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DF20A need help with stuck shifter

L

lexpen

New member
So I have a new to me df20a which I just got with a no start problem and also a stuck shift shaft ( shift handle on tiller is ok moves freely when disconnected). Prev Owner stated it had less than 100hrs ,and he thinks it's even less than 50hr but didn't keep track. No start was due to a bad hi pressure Fuel that was rusted and had 2 pistons stuck because of it. will replace it. The problem I'm trying to figure out is the shifter for forward and reverse. I can't figure out if it's stuck on engine side, or inside gearbox. The cable that goes from plastic pulley to the top of pull start area looks clean and corrosion free. The rod that goes to lower unit seems to bend when I apply pressure to turnbuckle so it's not that. How can I free the engine end square bar? I've soaked it with free-all but it's still stuck any help would be appreciated as I'm new to working on outboards.if I can get the shifter working and fuel pump replaced this will be a great engine.
 
Figured out it's the square bar that the lever linkage and plastic cable pulley is connected to on either side. Somehow it's frozen. Not sure what the next step is if anyone has an idea I'd be happy to try it. I've tried pounding it free from either end, soaking it with penetrant, still frozen. Seems like it rides in plastic bushings between square metal bar and engine holes that it pivots in, so not sure how that even seized tbh. This is a poor design on Suzuki part imo.
 
On that new to you motor you are going to want to change out the impeller or possibly the entire water pump assembly. Once you separate the lower unit from the mid section that will tell you if your issue is with the lower unit or the shifter shaft linkage. A genuine Suzuki service manual will be worth it’s weight in gold.
 
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