Suzuki DT2.2 splitting power head from leg .

[clyst]

Hi all , iv had cooling problems with the motor suzuki DT 2.2 today so total strip down of water ways is necessary . I need to separate the power head from the leg . Iv removed the 6 bolts holding them together and they are now separated by about 4 or 5 mm but won't move any further . As far as I know the power head should now lift off the splines of the drive shift. Anyone know if iv missed anything ? Regards Terry

 

[VicS]

Drive shaft rusted into the crankshaft.

Perhaps it is possible to release the driveshaft from the gear case by removing the E clip at the bottom end then lift off power head complete with drive shaft and separate them on the bench.

Grease the splines when reassembling to prevent it happening again.

 

[LadyInBed]

When I cleaned out my DT2 head waterway I don't remember removing the drive shaft, I just took the head off, piston to TDC then took a wire brush to both halves and poked some wire down the holes.

DT2 Parts list here: Downloads : Monty Mariner if you haven't got one.

 

[Steve65]

Drive shaft rusted into the crankshaft.

Perhaps it is possible to release the driveshaft from the gear case by removing the E clip at the bottom end then lift off power head complete with drive shaft and separate them on the bench.

Grease the splines when reassembling to prevent it happening again.

As Vic says.

 

[clyst]

Thanks for your replies chaps ....seems I have a difficult Saturday ahead . Wish me luck .

 

[QBhoy]

Hi. Likely you’ve got this covered and are well aware. But can I ask with the greatest of respect, if it’s genuinely overheating, or if perhaps you’re just recently in ownership of this usually great wee engine ? If the latter, I thought I’d maybe ask if it’s just presumed as such, after no highly visible tell tale water showing. Sorry to even ask. I’m sure you’ll likely know already that these don’t have a tell tale in the usual form at least.
All that aside and maybe not the case, it could then be blocked up with salt deposits. If so, I’d politely suggest not going ball deep into removing the power head or anything too invasive, without before trying the old tried and tested method of pouring vinegar into and through the thing. Either from the top and/or in through the water pump discharge port of the impeller…and turn her upside down or on her side at least. Let her soak…go again, soak, again etc etc. it has almost always worked for my in such a situation. Best of luck

 

[clyst]

Hi. Likely you’ve got this covered and are well aware. But can I ask with the greatest of respect, if it’s genuinely overheating, or if perhaps you’re just recently in ownership of this usually great wee engine ? If the latter, I thought I’d maybe ask if it’s just presumed as such, after no highly visible tell tale water showing. Sorry to even ask. I’m sure you’ll likely know already that these don’t have a tell tale in the usual form at least.
All that aside and maybe not the case, it could then be blocked up with salt deposits. If so, I’d politely suggest not going ball deep into removing the power head or anything too invasive, without before trying the old tried and tested method of pouring vinegar into and through the thing. Either from the top and/or in through the water pump discharge port of the impeller…and turn her upside down or on her side at least. Let her soak…go again, soak, again etc etc. it has almost always worked for my in such a situation. Best of luck

Hi thanks for your concern . Bought the engine new in 99 so had it for some 24 years ! As you say a lovely little engine and has never let me down till this . Yes definitely over heating and all resolved now .

 

[clyst]

Hi guys overheating now resolved ! Did as Vic s suggested and removed the little clip retaining the pinion gear in gearbox and pulled the shaft up still connected to the power unit. Once out it was relatively easy to remove the shaft from engine .one of the main cause of overheating was corrosion hole on the top bend of the copper tube feed pipe . Whilst it was all stripped down I replaced several other bits ..... but fellow owners beware .. according to the local suzuki agent parts for these 2strokes are now running short .Although not specified many parts are now not available .

 

[VicS]

Hi guys overheating now resolved ! Did as Vic s suggested and removed the little clip retaining the pinion gear in gearbox and pulled the shaft up still connected to the power unit. Once out it was relatively easy to remove the shaft from engine .one of the main cause of overheating was corrosion hole on the top bend of the copper tube feed pipe . Whilst it was all stripped down I replaced several other bits ..... but fellow owners beware .. according to the local suzuki agent parts for these 2strokes are now running short .Although not specified many parts are now not available .

Thanks for the feed back.
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