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Aluminum replacement plugs DF-140

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  • Aluminum replacement plugs DF-140

    Those of us with older 4 stroke suzukis, have probably heard about the
    corrosion problem with the models that have the steel plug in the engine holder.

    ****plug LLC of Bozeman MT is making a replacement plug using 6061 aluminum, these plugs are in the size 18 mm x 1.5 pitch and fit perfectly.

    I recently had the engine holder on my 2002 DF 140 replaced because I feared the that it was too far gone already, $1800.00 later ( live and learn) I found the original is still serviceable.
    I removed the old plug by using an undersize (barely) drill and, then cutting thru the remainder in 2 places with a hacksaw blade. The 2 cuts were about 60 deg apart, at that point the rest of the plug was in 3 peices and knocked out easily with a punch, and the threads were quite serviceable.
    If you can remove the old one check to see if the threads are useable,
    if so call Tim at

    ****plug LLC
    224 New Ventures Dr ste 9
    Bozeman MT USA 59718
    1-888-578-3851
    www.****plug. com

    I am not affiliated with, nor do I recieve any thing for this recomendation.

    Although I do have a 2002 Suzuki DF-140 engine holder in good cond, (about 250 hrs) with the plug already replaced (best offer) New ones are $ 800-900.00 ea.
    repost me if you need more info.

    Piscophile
    Last edited by captbill; 05-15-2012, 01:37 PM. Reason: the word **** removed

  • #2
    where is this plug? are they the ones with the allen key heads on the port side?

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    • #3
      Yes: Port side,You must remove the 2 motor leg covers on ea side,y below the cowl as you cannot see it due to a 6" h X 4" wide rectangular casting protrusion blocking your view.
      The plug is the first one on the left, under the protrusion, and to the right of the oil dipstick hole. It is about a 1" dia flat head with an allen/Hex head wrench socket molded in and has a soft aluminum washer for a gasket.
      There is also another of the same size to the right of that one, it and the other smaller Plugs in the casting are not known to be a problem.
      It should be noted that later models have done away with the offending plug.
      I am not sure what year they did away with it, 2005 comes to mind. Please dont take my just word for it, I am sure a number of folks on this forum can provide you with that info.

      Good luck
      Piscophile

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