broken bolt suzuki DT65

[Kreso]

Hi,
I have a broken bolt which is holding the lower unit on my 1996 DT65. It is a ninth bolt situated bellow the trim tab. The bolt broke 1inch from the head (it is 4inches long). Can anyone tell me if the hole for that bolt is threaded all the way through the lower unit (as I don't see a thread in the first part) or a thread is just in the spacer and driveshaft housing, so I can easily drill the bolt and not damage the thread.
thanks

 

[trendsetter240]

Re: broken bolt suzuki DT65

Hi,
I have a broken bolt which is holding the lower unit on my 1996 DT65. It is a ninth bolt situated bellow the trim tab. The bolt broke 1inch from the head (it is 4inches long). Can anyone tell me if the hole for that bolt is threaded all the way through the lower unit (as I don't see a thread in the first part) or a thread is just in the spacer and driveshaft housing, so I can easily drill the bolt and not damage the thread.
thanks

Hey kreso, thanks for posting your own thread. They are sticklers for the rules around here.

As for your bolt, I don't see how it could be holding the gearcase onto the midsection if there were no threads in the gearcase. You say that you have broken the bolt at the first thread therefore nothing would be holding it on without the head of the bolt in place.

Does the gearcase seperate at all or is it holding fast with no gap? Have you already disconnected the shift rod?

 

[Kreso]

Re: broken bolt suzuki DT65

Maybe only the salt is holding the bolt in place (thats why it broke) but I can't be sure about that. There in no gap at the rear side (where the bolt is) and there is a 2-3mm gap on the front side between the spacer and lower unit (where the shift rod is, I disconnected it).

 

[mphelle8vld]

Re: broken bolt suzuki DT65

Hi Kreso, I just dropped the lower unit on my 65hp, there are definitely no threads in either the spacer or lower unit housing for your bolt in question. You could try heat, liquid wrench, and a rubber mallet on your corroded bolt, but keep in mind that the driveshaft splines could be corroded into the crankshaft up top. I'm still waiting for a water pump repair kit so let me know if you have any other questions while my motors down.

 

[James R]

Re: broken bolt suzuki DT65

The spacer that you are referring to is, I think, is the shaft bearing housing. There should be no gap above or below that. If there is a gap the shaft seals will not seal. To remove the bolt in question the lower unit along with its bearing housing should be removed. The bolt will probably have broken off flush or near flush with the drive shaft housing. If that is the case access to a Mig welder and a method I have used many times may well remove the bolt.
Reassembly with OMC thread and gasket seal or Antiseize on the bolts, threads and shanks, will help prevent a bolt breaking off.

 

[pege]

Re: broken bolt suzuki DT65

The problem may be the case pins (refere to/ see DT 65 Fig 32 - Gear Case or Gear Case Pin, part 15 on the DT 65, Fig 8 - Water Pump in Suzuki DT 65 Party Listings) is corroded and stuck. It was on my 1978 Suzuki 7.5 hp. Had to use brutal force, the best tool was different chisels and screwdrivers with different angle / inclination to get in between the drive Shaft Bearing Housing and Drive Shaft Housing and Gear Case and forcing the parts from each other.
Hope this can be anny help for you.

Pege

 

[Kreso]

Re: broken bolt suzuki DT65

Hi Kreso, I just dropped the lower unit on my 65hp, there are definitely no threads in either the spacer or lower unit housing for your bolt in question. You could try heat, liquid wrench, and a rubber mallet on your corroded bolt, but keep in mind that the driveshaft splines could be corroded into the crankshaft up top. I'm still waiting for a water pump repair kit so let me know if you have any other questions while my motors down.

Thank you all guys, that's what interested me. As there are no threads I can drill the broken bolt without danger to destroy them. The funny thing is that the bolt is not corroded at all, but the salt crystals are what is holding it. I received only impeller from the water pump repair kit so I'll have to reorder! I suppose all parts have to be change at once.
Kreso

 

[Kreso]

Re: broken bolt suzuki DT65

The problem may be the case pins (refere to/ see DT 65 Fig 32 - Gear Case or Gear Case Pin, part 15 on the DT 65, Fig 8 - Water Pump in Suzuki DT 65 Party Listings) is corroded and stuck. It was on my 1978 Suzuki 7.5 hp. Had to use brutal force, the best tool was different chisels and screwdrivers with different angle / inclination to get in between the drive Shaft Bearing Housing and Drive Shaft Housing and Gear Case and forcing the parts from each other.
Hope this can be anny help for you.

Pege

I think it's not a case pin, as I managed to separate spacer from lower unit (just a few milimeters) on the front side, while the rear is holding completely.
Kreso

 

[zem]

Re: broken bolt suzuki DT65

hi i had the same problem with my engine mounting bracket on a dt 65 1990, it sounds like the bolt is being held there by the salt and the thread is fine once u get it prised apart the stud should wind out pretty easily, its surprising how a little salt build up can hold somethin so fast, i got mine apart with a hammer and chisel buti totally mashed up the bracket and some of the block so take care when prising as its only ali

 

[Kreso]

Re: broken bolt suzuki DT65

Thanks Zem,
the only problem is how to get the WD40 into the hole as the bolt is placed upside-down. I would have to turn the whole engine upside-down so that the WD can drain onto the bolt.
As the engine is at my summer house I'll have to wait for a few months before starting repair. I'll post about results.