Logo

2003 suzuki df 40 water pump problem

marv56

New member
Hi guys, pulling my hair out today with problems after fitting a new impeller to my DF 40 (2003)
fitted a new impeller, plate and gasket last week along with changing oils, run it up on muffs which gave an instent telltale spurt and ran fine for 5 minutes.
Today i put it back into the marina, started and very little water from the telltale, turned off and on again then had water, although not very strong. drove boat to the berth where it ran on tickover for at least 20 mins absolutely fine. turned it off carried out my other bits to do then started engine, hardly any water and it started to overheat. turned off left it and started again, fine but when running at 2000rpm, water stops and overheat alarm. managed to drop lower unit far enough to check impeller and all seems fine, put it all back together and all good until 10 minutes later and again overheat alarm and steam coming from telltale. later i tried it and a steady stream for 20 minutes. very wary on taking it out on the open water now.
Made sure i put everything back as it came apart and turned shaft clockwise to ensure blades were correct. The other thing is, what is the ribbed black collar on the shaft ? it just sits there, no keyway, just spins on the shaft, or did the last person leave something adrift.
Thanks
 
https://www.boats.net/catalog/suzuki/outboard/40hp/df-40tlk3-beginning-vin-04001f-371001/water-pump

See part #17, Key. As far as a black ribber collar I have no idea. I thought it might be an old impeller with the vanes torn off but there is no way the new impeller would fit inside the housing with the old one still in place. Have a look at the link, I don’t see anything that resembles what you describe.

Thanks for your reply, key was replaced with the impeller and was secure when the impeller was pushed down. When i was looking at it yesterday i noticed that when i took the hose off the thermostat while running there wasn't a lot of water but quite a lot of pressure so to speak. same for the telltale hole, as if the pump was working well but only pushing air through. The collar i was talking about is a bush of some sort, although where it is placed it doesnt seem to be doing anything. it was actually sitting on top of the impeller housing. found a link to it after loads of searching.
https://www.boats.net/product/suzuki/57130-94301
 
https://www.selffixer.com/outboard.motors/suzuki/1996-2005.DF40.50.Service.Manual.htm

Above link might help, a genuine Suzuki service manual. I’ve purchased service manuals from this website and no funky changes on my Visa. Would suggest you get a service manual. Looking at you link it appears the bushing belongs under the water pump but it’s only a guess. Suggest you join this forum with your questions, much like this site very knowledgeable people. Sorry I can’t be of help.

https://www.suzukioutboardforum.com/index.php
 
Back
Top