Any bad DF years?

[mako238]

Looking into possible repower. Any years I should be cautious about?

[Moonlighter]

What horsepower you looking at?

There are only 3 "known issues" that I am aware of re the DF Suzuki 4 strokes.

One issue is the earlier DF90-140 series engines, up to around 2006. There was a steel 1" plug (like a welsh plug) in the alloy engine holder, just above the fresh water flushing connection on the port side, that can corrode out due to dissimilar metals. Later models, the engine holder changed and this plug no longer exists in the casting. This issue can be fixed by removing the steel plug and either welding over the hole or replacing with an after-market alloy plug.

The other is the tiny screws in the butterfly's on the intake manifolds of DF250's - some may not have been loctited correctly at the factory, come loose, and the engine may then swallow the screws and/or the butterfly flaps themselves. Which can be nasty, even fatal to the engine, of course. Easy to check these and tighten/fix permanently. Not sure what model years affected with this issue, though.

The only other generic thing to look for is the internal engine anodes. It seems that some people totally neglect to check and replace these anodes, which of course provide vital internal engine corrosion protection. I would insist on them being checked on any 2nd hand engine I was looking at. Again, they are easy to check and it's very obvious if they have or haven't been replaced as part of normal service routine.

The third is one that shouldn't be around any longer. The very first CR DF 300's had a gearbox fault that was recalled and fixed, if it wasn't, then within 50 hours the bush failed and the gearbox lunched itself. But as I say, that was so long ago now that either they will have been fixed under recall/warranty, or the gearbox would have failed and been replaced by now. Only affected Left hand (CR) motors.

That's all I'm aware of.

[mako238]

Thanks for the quick and detailed reply. Looking at DF250

[Auburn02]

Moonlighter, you just reminded me of the engine holder corrosion issue that I've never looked into on my '03. It's got about 380 hours on it if that makes a difference (good or bad), and is used primarily in salt water. I don't think I have a hole in the engine holder else I would have noticed by now, but I worry about causing more harm if I try to remove the plug. Any tips? Of course, I probably won't do anything til end of summer, no point ruining the rest of the season if I can avoid it.

[Moonlighter]

Look, the issue obviously doesn't arise on every single motor. It might or might not happen on yours.

But it's well worth keeping an eye on that plug for any early signs of deterioration, as you don't want to be 20 miles from land to have the heat burn through nearby wiring and leave you stranded. Or worse.

Some people take the precautionary approach and remove the plug and replace with the aftermarket alloy one, or have it welded over. It's a judgement call that you'll have to make yourself.

You won't notice it easily unless you take the side covers off the engine. That's not very difficult, and has to be done anyway when you drop the leg to service the lower unit anyway.

If you don't replace the plug, I would be inspecting it every 6 months if it was mine.

[Auburn02]

Oh yeah, I've pulled the side panels numerous times for various things, as I do most of my own maintenance. If my engine holder did ever need replacing, I would have no worries doing it myself. But from what I've read, sometimes even by looking from the outside it's difficult to tell if it's started corroding on the inside - so based on that I'll look at replacing the plug after the summer. And worst case scenario I break the housing while trying to remove it like I've seen happen to some people, I'll replace the holder or have it welded up.

[Nestor PR]

Oh yeah, I've pulled the side panels numerous times for various things, as I do most of my own maintenance. If my engine holder did ever need replacing, I would have no worries doing it myself. But from what I've read, sometimes even by looking from the outside it's difficult to tell if it's started corroding on the inside - so based on that I'll look at replacing the plug after the summer. And worst case scenario I break the housing while trying to remove it like I've seen happen to some people, I'll replace the holder or have it welded up.

I need your help, I pulled the panels off my DF300 and now I can't get them back on, the tabs at the top won't engage the rubber slots. Is there a magic trick to it?