1994 Suzuki DT40C how to remove lower engine surround???

[Ms54Coupe]

I removed the engine cover on my 94 DT40C because I need to replace a gasket on the exhaust plate cover...well like six of the M6 bolts snapped in the aluminum engine (Great job Suzuki put stainless hardward into aluminum in a location where constant thermal cycling will occur...not to mention add moisture).

Now I need to try and extract the bolts from the aluminum but the lower engine surround which the engine cover attaches to is not looking like it will come off very easily...does anyone know the best way to remove this portion of the motor?

Thanks,

Nate

 

[Ms54Coupe]

Re: 1994 Suzuki DT40C how to remove lower engine surround???

I am trying to post an image of the side of the engine but need to find an image hosting site first...will update later

 

[deejaycee_2000]

Re: 1994 Suzuki DT40C how to remove lower engine surround???

Pull the powerhead, its much easier, because it will not be an easy task removing those snapped pieces .... you must always use heat to extract ....

 

[Ms54Coupe]

Re: 1994 Suzuki DT40C how to remove lower engine surround???

Is there a good write up on pulling the power head?

 

[lakensea]

Re: 1994 Suzuki DT40C how to remove lower engine surround???

Is there a good write up on pulling the power head?

Yup - factory service manual.

 

[Ms54Coupe]

Re: 1994 Suzuki DT40C how to remove lower engine surround???

If I had the manual I wouldn't be asking...

 

[James R]

Re: 1994 Suzuki DT40C how to remove lower engine surround???

If you are serious about working on this motor then spend the buck on a manual. Even a Seloc or Clymer is better than nothing.
Unfortunately Suzuki bolts are renowned for their seizing especially if the motor has been near salt water. Heat is usually the only answer.
The skirt which covers the power head mounting bolts comes off by removing the bolts inside the lower cover. As I remember, to remove the lower cover you have to pull the power head. Plug in Brownspoint and go to the parts section and look at the drawings. Since the storm washed out their business in NJ I think everything is PDF and a bit slow.