Johnson / Suzuki DF 140 corrosion problem. Read description for whole story.

A temporary fix of a common problem on Johnson and Suzuki Df- outboardseries. From 2001 to 2007 theese machines came with an ironscrew that was screwed into the aluminium. This causes corrosion. In this case it had gone so far it made a hole and made exhaust leak out under the enginecover and caused the engine to not run properly/stop. This is a 2005 Johnson Df 140. Temporary fixed using JB-weld. This is possibly also a problem for Suzuki and Johnson df 115 df 90. Replace the ironscrew with a goldplug before the corrosion makes a hole like this. EDIT 2023 : Tried to replace the ironplug this spring, but the whole thing snapped off, included the JD-weld fix. Leaving a big hole about 1 inch wide. Took it to a pro welder who had done this job many times, and he fixed it for about 300$ Here is a link to the result: • Welded Johnson DF 140

[@sk2283]

I had the same problem on my 2003 - I tried to remove the steel plug but it snapped out leaving a hole, so I used a grinder and dremmel to clean the metal back and leave a flat surface (almost flat!) then made a plate from aluminium to cover it, drilled and tapped 2 M4 screws to hold in place. Smothered it in Hylomar Exhaust repair putty then fixed the plate sandwiching the putty between the case and plate to make a seal. dried and painted with black VHT looks good and works a treat

[@joerant]

I ended up the same way this spring. It snapped when I tried to remove the plug. Took it to a pro welder to fix it. Turned out very nice. Paid about 300$

[@sk2283]

@@joerant yes best way long term, I wanted to get mine welded, had 2 guys look at it, one said he would do it then neither would answer their phones when I wanted the job doing. It's not something every welder will take on so good you found someone good enough 👍

[@joerant]

@@sk2283 Here is the result after welding ua-cam.com/video/6Dpr6pR0S2s/v-deo.html

[@sitrucual3956]

Common problem. I did a similar fix but I was able to get the steel bolt out by drilling and using a flute extractor. Once it was out I cleaned both sides and used JB Weld. I sealed the hole with a Gold Plug from Amazon. Specifically meant to repair this problem.

[@joerant]

I will try to replace the steelbolt after this season. If possible 😊

[@joerant]

You got a problem with the Wires inside that thing hanging right over the plug? Corrosion inside?

[@icantdo55]

These motors unused in Salt or fresh?

[@joerant]

I use mine in saltwater

[@harveyfloyd6045]

Can't watch the second video because it is "Private."

[@joerant]

Sorry, It’s Working now 😊

[@dustin9035]

How long did it last?

[@joerant]

Well, I expect it to last for years, but I will try to remove the ironplug after the season or weld in an aluminiumpiece instead. But it works fine so far.But the corrosion will continue if the plug isn’t removed. This fix will just hold it back for a long while.