also have usually have decent stock of OBs if it has to be replaced.
 
Thanks Dave and Brian.
No dipstick on this little engine. Just an oil fill/drain plug and the little window to check levels.
Spent 2 hours on hold with Suzuki Customer Service this morning before giving up and leaving a voice mail.
A local Suzuki Authorized Service Center in Seattle (Waypoint Marine) is going to take it tomorrow and work with Suzuki on the repairs.
Hopefully it will be back in service for our next cruise four weeks from now.
 
scross":3ei2ra49 said:
Thanks Dave and Brian.
No dipstick on this little engine. Just an oil fill/drain plug and the little window to check levels.
Spent 2 hours on hold with Suzuki Customer Service this morning before giving up and leaving a voice mail.
A local Suzuki Authorized Service Center in Seattle (Waypoint Marine) is going to take it tomorrow and work with Suzuki on the repairs.
Hopefully it will be back in service for our next cruise four weeks from now.
Click to expand...

My experiences with Waypoint have been pretty terrible. Don't count on them being timely (or cheap).
 
The new four cycle low HP engines can, in my opinion, be more trouble than they are worth. I recently bought a 4HP Tohatsu and have had problems with it from the get go. Especially, when I used ethanol gas. I have now reverted to the motor I had when I was in the seventh grade, about 67 years ago, a 1950 Neptune Mighty Mite. It is 1.5 HP and only weighs 17.5 pounds. It starts every time on the first pull and pushes my inflatable along at displacement speed.
 
You have me beat! I usually leave my 4 cycle 4 HP Merc/Tohatsu behind on the longer trips and take my 1970 Evinrude 2 HP. I love that sweetheart dingy pusher. Lighter, always starts beautiful design.
 
scross":3ltt2axe said:
Thanks Brian!
Literally on the water in Sucia Island tonight. Yes, there was exactly the right amount of oil in the engine. Overtons filled it with oil prior to shipment and test ran it. I spoke with their customer about this when the engine was delivered. I checked the levels twice before use. Little window on the engine makes that easy.
The engine started on the first full pull 3 different times this week before failure. I’ll pull the spark plug tomorrow and try your test. We have less than 1 hour and 1 mile of usage on it.

UPDATE: I pulled the spark plug, put the engine in forward and tried to turn the prop. No movement. Rechecked the oil. It’s not showing in the window. No signs of oil leaking anywhere. Spark plug looks normal, not oil fouled.
Click to expand...
If you checked the oil twice and was all good before starting and now there is no oil showing is concerning. If it didn't leak then it had to have been burnt. Not many other options.
 
Per Overtons customer support, they filled the oil and lower unit and test ran the engine before shipping. This was unusual enough that I spoke to both Overtons and Suzuki USA when the engine was delivered back in February. Suzuki thought shipping with oil was very odd. I also didn’t get a manual in the shipment and Suzuki e-mailed me the link. I also discussed with Suzuki in February the break in period and process since it’s pretty specific for that engine.
After my two hours on hold a few days ago trying to contact Suzuki, I called back later that day and got right through. They were fairly helpful.
After the engine froze I pulled the plug per Brian’s suggestion. After a further inspection the following morning I believe I identified the reason that most of the oil (approx 1 cup) was pumped out of the engine during the first hour of use. It’s ended up at Performance in Everett for evaluation. I have started a warranty claim so I won’t discuss further at this time other than it was a dumb mistake made by Overtons during their test that, in retrospect, I could easily have found but didn’t even think to check.
 
Sorry to hear about this.

I have a Mercury 3.5 HP (really Tohatsu) that had issues due to dealer negligence. They sold it to me without checking it over or looking at documents. Got stuck with it, wouldn't start. Had over an hour row back to the boat. Turned out there was a recall on the fuel pump the dealer had not resolved while he had it in stock. When I brought it in he was like "oh yeah, there's a recall. Sorry about that." I learned later that engines that were fixed have a green dot near the fuel pump. All the dealer had to do was take the cowling off to check that.

I have had my DF 2.5 for four years now and its been reliable. Hopefully, your motor issue will get sorted out.

-martin610
 
You mentioned no signs of oil leakage. I cup of oil getting pumped out would leave a trace somewhere, no?
 
I never saw the engine leak oil. That would have been a big red flag. The total amount that leaked was under a cup. I only saw oil on the exterior after I took the cover off. Even then, I only saw a drop or two. I think it was only leaking when the engine was running - not leaking when it was on the stand at the transom or when not running on the dinghy.
 
Update: Outboard fixed and running fine. Suspected low oil level due to drain/fill cap loose on engine as delivered by selling dealer. No further explanation by repair shop. Charged for 1 hour labor. Rest of expenses, if any, covered under warranty.
Key learning: Even though it’s a brand new engine, give it a full pre-flight before use. Don’t assume professionals don’t make mistakes.
 
nice! congrats!
 
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