Water in oil, 2004 Suzuki DF115

[berzerk22]

Re: Water in oil, 2004 Suzuki DF115

sorry guys for not replying before now. I did find a machine shop and they found the head to be ok. The block deck was out of tolerance (.0024 in or ,06mm is the allowable tolerances). The deck was out but only a little but the machine shop said when your talking about aluminum, it was probably enough, especially when there was no other problems found. THey put the head under pressure and put vacuum on the block, found every thing o.k. I had the shop to "shave" the head a little and "deck" the block enough to get it back perfectly flat. I also had them to "hown" the cylinder walls. I ordered new gasket set, rings, thermostat and water pressure valve. I got the engine back together about 2 weeks ago but until yesterday, had not a chance to run the engine. So the big day, friday, put the boat in the water, cranked the engine, ran, no smoke, no bad noises, so far so good. Let the engine run for a minute or two, no water from the indicater outlet. Still let it run for another minute or so. I cut the engine off, took the big hose off of the water hose going to the engine and water was there and engine seamed fine. I figured was probably something i hooked back up wrong. Fired the engine back up, put in gear, and accelerated. THe engine spits and sputters, pops back doesn't run right at all. I must have got something wrong fuel or fireing wise. I still have to figure that out but feel confident about the engine rebuild. will keep you posted on progress.

 

[karlow1]

Re: Water in oil, 2004 Suzuki DF115

Hey you have to get back to work?
My Df70 has water in the oil. I have been waiting for you to fix yours so I can fix mine.
My plain is to start by pulling the head. But I will take a look at the oil filter mount first to make sure there is no cooler/O-ring issue.
KP

Good luck to the both of us!
It's a great motor except the drinking issue.

 

[Starquirk]

Re: Water in oil, 2004 Suzuki DF115

2002 df140 - oil in water.been reading your threads for some guidence.
my motor runs but i suspect block damage from a weld i had put on the block over the water jacket. it was jb welded when i bought it and as long as it held, no problems. Now i have water in oil making my beloved boat a yard ornament.
i'm not machanically inclined. i will attempt to take off the head gasket and examine the damage myself. i figure i have nothing to lose. any recommendations?

 

[berzerk22]

Re: Water in oil, 2004 Suzuki DF115

Hey guys, found the problem with both of my issues. A dirt dobber had clogged the nipple on the bottom of the exhaust manifold, this fixed the water indicator issue, and the firing issue was a bad spark plug. I put 4 new plugs and one was bad, what are the odds! Put the boat back in the water, man this thing runs great! So far so good! no water in oil, runs smooth, accelerates good. I put approx. 4 hours on it this weekend and lets keep our fingers crossed. As far as the last posts, i know this engine pretty well now. My advice to you is sure, check the easy stuff first, the JB weld, the head gasket, and especially the number 4 cylinder water jacket. Berzerk above has a great picture and is exactly what mine looked like. unfortunatly, this was not where the water was getting in, my block was out of tolerance on the number 2 and 3 cylinders. 1 and 4 where tight. when you take your head off, get a machinest straight edge, a good one, and check the block face and the head. If it is out more than .0024 inches, this is your problem. It doesn't take much for aluminum, evidently. If you are close, try just replacing the head gasket along with coating it well with "copper coat" which can be purchased at any parts store. The first time with water in oil for me, i did this and it fixed it for about 30 hours, but just wasn't enough to compensate for the unflat block deck. Thanks to all that replied. If not for this thread, either it or my wallet would be broke, but now neither is! Thanks for your help, and if anything changes with my engine, i will post. Good Luck!

Berzerk22(north carolina)

 

[Starquirk]

Re: Water in oil, 2004 Suzuki DF115

View attachment 123813
thanks zerk - this is my messed up block. runs good but i change milky oil each time.
what probability do i have of successfully removing cylinder head as i've never worked on a motor?
do you think the leak will be apparent?
i wonder how much i can run it like it is.
ill get one more day on the water before i tear it apart - wish me luch.
any suggestions appreciated

 

[karlow1]

Re: Water in oil, 2004 Suzuki DF115

Berzerk22,
You are my hero!
Thanks for the feedback. I'm digging into my DF70.
It took a day to get the exhaust off! One stud had some corrosion, just one at the bottom.
I had to use the slide hammer, impact, and the hot wrench on her, just to get her on program.
Next the flywheel was a bit of a problem. I used the 1/2 drive whammi gun and a little love tap.
Today's problem is the head, I have pulled then bolts under the valve cover, and the two nut under the head.
No love here it will not budge.
What gives is there some hidden hardware somewhere else?

A little help please! I would hate to break something.

KP

 

[fragged]

Re: Water in oil, 2004 Suzuki DF115

i run a merc 115hp 2006 in the Uk and just had a watery oil change, still don't know
the cause for sure but did read online that it could be sucked in through the sump plug
if the seal is a bit cracked or corroded.

Rich

 

[berzerk22]

Re: Water in oil, 2004 Suzuki DF115

Ok KP, I have been thinking all weekend how to reply to your post. I will first say that i am not a mechanic! You need a service manuel before you go any farther! you will have trouble putting this thing back together with out it. It tells you everything you need to do step by step. you will also need a torque wrench to get all the bolts back at the proper place. I couldnt open your attachment for some reason, but it dont matter anyway. I think you are on the right track with the head gasket. Again, the service manuel is the best friend and advice you will have. I will say, I talked to a service tech at the factory when i was investigating, and he said that unless the engine was abused or got very hot, they were very reliable, but they did have some issues with the head to block tolerances, this is why i really checked these areas close. also, when you start reading the service manuel, it will say you need all these special tools by the manufacturer, you will not, but you will need a puller to get the flywheel off. Oh, you will have to take the bolts out to seperate the engine from the lower unit and raise the engine upward approx and inch to get the head off, so a hoist will help with this, again, get a manuel, it will tell you step by step dissasembly and reasembly. It will make you project fun, not frustrating! I ran my engine this weekend, approx. 8 hours at all rpm's and so far so good!

 

[conkopec]

Re: Water in oil, 2004 Suzuki DF115

I have a 70 hp doing exactly the same thing, had all the work done that you have and no luck to date. Did you ever figure out the problem? PLEASE SHARE!

respectfully
Berzerk22

I havew a 2010 Suzuki DF6. Bought it new. I use it on a Sea Eagle 12.6 inflatable. I got water in oil first time I used it and I get water in oil when the lakes are rough and there are waves. I also got water in the oil when fishing the mouth of the Rogue in September with wind generated large waves. No help from, authorized service centers, dealers, or Suzuki. Did a little investigation myself and found that when I hose down the cowl( engine cover) I get water in the engine oil. Do not know how it gets in but it does. There are holes in the base of the cowl for air entry(?) to Carb. Also when hosing cowl the engine starts to sputter and almost dies unless I stop the hosing.

Hope this helps somewhat on a possible source of entry.

 

[conkopec]

Re: Water in oil, 2004 Suzuki DF115

I was just reading an old post about a guy who had water in the oil in 2004 DF115. I have the same problem and am wondering how the situation turned out? This motor has been well maintained, only has 500 hours on it and has been religiously, flushed after every use in the salt.

Last fall I thought I blew a head gasket while fishing salmon off the mouth of the Columbia river. I have owned this motor since new and it had always been bullet proof. Well, long story short, I didn't realize there was salt water in the oil for a couple fishing trips, until the motor started running bad. While trouble shooting, I pulled the dipstick and found the engine full of the white crap. I took it to 2 shops here in Portland and found one that agreed to pull the engine apart. I had them rebuild the motor, and valvetrain, complete with new cams. It cost me 3800 bucks. I got the motor back in November and moth balled it till May. I took it out a few times, did the break-in proceedures and after about 12 hours run time, found water in the oil again.

Back to the shop to tighten everything and recheck all gaskets. The motor worked fine for 2 short trips. Took the family out over the fourth of July for about 8 hours. Motor worked fine but I had a hard time keeping it running at initial start up. It seemed like fuel pressure, because after pumping the fuel ball for several minutes the motor finally ran. I checked the oil at the end of the trip and guess what??? Water in the oil, about a quart.

I took it back to the shop and they are telling me that their tech has no idea whats going on and Suzuki has no answers either. The owner of the shop doesnt want to put more labor into this and basicly I have a motor that runs great but leaks water into the oil. I'm screwed out of 3800 bucks. They want to sell me a new motor.. (of Course). It seems to me that there is a fine crack somewhere that is misting water into my lube system. The problem is, Where in the world is it coming from??? Could the engine holder be the culprit? The mid and upper engine have been pressure tested and hold at 70 and 30 pounds respectively. It seems that it doesnt leak until the motor is really warmed up.

Any ideas will be helpful. HELP??????

Was the wind blowing and generating waves that splashed the motor housing hood. Thsi appears to be the source of water entry into my DF6

 

[Allinson_Associates]

2004 Suzuki DF115 ... oil in raw water discharge not water in engine oil. Engine torn down, oil pan is fine. SAND found in water jacket around cylinder #4 as well as throughout the rest of the raw water gallery. Oil seen in the tell tale discharge. Oil leak occurs only when the engine is started and the oil system is pressurized. Compression test acceptable for all cylinders.

 

[GA_Boater]

2004 Suzuki DF115 ... oil in raw water discharge not water in engine oil. Engine torn down, oil pan is fine. SAND found in water jacket around cylinder #4 as well as throughout the rest of the raw water gallery. Oil seen in the tell tale discharge. Oil leak occurs only when the engine is started and the oil system is pressurized. Compression test acceptable for all cylinders.

I guess there is a question in there somewhere? This is an old thread - Over 4 years. Look at the Help Tip on top of the page and start a new topic. Thanks.

Closed.