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Old 15 September 2011, 06:33   #1
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Suzuki DT75 Reverse Gear slipping - Help wanted!

I've just bought a 4.7 Searider with a 1990 Suzuki DT75 on it.
The engine runs fine but when in reverse the gears slip (I did know this when I bought it) - in forward it's fine.
Before I try and get a new gearbox/lower unit (or maybe replace the engine) I want to take the old gear casing apart in case it's something I can fix.
I've drained the gear casing oil and there are no bits in it and it's not milky - so no water has got in!
However - my first hurdle is I don't understand some of the teminology in the service book I've got!
I'm stuck on part 7 of the attachment - there is no photo if where the cover is at the front of the clutch rod, and I'n not sure what I'm looking for!
Any help much appreciated!
Thanks
Trevor
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Old 15 September 2011, 06:41   #2
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Don't know Soozys at all but I'm guessing they're referring to the top end of the gear linkage somewhere on the side of the engine. On pretty much any outboard this has to be disconnected before dropping the gearcase which is pretty much the next step on that page in your manual, or that's what it's leading up to at least.
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Old 15 September 2011, 07:24   #3
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Trevor

Suzuki tend to call the shift rod the clutch rod, and it has a joint in it somewhere between where the lower unit bolts onto the leg and the undertray of the engine, dependant on what model you are looking at. As the instructions suggest, some are covered by a plastic housing.
On my 200V6 it’s just a couple of inches above the lower split.

If I was at home I’d scan a manual, but that will be later tonight.

I suggest you take a look at the microfiche type images on Browns point Suzukis web site, as they are better than a workshop manual.
Suzuki Outboard Parts Catalog Microfiche - Browns Point Marine Service

Edit
Should have said, I’ve made several copies of Suzuki special tools to get into the lower unit on my 200, I’m not sure they will fit your engine, but you’d be welcome to try.
Once inside it’s all pretty basic stuff as long as you don’t replace anything that will affect the shimmed length of the assembly.
Replacing items like the dog clutch, which might be your problem, doesn’t effect it for example.
I assume you’ve tried adjusting the shift rod etc already.

Nasher.


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Old 15 September 2011, 07:31   #4
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There's no cover in front of the clutch rod on a DT75. You need to disconnect the top of the clutch rod from the linkage below the carbs.

Sounds like your clutch dog and/or reverse gear are worn and need replacing. It's a lengthy re-shimming job if the reverse gear needs changing, but the clutch dog alone is straightforward enough.

Clean gear oil could be down to a recent oil change. As you've recently bought the boat, I don't suppose you have detailed history of when the lower unit was last checked and the gear oil replaced?

Did I mention that I've got a DT75 for breaking?.......
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Old 15 September 2011, 07:34   #5
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Trevor

Have a read through this with a cup of tea

DT200EFI Reverse Woes.

It will either frighten you off, or show you at least some of what is going on inside.

Nasher
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Old 15 September 2011, 11:56   #6
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Quote:
Originally Posted by Nasher View Post
Trevor

Have a read through this with a cup of tea

DT200EFI Reverse Woes.

It will either frighten you off, or show you at least some of what is going on inside.

Nasher

OMG!!!! I have just read through the link.... my hair turned grey then fell out
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Old 15 September 2011, 12:01   #7
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Quote:
Originally Posted by Downhilldai View Post
There's no cover in front of the clutch rod on a DT75. You need to disconnect the top of the clutch rod from the linkage below the carbs.
Here's a couple of photos of what I think I need to take apart.
I think that it's the split pin and nut in the 2nd photo that are the cotter pin and connector pin, although the descriptions don't really sound right....
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Old 15 September 2011, 12:11   #8
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I bought a 90 hp Honda with a reverse gear that was knackered. It was the clutch dog as you can see from the photos the previous owner used to slam the boat into reverse whilst going fowards (RYA instructor) .
The first pic shows the reverse side which would jump out of gear and make a nasty crunching sound which is a similiar to the sound that your missus makes whilst driving your car. The other pic is of the forward side which went in to gear fine. Just thought I would show what is good bad and ugly.

Hope this helps, Good Luck.
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Old 15 September 2011, 14:55   #9
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Trevor

I think you're looking in the wrong place.
You are looking at parts 2 and 3.

The vertical shaft needs to be split from the horizontal one at the other end.

Nasher.
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Old 15 September 2011, 15:03   #10
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Quote:
Originally Posted by Trevor G View Post
I've just bought a 4.7 Searider with a 1990 Suzuki DT75 on it.
The engine runs fine but when in reverse the gears slip (I did know this when I bought it) - in forward it's fine.
Trevor, when you say it slips, does it click like its not in gear properly?

Chris
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