Lower Unit Won't Separate DT65

[rdxgator]

I have a 1994 Suzuki DT65. Trying to remove the lower unit to change the water pump components. All of the bolts (including the long one in the rear near the anode) and the gear linkage are removed and disconnected.

The unit will drop about 1/2 to 3/4 of an inch and then NOTHING. I've put some considerable elbow grease into trying to break it free. My manual said to place the gear into Forward and I have double checked that.

What am I missing? Is it simply seized up and needs more persuation? PLEASE HELP if you have any insight.

Thank you.

 

[deejaycee_2000]

Re: Lower Unit Won't Separate DT65

As far as I know it should always be in neutral not into gear when dropping the lower unit .....

 

[rdxgator]

Re: Lower Unit Won't Separate DT65

the Clymer manual clearly states "place it in forward" but heck, I'll give it a try. Also, When I tilted the engine up, gear case oil spilled out (looks nice and clean though so apparently my roughing it up broke a seal/gasket).

thanks.

 

[pine island fred]

Re: Lower Unit Won't Separate DT65

I get chills when I read about this problem. Been away from the board for awhile due to illness but am sure the problem comes up on occasion. Hope someone comes up with a solution on getting it seperated.
Only comment I can make is if it gets to the point you have to cut a hole and cut the shaft with a sawzall ( might be suggested in the manual) dont bother. Cost of a new shaft and tooling necessary to get the shaft out of the leg is prohibitive. Then you still have to get the half of shaft out of the power head. I could not.
When I see a question on what to look for when buying a used motor, my first suggestion is to always make sure the leg will drop off. Talking from experience. good luck FRED

 

[rdxgator]

Re: Lower Unit Won't Separate DT65

hi fred, we're glad you are feeling better...

I spoke with Paul from Brown's Point Marine in NJ yesterday. He said that as long as I am sure that the shift rod is not hanging up on something and that all the bolts are out, it should drop. He said it must be corroded and needs extra elbow grease!

I'm going to get a buddy to come and give me an extra set of hands and see if we can pursuade it to come off. I hope a new motor is not in my future just yet. It was running great.

 

[lunchman3815]

Re: Lower Unit Won't Separate DT65

Stupid question but are you seperating the lower unit from the (top)water pump housing or below the water pump housing. First time I dropped my lower unit I thought it was a spacer and did'nt realize that that it would not budge(held in by a spring) among many other parts. Just a suggestion.

 

[rdxgator]

Re: Lower Unit Won't Separate DT65

Tell me what you mean Lunch man...? Because it feels as if there is a spring pulling on the unit... I can pull it out about 2 inches and then it wants to slide back up an inch like there is a spring pulling on it.

I'm frustrated for sure.

 

[deejaycee_2000]

Re: Lower Unit Won't Separate DT65

Check the parts breakdown for the motor on brownspoint website, there you will be able to check that ......

 

[rdxgator]

Re: Lower Unit Won't Separate DT65

There is a "spacer" section. I can get it partly separated on the back 1/4 but the forward section isn't budging. I'm scared it will break. I'm thinking that the bolts that broke off are holding it in place.

Does anyone know if this section is threaded? I wouldn't think so but it is holding fast!

 

[rdxgator]

Re: Lower Unit Won't Separate DT65

That was it. I got the "spacer" off and removed the lower unit.

Problem #2. The oil from the lower unit poured out when I tilted the lower unit after removing it. That's not normal is it?

The good thing is that there are no signs of any water in the oil. Did a damage a gasket or seal somewhere in my attempts to remove the lower unit?

 

[mikesea]

Re: Lower Unit Won't Separate DT65

Whats probably happened is the drive shaft splines have rusted into the crankshaft,thats a big reason why a lower should be dropped and lubed throughout,including the top of the shaft before installing into the crank.What Fred posted is the common fix. But ,I was shown another trick,workes sometimes,maake a few wedges,start the engine.While its running ,try placing wedges between the seperation,or shake the lower all around.Dont run it too long though .Dont want to fry it.Between the vibration ,a little heat ,and some persuasion,you might get it. You will burn the water pump up.Alternative will cost you a new shaft and having the gear housing disassembled and resealed. Its big bucks. More that the motor is probably worth.

 

[CB]

Re: Lower Unit Won't Separate DT65

I saw this thread and want to see if any of you can help me. I got a dt65 suzuki i was tryin to get the lower unit off. seems like my problem was stupidity. I got to the point of seperating the l/u (nothing seemed frozen and moved freely0 but i didnt know how to disengage the clutch? shaft. So I went to put it back together and it was like a spring, where it didnt want to go back in to place. after playing with the gear shift, I managed to get it to the point where the bolts threaded and i put it back on. But now i am stuck in reverse. I even busted the plastic arm that connects the rod from the remote control because I tried to put it (with too much force) back into nuetral. When Ihave time, i would like to take it off to service (impeller and all) and hopefully by then figure out how its supposed to go back in w/o breaking it or it being stuck in reverse. Any pointers?... also, I drained the lower unit oil. Could this cause it to get stuck. i didnt run it after the drain, for fear of burning it out, but havent had a chance to get more lube. Thanks.

 

[Kreso]

Re: Lower Unit Won't Separate DT65

Hi,
I have a problem with my 1996 DT65. I want to change the impeller so I need to remove the lower unit. When I was trying to unscrew the ninth bolt which is situated bellow the trim tab it broked at the first thread, which is aprowimately 1inch from the head. All other eight bolts that are holding the lower unit came out nice. My question is: is there a thread in the spacer or this bolt just passes freely and screws upside in drive shaft housing? I think I'll have to drill it to get it out if the thread goes through the spacer also. If there is no thread in the spacer maybe just salt crystals are holding it in place.
Thanks for help
Kreso

 

[stylesabu]

Re: Lower Unit Won't Separate DT65

I own a 75 dt 1986 and have replace water pumpo and prop shaft.You have to disconnect forward reverse linkage under bottom carb. the fact that you have dropped it an inch or so indicates that you must disconnecty linkage. here's a picture

 

[trendsetter240]

Re: Lower Unit Won't Separate DT65

2006 called...it wants it's thread back.

 

[Kreso]

Re: Lower Unit Won't Separate DT65

I own a 75 dt 1986 and have replace water pumpo and prop shaft.You have to disconnect forward reverse linkage under bottom carb. the fact that you have dropped it an inch or so indicates that you must disconnecty linkage. here's a picture

Hi,
I know I have to disconnect forward reverse linkage (thanks for picture) but I have a broken bolt which holds the lower unit (central bolt situated near the trim tab, and goes through the spacer and screws in the drive shaft housing). Although it is broken it still holds the lower unit and I don't know why. Maybe it is just salt, in that case I could use force to remove it. But maybe the bolt screws all the way from beginning in lower unit through spacer and the threads are still holding. In that case I will have to drill the bolt.
Can you remember, when you were removing or screwing this bolt, does the thread start in the lower unit or you can just push the bolt through and it only screws in the upper part (spacer and drive shaft housing). Can anyone please check it. This bolt is part No. 09117-10024-XC0

 

[Kreso]

Re: Lower Unit Won't Separate DT65

2006 called...it wants it's thread back.

 

[99yam40]

Re: Lower Unit Won't Separate DT65

Start your own thread, do not add to one that is years old

 

[pege]

Re: Lower Unit Won't Separate DT65

Probably is the bolt frozen and it prevents seperasjon. If are you sure all the bolts are gone and that the shift rod is free, you must only use power, I have a dt 65 mod 88 and has had some problemes with it. Among other things, the lower unit. I had problems when I was bout to change impeller. Seperasjon of the lower unit went smoothly, but I was unlucky to pull the gear shiftrod. and because a small cotton pin was corroded away, the gear sift rod came so far up that it would not go back. From Suzuki Parts Listings you can see that it is because the small ball for the neutral position has come under the gear shift rod. I had to separate the propeller shaft and it was difficult and a lot of work, The bearinghouse were frozen and the workshop gave up, they were afraid to destroy the entire unit. I was "desperate" and I use heat, power, hammer, hydraulic press and finally got the bearing out, unfortunately the bearinghouse was destroyed,Bought an new one and now I also could cleen and check the interior and replace all gaskets, o-rings and cotton pin and also fix the gear sift rod, Installation went without trouble.

 

[Kreso]

Re: Lower Unit Won't Separate DT65

Hi Pepe,
The bolt if frozen for sure, as it broke. But can you remember if the hole is threaded in the lower unit?