1996 Suzuki DT25C Oiler Removal

LukeFishWalker

Petty Officer 3rd Class
Joined
Jul 23, 2015
Messages
95
I recently purchased a used '96 DT25C that I was told wasn't used a whole lot.
After closer inspection and thermostat removal I've come to a different conclusion.
The lower unit has a pretty good amount of wear in the gears.
The throttle cables have significant wear and needed to be replaced.
All the fuel lines needed to be replaced despite the fact the cowl paint was pristine.
All these signs lead me to believe that this outboard has been well used because
compression is 110 115 110 and not the 130 it would be in an outboard not used a lot.

I've done a small amount of reading and feel uncomfortable to continue using the
auto-mixing feature.
The tank and mixing valve removal is pretty straight forward.
My question is (And I'm Certain You've Answered This Before, But Please Bear With Me))
To remove the oil pump and not compromise the crankcase volume, do I leave the pump shaft?
Or should I make a blank plate with an attached spacer to take up the increased volume
and completely remove the drive gear shaft? Or, just remove the shaft and grind
the helical gear to prevent it from contacting the crank gear?
I read elsewhere on another forum that by removing the pump gear, it will increase the
volume in the bottom cylinder and thus will decrease the performance of #3.

Thank You For Your Time & Patience,
Lukus
 

LukeFishWalker

Petty Officer 3rd Class
Joined
Jul 23, 2015
Messages
95
Ok, I've taken it upon myself to remove the gear and grind the helical
portion of the gear that makes contact with the crank gear.
After the pump gear would no longer make contact with the crank gear,
I removed another 1/8 inch to completely avoid contact.
I then made a blank plate, gasket and shortened the 2 allen head
bolts that were totally to long since they are in such a tight area.
I left just under 1/2 inch of thread to tighten the blank plate.
I will post results tomorrow.
Here's a picture of the pump gear with the material removed. Suzuki Gear.jpg
 

LukeFishWalker

Petty Officer 3rd Class
Joined
Jul 23, 2015
Messages
95
I have success with this method.
I ran the motor for over an hour and had no issues
 
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