89' DT-85 Suzuki Forward Shift popping out

[Andy Hatch]

My first boat and my first post on any thread/forum. Imagine That !!!

I was out running the boat at full throttle, like normal when going fishing, and it jumped in and out of gear twice and the rpm's climbed a lot. I pulled the remote to neutral and shut it down. Trimmed the motor up and checked my newer prop for visible damage. None there. Started the motor back up just fine and put in reverse. Works perfect in reverse at any rpm's. Put it in forward and works great until I give it any throttle. She jumps in and out of gear and vibrates a lot. I put it in forward with no throttle and limped back to the dock. Got home and checked out the linkages. All's well. Disconnected the shift cable and it works smooth. I also, adjusted the cable forward until I lost my reverse shift and backed it down 4 turns. Nothing changed. No problems at home. All is well until I water test at the dock and get the prop under a load. Same problem occurs.

Anyone have a service manual download of this motor?
Any suggestions? Thanks....

 

[Mark_VTfisherman]

Re: 89' DT-85 Suzuki Forward Shift popping out

The drive coupler needs replacing probably, or the shaft that runs down the motor leg needs service. Not a big deal to fix. Don't have a guess as to cost on that motor but it likely won't break the bank.

 

[Andy Hatch]

Re: 89' DT-85 Suzuki Forward Shift popping out

Mark,

Is the drive coupler located inside the lower unit? If so the I have a much bigger problem. The lower unit has a 1.25 inch long crack starting near the port side right by the prop on the cone going straight forward. Bigger problem, one of the housing bolts to get inside the gear case has broken off right at the bolt. Sucks. Only two places in town have this lower unit. Both are used and guarantee them for 30 days. $500.00 each. Good buy or not?
I'm not sure what the best thing to do is. Break Out Another Thousand

 

[pine island fred]

Re: 89' DT-85 Suzuki Forward Shift popping out

Cheaper than buying a new motor. FRED

 

[Andy Hatch]

Re: 89' DT-85 Suzuki Forward Shift popping out

Thanks everyone for the help. I went to the local bone/ repair shop and picked one up for $375.00 with new thermostat and 90 warranty. Put it in this afternoon and it runs like a bat out of hell. Faster than the old lower unit ever pushed the key west boat. Snook season opens sunday and I'm on my way to the inlet. Look out snookers, here I come.

Break Out Another Thousand

 

[Mark_VTfisherman]

Re: 89' DT-85 Suzuki Forward Shift popping out

Glad you got out of this well. The crack in your old lower unit WAS a big deal!

What's the fishing report?