2003 Johnson 90 4stroke Trim leak

[Bwhntr31]

OK, I have a rebranded Suzuki DF90. My trim won't go up. I've bled it, refilled it, and gotten it to work for a day at a time, but then the fluid gets milky and gives me problems again. So I must have a leak to the outside (underwater when the boat is running). The only fluid that I can find on the assembly is some residue between the upper cylinder cover and the lower unit of the cylinder. I've looked over forums and it seems to be a common issue with these motors. My question is what parts do I need to order? I'd like to replace the bushings while I have it apart. The only O ring in the diagram is the big one for the cylinder cover. Don't I also need to replace the o rings between the pump manifold and the cylinder? Wasn't there some sort of upgraded part associated with the reservoir from plastic to aluminum?

 

[jakedaawg]

I would pop the motor off and make sure it's not leaking between pump and motor. That's the most common repair I do on those. Thin little o ring goes bad.

 

[Bwhntr31]

Is that the big o ring for the cylinder cover? I don't see any of the smaller O rings on any of the diagrams. Do you have a part number? I would agree that it is probably between the pump and motor. It only acts up going up. It goes down fine. That leads me to think that the O ring on the up side of the manifold is bad. I can pull the assembly easy enough, but don't want to take it off and disassemble before I have the parts in hand since I can still rig it to work for a day at a time to keep fishing. It's a PITA, but it is what it is......

 

[jakedaawg]

I was referring to the electric motor to pump seal. 5032915. That number has been superceded probably but a dealer could tell you the new number.