2025 Suzuki 115 outboard lower unit pressurizing

[Oldgregg]

I was trying to perform the 100hr service on the lower unit. Removed vent cap and drain screw, seemed to drain ok but maybe slow. Attempted to refill and pumping the oil in pressurizes the lower unit to the point of shaft seal failure. removed the pump line and pressurized oil mess. attempted to fish a piece of welding rod in the hole to see f I could free something up but no bueno. Attempted blowing pressurized air from both sides but nothing. Not sure what to do.

 

[William01]

Something isn’t adding up. With the vent screw(top) out and you pumping oil in the drain screw(bottom) oil has to come out the top. It takes awhile for me to get 850ml in with a hand pump on my Suzuki DF90A but the oil does come out the top when full.

I can’t see how you can blow oil out of the shaft seal with a hand pump. You are using a hand pump?

Time to call your dealer, you should be covered under warranty.

 

[racerone]

I would say you have made a mistake somewhere.