Suzuki df140 corrosion issue.

 This may have already been done to death but if it hasn’t and you own a Suzuki df140 or it’s white cousin the Johnson 140 like I do between the years 2002 and 2007 it might be worth reading this. I will cut a long story short in the wisdom of the gurus at Suzuki they decided to place a mild steel plug in an alloy exhaust jacket component which is exposed to salt water and hot exhaust gases. Dis similar metals in that environment spells disaster a hole in motor and hot exhaust gasses burning out a wire loom that runs next to the fail zone. I just recently removed the plug by tig welding a 10 mm bolt to the plug once removed the corrosion was obvious. There was only one thread left on the female part of the thread. I have heard of people welding up the hole, I cleaned it up and built up the corroded area with plasti bond  which is temp rated and bonds very well with Alli , get your hands on a m18 x1.5 tap and tap hole. Purchase a gold plug which are made for this issue. For more info on this issue google df140 engine holder corrosion. If ya got one of these motors looking at buying a pre loved boat motor package or know someone who has one worth looking at. I will try post some pics but not sure how. Hope this helps cheers Todd

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Ron Ashcroft's picture

Posts: 95

Date Joined: 22/11/07

 Thanks for sharing this mate

Tue, 2019-08-13 17:10

 Thanks for sharing this mate i was aware of this but have been slack with it. I will have to get on to it. Where did you source the gold plug? When i researched it before you coild only get them from America cheers.

wangler's picture

Posts: 602

Date Joined: 26/04/08

I have a new gold plug

Tue, 2019-08-13 17:20

 for sale $40

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todd davies's picture

Posts: 27

Date Joined: 14/03/16

Don’t leave it.

Tue, 2019-08-13 17:36

  Www. goldplug.com and yes there from the USA.  

Rob H's picture

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Not only 140, 115 and 90

Tue, 2019-08-13 19:33

Not only 140, 115 and 90 also.
See my thread from a few years back

http://fishwrecked.com/forum/suzuki-df90-115-140-exhaust-issue

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todd davies's picture

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Date Joined: 14/03/16

Wasn’t 100%sure

Wed, 2019-08-14 09:21

 Yer thought as much but wasn’t 100% sure on the 90 and 115. It can be a show stopper if it lets go the more people aware the better. 

Rob H's picture

Posts: 5148

Date Joined: 18/01/12

If you get the engine code

Wed, 2019-08-14 19:28

If you get the engine code flash up you can get home with cowling off. 

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 Give a man a mask, and he'll show you his true face...

 

 

The older you get the more you realize that no one has a f++king clue what they're doing.

Everyone's just winging it.

 

Posts: 119

Date Joined: 28/11/16

That gold plug looks schmick

Tue, 2019-08-13 20:03

That gold plug looks schmick  

Faulkner Family's picture

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Date Joined: 11/03/08

 Cheers for this info. I have

Wed, 2019-08-14 04:31

 Cheers for this info. I have a 2006 140hp jhonno. Will be looking at mine when I get home from work

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reelentless's picture

Posts: 33

Date Joined: 13/02/07

 Had the same issue with an

Wed, 2019-08-14 08:04

 Had the same issue with an old boat, took me a while to figure out what was going on. Ended up making a plug from aluminium bar and welding in there as my thread was knackered. 

Ron Ashcroft's picture

Posts: 95

Date Joined: 22/11/07

 Thanks for the offer Wangler

Wed, 2019-08-14 18:45

 Thanks for the offer Wangler but i reckon i'll just get it welded up cheers.