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2002 Suzuki DF140 four strokes Corrosion Problems?
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2002 Suzuki DF140 four strokes Corrosion Problems?
So here is the issue I am having with my engines and wondering if anybody else is experiencing similiar problems.
Problem started in the port engine. Would start and idle fine, then after running it for 20 minutes or so when you back down into Neutral it would stall. From that point on it wouldn't idle, until it would sit for and extended time. Than next time out same issue. Well after alot of trouble shooting took to the dealer who found a port in the engine mount had totally rust throught to the point when he took it for a test ride it blew a hole in the port and destroyed the wiring harness. Dealer replaces the engine mount and warns that it is happening in the Starboard and that should be replaced over the winter. Claims a bad design resulted in exhaust getting trapped and causing the corrosion. So took it in to have the starboard engine looked at, since than they have had other 2002 engines same model come in with corrosion issues. So they took apart the starboard engine and found the same corrosion in the engine box as expected, but in addition found the Drive shaft housing completly corroded, the oil pan completly corroded. Some of these parts stay completly dry according to the mechanic and I am having a hard time understanding that the exhaust is causing this. They are going to look at the port enginge again to see if they find the same issues with the driveshaft housing and the oil pan. Waiting for a quote on repairs but having a hard time justifying dropping thousands into these engines at this point.
The dealer said this problem will start showing up in the 2002 models due to the bad design which they since corrected. They think mine since they had 1400 hours maybe be earlier due to the high hours.
So anybody else experience or hear of this issue?
__________________ 2640 Glacier bay twin 150 suzuki's
Here are some pictures of a 2004 Johnson Df140. I was told that all the required service was being done by the dealer. Come to find out that the internal zincs were never changed. The hole is on the port side of the exhaust adapter.
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I just found out that I have EXACTLY the same problem on my 2004 DF140 with 520 hrs. Service by dealer every year. Flushed after each use. I have praised this engine for 6 years, runs great! Had some random stalling problems at idle speed this year. Dealer says it was "choking on fumes".
There is a plug in the port side of the "engine holder". This part is on DF90 thru DF140. The plug is ferrous metal in an aluminum housing that has hot exhaust behind it. It was intended as a potential place for service to install an O2 sensor which they ended up never using. The corrosion is from the inside out. Its not salt corrosion because there's no water there. Its bimetalic corrosion and clearly a defect in material or design. My guess is cheap chinese stainless steel plugs and some get lucky, some don't. Hence, Suzuki has stopped tapping/plugging the hole in newer models. I didn't ask what year. Mines's a 2004.
The dealer said he has seen exact same problem in 3 older engines. One was in a twin configuration with one motor badly corroded so they took the other apart and it was fine.
Estimated cost to repair $1800 ($1018 for parts). Hopefully he doesn't find corrosion in the head or oil pan.
Yep- my next door neighbor had the same issue-engine holder and oil pan on a Zuke 140. $2500 later he's back in business. So, we started poking around my '02 Honda BF 225 and we found similar issues. Looks like the early 4Strokes had some corrosion issues. Don't hear too much about the newer 4S but maybe it's too early. I'm like you, I loved my Honda until these issues popped up.
And here I've been praising zukes for not having the corrosion issues of the yams.....as asked above, and a good question, when did they change the design, and is this the only major area of design for corrosoin on the zukes?
Maybe during the 2009 model production from what info I got from local shop. If you order the engine holder part, you get the one without the plug no matter what. Local shop says that is the only "common" corrosion item they see. To fix 2006 with 340 hours they wanted $900 in parts and 4-5 hours labor, plus tax, so about $1500. For now I fixed it with exhaust manifold patch since it rated for higher temperatures.
Etecs have no problems...keep telling yourself that.
Quote:
Originally Posted by floridarob
And here I've been praising zukes for not having the corrosion issues of the yams.....as asked above, and a good question, when did they change the design, and is this the only major area of design for corrosoin on the zukes?
__________________ My Suzuki 200's have tons of Torque, please no more lame talk about having to change the oil. Fish On...
We tried that with my neighbors Zuke but it blew out. He is one of the most anal guys I know and he put alot of hours into that patch before giving up and going to Zuke Service.
Hope your luck is better
My 2005 DF 140 had the same problem. First mechanic plugged the leak with Marine Tek, that last about a year. Just paid $350 to have it welded, we'll see how it holds up. The engine is running fine again for right now.
I just found out that my 2007 140 has the exact same problem, does this look familiar? I'm still contemplating a JB weld fix if it works for the time being as it sounds like this won't be covered by my 6 year warranty.
It is not covered by warranty, parts run about $1000 and about 5 hours labor. You have the classic Suzuki design flaw that they won't admit to. JB Weld won't hold. Exhaust manifold/header patch putty may work for a while [mine lasted about 50 hours]. I have since got it welded.
Have a 2006 DF115 without the problem but it concerns me. Has anyone tried removing the plug, cleaning it and coating it with some high temp Never Seez or other lubricant? Maybe doing it on a yearly basis with other maintenance would halt the problem?
Looks like it would be simple IF it will unscrew the first time without taking out the aluminum threads on the engine part.
2002 Suzuki DF140 four strokes Corrosion Problems? 
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