Suzuki Clutch

[bearbait]

I have a problem with a dt55 staying in forward gear. I bought this 1991 motor used and the gears chatter and it won't stay in forward, reverse works fine. I have the lower unit removed and with the hub assembly removed I can push the prop shaft in and the clutch dogs barely engage. The forward clutch dogs are slightly worn but less than 1/16' of the edge is worn, the dogs on the forward gear look fine. It looks like the follower that rides against the shift cam is about in the middle of the forward lobe and if I could lower the shift rod 1/4" it would allow the clutch to come forward far enough to engage the clutch dogs. Does this make any sense? Is there any way to adjust the shift rod up and down? Am I overlooking something simple? I'm certainly no mechanic so if I'm barking up the wrong tree please let me have it. I would take it to a Suzuki dealer but the nearest is 400 miles away. Thanks

 

[Silvertip]

Re: Suzuki Clutch

What you should have done before tearing this unit apart is to simply disconnecct the shift cable and operate the shifter manually. Chances are the only problem was shift cable adjustment. Lengthening or shortening the shift rod to compensate for forward, means you will create a problem for reverse. IF the shift rod is adjustable, there is only one position it can be in and that's the factory setting.

 

[bearbait]

Re: Suzuki Clutch

I did check to see if things worked properly with the cable disengaged. With the cable disengaged I could spin the prop in both directions in forward gear while feeling the clutch dags barely catching. Reverse was fine. I'm stumped. The shift cableswere replaced shortly before I bought it so I first figured it was improper adjustment.

 

[bearbait]

Re: Suzuki Clutch

Does anyone else have any ideas. I just reassembled the lower unit and when in forward gear, with the shift rod pushed all the way down, I can turn the prop shaft by hand and it will spin the driveshaft until I hold the drive shaft, then the dogs will start slipping. Could anything be bent? Could the previous owner have assembled something wrong? Most bolts seemed pretty corroded so I don't think it had been recently torn apart but I might be wrong.