2016 Suzuki df150 - powerhead removal question

[briscoe]

Supagruv, any progress on pulling that shaft?

[supagruv]

We did our best and couldn’t get it to work… So we drop off the powerhead at the Suzuki dealer tomorrow and see if they have any luck… I have a feeling they will have to cut the gear out and replace it.

[ECU1984]

Dang, wonder why it seized like that?
I may would try a machine shop before the Suzuki dealer's shop.
Machine shops do this type stuff regularly on different machinery, tractors, axles, etc

[supagruv]

Hmm... ECU1984 that is an idea... not sure why I didn't think of that first. Well we made this appointment with the shop over a month ago and tomorrow's the day. Good thing is that we're on good terms with them (it's an owner/mechanic shop) and they have always been very honest and fair with their work and our options. At this point our boat restore project is 98% complete and been on hold for 1 month+ while we try and do a "quick impeller change"... lol. Hopefully we just get the ball rolling again.

Photo Oct 16, 12 55 53 PM.jpg
Photo Oct 16, 1 43 00 PM.jpg

[supagruv]

Well we took it to the shop today and they couldn't get the shaft out either. But thankfully since we took the powerhead off it should be less than 2 hours of shop time to remove and replace the main drive gear so ~$500 to get a new gear installed including parts and labor. Will be great to get the motor running again... WITH a new impeller.

[briscoe]

Well, we knew if u couldn't get they would need to change that gear. The outcome is still good. Replacing that gear gives peace of mind. Thanks for the update.

[silver.wave]

4a.jpgI own a 2017 Suzuki 150DF from 03/2021. The engine has 700 operating hours. According to the authorized service, the last replacement of the impeller was at 400 hours in 2020. Before this season, an attempt was made to replace the impeller. When trying to lower the lower part of the engine, it was blocked. After about 10 hours of various tricks and magic, the service technician decided to cut off the drive shaft. After disassembling the entire engine on the press machine he managed to eject the drive shaft. After inspecting the parts, the service technician believes that corrosion destroyed the guides on the drive shaft because no one has ever changed the impeller and lubricated the shaft.

[briscoe]

I would have thought Suzuki's grease at time of manufacturing would have done better than that on an '17 engine. ***

[supagruv]

Yeah well in the end after about a month of various "tricks" got the powerhead back from the shop and they removed the driven gear successfully! We have the stuck shaft as a souvenir hanging in our shop.

New powerhead gasket and new intake gaskets and about a day to put everything back and clean stuff... then put new impeller and put oil back in the system... and boom! It starts right up. Wish we knew how bad it was from the get-go and we would have gone straight to this... most of the motor looks like new but yeah I bet the splines look like yours silver.wave.

Anyway, we had our first sea trial with the new boat and motor yesterday... felt great... except now we're facing a new issue... it won't go more than about 3700 rpms. But that's another story... going to make a separate post for that.

In the end, YES it would be great if Suzuki could have used something to make the drive shaft splines not stick so badly... sure it probably was due to some level of neglect, but these are 2016 and 2017 motors!

Anyway... thanks everyone for chiming in and for the ongoing support. It's much appreciated.

stuck-driveshaft.JPG