I have a 1990 Suzuki DT85 and I'm trying to get the lower unit off.  I've taken out all the bolts that connect the lower unit to the middle section and I can get the lower unit to drop about 6 or 8 inches.  The clutch rod is still attached at the shift mechanism up in the motor and I know I have to get that off the get the lower unit off, but it doesn't want to come off.  I have the shop manual and it says to remove the cover at the front of the clutch rod pin and then pull a cotter pin and then pull out the pin connecting the clutch rod.  Well, as far as I can tell, there is no cover in front of the clutch rod and there is no cotter pin.  

I can see where the top of the clutch rod fits around a pin, but the pin looks like it's part of the shifting mechanism and it doesn't simply slide out.  What's worse is that the connection between the clutch rod and the shifting mechanism is in an impossible place to get to directly under the lowest carburator.  I can push the clutch rod with a flat screwdriver a little bit so that it slides on the pin, but then the rod hits the side of the motor housing and it won't slide all the way off the pin.  How in the heck do I get that clutch rod off that pin without taking the motor apart?

They didn't make it easy, did they?   ;D

I've got a DT65 and just went through that whole mess.

On mine, there is a small rubber plug on the lower cover that pulls out so you can get a socket on the nut holding the clutch rod to the shift linkage.

Looking at the diagrams here:

http://store.brownspoint.com/DT85/858800.asp

I do not see such a cover on yours.

According to this diagram:

http://store.brownspoint.com/DT85/fig010-858800.asp

The setup is virtually identical to mine.

What you need to do is remove part #3 in the above diagram (nut, should be 12 mm), which will allow you to slide part #1 (clutch shaft) out of the shift linkage.  That will free up the clutch rod.

It really is a two person job to reconnect as you need someone to play with the shifter while the other person uses a long flathead screwdriver to slide the clutch shaft into place.

Without the rubber plug, I imagine it would be quite a PITA.