suzuki df90 shift linkage

[Reezos]

Hello,
Just got into my spring maint on my 03 Suzuki DF90 and after changing lower unit gear oil I went to work the throttle and gear controls to make sure they move freely, the gear lever is froze, disconnected the cable from the engine, the control box is fine, tried to move the shift lever on the motor, frozen solid. any ideas?
Everything was fine last fall when I put it away for the winter.

Thanks

 

[clanton]

Re: suzuki df90 shift linkage

There are 20 pieces of linkage before you get to the clutch/shift rod. Drop the gearcase, then try to move the lever. If the lever will move. The detent ball, spring, and slider are the problem. Two places to lubricate the lever and linkage.

 

[BOAT DOCTOR]

Re: suzuki df90 shift linkage

drop the lower unit.try to shift the control box on if you no for sure the cable moves freely when not hooked up.if it still dosent shift take a look at the top of the shift shaft.where the shift goes in little bracket with two 12mm bolts has a plastic bushing in the middle of the bracket that probaly frozen there thats where i would look.

 

[Reezos]

Re: suzuki df90 shift linkage

I know the shift box works when I disconnect the cable, so I'll go after that piece of linkage at the top of the shift shaft first. I'll let you know.

Thanks!!

 

[Reezos]

Re: suzuki df90 shift linkage

Well, I'm back on the water, turns out it was the bushing on the shift linkage that sits on top of the shift shaft. I took some penetrating oil, sprayed the heck out of it, then LIGHTLY tapped it with a hammer and it moved, repeated for constantly for two nights unil it loosend back to normal, thanks for your suggestions they steered me in the right direction.

Reezos

 

[Mr Den]

Re: suzuki df90 shift linkage

I have a Suzuki df70 (year 2000) I had a problem with the linkage sticking on the engine and fixed it. Being an unknowing fool I also took off the control box without noting the linkage positioning. Now it seems with the control box shift lever in neutral and the engine neutral switch engaged and accelerator closed the cable no longer fits the linkage in the control box. The cable is too long but I never did anything to the cable just the linkage on the motor. So with the neutral switch engaged and the accelerator closed where should my linkage be in the control box? I have been looking on the web for a week and cannot find information on the correct position for the shifter linkage and the accelerator linkage in the control box.