First things first, never let your lower unit lube be low. It should be changed every 100 hours of use, or at least checked after big trips with prolonged use. If it is low, but does not look grey, milky or burnt, then just add from bottom plug until it comes out of the top plug. Now, the water pump is completely separate from your oil situation. Whether or not your motor has what is called a "pee stream" does not necessarily mean you have a bad water pump. Often times the water flow indicator, or "pee stream" on your engine will be plugged, which is okay, it\'s just an indicator. However, if you were to test run your engine on a garden hose at home, and there was no flow out of the propeller hub, which is actually where the exhaust flow exits as well as your cooling water, then you\'ll need a new water pump impeller and/or possibly a water pump kit. This should be around 40 to 75 dollars in parts, and about 1.5 hrs in labor if you were to take it to a shop.
SOURCE: 2008 Yahama 90 2 stroke outboard lower unit fluid leak
Ok by fluid I assume it is gear oil leaking yes?
There is every chance there is the smallest seal leak there that may only be present once the gear case gets a little pressure in it, either through use, or through expansion as the leg heats sitting in the sun even. Have you got a new washer installed under this screw to properly seal it? Usually a nylon type washer is best.
Also, how do you know the lower unit is not leaking or have water intrusion? Have you drained the gearbox oil recently? If so what color was the oil, milky looking at oil or good semi-transparent oil color?
SOURCE: Free wiring diagram for 1978 Mercury Outboard 115 HP boat motor
I have a maintainance manual for this engine (I have the same one) with pages of wiring diagrams. What specific system/area are you interested in, I could scan in the page(s) and email them to you.
Mark
SOURCE: suzuki outboard motor 65 hp --oil sensor keeps
assuming you are not out of oil in your oil reservoir you probably have a bad sending unit in the reservoir. never bypass it or eliminate it as you could permanently damage your motor or ruin it if you ran it out of oil.
SOURCE: The low water pressure and
Not seeing anything particular, especially on this motor, there have been overheating on different models but nothing new like yours. Since it is new, please call the dealer who sold this to you, there is factory warranty that you need to use, if you alter anything then the warranty will be void. With that said, always make sure the stern is in the water deep enough to draw the water in, if trimmed it losses its ability to draw water like it should. The Poppet valve could be sticking or the thermostats can be bad, this is not that uncommon. Ther is also the hose that connects inside to the water jacket that may have come loose and not impossible but maybe you sucked up something that hurt the impeller for the water pump. Bad timing can cause this as well as a cylinder not getting the correct amount of oil. These thing can fall under the lemon law just like cars, if the motor had issues when you bought it, the manufacture is required to fix these issues. I wish I had a canned answer to this but there is none. It could be as simple as a bad temp gauge giving you a false reading. Does the motor actually seem like it is running hot or is the alarms just going off? 10 hours isstill a brand new engine and the dealer should have to remedy this. You need to find out if it is overheating or there is some other problem like running lean, as either one will destroy a motor if you keep running it like that.
I assume you checked the intakes for blockage, and the water coming out of the weep hole is strong and warm. You can try cleaning the weep hole with some weed trimmer string to see if something is blocking the exit.
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