Suzuki mechanic recommendation df90 leg stuck

[Aridhol]

Hi, I have a 2016 Suzuki DF90 outboard that I was going to change the impeller on but I can't for the life of me get the leg off.

I've triple checked (I think) that I have all the bolts out but I just cannot get the thing apart so I need professional help to look at it and see how screwed I am.

Its been trailered in and out since new and flushed with saltaway every time so I didn't expect it to be seized but...

Other than getting the leg apart it runs like a dream and starts great so I'd like keep it around if I can.


About 470 hrs I think on it.

Any recommendations, tips or advice is welcomed.

 

[kingblazer84]

Got any pics of the mounting seam of the lower unit? Any hint of corrosion?

 

[Aridhol]

I'll take some, nothing I can see.

 

[CIVANO]

Do you have a bolt under the trim tab?

 

[Aridhol]

Yep there's a bolt under the cav plate? That is recessed and I got that out. There is a zinc there too.

Its not actually bolts that go up, its bolts that come down towards the propeller with nuts on the end, the nuts and washers is what I've removed. Hope that makes sense.

Just at son's ball game, will take some pictures when I get home

 

[sly_karma]

I'm not familiar with Suzukis at all, but don't forget to disconnect the shift rod.

 

[brutus]

? so the lower unit has never been taken off ??? If this is the case then hope the shaft is not seize in

 

[Aridhol]

I'm not familiar with Suzukis at all, but don't forget to disconnect the shift rod.

I will have to check this.

 

[Aridhol]

 

[Aridhol]

? so the lower unit has never been taken off ??? If this is the case then hope the shaft is not seize in

I believe it has but only once. I did not have possession of the boat at that time.

 

[scott craven]

You may have to use some plastic shims once you're sure all the bolts are free.
Gently tap the shims in switching sides frequently.
It can take some persuasion but hopefully it'll break free.

 

[brutus]

Looks like the studs are crusted in salt built up, spray salt away on them and try to break them free from the lower unit with small wedge, like Scott says side to side round and round lol, you will see movement, if it’s not budging then you might have a bigger issue,

 

[Zuktaylor]

Put the nuts on a few threads, hammer on the studs then hit them with a torch.

 

[InterMechanico]

I would soak the threads thoroughly with Deep Creep or Moovit, wrap it in a plastic bag and come back to it in a few days time.
This is what I do with diesel exhaust manifold studs and it works really well every time

 

[Thunder21]

This is a common Suzuki issue. I bet the reason it won’t come is the shaft is seized into the bottom of the powerhead due to a lack of grease. They need to be dropped every year and grease applied.

 

[Aridhol]

This is a common Suzuki issue. I bet the reason it won’t come is the shaft is seized into the bottom of the powerhead due to a lack of grease. They need to be dropped every year and grease applied.

this sounds like a costly problem, what would I be looking at $$$ to fix?'

 

[wolf]

When you do get it off make sure to get the "blue" spline grease(also on prop shaft) . grease is your friend, I was taught looonnngg ago put grease on every nut and bolt on marine .
My mechanic freind who is a marine tech likes to use grease 2-4-c on all bolts makes life easier down the road. last year we dropped my leg there wasnt a drop of grease on any thing from factory when we did water pump,internal zinc,etc everything got a dab

 

[Tideline]

I have a Suzuki 140 (20010) and near 2013 was advised by a friend that others had problems taking the leg off the same motor to do the water pump a couple of years from new. It was supposed to be a problem with grommet that stabilizes the shaft. The grommet siezes to the shaft. One person had destroyed the upper leg getting it apart.
At about 800 hours I decided I had better attempt taking it apart in the off season to forestall having to do it if the pump broke down in fishing season. I backed the boat up so the motor was hanging over a drop and I could rig a couple of hundred pounds of lead with straps to let hang on the leg. I sprayed it all up with screw loose or something similar, loosened the nuts enough that the leg would drop a quarte inch or so. All ready to go and I decided to give it a try first. I gave it a tap at the joint with a 3# deadblow hammer and it dropped free onto the nuts...
I replaced the water pump, which was fine, and lubed everything up and put it back toegther. You might try the lead thing if nothing else works. Some guys say the splines on the shaft sieze in the socket it plugs into. Good luck

 

[bpsuls]

This happened to my Yamaha F200. The shaft seized into the block. Even though I had greased it a few years earlier. I did get it apart but it took an unpleasant amount of force, like I mean jumping on it amount of force. Now I take it off every two years, and change the impeller while I'm at it and put never seize back on it. It's just part of my routine now and no more problems. Don't use marine grease it just cooks and turns into glue. Use never seize.