UPDATE 2014
If your reading this chances are its to late and you have problems. Good info below and please if you see others with Suzuki DFs at the launch ramp tell them about this so they dont learn.....the hard way
As more people are buying Zukes ( Suzuki) this thread will continue to be a good resource.
I have 2 115DFs on my 2006 inflatable.
If you have the steel plug you NEED TO REMOVE IT. Cause if you dont, regardless fresh or salt water, it will cause failure. I had seen mine rusty looking on one motor and thought someday I should fix that. To late. Many times when the corrosion eats thru the aluminum it ends up BURNING UP the wire harness/computer above the plug because hot exhaust is not torching everything under the cowling as your cruising along the water. ( Plug is located right below the ECM computer on the left/port side of engine. $$$ 2000 just for that etc etc
Hope this info helps.
I found a awesome thread LINK BELOW that explains symptoms and a weld repair with photos. Check it out below. I did the weld repair at a welding shop in Laguna Hills Ca called Nine Iron Design and so far, so good. On my second engine I used a magnet and sure enough the other plug is also steel. But did not change it in time, few days after one motor plug let go, the other now has lots of water in the motor oil. Possible engine holder failure. There are 3 steel plugs on the left side of engine.
. Two are in the engine crank case with oil behind them (not a factor) , the ONE YOU WANT TO REPLACE is the one above the water flush below the ECM computer on left side ( see link below great pictures), it is a steel plug and behind that plug is exhaust and water. This plug MUST come out. DONT FORCE IT.
You will either strip it or break the case. I would not even try taking it out, heat the Alum first, or you could strip the allen hole What I did was use a SMALL TORCH that I bought to heat shrink wrap from auto parts store and heat the area around the plug).
Very small torch worked awesome. Heat the aluminum, it will expand. Dont burn wires or anything, just have the blue flame tip in circles around the plug heating the aluminum ( dont waste time heating plug, heat the alum in circles directly around the plug.)The alum will expand and should release the plug as you turn it. Then attempt to remove the plug SLOWLY turn it should break free. DONT FORCE IT. DONT USE BIG TORCH.
Once I got the alum hot enough it worked. But then it started to get hard to turn again DONT FORCE IT. I heated the alum again and the plug came the rest of the way out CLEAN. (keep your dog or kids way the plug will be scolding hot, i dropped it in a thing of water totally suck to drop it on the ground and burn your dogs nose, your foot or what ever. Careful)
The steel plug was totaly corroded on the inside. This motor has WATER IN THE OIL and all indicators is that the engine holder has corroded. Plug looked fine on the outside no corrosion, paint looked brand new over the plug, but totally corroded inside. There is a guy on ebay who makes alum plugs with alum washer ( DO NOT USE STEEL WASHER) the site is
http://goldplug.com/suzuki-df/2014/suzuki-df-motor-owners-find-our-fix-here/ $18 including shipping. I bought it from him thru Ebay. GET IT DONE. There is internal corrosion going on that will destroy your motor. I SALT AWAY flushed my motors after EVERY USE and still this happened. If you think for some reason your motor wont have this problem, think again. And when it does it will totally suck.
Here is the awesome repair link, i had the same symptoms mentioned in this article, running rough, check engine light on. Pull cowling off motor runs fine. Then I saw the corrosion with exhaust and salt water blowing into the engine compartment. Good thing I did not ignore this, the exhaust gets so hot it melts the computer that is right above the steel plug. BIG BUCKS. I agree Suzuki should realize this defect but these threads date back to 2002 I wont hold my breath. These have been super good quit dependable motors. This is the weak link. Fix it before it fixes you.
read this awesome article
http://www.thehulltruth.com/boating-forum/395845-suzuki-df140-engine-holder-corrosion-fix.html
gold plug site ( i wish I would of found him sooner)
http://goldplug.com/suzuki-df/2014/suzuki-df-motor-owners-find-our-fix-here/
Aloha
DolphinDog
www.theDolphinBoat.com