Suzuki DT 25 Lower unit

[Hektor 403]

I can not remove the Lower Unit to change the impeller although I have remove all 6 screws. I tried also with a bit of force but seams it is welded inside somehow. Any suggestion how to remove Lower Unit

[Hoosmatroos]

Did you also disconnected the shift rod? And in the gear case the are some pins that can be stuck.

[Hektor 403]

Did you also disconnected the shift rod? And in the gear case the are some pins that can be stuck.

Yes I disconnect the shift road, but I did not find any pins in gear case and I do not know where to look for them.

I simply followed same steps from video.

Pt.1 Suzuki DT25 Outboard Water Pump Service At D-Ray's Shop

https://www.youtube.com/watch?v=gaFkGbC8bhY&t=276s

I tried to hit with wooden hammer to remove the lower unit but is impossible

[Solarman]

what year is your motor?
Does your motor have a hidden bolt under the trim tab?
If only 6 bolts then possibly the driveshaft is stuck in powerhead, or those 4 locator pins at the flange you are trying to separate are frozen into the upper flange?
If you can get a thin flat putty knife between the sections you can locate those pins, to spray some penetrating lube where you run into each pin (do not try to separate the flange w/putty knife, just locating for penetrant). Then you can use 2 bolts to pull back together, and loosen bolts then using wooden block knock back down. After several up & down movements, you should be off those pins, if you can't get more than 1/2" separation, and still stuck, might be crank and driveshaft are stuck. Just have to work that loose best way you can without damaging the aluminum housing.

Good luck, post back when able to let us know how it's going.

[Hektor 403]

It is Suzuki DT 25 ACRL from 1994 with serial number 02506-461030 made in Japan.
To be honest this model and serial number I cannot find in any specifications regarding model-year.
I do not know about any hidden bold under trim tab since I was referring to methodology that I saw in YouTube, but I will check it if there is any hidden bolt today and let you know.
Thanks a lot.

[Solarman]

your serial number must be, 02507 ... because they don't list anything/ any year for 02506... the numbers jump from 02501, to ...03, to ...07. No mention of 02506, according to Brown's point listings (see link).

Suzuki Outboard DT 25 Model & Serial Numbers - Browns Point Marine Service, LLC

And your motor doesn't appear to have a hidden bolt. So it is stuck because of the 2 knock pins (corroded), or the driveshaft is grease-dry-locked (grease dries up, then acts like glue when not replaced often enough).

Always re-grease top of driveshaft (splines) when removed for maintenance or repairs.

Just have to keep working on it, carefully.

Good luck with that. Post back how it's going when able.

[Hoosmatroos]

The pins I mentioned are those locator pins indeed. If those are corroded then its alway a pain to remove the leg. But also the driveshaft is difficult because there is no way you can use lubricant.

[Hektor 403]

In fact I am also surprised with model and serial number but realy the Model is DT 25 ACRL and this model is not in list at all anywhere and the serial number is 02506-461030 also not in any list

[Solarman]

What country do you live in? I'm not sure what the "06" stands for; the "25" is size; the "4" of 461... is year "94". On some other Suzuki motors the "06" indicated what decade the motor was manufactured. But doesn't seem the case with yours.

As far as the lower unit, if you get 1/4"+ separation, the knock pins aren't holding you back. It is the old grease on the driveshaft.

Good luck.

[Hektor 403]

I live in Albania, but I bayed the boat with motor in Italy last year.

As far as the lower unit, the separation is cca. 3 mm. Is there the possibility to remove from upper part by removing power head or whatever.

One Service Provider here in Albania said that only possibility now is if I open a single hole and cut the drive shaft dhe to try to remove. Is there any logic to do this?

[Solarman]

well, if you are able to tie the lower unit with straps down to the floor tight, with boat tilted up, then you could use a lift, or pulley and carefully pull/lift entire motor and boat up, the driveshaft would pull loose. That is the only way i can think of lifting it apart.

There is not away that would be simple to remove powerhead, if lower unit won't come apart.

Good luck. Don't break any aluminum doing this. Post back what you do.

[Hoosmatroos]

+1. There is an option to make a hole in the leg that you can later plug with a rubber cap. Cut the drive shaft as a last resort. First try everything else. The method Solarman suggested is the best option to start with.