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Old 15 April 2014, 17:18   #1
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Country: Other
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Make: Valiant PT-520
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Suzuki DF 90 "check engine" light codes

Last weekend, when cruising at normal speed (4000 rpm), I had the "check engine" light in the RPM meter flashing 3 fast flashes followed by a small interval and 2 fast flashes. After a longer interval this (3+2 flashes) sequence repeated for quite some time but no additional warning lit was on.
After a while the flashing stopped.
Any hints about the meaning of the flashing code?

Thanks

Antonio Carrapatoso
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Old 15 April 2014, 17:46   #2
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map sensor if I remember rightly.
the DF90 and 115 of a certain age had a problem with a mild steel bolt in the aluminium alloy adaptor plate between the powerhead and the lower unit. All that lovely salt water and exhaust gasses plus dis-similar metals causes corrosion around the plug. Take the covers off and have a look (port side under the powerhead) and see if yours is leaking a tiny jet of red hot exhaust gasses out of the plug. The new part is the best part of 1k but it can hopefully be repaired if indeed that is the problem.
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Old 16 April 2014, 06:06   #3
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Thanks Dave.
I will try to check it the next time I use the boat.

Antonio Carrapatoso
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Old 16 April 2014, 06:41   #4
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no probs...it could just be the map sensor which was the general opinion on here when I had the same fault. However I bought a new sensor on the strength of those opinions and suffice it to say I now have a spare sensor! Expensive things - so I have one here somewhere if needed. I'll put some photos of the corroded bit on here when I get a spare minute. Lots of stuff on the net about the fault when I looked esp from the States with a lot of unhappy people threatening class actions etc etc against Suzuki who basically did not want to know! Which is why I did not replace my Suzi with another one when the time came. Shame cos we really liked the motor otherwise.
But it is fixable with some ingenuity, a bit of spare stainless, a squeeze of plastic metal and a couple of s/s self tappers.
We patched ours up with the cheap fix and it ran faultlessly afterwards for the several more years we kept it.
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Old 20 April 2014, 10:31   #5
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hole in port side of adaptor plate between powerhead and bottom end. Its been cleaned up and drilled ready to accept "the fix"
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Old 20 April 2014, 10:44   #6
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and this is the little ******** that caused it. Now which designer/engineer/or normal person would put a mild steel radiator type plug which serves no purpose into a aluminium alloy casting where it is washed over by corrosive exhaust gasses etc etc. Suzuki didn't see the problem was of their making however
Apparently adaptor plate or whatever was modified several times in a short period (according to the parts supplier when we went to order one-we didn't order one when we found out the price!).
It could be a few other things irritating the map sensor but the symptoms of this one, apart from a red hot needle jet of gas from around the stud, were that it would run fine with the cowling off esp when on flush muffs but with back pressure from being in the water and the cowling on to keep those gasses contained it set the sensor off.
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Old 20 April 2014, 10:50   #7
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DF140-hole in exhaust


376579-Engine-holder-problem-anyone-else
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Old 28 April 2014, 17:47   #8
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fix it before it's broken

Suzuki Outboard DF140 Engine Exhaust Port Replacement Drain Plug Inspection DF | eBay
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Old 29 April 2014, 05:27   #9
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a good find! seems everyone will admit to knowing there was a problem except Mr Suzuki. I would be wary of replacing a stud that's not leaking "yet" as the threads must be the first bit to rot away? Ours was a complete disaster area around the stud-just fell away when prodded a bit. The part was modified X number of times we were told by the parts wholesaler so not everyone will have the problem now.
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