'02 DF140 Clutch Dog question

Joined
Sep 8, 2008
Messages
8
So I was having a problem where I could not shift into reverse while the engine was running. I disassembled the lower unit to check the clutch dog thinking it is going to be eaten up pretty bad, but it doesn't look like it to me. You can still clearly see the back cut in the teeth and just the corner has the slightest rounding.

I went to the local Suzuki dealer and was told I needed a new clutch dog and gear set. They said that even though it looks good that will not work.

Is this true of Suzuki gear sets that the slightest wear on the clutch dog teeth will cause failure where any other brand will run fine with ten times the amount of wear? (I was told that as well)
 

clanton

Rear Admiral
Joined
Jul 9, 2001
Messages
4,876
Re: '02 DF140 Clutch Dog question

If it is jumping/slipping out of reverse, it may need the gear set. If it is very hard to get into reverse gear, and will stay in reverse after engaged, the shifter parts are binding, caused by galling of the small shifting parts. A lot cheaper then a gear set.
 
Joined
Sep 8, 2008
Messages
8
Re: '02 DF140 Clutch Dog question

It is jumping out of gear, but seeing as how there is not substantial wear on the teeth I was wondering if I was missing something. Here is what they look like.
DSC07500.jpg

DSC07501.jpg

DSC07502.jpg


As you can see it's not as if they're trashed. I just can't believe with just a little wear it jumps out of reverse.
 

clanton

Rear Admiral
Joined
Jul 9, 2001
Messages
4,876
Re: '02 DF140 Clutch Dog question

Looks ok to me, you have to check all of the shifting parts, should be able to shift by hand before you reinstall on engine. Cables and throttle/shift should be in good working order, and adjusted properly to insure clutch dog is completely engageing.
 
Joined
Sep 8, 2008
Messages
8
Re: '02 DF140 Clutch Dog question

Finally got it fixed. Disconnected the controls and put a pair of vice grips on the shift shaft where it's visible near the lower unit. I found the right position where it will shift into reverse and worked the shift shaft back and forth not ramming but bouncing it against the full reverse position. It started traveling a little further after a while and once I got as much travel out of it I could I readjusted the shift linkage for it and it now seems to work in the driveway at least.

Moral of the story: Even if your shifter will move freely with the controls disconnected, it may not be moving as far as it should.

Thanks for the help Clanton!
 

fixithelp

Recruit
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Oct 30, 2008
Messages
1
Re: '02 DF140 Clutch Dog question

Wait to be in the water to try again but unfortunately it may not work as well as it works on your driveway.
Recently I had a reverse shifting problem on Johnson 2001 50HP; the dog clutch and the reverse gear were very little round off but enough to slip in reverse and I had to replace both of them.
I hope I am wrong!
 
Joined
Sep 8, 2008
Messages
8
Re: '02 DF140 Clutch Dog question

Actually I got lucky and it does seem to work fine after a sea trial. I know what you mean about the driveway though. I thought I had it fixed more than once only to find out otherwise at the boat ramp. After the second time I brought home a 55gal plastic drum from work and cut it in half so I could test it under power.
 
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