Suzuki mechanic recommendation df90 leg stuck

i completely disagree on not using spline grease. there is a reason every manufacture has marine spline grease. it is bluish purple use on mainshaft splines and propeller
You should use what works for you. It was my experience.
 
YES to spline grease!!!! grease is your friend in the marine world!!!
 
Last edited:
There's alot of different formulas of grease out there. Some of the larger industrial applications we use what we always called long strand grease. It's basically just the variance of tackiness in the grease. Have to be careful with that though because some of the really tacky grease will overheat a bearing. When I'm building engines, I use really light grease suitable for a bearing that has enough tackiness to hold something like needle bearng in place but not stay there. I want that grease to disappear. In applications like a fastener, a spline, or a on say a tractor with a big joint where you need that grease to stay put, then the sticker the better. In Marine land, I just use the evninrude tripple guard on all splines and fasteners. It's nice grease.

Also you don't need to grease the top of a driveshaft on an outboard. Just the sides. Same with those shift shafts on mercs and yamahas. The dimple in the end of the shaft is there for a reason. Don't fill it up with grease. Some of the other outboards, mercs especially, you don't want a long strand grease on the shaft at all. Some shafts go through seals and orings. Which a real long strand grease will overheat that seal or oring and cause major premature life on that part. So use the proper grease for the proper application.

Never seize is banned in my shop
 
FYI, one of the most effective penetrating oils is a 50/50 mix of acetone and transmission fluid. I'm sure PB Blaster, Liquid Wrench, Lloyd's Penetrating oil are all fine - just don't bother with WD-40. Penetrating oil on its own is good, but if you can heat cycle the surrounding area a few times (re-applying the penetrating oil each time) its works way better. Different materials expand at different rates when heated. The gear case is aluminum, the bolts are steel - heat cycling opens up microscopic gaps that can help the penetrating oil get where it is needed. Apply the heat to the thing that needs expanding (you always heat the nut, never the bolt). I don't know if I'd want to take a torch to paint finish, so I'd suggest getting an electric heat gun or maybe even starting the motor on muffs and letting it idle for a while (use exhaust temp to heat up the lower unit). After you have heated it up and have applied penetrating oil, I wouldn't be shy about giving the lower unit a few whacks with a dead blow hammer to help massage it a bit before you start with the wedges.

Try everything you can throw at it - lubrication, heat, vibration - it all helps.
 
The grease that didn't work on my spline was Evinrude triple grease. Great stuff. But I don't use it on the motor output spline anymore. Glad to hear it works for others though. Loctite LB8023 is specifically made for marine use. Like I said, use what you want but I have empirical evidence that shows my method works too.
 
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.
 
There's alot of different formulas of grease out there. Some of the larger industrial applications we use what we always called long strand grease. It's basically just the variance of tackiness in the grease. Have to be careful with that though because some of the really tacky grease will overheat a bearing. When I'm building engines, I use really light grease suitable for a bearing that has enough tackiness to hold something like needle bearng in place but not stay there. I want that grease to disappear. In applications like a fastener, a spline, or a on say a tractor with a big joint where you need that grease to stay put, then the sticker the better. In Marine land, I just use the evninrude tripple guard on all splines and fasteners. It's nice grease.

Also you don't need to grease the top of a driveshaft on an outboard. Just the sides. Same with those shift shafts on mercs and yamahas. The dimple in the end of the shaft is there for a reason. Don't fill it up with grease. Some of the other outboards, mercs especially, you don't want a long strand grease on the shaft at all. Some shafts go through seals and orings. Which a real long strand grease will overheat that seal or oring and cause major premature life on that part. So use the proper grease for the proper application.

Never seize is banned in my shop
What do you use for treating lower unit bolts so they don't seize up from the aluminum/stainless connection?
 
Another trick we use in the automotive world, is heating up those studs and pushing a wax candle when it’s hot and the wax moves its way up the bolts and loosens up a lot of seized components.

Don’t know if you can warm that seam then try to push crayon or candle wax into it and the hit it with a dead blow rubber mallet
 
The salt around the lower bolts is not that bad, I am not a pro by any long shot and I’ve pulled some nasty ones, salt away is what worked for me, no heat, just salt away over and over, the wedge and rubber hammer,. Never dealt with a seize shaft, that’s the part that I would be worried about, lots of story of it happening
 
Some greenhorn won't say names here but came from the valley with a 1 year old install. Seized steering cable and those guys used anti seize. What a mess. Haven't even taken the assembly apart yet.


20250504_172916.jpg
 

Attachments

  • 20250504_172916.jpg
    20250504_172916.jpg
    159.8 KB · Views: 1
Back
Top