'97 DT-90 Lower Unit Removal Troubles

[crappie-attitude]

Hi guys; I'm new to this forum and did some searches, but did find anything that helped. I was trying to install a water pump kit on my DT-90 over the weekend and couldn't get that darn lower unit off for anything. I have a service manual and removed the linkage pin at the top of the L.U. (beside the speedo cable) as well as all 7 bolts- 3 on each side + 1 in front above the prop. Am I missing something else? That's all the 'Zuki service manual mentioned. Anyone have any tips or tricks? Is it necessary to have it in gear?

The service manual did say that for re-assembly, to use Suzuki Silicone Seal on the face of the lower unit. Could that be my problem and does anyone use that for re-assembly? If not, what do you guys use for re-assembly, if anything?

Thanks in advance for your help.

 

[Marion Moore]

Re: '97 DT-90 Lower Unit Removal Troubles

How did this work out for you? I have a DT140, not the same but close. I'd guess the housing may need some tapping to come loose. There is a place on the rear of my DT115/140 unit for a screwdriver to use to pry it apart while you tap with a soft face hammer.

The mating surface could be "sealed" as well as the alignment pins could be corroded. If the drive shaft was not coated well with grease it could be stuck also.

 

[James R]

Re: '97 DT-90 Lower Unit Removal Troubles

Hopefully your drive shaft splines are not frozen.
There are two locating pins between the lower and the housing. These often
hang up.
Dont beat on the Skeg or anticavitation plate. They will fracture.
Use a soft faced mallet alternately on each side of the nose of the lower. Go carefully. This should free up the lower. Be ready to catch it. The gap at the rear of the lower above the prop can accept a large screw driver. Twisting the screw driver in the slot can also help.

 

[JUSTINTIME]

Re: '97 DT-90 Lower Unit Removal Troubles

dead blow on the bullet of lower unit