Suzuki dt65 lower unit removal. Apr 10, 2013 · Yamaha & Suzuki Outboards . Mar 22, 2004 · 2. After closer inspection and thermostat removal I've come to a different conclusion. Good luck with your efforts. It wont move. But do not race it continuously, just snap the throttle on and off 5 or 6 times. Suzuki DT 55 65 50 lower unit gear case housing assembly. use 12mm socket to loosen the nut almost off and then push the assembly in. $2,250. To order, please get in touch with our experienced parts staff. Prop shaft must be removed to replace lower shift shaft. The guy I bought it from decided to rip the lower unit into pieces. mine drops 1/2" and then stops) Jan 2, 2016 · Hi guys, I have a 1997 suzuki DT65. IDK111140035-01 . Aug 19, 2010 · I HAVE A 75 HP SUZUKI OUTBOARD AND TO DROP THE LOWER UNIT TO CHANGE THE IMPELLER. 1142 posts · Joined 2004. Even though I have done this the unit still will not drop I Mar 19, 2010 · "Any help with this gearcase r "Any help with this gearcase removal would be awsome. Jan 25, 2019 · It sounds like it is not going all the way into gear, has lower unit been worked on, or water pump, connecting linkage been messed with? Possibly shift cable from remote control damaged, not engaging shift linkage completely? Remove cable, and shift by hand if possible, to see if motor shifts all the way into gear without cable? Welcome, I will be happy to assist you. Feb 10, 2022 · 1986 - 1989 Suzuki DT150 150hp outboard lower unit removal. Ensure that shift rod 2 is at neutral position. Is this a relatively easy job, or something better suited for a marine mechanic?? Thanks in advance. Refer to “Lower Side Cover Removal and Installation” in Section 2A (Page 2A-2). I just bought a boat a couple weeks ago and it came with a DT65 mounted on the back. 04-06-2015, 01:39 PM. 99000-25160: SUZUKI WATER RESISTANT GREASE. 3) Remove the breather hose (2) from cylinder head cover. Our local dealer has closed. to service the impeller and cooling system. A magnet in the oil flow will do the job well. Another O'ring seal for the outside Jul 24, 2020 · 99000-25160: SUZUKI WATER RESISTANT GREASE Propeller nut: 55 N•m (5. The propshaft pulls the rear bearing which pulls the housing. 321. If you have further problems let me know. Re: Suzuki dt65 . Remove the four bolts holding the water pump together from the water pump housing with a socket wrench. Possibly he means the cross shaft at the top, the one you have to push back in order to drop the lower. Glad i didnt try to force it. 07-04-2011, 10:42 AM. No biggie. The dealer can't get to it until about 10 Set the lower unit upright in a bench vise. $361. Oct 4, 2010 · 10-19-2010, 09:59 PM. While waiting for some parts for my trim/tilt unit I've decided to do some maintenance to the lower unit. bornagainboating. sometimes you need it hanging on the lift eye then take a dead blow hammer and wump the the lower unit tower a few times where its sturdy, the heat can really glue the gasket together, you sure you got all the bolts out from under the May 17, 2009 · It took awhile (1 year) after buying the boat for the forward gear to go, it already did not have reverse and I knew going in that I was facing a repair eventually. The throttle cables have significant wear and needed to be replaced. Re: Need help on Suzuki DT-65 idle. Detach the power unit with the lower cover. Most lower units have a total of 8 seals. – Water ingress (white, milky appearance) Oct 7, 2003 · He looked at the manual and thought that looked "a bit hard" Then he welded up an adaptor that consisted of a nut for the prop shaft to shaft of a slide hammer. 5 4 stroke. More I look at this ,,, looks like drive shaft bearing must be going out since motor was idling in neutral. no oil should ever be able to leave the lower unit in any situation, the top cover that seals in the lower unit oil for the lower unit is where you install the impellar. #6. When draining lower unit gear oil, check the following points. Aug 18, 2010 · The shift rod needs to be disengaged. It's tough to see what you are doing with such limited access and visibility. Jul 18, 2007. • When draining lower unit gear oil, check the following points. on a 99 DF 30 to change water impeller. 02-12-2012, 02:36 PM. The lower unit should be entirely free from the motor after you perform this step. Suzuki Marine. I need to remove the lower unit from my 1980 DT25. This is evidenced by a milky looking oil. Step 1 is: Remove the four engine mounting bolts. Tunnel 140mm for Stern Thruster Btq140. Jun 22, 2014 · 06-22-2014, 12:16 PM. During the many, many, times I have removed the lower unit I have made sure all water pump input passages are clear and remain clear. $285. Put the engine and controls in neutral. Apr 23, 2014 · Messages. When you rotate the drive shaft always rotate the driveshaft in a clockwise direction otherwise you run the risk of bending a vane or two in the wrong direction. 1997 dt 140 lower unit removal. 13. I grabbed a copy of the service manual and you have to remove the lower starboard side cover and release the clutch rod. Free shipping on many items | Browse your favorite brands | affordable prices. Product 1944/2337. Brand new OEM, lower unit assemblies do not include shift shaft, water pump, or propellers. Re: Suzuki dt65 gear shift. $162. Apr 24, 2010. . Feb 17, 2014 · Don't play with the shift linkage if the lower unit is off the motor. 15 New. It was left in neutral when I did this. Place the lower section of the PTT unit in a vise. Took him about 15 minutes all up with no damage to the parts. 05-02-2024, 07:48 PM. Managed to disconnect the shift rod under the Check out our lower units for engines from DF9. 0 lb•ft) LOWER UNIT INSTALLATION. Guys, Im trying to remove the lower unit from my DT85 1981 model as the casing has split, & replacing it with another I have as managed to get another outboard the same. There is a turnbuckle between shaft just screw it. 1987 Suzuki DT150 150hp lower unit removal #nashville #percypriestlake suzuki, Automotive Item for sale is a used crankcase block off of a Suzuki DT 115 hp stroke Precaution for Lower Unit. Disconnect the pump lead wire connector (5) at high pressure fuel pump. Black Red. Apr 25, 2013. Most of the time the driveshaft into the crankshaft is the major problem. Lots of heat around the housing and then basically tapped it out. It would be a guess that bolt patterns are similar configuration but the physical size of the 85 being larger than the 55-65 models makes the parts not exchangeable. See the attached images Dec 5, 2014 · 12-05-2014, 05:14 PM. $550. Apr 25, 2014. Suzuki Outboard DT55 DT65 Transmission Gearcase & Housing Assy 20". Aug 21, 2005. It will have 2 seals for each shaft location. Is there any way to get it - Answered by a verified Marine Mechanic The lower unit is fine - when i took the new to me engines water pump housing off to replace the impeller etc, the aluminum around the drive shaft was corroded and missing pieces. Jul 24, 2020 · Always disconnect the battery cable, before removing lower unit. 00 shipping. Mar 28, 2013 · Messages. Have to change the impeller ASAP. Apply Water Resistant Grease to clutch rod splines, then install clutch rod 1 by aligning clutch rod splines with splines in clutch shaft. This will actually detach the lower unit from the motor. This will be my 1st time removing a lower unit. 18-0460 Water Pump Gasket Jun 22, 2010 · its a 1989 suzuki dt 85 outboard removing the lower unit to replace impeller . • Shift into neutral and remove the emergency stop switch lock plate so that the motor cannot be started accidentally. Loosen it only about three turns while pushing the shaft over until the pin slides out of the shift rod. For any inquiries please comment and let me know what you would like to see or any Professionally Remanufactured Complete Lower unit Assembly with 1yr Warranty Jul 19, 2007 · 35. Broke 4 of the 6 bolts on the gearcase. The lower unit has a pretty good amount of wear in the gears. Hi,,i will be attempting to remove lower unit and change impeller. but am confused about a possible turn buckle on the shift linkage? Suzuki DT 55 DT 65 Lower Unit Gear Case. #5. 6. Oct 10, 2018. All the fuel lines needed to be replaced despite the Sep 14, 2011 · Re: dt65 Suzuki does not want to push in forward. May 3, 2009 · If all is well then check the gear shifting works and is smooth. 9 to DF350, including but not limited to Suzuki DF140, Suzuki DF150, Suzuki DF200, and Suzuki DF300. Need to change the impeller on a 2006 Suzuki DF2. You may need to align the drive shaft splines so they slide in, if your not in neutral you can’t rotate the driveshaft. It takes very little effort to pull on the shift rod and render it inoperable. Offering discount prices on OEM parts for over 50 years. #11. May 22, 2009 · Step 3 Remove the last bolt from the lower unit. Check for water in the oil. ---- Used. This should clean out water pas-sages. Remove the emergency stop switch lock plate from the emergency stop switch. Hi Guys, I have an older DT50 and I was hoping to take the gear case apart, but I can't figure out how to get around it. Apr 15, 2014 · I could not find any videos online explaining how to remove the lower unit on a Suzuki DT50 to install a water pump. Remove the lower unit oil plug and drain the oil. $195. Apr 26, 2014 · I'm hoping someone can help me. figure this one out! Saltaway is just an acid. 00. Ok. Good used. I placed the throttle in forward gear, removed the 6 retaining bolts and the trim tab, whacked on it a while with a rubber mallet and eventually cracked the cavitation plate. After messing around for couple days, i inserted small Service Manual DF140A, DF115A, DF115, DF115AZ, DF140AZ, DF115AS Left Hand Rotation Unit [24] [Df140A, Df115A, Df115, Df115Az, Df140Az, Df115As] Mar 8, 2012 · Hi Fishos, Raining weather has given me an oportunity to work on my tinnie and motor, On my last outing I noticed the water pump strugling so Ive decided to replace the impella, Ive removed the bolts to the lower unit but cannot figure out how the shift rod disconnects from the upper body. Can I remove the lower Apr 6, 2015 · Tweet. If you pull too hard on the shift linkage (due to snag or messing about with shift rod) it can lift up too high and it can dislodge the shift cam in the lower unit, spring loaded parts will move and then the lower unit requires complete disassembly to put things right . 9. Use a bright flashlight to check out the splines in the crankshaft if the driveshaft is stuck. @suzukimarineusa Things you need: Jul 24, 2020 · Precaution for Lower Unit. Thread starter 1997 dt 140 lower unit removal Google up: Yamaha Maintenance Tips Andy, for some good Suzuki Dt100 Outboard 20 Shaft Lower Unit. No special tool needed. Junior Member. Look at the drawing for the clutch. #4. You can work through there to remove the nut, disengage the pin, and then your lower will drop free if all bolts have been removed. Now the lower unit should come straight down. Re: suzuki dt85 lower unit removal. Any ideas on removing a lower unit from a 2001 DT 225 that has been used in salt water and apparently never had the water pump serviced ? Of the 7 bolts holding it on, 4 twisted off and the holes on the other 3 that came out are probably stripped. Dec 31, 2014 · I have a 1996 Suzuki DT 115. I recently removed the lower unit from my DT65 following PDF manual but did not detache the clutch rod completely. Then an O'ring seal for the upper bearing case (under the water pump assy) and shaft seal for the drive shaft. Jun 25, 2019 · If you can not buy the correct puller for your motor, you will have to be creative and make something that will work. 2. • Wear gloves to protect hands, and lock the propeller by placing a block of wood Sep 26, 2008 · Re: Suzuki DT65 leak? No problem removing the lower unit on these motors. Remove the lower unit bolts and pull the lower out carefully. The nut #3 has to be backed of untill the shaft can be pushed in far enough to release the shift rod. Dry the PTT body with compressed air. Feb 15, 2016 · Quick and easy how-to video showing the procedure for removing the lower unit and water pump impeller for a 4hp model DT4 Suzuki outboard motor. I guess I'll pull the lower unit tomorrow to check it out. Lower Unit: general information, shifting principles, standard rotating unit, counter roatating unit, troubleshooting the lower unit, propeller removal & installation, lower unit, no reverse gear, lower unit with reverse gear. Count threads before turning. 07-15-2012, 12:33 PM. View parts diagrams and shop online for DT65 : 1988 Two-Stroke Outboard 65. Have a look at this picture and hopefully it will be solved. An O'ring seal for the casing and shaft seal for the prop shaft. The spring and ball I am referring to are items 30,32,33. com. Ask the experts on our Suzuki Outboard Forum for repair issues, diagnosing problems, links to diagrams, suggestions on buying parts and more. Here's a photo of how it looks: Click. Refer to “Power Trim and Tilt Unit Removal and Installation (One-Cylinder Type)” (Page 2B-20). In this episode I show you step by step on how to do Maintenance on a Suzuki Outboard engine Lower Unit - Gear Oil Change. I think only thing moving in neutral are water pump and drive shaftin lower unit. Aug 1, 2007 · Aug 2, 2007. Make sure the shift rod doesn't hang up on anything as you lower the gearcase. Failure to take proper precautions when installing or removing the propeller can result in severe personal injury. Nov 13, 2004 · Nov 13, 2004. I've done this, but the power unit seems to be firmly stuck. Like. What you want is the torque of the engine and the loose fit of the lower unit Jan 23, 2010 · So its gotta come off. 1. Sprayed it with WD, heated it, banged on it forever. Disconnect the cable at the motor and, without the motor running, try shifting at the motor. Be careful so the rod does not come loose in lower unit where there is a ball/spring (if that happen I think it is time for marine mechanic to Apr 24, 2014 · 321. If you have a question or need clarification please post back at any time. Any bo May 2, 2024 · lower unit removal. Dec 14, 2020 · Hey Guys, Ran into an issue after I replaced my Water Imepellar. ebasicpower. Run motor in a 50 gallon drum of water and add a quart or 2 of muriatic acid (hardware store) to 50 gallons of water, watch for foaming action of the acid on the calcium/mineral deposits, run 15 minutes, add bicarbonate of soda to neutralize acid with motor Apr 27, 2019 · I recently purchased a used '96 DT25C that I was told wasn't used a whole lot. I recently picked up a 1998 DF 40 that has seen little use (less than 50 hours) and has been sitting for about 10 years. My question is this. Hi,<br />I had a Suzuki DT65 (1991) before and I had the lower unit off without problem. Nov 21, 2019 · Ordering all the right parts to replace the damaged shift rod. Re: Suzuki Pinion gear removal. I have read several things about it. or Best Offer. Sort by Oldest first. OEM SUZUKI DT150 DT175 DT200 DT225hp 2 STROKE LOWER UNIT 25" 55110-97D21-0EP. Slide the impeller from the lower unit and slide them up and off the driveshaft. • If reassembling with original components and gears, do not omit or add any shims or thrust washers. Get the best deals on Suzuki Complete Outboard Lower Units when you shop the largest online selection at eBay. Sep 11, 2007 · 1. i have removed all the bolts and the unit slid down a bit but it is still heing n … read more NicholasH311 Apr 10, 2010 · Re: '88 Suzuki DT75 Lower Unit/Impeller On some of the older Suzuki's if you tug to hard on the shift linkage you can dislocate the detent ball from the clutch dog inside the lower unit, not allowing for shifting . Jul 24, 2020 · Removal. With Prop Like New Unit 15 Shaft. #1. May 19, 2018 · While replacing the impeller on my dt65 Suzuki the shifter rod came lose e in the gear box. #2. Still have the overheating problem. Hello, I'm trying to replace the Impeller on my Suzuki DT150 (2003) but I cannot get my lower unit to budge. Remove the bolts (3) and fuel pump guard (4). It is actually very easy and this short This works better if lower unit is not on the motor. 65 shipping. Thanks for watching#nashville#percypriestlake#suzuki Nov 5, 2013 · Ask the experts on our Suzuki Outboard Forum for repair issues, diagnosing problems, links to diagrams, suggestions on buying parts and more. I am trying to figure out how the water cooling system works. Shut the engine off, and then remove the bolts and see if it drops or not. When the lower unit is dropped it pulls the clutch rod up inside the gear case. Filmed with Olympus TG Tracker in 4KThanks to Ross Sep 27, 2014 · Lower Unit Removal. While removing the lower unit for impeller replacement, the unit dropped before the owner - Answered by a verified Marine Mechanic So I switched lower units of the two outboards. shifter shaft. However, there is a round hole in the lower part that seems to be blocked (or it is just a dead space?). Next, start the engine up, and in neutral, start snapping the throttle, almost like you were racing the engine. • Wear safety glasses if using compressed air. No progress. budnate. NOT SURE WHAT YEAR IT IS BUT SERIAL # - Answered by a verified Marine Mechanic Jul 24, 2020 · Remove both lower side covers. IDK111140034-01 . May 14, 2007 · 3. $155. df150, lower unit seals. Re: Suzuki dt65 gear shift problem. Dec 13, 2015 · In looking at the lower unit for a 88 65- it appears compatible with many years of 55 & 65 engines but not 85's. 09-27-2014, 01:13 PM. They can answer questions for any Suzuki outboard model or horsepower. Re: SUZUKI DT55 Clutch Rod/Shifter Pulled Out. Dec 16, 2009 · Dec 17, 2009. The shaft is probably corrosion welded to the power head. Put the motor in full up condition. You may need to rotate the prop by hand to make the shifts. Yes your thinking is correct. B. Messages. Any advice on how Aug 16, 2019 · Suzuki 89 DT65 rebuild - how to get the right technical specs for the job. Hello all, I am working on a 1991 DT115 Suzuki lower unit. Suzuki 8 Hp Dt8 Lower Gearcase Assy. Pretty new to all of this, but I took my lower Unit off and replaced the Water Impeller. The manual is somewhat limited on instruction. To check (without a manual) 1. Many not all DT55 DT65 DT50 outboard motor. Re: Suzuki DT30 water pump removal impossible! Help ! I just changed my water pump. There is no easy way to remove a stuck gearcase. # Qty. there is a rubber tab on the starboard side that you pop off. I have removed the 4 bolts and uncoupled the shifting rod about half way down the leg under a small cover. Handle this step cautiously to avoid having your lower unit slide out uncontrollably. Art. Previous Jul 4, 2010 · If you are certain you have all the bolts out then try to drive some wood wedges between the lower unit and midsection. Look for the clutch shaft, remove the nut #3 then remove the clutch shaft from the clutch rod. There is a hole on the starboard side of the lower engine cover. FAST $4. See details. Jun 21, 2011. Only 1 left! This high quality PDF service manual contains instructions, specifications and illustrations for any repair your 83-92 Suzuki DT40 outboard motor may need from top to bottom. Aug 2, 2006 · (by the way, any advice on how to remove the lower unit would be appreciated. Thanks Moonlighter for the advice. Learn More About Your Boats Systems By Joining The Born Again Boating Academy! https://www. 5 kg•m, 40. Tried hammering a wooden bloc all over the bottom unit to no avail. This is the same manual professional marine techs use to service and overhaul the motor. When I put it back on and reinstalled the shift shaft it is stuck in forward gear. May 14, 2007. $545. After shearing the heads off 3 lower unit bolts and having to pry the gear case away from the motor, I was able to open the water pump housing, impeller and gasket. simon-2. It cranks but I can't get any spark and I can't find the emergency 34800-87D00. Re: Dt55 clutch rod disconnect for lower unit removal suzuki. com/Get Your Born Again Boating Clothing! https:/ May 11, 2020 · It seems more likely that his problem is therefore a more traditional stuck lower unit due to corrosion in the connecting bolts and locating pins, especially since he has mentioned that the heads of several gearbox bolts were broken off when trying to remove them. 2000 Suzuki 30 HP DF30 Lower Unit Long 20" 55100-91L20-0EP Fits 2000+. Hi, Im working on a Suzuki dt65, I just removed the nut you are talking about, It comes off counter clock wise, I used a socket and ratchet and wedged a large crescent handle in behind the ratchet to keep it from slipping off the nut, The large gear came out without pulling the smaller one Jul 24, 2020 · When installing or removing the lower unit: Always disconnect the battery cable, before removing lower unit. Chipped cav plate so I need to remove lower unit. So please check all information available such as the following to identify your engine to the correct part. Every single time the pinion gear has been completely annihilated in one Mar 29, 2015 · In this video I will show you step by step how to How to remove the lower unit on a outboard engine. Am looking for help in removing Lower Unit. Get a manual and read it or you will cause damage. 32170-94710. • When installing or removing the propeller, shift into “Neutral” and remove the emergency stop switch lock plate so that the motor cannot be started accidentally. . So, even though it seemed impossible, I put on a new OEM water pump housing. Task level : easy. Feb 4, 2019 · Looks like my initial guess was correct. Pre-Owned: Suzuki. Ignition timing Coil. I have removed the exhaust cover plate and cleaned it from salt. The service manual says to release the lower unit, the power head needs to be removed. Look under your bottom carb with a flashlight, follow your shift linkage and find a large chrome nut. Remove the bearing carrier retaining bolts. I got the motor running perfectly but wanted to replace the impeller as a precaution. Mine is a 1983 DT-50 and it works this way. Jul 4, 2011 · DF 30 Lower Unit Removal. WATCH this Subscribe(its free)!!! I will tell you what y This is how you remove the lower unit of your suzuki DF70/80/90A. com Seal Kit Lower Unit for Suzuki Outboard DT55 DT65 25700-94700 [SIE18-8339] - Seal Kit Lower Unit for Suzuki Outboard DT55 DT65 Replaces: 25700-94700 CONTAINS Part # Description O. Pull the impeller plate off the lower unit and slip it off the driveshaft. Before removing PTT motor, wash the PTT body with a stiff bristle brush and hot, soapy water to remove sand or dirt. Check for metal in the oil by rubbing a little oil between finger and thumb. OK I figured it in case anyone searches. 75. Looking at your previous postings, if you applied any force to try and remove the lower unit with the shift rod still attached at the top, it's time to take it in for repair. Thanks to Brownspoint Marina Service. The prop should have a 'locking in" point in both forward and reverse and free in neutral. I've seen at least 7 of these lower units fail abruptly with under 400 hours on them. #2 · Jan 23, 2010. 95 shipping available. NO Prop X. I sent replay before. I just went through something similar on my DT-85. Apr 24, 2014. Suzuki DF250 lower unit removal and inspection after collision damage. Find many great new & used options and get the best deals for Suzuki DT 115 Lower Unit 20" Fresh Water at the best online prices at eBay! Free shipping for many products! Jul 15, 2012 · 1978 DT65 no spark. you can see the connection under the carbs from the port side. Gearcase housing P/N 55100-95303-02M driveshaft P/N 57110-94740 57110-94741. $55. I had same problem trying to remove lower unit, it didn't want to come off after removing all the bolts and disconnecting gear shift under the motor, lower unit will drop about 1/8 to 1/4 in and then get stuck. I ordered some hard to find parts put it back together and went to try and start it. Re: suzuki dt55 lower unit. View parts diagrams and shop online for DT65 : 1985 Two-Stroke Outboard 65. In addition to removing the 6 bolts that hold the lower unit (gear case housing) to the Drive Shaft Housing you need to remove the clutch turnbuckle and lock nut on the shift lever (clutch schematic #5 and #19 respectively on the Suzuki May 6, 2009 · Re: Suzuki DT65 Impeller Hi not sure if you have solved your problem but I think I have the answer. bob Ask the experts on our Suzuki Outboard Forum for repair issues, diagnosing problems, links to diagrams, suggestions on buying parts and more. Last edited by Moonlighter; 05-11-2020, 05:53 PM . if oil comes out of the water intake holes then it must be comming from the lower unit, possably from a bad sealing o-ring gasket, a crack, or a corrosion Jul 8, 2016 · This Compatible with Suzuki Lower Unit Seal Kit will fit all 65 Hp DT65 2 Stroke WSM 18-8339 OEM# 25700-94700 Year - 1985-1997 Please be advised that Suzuki motors DO NOT go by the year they were produced. If container is large enough add 3-5 gals of vinegar in container and run motor for a couple hours in solution (if solution gets too hot let it cool down, and run again till hot, until you have run for 2 hours. 35. DT115 Lower Unit Teardown. Go to the clutch diagram. Have undone the 9 bolts & disconnected the gear shaft but it still won't budge. I need to remove everything on the left half of the picture. But, get a 1985 Wellcraft 180 Fisherman with a 2 year old floor, 2 year old rebuilt stringers, 2 year old rebuilt transom, new 40 Oct 10, 2018 · Aug 13, 2018. #3. Remove Power Trim and Tilt unit. However, I cannot get the lower unit to separate. E. Sure enough, the exact problem switched engines. bi gf tf wv oc jo ot gg sy ai