How to remove gearcase on Suzuki DT50?

[river_bouy]

Hi,
I was wanting to remove the gearcase on a 1984 DT50. I have the manual but was still a bit unclear about how to do this.

The part I don't understand in the manual says "...remove the grommet from the starboard side of the lower support. Insert an appropriate socket wrench and remove the clutch shaft nuts, then disconnect the upper and lower shift shafts with a suitable drift and mallet."

Can anyone help by explaining this in simpler terms?

Do I do this all in the area under where I have removed the grommet?

Thanks in advance.

 

[James R]

Re: How to remove gearcase on Suzuki DT50?

You are not the only one to be confused,however if you have as you say a 1984 motor please go to www.brownspoint.com and go into parts. Look at the drawing for DT 50 1984 clutch. You will see that by backing off the nut in the drawing you can push the connecting rod so that the pin will clear the clutch rod. This will allow the lower unit to be pulled after the lower bolts have been removed.

 

[river_bouy]

Re: How to remove gearcase on Suzuki DT50?

Thanks James, just what I needed.

So, if i unscrew the nut (number 4 in parts diagram), then I will be able to unhook the clutch shaft (number 1 in the parts diagram), from the clutch rod (number 11 in the diagram).

I then assume the whole clutch rod will off still connected to the gearcase when I remove it right?

Thanks again.

 

[James R]

Re: How to remove gearcase on Suzuki DT50?

That is correct. It can be a pain getting the two to line up again. Put the shift in whatever position gives you the best view before separation and be sure to maintain that position with the clutch rod. Avoid pulling the clutch rod up as this may disengage the slot cam from the shift plunger. If that occurs the whole lower unit has to be diassembled and thats another story..

 

[fust]

Re: How to remove gearcase on Suzuki DT50?

I know this is an "antique thread," but I am having this same EXACT issue with my DT50 (1979).

"...remove the grommet from the starboard side of the lower support. Insert an appropriate socket wrench and remove the clutch shaft nuts" says the manual, but there is NO grommet I can find anywhere, where removal of which might allow me to insert a socket into something, appropriate or otherwise (snicker).

I took a look at the Browns Point parts diagrams for both the 1984 and the 1977-1979, and while I was able to see the nut in question in both, I don't know how to get to it. Where is the sucker?

Anyone want to wake the dead and resurrect this thread for me?

Thanks in advance!

 

[99yam40]

very old thread
start your own with all of your info