Suzuki 70HP Flush Plug Corrosion Frozen in Place

[edanish]

I've purchased a used boat with a 2001 Suzuki 70HP 4 stroke engine. One of the features I liked was that after use in salt water the engine could be flushed without using the "ear muffs" or running the engine. However, the flush plug, clearly meant to be finger tight won't budge. At this point I have completely bunged up the outer ring and an wondering how to proceed to remove this plug. I have located and purchased a replacement plug.

Thanks for your help,
Andy

 

[gm280]

Welcome aboard there edanish :welcome: We like new members wity interesting questions about their boats.

Not being able to see what you are dealing with, it is hard to suggest any useful ideas to remove that plug. Maybe post a picture of what you have to work with. Other then that, any way to even butcher it up now to remove it will work, being how you ordered a new one. But be very careful not to mess up the threaded part of the motor so that you can't replace the new one without issue... You could drill it and use an easy-out... Can't really tell because I don't know the area it is located in or how thick the flush plug could be... JMHO!

 

[DangarStu]

It's unusual for an outboard motor to have something stuck by corrosion. There are plenty of ways to get it out though depending on what it is made from and what it looks like. If it is just rounded off you could try filing two flat sides on it and then using some multi grips. You can sometimes be lucky. Drilling a pilot hole and putting a matching easy out is a fall back option, and it that doesn't work you should be able to drill it out completely. When drilling it out if you are lucky you will be able to stop just shy of the threads and then break the remaining pieces out. If not you may have to tap the hole 1mm bigger and buy a new plug (shouldn't be hard to find). This would be a last resort and would require knowing what is behind the plug. ie, just it just go into a cavity in the leg or does it go directly into a cooling water hose. If that is the case then you may not have that final option.

 

[edanish]

Thanks for your input. Its pouring down rain today, so I'll get a picture after it clears up a bit and post that. Appreciate the ideas.

 

[edanish]

No picture necessary. I worked on the plug today with a torch and got down to what appears to be epoxy. My Suzuki mechanic tells me that this plug sometimes "blows out" at higher RPMs and the previous owner must have GLUED IT IN! So I'm giving up because the repair would involve rebuilding that part of the engine around a new aluminum casting. Flushing muffs are my only option.

Thanks again for your thoughts and advice.

 

[Jaxsailor]

Had something similar happen to me on my Suzuki DF 140 the flush port is stuck. Tried to remove it with vice grips and the knob broke off. This is what it looks like! Please help!