93Suzuki DT85 Power Head Removal

[mscheopner]

I'm trying to remove the power head on my DT85. I've removed all 8 bolts under the covers. Is there something I might have missed. My book says to rotate the prop if you have problems pulling the head. I tried that and it didn't work so I pulled the lower unit with no problems. The book I have isn't very good. Please help. <br />Thanks <br />Mike

 

[jim dozier]

Re: 93Suzuki DT85 Power Head Removal

Did you get the 2 nuts on studs at the back of the powerhead. There are 8 long bolts on either side (which you apparently removed) and 2 additional nuts on studs in the back. If all of those are out and the drive shaft is out, the only thing holding it will be gasket.

 

[mscheopner]

Re: 93Suzuki DT85 Power Head Removal

Hi Jim<br />Thanks for responding. I found 1 nut that I had already removed. There are 2 of the long bolts that were busted off when I pulled the covers, one on each side. Can I drop the Shaft housing without pulling the power head? That would enable me to possibly get those out without drilling them.

 

[jim dozier]

Re: 93Suzuki DT85 Power Head Removal

Once you have either removed or busted the heads off of the 8 long bolts and removed the 2 nuts, the only thing holding the powerhead will be the grip of corrosion (which can be very tight) on the remnants of the broken long powerhead bolts. I had considerable difficulty removing my powerhead because of 1 stuck bolt shaft. I hung my outboard from the garage rafter and used a drift to tap on the remnant of the broken stud. The problem is that the more you bang on the stud the tendency is to mushroom the end causing and even tighter grip. I was able to get some movement (glacial speed) and by grinding down the mushroomed end I was e v e n t u a l l y able to get the booger off. Use lots of heat, penetrating oil and patience.

 

[mscheopner]

Re: 93Suzuki DT85 Power Head Removal

Thats what I figured. Thanks for your assistance, I'll keep you posted as to how this turns out.

 

[mscheopner]

Re: 93Suzuki DT85 Power Head Removal

Hi Jim,<br />You said that there are 2 nuts at the back of this motor. I can only find 1. It's right behind the drain tube for the lower cowling. Should there be some in another area? I can't get this power head to budge. <br />Thanks for your help with this.<br />Mike

 

[jim dozier]

Re: 93Suzuki DT85 Power Head Removal

No, you are right, theres just the one. I was going from memory (shows you how good that is). I checked the exploded parts diagram, 4 long bolts either side (total 8) and one nut in the back. If you have those listed above out, and the driveshaft (lower unit) is already out the only thing holding it is the gasket and corrosion on any remaining bolt shafts. If you broke the head off of one of the 8 long bolts it isn't because the threads are corroded its probably because of corrosion around the shaft where it goes through the engine holder. When I finally got my powerhead off I had to drill out the holes in my engine holder (the thing the powerhead sits on) in order to get the new bolts back in. There was a layer of corrosion that was quite thick and dense. I believe you will have to work on the shafts that you said are broke off.

 

[jim dozier]

Re: 93Suzuki DT85 Power Head Removal

Here's something you might try if you can't get any movement. You could drill a small hole from the outside of the engine holder into the bolt shaft hole (you'll know when you get through the aluminum and hit the bolt). You could use this hole to get some penetrating oil around the remnant of the bolt shaft. You could fill it in later with JBweld epoxy. It might help loosen the grip of the shaft. The problem with these long bolts is you cant get any oil in there because they are so long. Use plenty of heat, alternately spraying in the penetrating oil. You may want to let the oil sit for a few days. Good luck and keep pounding.

 

[mscheopner]

Re: 93Suzuki DT85 Power Head Removal

Ok Jim <br />Thanks for the tips. I'll keep on trying. I really appreciate you helping me out with this. It's kind of nice to get another opinion.<br />Mike

 

[mscheopner]

Re: 93Suzuki DT85 Power Head Removal

Hey Jim<br />I finally got the motor apart. Boy what a headache. The problem now is it's not just the gaskets.The housing for the exhaust tube has eroded away and the plate on the engine holder where the shifter rod goes through has eroded away and broke off. Any ideas on where to find these parts?<br />Thanks again <br />Mike

 

[jim dozier]

Re: 93Suzuki DT85 Power Head Removal

You can always try Ebay. There are motors and parts there off and on for your motor. The DT75 and DT85 are the same except for the carbs and a few minor things. Sorry for your bad luck. <br /><br />By the way, how did you finally get it off?

 

[mscheopner]

Re: 93Suzuki DT85 Power Head Removal

If you take the nut off the bottom of the pivot shaft you can drop the shaft housing. That enabled me to get to the snapped off bolts. Then I could get a straight shot at drilling them. Kind of a last resort but with one broke off on each side I couldn't get it to budge. Thanks again for all your help.<br /><br />Mike