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Old 29 September 2013, 15:01   #1
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Suzuki dt115 no telltale @ wot

Hi

Just done a complete powerhead rebuild of my 1998 Suzuki DT 115, pistons, rings, rebore, thermostat, prvs, bearings, complete new gaskets, seals the works and it runs like a dream but after 3000rpm tell tale gets weaker as revs increase until it stops at wot and it over heats.

The water pump has had new gasket and impeller and the telltale is strong up to 3000 revs

This is really doing me head in now any help greatly appreciated
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Old 29 September 2013, 16:46   #2
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How are you testing this?
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Old 29 September 2013, 17:08   #3
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Could it be a cylinder or exhaust leak pressurising the water jacket and overpowering the impeller force?
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Old 29 September 2013, 17:24   #4
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How are you testing this?
Out on the river
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Old 29 September 2013, 17:26   #5
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Could it be a cylinder or exhaust leak pressurising the water jacket and overpowering the impeller force?
If it is that not sure from where as all faces skimmed and the power head has been completely rebuilt with new gaskets and all was good
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Old 01 October 2013, 14:46   #6
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Could it be a cylinder or exhaust leak pressurising the water jacket and overpowering the impeller force?
Hi checked compression again all good and removed exhaust jacket cover, it is all immaculate.

THis beginning to be a nightmare.
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Old 01 October 2013, 17:13   #7
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Did you change complete water pump kit ? If not, change. When running on rivers, sand, suspended small particles on water can extremely polish your impeller and liner badly, will experiment pressure loss and probaly engine overheat. There should be market available a hevy duty stainless steel water pump kit, check with Suzuki.-

Happy Boating
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Old 01 October 2013, 17:22   #8
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Missing the key in the impeller? When the shaft is spinning slowly friction is enough to make it spin along with the shaft, as the shaft speeds up the impeller slips?
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Old 02 October 2013, 04:47   #9
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I had a problem some years ago on my DF90 which started overheating. I couldn't find anything wrong with the cooling system but after popping a new impellor in it was resolved. My conclusion was that the metal insert in the impellor was slipping and although the key was present it failed to pump water.
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Old 02 October 2013, 12:35   #10
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Swesandy

Most likely to be a jammed or malfunctioning thermostat. This should be opening when the engine has warmed up, and it sounds like it is jammed only partly open

Alternatively it might be some of the water-cooling passages are partly clogged with something used during the rebuild

regards Peter Bryson
y
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