See full version: Yamaha 2hp 2 stroke how to dismantle
Unfortuately you are in a bit of a catch 22 situation. I had exactly the same problem with a 4hp yamaha. The shaft would not pull out of the crank due to seizure and removing the circlip at bottom dosen't help as the pump impellor has a roll pin through the middle and a cover bolted over the top. You cannot remove the lower casing from the leg without removing the shaft from the crankcase first.
Woah!
Does this motor have gears or neutral?
If not the impellor will probably be behind the prop.
This diagram from the Tohatsu (same motor) [links]
P.S. I have got the Full Repair Manual supposedly for all Yamaha outboards 1984-1996 2-250hp. If you pm me I can email you the manuals that should cover something that resembles your engine! [links]
Re: How can I remove the Prop. Shaft Housing on Suzuki? here
My gearcase was badly corroded but the guy who took it out had a very simple approach. He looked at the manual and thought that looked "a bit hard" Then he welded up an adaptor that consisted of a nut for the prop shaft to shaft of a slide hammer. Lots of heat around the housing and then basically tapped it out. The propshaft pulls the rear bearing which pulls the housing. Took him about 15 minutes all up with no damage to the parts. Of course the seals all needed replacing ater heat is applied. B ut you bet I was IMPRESSED more
Re: How can I remove the Prop. Shaft Housing on Suzuki?
This looks like the same gear box as on my DT150. I had to use a crank puller to get the housing out. They stick in pretty well for something sitting in oil. They pop out pretty easy when you have the right tools.<br /><br />craw
You must use a puller. Two threded holes are present at the case end. It attaches to the shaft and uses leverage to pull it out. <br /><br />You did not say, but is this a salt or fresh water unit? If salt, prepair for some work to get it out, back in, and making it work correctly. If fresh, it will be better, but if you have little knowlege of this case, you will find it difficult to put back togather. This is one of thoses "you need to see it to do it" jobs. While the book is fine, some things are just a hands on matter. With the costs of the materials involved, you may wish to consider getting a used lower unit. I happen to have one that is in good shape. If you want the entire lower end, hydrolic trim and some electrical parts, I will sell it for $525.00, shipping included. If you just want the lower end, it would be $380.00. You will not find a better deal, or better parts. <br /><br />I have a working dt85 as well. It is a good working unit, but found it has a tendancy to run hot due to poor water intake. Also eats impellers. Make sure you clean every jet in the carb before you put this back togather. <br /><br /> here
I have NOT managed to do so, same with the Prop. shaft housing, do I need any special tools to accomplish this??
And now when it's finally working great, I found out that the propeller shaft is bent out of shape, so I need to remove/change it.
ANY help would be very much appreciated, im currently stuck and dont know what to do
I purchased 2 old DT-40 motors, one for parts and the other as working (had to do some maintenance to make it that way). more
And also should I remove the water pump house first or anything like that??
Re: How to get a stuck prop off?
I went through this last year, and we had to heat it with a propane torch(wal mart $20) and tap(not wack) it evenly, as we went.
Slow process, to be sure, and you only want to heat the prop.
This worked for us, a prop puller is never a bad idea though.
Good Luck!
Re: How to get a stuck prop off? [links]