2003 Suzuki DF 140 water in oil

Took the boat out this weekend and when I was heading back to the hill and slowing down, I noticed a noise that sounded like a small exhaust leak. Not loud and not like the clunk of a bearing. Motor had been running fine but now idled a little rough. I opened it up to get on plane and it hesitated then acted normally. When I got back to the house I started checking the motor and found water in the oil (milky). The motor has been serviced regularly and use Salt away when flushing the motor. Money is a little tight so I want to do as much possible myself before taking it to the shop. Here’s my plan but am open to advice/suggestions:

  1. I’ve read that there is a water jacketed oil cooler near the oil filter and that the o rings can go bad.

  2. Read that another problem area is the oil filter itself. Check those two items first.

  3. After that it seems that things become more expensive and requires much more work than I want to do in my back yard.

Is there something else I should check or do?

Thanks in advance,

Tony

You may find this interesting.
http://www.suzukioutboardforum.com/suzuki-outboard-parts-forum/2636-df140-water-oil.html

ZX

Thanks tanksgt, I had seen that and I’m hoping for the best. I’m getting ready to take the oil cooler off now. I’ll keep anyone interested on my progress. Wish me luck!

oil cooler is the first place I would start

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Thanks Chris V, I’ve removed the oil cooler but not to sure on how to disassemble it. Found that the orange colored gasket that seals it to the block has a nick in it but it appears that any communication between the oil and water would be internal. I hope to be able to replace any o rings inside since a new one is $175.

I always flush for several minutes and use Salt Away! Lesson learned, cleaning the oil cooler at least once a year should be added to the PM. I hope this solves my problem, some of the internal o rings were distorted, one looks like it had partially melted! Now to clean this up and put in some new o rings.

I think you may have found your problem and taught a lot of us a lesson! Thanks for posting!!

Hmmm, that’s given me something to think about. Thanks for posting that picture.

'06 Mckee Craft
184 Marathon
DF140 Suzuki

clean it all up, put it back together, change your oil, and let it run in the driveway for an hour or so, to give any residual moisture a chance to burn off.
pretty sure that cooler wasn’t cooling much.
that same thing happens to the bottom of the head where it meets the block.

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Well after cleaning up the oil cooler with salt away, major corrosion inside so I’m going to have to replace it. Chris V, I was thinking about that, if there was a blockage there, it could be in other places as well. I have a MST Guardian flushing system on the motor that I sometimes use when I can’t run the motor. Is there some better way I can flush the motor?

you could try the vinegar flush
http://www.thehulltruth.com/boating-how-s-kerno-memorial-forum/368827-how-cleaning-your-cooling-system-vinegar.html