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1987 DT200 Gear Chatter

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firemanjoe789

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"I am working on a 1987 DT200

"I am working on a 1987 DT200 that sat for several years. When idling it jumps into and out of gear with the shifter in the neutral position. I tried running it IN gear today and it slipped a few times. I am guessing it's the clutch but don't really know where to start. the manual only really covers removal / rebulid, which I don't have the specialized tools for. Any suggestions before I haul it to the mechanic ? I'm going to drain some fluid today and look for metal shavings. Thanks"
 
Try disconnecting the shift ca

Try disconnecting the shift cable at the motor end then operate the linkage manual. Neutral should have a distinct "feel" as it drops into place. Outboards need to be running to change gear properly but if you disable ingition and spin the prop by hand slowly while moving the linkage it should select gear. When you check the oil if it is is milky in colour the gearbox is most likely needing rebuild.
 
"sirlespat
like he says
pul

"sirlespat
like he says
pull the shift cable off and try
u have nothing to worry about

no shifty, drain lower unit fluid and look

saltwater motor?"
 
"Thanks for the responses, I p

"Thanks for the responses, I played around with it after disconnecting the shift / throttle cables and it had alot of play. It wouldn't lock into any gear or neutral. I was guessing a bad clutch. There wasn't any murky fluid or shavings in the fluid so I hauled it to the local Suzuki shop everyone reccommended. Turns out the shift yoke at the bottom of the shift rod broke in 2 and the Clutch Dog and planetary gears were basically bouncing off of each other. Over $600 in parts alone so the search is on for my next engine. It's not worth dumping any more into this one. I have seen a couple of used lower units but I think I'll just sell this motor for parts instead and get something more suitable for me. Thanks again for the feedback."
 
"i am not sure what state you

"i am not sure what state you are in but i am in the market for a 200 suzuki power head
if you are going to sell that motor email me at
[email protected] or call 727 420 8799
i can give you some money that would go towards your new motor
thanks jeff"
 
"G'Day Firemanjoe I have a

"G'Day Firemanjoe I have a DT200 1987 and have a problem with the starter motor,the motor cranks over slow with fully charged batteries.The starter motor is a Hitachi-S114-436 could you tell me what make and numbers are on your starter motor as I think mine is the wrong one for this size motor.If you could give me this imformation it would be most appreciated,Thankyou

Regards Kevin.Burns"
 
"Kevin - Sorry I can't hel

"Kevin - Sorry I can't help you on this one, I sold the entire motor to a shop that rebuilds them. I'm running a 1997 225 EFI now. Better fuel economy / FAST throttle response. Unfortunately I didn't see Jeff Joker's post first or I would have sold him the powerhead instead."
 
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