Suzuki 4-stroke engine holder problem - serious corrosion

[Isaac]

Gents if you own a Suzuki 4 stroke DF 90-115-140 from 2001-2007 there is a galvanic corrosion issue that will cause a lot of damage if it hasn't already. The engine holder has a carbon steel plug in the exhaust port, this plug is corroding from the inside out and will eventually blow out.

The plug was for a oxygen analyser that was never put in. Suzuki changed the engine holder in 08 but have known about the issue since 02 but have not done anything about it or even told dealers, customers - no-one.

I'm not going into how I found this out but do a search on google for suzuki engine holder problem, suzuki corrosion problem and you come up with;

http://www.marineengine.com/boat-for...em-anyone-else

http://www.thehulltruth.com/boating-...osion-fix.html

http://www.suzukioutboardforum.com/s...-location.html

http://www.suzukioutboardforum.com/s...questions.html

http://forums.iboats.com/showthread.php?t=375312

http://www.thehulltruth.com/boating-...roblems.html#b

Cheers Isaac

[MTAQ/BTAQ]

Does this apply to 70hp four strokes, mine was new in December 2007?

[Isaac]

I'm not sure about the 70's, pull the cowl and lower plastic cover off and have a look, like I said in the original post the engine holder was changed in the 08 models. Cheers.

[MTAQ/BTAQ]

Thank you for all those links, I have read through them and apparently the 70hp does not have those issues but the news is not good for those 90hp/115hp/140hp.
Thanks again.

[purnong]

Wow, Read through those threads and that is scary
Why the hell would an outboard company put a metal plug in an alloy section of the engine, It's not like dissimilar metal corrosion issues were unheard of at the time

[Noelm]

that "issue" has been around for years, but like other motor brands, we (here in Aus) for some reason defend our brand to the hilt and tend to close our eyes to stuff like this. I raised this about 3 years ago and was more or less told "nah, no way" there is a couple of options, replace the steel plug while it is still OK, replace the engine holder (the replacement part does not have the plug) or if you have the damage, weld the hole up, it can cause some other issues too, as in melt the wiring harness if it actually "blows out" and that is not cheap to replace.

[WalrusLike]

My mate said they were Dispirins... dissolve in water. Now I know why.

[Noelm]

no, not true, the early ones were a bit sus, and to be fair, the same name was pinned to Hondas when they hit the market here in Aus, all makers have had their share of problems, some very serious and some just hear say and have no factual evidence, some rectified the problems and stood by their customers, some just fixed problems while still under warranty and after that, you are on your own, Yamaha has had dramas, Suzuki has, Mercury has, OMC/BRP have, most get fixed and the owners are happy and will buy another one, some get the run around and that brand is never gong to be purchased again.

[Noelm]

I'm not sure about the 70's, pull the cowl off and have a look if you have a plug there, if there is take it out and put a magnet on it to see if it's steel or ali. Cheers.

You cannot see it with the cowl off, you need to remove the lower cover too. The later ones are NOT alluminium, the plug is not there at all, we need to be accurate on this.

[WalrusLike]

......we need to be accurate on this.

Yeah good point. I added to the fud with my comment above... thanks for the correction.

[preso]

I have a 115 johno (suzuki) 2005 model. After reading all this went and checked mine. No sign of rust all looks brand new. But I would like to change it out just the same. Does anyone know where to get a replacement plug?

[webby nq]

Thought id check it out myself with my 2005 model Suzuki which I bought second hand and this is what I found,

Attachment 82624

slight bit of rust on all 3 bolts, all look the same material

Attachment 82625

Took a bit to crack but was relatively easy to remove , thread looks to be in good condition , and the bolt thread is good and has a little bit of corrosion on the inner part.

Attachment 82626
Suppose its worth getting some new bolts and replacing them especially after seeing those photos from other sites hey, something so easily fixed but has caused a lot of damage,
thanks for the posts guys
Webster

[Noelm]

I don't think there is anything available "off the shelf" to fit that plug/thread, most have got one made as a one off by an engineering shop, they charge a bit, but in the long run, it works out a cheap and permanent fix. OH, and Webby, the pictures do not work.

[Spiderpig]

http://www.suzukioutboardforum.com/s...-df-140-a.html

I wouldn't be stressing too much until it actually happens.

[Noelm]

so, you suggest you wait untill you require a hefty repair bill rather than spend an hour and fix the potential problem now? I have been a member of the Suzuki forum for yonks now, and this has been raised time and time again, it IS a problem, but it can be a simple fix if you do it NOW. I have personally seen motors damaged and wiring hanesses burnt to a crisp, do the right thing and do it now, if you own a Yamaha 225 a few years old, you need to do some searching on some US sites.