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Thread: Honda 135 Issue

  1. #21
    Join Date
    Dec 2010
    Posts
    30,741

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    outboard that runs with the cowl off but stalls with it on indicates an internal exhaust leak, where poisonous exhaust gases are trapped inside, forcing the engine to burn oxygen-depleted air. Common causes include a failed powerhead-to-adapter gasket, a leaking engine holder due to corrosion (especially on DF115/140 models), or damaged exhaust manifold gaskets.
    Common Causes & Symptoms
    Corroded Engine Holder/Plug: On older 4-stroke Suzuki models, exhaust leaks from the engine holder (exhaust manifold) area, often near the flush port, caused by saltwater corrosion.
    Powerhead Gasket Failure: The gasket at the bottom of the powerhead (powerhead-to-adapter plate) fails, releasing exhaust inside the cowling.
    Symptoms: The engine idles fine with the cowl removed because the exhaust dissipates, but with it on, it stalls, runs poorly, or runs very rough.

  2. #22
    Join Date
    Feb 2004
    Location
    SC
    Posts
    4,857

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    Quote Originally Posted by ecu1984 View Post
    outboard that runs with the cowl off but stalls with it on indicates an internal exhaust leak, where poisonous exhaust gases are trapped inside, forcing the engine to burn oxygen-depleted air. Common causes include a failed powerhead-to-adapter gasket, a leaking engine holder due to corrosion (especially on DF115/140 models), or damaged exhaust manifold gaskets.
    Common Causes & Symptoms
    Corroded Engine Holder/Plug: On older 4-stroke Suzuki models, exhaust leaks from the engine holder (exhaust manifold) area, often near the flush port, caused by saltwater corrosion.
    Powerhead Gasket Failure: The gasket at the bottom of the powerhead (powerhead-to-adapter plate) fails, releasing exhaust inside the cowling.
    Symptoms: The engine idles fine with the cowl removed because the exhaust dissipates, but with it on, it stalls, runs poorly, or runs very rough.
    Awesome! Thank you brother!!!

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