Suzuki DT-40 (1985) - Removing propeller shaft?? HELP!

[andreeb]

Hi there.

I purchased 2 old DT-40 motors, one for parts and the other as working (had to do some maintenance to make it that way).

And now when it's finally working great, I found out that the propeller shaft is bent out of shape, so I need to remove/change it.

I have NOT managed to do so, same with the Prop. shaft housing, do I need any special tools to accomplish this??

And also should I remove the water pump house first or anything like that??

ANY help would be very much appreciated, im currently stuck and dont know what to do

[Solarman]

You should get a dt40 service manual. The service manual will take you through disassembly and reassembling the gear case/ transmission. It is not real difficult, but yes, you well generally have to remove the shift rod housing, water pump housing, drive shaft bearing housing, and prop shaft housing which includes the prop shaft bearing.

Good luck.

[andreeb]

I have the manual, but it did not help that much.

However...

After alot of hours we finally managed to remove the broken prop.shaft housing on the defective motor (this one had a gearhouse/shaft in good condition)!
We lacked the correct/special tools for the job, so after hours of hammering and thinking we took two small carjacks, the cheap ones that usually comes with cars.
We screwed the nut back on the propeller shaft, added a round thick metal plate I had before we added the nut, and put a carjack between the housing and plate/nut, on each side.
After some minutes/few tries we managed to get the broken housing+shaft out of the gearhouse, without damaging the shaft or gearhouse

We then used a bladecutter on the working motor, and cut a rectangular "hole" in the gearhouse (this gearhouse had a defective/bent shaft, but the prop.shaft housing was in good condition)
Then we just used a small rubber hammer and got out the whole housing w/shaft in mint condition!

We then added the parts together and now I finally got a gearhouse with a good prop.shaft/housing !

Hard work always pays off I guess! =)

Please excuse my engish, it's not my native language!

[Solarman]

English may not be your language, but you are doing very good.

I'm glad you were able to get all the parts back together.

Good luck

[andreeb]

English may not be your language, but you are doing very good.

I'm glad you were able to get all the parts back together.

Good luck

Thanks alot Solarman :-).

I thought it was running abit hot when running in idle (had it in a large bucket with the clamps/hose on)

I then decided to check out the termostat, figured that was the last part I hadn't inspected since I got it, when I removed the lid there wasn't any termostat there :S. Not sure how long the previous owner have ran it without one.

However, prior to doing this I removed the termostat lid on the sparemotor, and there was a termostat there, so I cleaned it up, heated it up on the stove to be sure it was working, and put it inside, now it's not running hot when idleing!

Put the engine on my boat today, and it ran like nobodys business

Sweet engine, I paid about 450USD for both engines, not working, pretty f satisfied with that price now, even if I used 10-15+ hours to get it in perfect condition!