SUZUKI
SUZUKI AMERICA CORPORATION
3251 E. Imperial Way
P.O. Box 1100 Brea, California 92621
SUZUKI DT2
1b determine model and year of manufacture of Suzuki outboard motors, refer to numbers located on motor clamp bracket. The first six characters indicate the model and second six characters are motor serial number. The first character of serial number indicates year of manufacture. The years 1977, 1978 and 1979 are identified by the letters "C," "D" and "F" respectively. Starting with 1980, the first number in serial number corresponds with model year. For example, if first number in serial number is 1, model year is 1981.
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
SERVICE MANUAL
TUNE-UP
Hp/rpm ......................... , ... . ..... 2/4500 SIZES-CLEARANCES CONT. Crankshaft Runout at Main Suzuki OT2 Bore ....................... . ........... .41.0 mm Bearing Journal (Max.) _ 0.03 mm· (1.614 in.) Stroke 37.8 mm (1.488 in.) Displacement ......... . ...................... 50 cc (3.05 cu. in.) Spark Plug: NGK .................................... BR5HS Electrode gap ...... . .................. 0.5-0.6 mm (0.020-0.023 in.) Magneto: Breaker point gap ................ , .... 0.3-0.4 mm (0.012-0.016 in.) Carburetor: Make Mikuni Model VM-11-10 Fuel:Oil Ratio ................. . ..... . _.... See Text SIZES-CLEARANCES Piston Ring End Gap 0.10-0.25 mm (0.004-0.010 in.) Piston to Cylinder Clearance 0.053-0.060 mm (0.0021-0.0024 in.) Piston Pin Diameter ............... 11.996-12.000 mm (0.4723-0.4724 in.) (0.0012 in.) Connecting Rod Small End Side Shake (Max.) , 3.0 mm (0.118 in.) TIGHTENING TORQUES Cylinder Head ............................ 8-12 N'm (6-9 ft.-Ibs.) Crankcase , 8-12 N'm (6-9 ft.-Ibs.) Reed Plate 0.5-0.75 N'm (4.5-6_6 in.-Ibs.) Flywheel Nut ............... . .......... N'm (30-37 ft.-lbs.) Standard Screws: 5 mm 2-4 N'm (18-36 in.-Ibs.) 6 mm · .4-7 N'm (36-62 in.-Ibs.) 8 mm ....... _. ........................ 10-16 N'm (89-141 in.-Ibs.) 10 mm 22-35 N'm (195-310 in.-Ibs.)
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
LUBRICATION
The power head is lubricated by oil mixed with the fu el. Fuel:oil ratios should be 30:1 during break-in of a new or rebuilt engine and 50: 1 fo r normal service when using a BIA certifi ed TC- W engin e oil or Suzuki "CC I" oil. Wh e n using any ot her type of two-stroke engine oil fuel :o il ratios should be 20 :1 during break -in and 30:1 for normal service. Manufa cturer recommends regular or no-lead automotive gasoline having an 85-95 octane rating. Gasoline and oil should be thoroughly mixed.
The low e r unit gears and bearings are lubricated by approximately 85 mL (2.9 ozs.) of SAE 90 hypoid outboard gear oil. Reinstall vent and fill plugs securely using a new gasket , if necessary. to ensure a water tight seal.
(0 .00 20 -0 .0026 in .)
FUEL SYSTEM
CARBURETOR. A Mikuni BV-18-15 carburetor is used. Refer to Fig. SZ2-1 for exploded view Initial setting of pilot air screw (15) from a lightl y seated positi on should be 3/.-1 1/. turns Final carbur etor adjustment should be made with e ngine at normal operating temperature and running in forward gear. Adjust throttle stop screw (12) so e ngine idles at approximately 900-1000 rpm . Adjust pil ot air scr ew so engine idl es smooth and will accel e rate c1eanlv without hesitation. If necessary. readjust throttle stop screw to obtain 900-1000 rpm idl e speed. Main fuel metering is controlled by main jet (2). Standard main jet size for normal operation is #90 Standard pilot jet (14) size is #15
(16-25 ft.-Ibs.)
To check float level remove float bowl (7) and invert carburetor body (1). Base of float (6) should be 12-14 rnm (0.470.55 in.) away from sealing ring surface of carbur e tor body with sealing ring (3) removed. Adjust float level by bending float tang .
FUEL PUMP. A diaphragm fuel pump (Fig SZ2-2) is mounted on the side of power head cylinder blO Ck and is actuated by pressure and vacuum pulsations from the engin e crankcase. When servicing pump. defective or questionable parts should be renewed Diaphragm should be renewed if air leaks or cracks are found. or if deterioration is evid ent.
REED VALVE. Th e reed valve is located in a reed plate that is locate d
SERVICE MANUAL Suzuki 013.5 SUZU KI
DT3.5
TUNE·UP SIZES-CLEARANCES CONT. Hp/rpm 3.5/4800-5300 Piston Pin Diam e ter ... . ............. 11.996-12 .000 mm Bor e 46 mm (1.81 in ) (0.4 723-0.4 724 in.) Max Crankshaft Runout at Main Strok e .............•...... .. ......... ... .... 42 mm (1.65 in .) Bearing Journal 0.0 3 mm Disp lac ement 69.8 cc (4.3 cu in .) Spark Plug: (0 .0012 in.) Max Connecting Rod Small End Side Shake .. . . ... . ............ . . . . . . . ..... . 3.0 mm NGK BP6HS (0.12 in.) El ec trod e Gap 0 6-0 7 mm (0 .02 4-0.028 in.) TIGHTENING TORQUES Ignition Type Br eaker Point Power Head Mounting Scr e ws and Nuts 15-20 N· m (11-14 ft.-Ibs.) Break e r Point Gap 0.3-0.4 mm Crankcase 8-12N·m (0.012-0.016 in .) (6-8 ft .-Ibs.) Ignition Timing@ 5000 rpm 23.5° BTDC Carburetor: Flywh eel Nut 40-50 N· m Make Mikuni (29-36 ft .-Ibs.) Standard Screws : Mod el BV-18-15 5 mm 2-4 N'm Idle Speed (in gear) ........... . ......... . 900-1000 rpm (1-3 ft.-Ibs.) Fuel:Oil Ratio 50 : 1 6mm ............... .... ................. 4-7N·m (3-5 ft.-Ibs ) SIZES-CLEARANCES 8 mm 10-16 N'm Piston Ring End Ga p ......... .. .. .... .... 0. 15-0.35 mm (7-11 ft .-Ibs.) (0 .006-0.014 in ) 10 mm ..... ... .......... .... .. .... ... .. 22-35 N'm Piston t o Cylinder Clearance 0. 052-0.067 mm
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SUZUKI DT4
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
LUBRICATION
The power head is lubricated by oil mixed with the fuel. Fuel:oil ratios should be 30: 1 during break-in of a new or rebuilt engine. For normal service, fuel:oil ratio should be 50: 1 on models prior to 1986 and 100: 1 on 1986 and later models when using Suzuki Outboard Motor Oil or a good quality NMMA certified TC- W engine oil. When using any other two-stroke oil, fuel:oil ratio should be 20: 1 during break-in and 30: 1 for normal service. Manufacturer recommends regular or unleaded automotive gasoline having an 85 minimum octane rating. Gasoline and oil should be thoroughly mixed.
The lower unit gears and bearings are lubricated by approximately 190 mL (6.4 ozs.) of SAE 90 hypoid outboard gear oil. Reinstall vent and fill plugs securely using a new gasket, if necessary, to ensure a water tight seal.
FUEL SYSTEM
CARBURETOR. A Mikuni BV-18-15 carburetor is used. Refer to Fig. SZ3-1 for exploded view. Initial setting of pilot air screw (6) should be 1 to 1-112
turns out from a lightly seated positi o n. Final atljustment should be made with engine at normal operating temperature and running in forward gear. Atljust throttle stop screw (9) so engine idles at approximately 850-900 rpm. Atljust pilot air screw so engine idles smoothly and will accelerate cleanly without hesitation. If necessary, readjust throttle
stop screw to obtain 850-900 rpm idle ·speed.
Main fuel metering is controlled by main jet (2). Standard main jet size for normal ope ration is #97.5. Standard pilot jet (10) size is #45.
To check float lev e l. remove float bowl (12) and invert carburetor body (1) Base of float (3) should be 12-14 mm (0.47 -0.55 in.) away fr om gasket surface of carburetor body with float bowl gasket removed. Atljust fl oa t level by bending float tang.
FUEL PUMP. A diaphragm fuel pump (Fig_ SZ3-2) is mounted on the side of power head cylinder block and is actuated by pressure and vacuum pulsations from the engine crankcase.
When servicing pump, defective or questionable parts should be renewed. Diaphragm should be renewed if air leaks or cracks are found, or if deterioration is evident.
SPEED CONTROL LINKAGE. Engine speed is controlled by position of throttle linkage. Ignition advance is electronically controlled. A twist grip at the steering handle is used to control throttle settings.
Suzuki DT4 OUTBOARD MOTOR
TUNE-UP Hplrpm 4/5000 Bore 50mm (1.97 in.) Stroke . . .................. . ................. 46 mm (1.81 in.) Displacement 90 cc (5.5 cu. in.) Spark Plug: NGK ...... .. ...... . . ..... .... . ........... BP6HS Electrode Gap 0 6-0 7 mm (0.024-0.028 in.) Ignition Type CD! Carburetor: Make Mikuni Model BV-18-15 Idle Speed (in gear) _ _ 850-900 rpm Fuel:Oil Ratio See Text SIZES-CLEARANCES Piston Ring End Gap 0.15-0.35 mm (0.006-0_014 in.) Piston to Cylinder Clearance 0_052-0_067 mm (0.0020-0.0026 in_) Piston Pin Diameter ..... __ .. _. _..... 11.995-12.000 mm (0.4 722-0.4 724 in.) SIZES-CLEARANCES CONT. Max. Crankshaft Runout at Main Bearing Journal .................. . ____ ... 0_05 mm (0.002 in.) Max Connecting Rod Small End Side Shake __ 4.0 mm (0.16 in.) TIGHTENING TORQUES Power Head Mounting Screws ... .. . .. ....... 15-20 N· m (11-14 ft.-Ibs_) Crankcase ... .. . . .. . . _. __ ... __ .. ...... . _.. 8-12 N • m (6-8 ft.-Ibs_) Flywheel Nut _ 45 N'm (32 ft.-lbs.) Standard Screws : 5 mm ............ .. . . . , .. . .... ........... 2-4 N' m (1-3 ft.-Ibs .) 6mm , 4-7N·m (3-5 ft.-Ibs.) 8mm .................................. 1O-16N·m (7-11 ft .-I bs.) 10mm 22-35N·m (16-25 ft.-Ibs.)
10 B 7 6 9 I 11 1 _ '--8-<
5--:'0"
1. Bods 2. Main jet 3. Float 4. Screw .5. Plug 6. Pilot air screw 7. Choke le ("t 8. Choke k.nob 9. Idle 10. Pl/ot)et 11. <4skl't 12. Float bowl
Fig. SZ3·1- Exploded vi 01 ""tunl 8'1-18-15 c.rbur.fOr.
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CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
The power head is lubricated by oil mixed with the fuel. Recommended oil is Suzuki Outboard Motor Oil or a good quality NMMA certified TC-W twostroke engine oil. Fuel:oil ratio should be 30: I during break-in of a new or rebuilt engine. For normal service, fuel:oil ratio shou ld be 50: 1 on models prior to 1986 and 100 : 1 for 1986 and later models. Manufacturer recommends regular o r unleaded automotive gasoline having an 85-95 octa ne rating.
Gasoline and oil shou ld be thoroughly mixed.
The lower unit gears and bearings are lubri cated by approximately 240 mL (8.1 oz.) of SAE 90 hypoid outboard gear oil. Reinstall vent and fill plugs securely using a new gasket , if necessary, to ensure a water tight seal.
FUEL SYSTEM
CARBURETOR. A Mikuni BV-IB-15 carburetor is used on DT5 models, Miku-
ni BV-18-14 is used on DT6 models and Mikuni BV-24-18 is used on DT8 models Refer to Fig. SZ4-1 for exploded vi e w. Initial setting of pilot air screw (13) should be :3 / 4 to 1-114 turns out from a lightly seated position on Models DT5 and Drs , and 1-3 / 4 to 2-114 turns out on Model DT6. Final carburetor adjustment s hould be performed with engine at normal operating temperature and running in forward gear. Adjust idle speed screw ( 11) so engine idles at approximately 600·650 rpm. Adjust pilot air screw (13)
Suzuki DTS, DT6 & DT8 OUTBOARD MOTOR SUZU KI DT5, DT6 AN 0 DT8
TUNE·UP Hp/rpm .............. . ............. . .... 5/4800-5500 Bore: 6/5200-5700 8/5200-5700 5Hp 43mm (1.69 in.) 6&8Hp 0 50mm (1.97 in .) Stroke: 5Hp ............. .. . . . ................ . .. . 39mm (1.54 in.) 6&8Hp 0 42mm (1.65 in.) Number of Cylinders ........... .. .................. 2 Displacement: 5 HP 113 cc (6.90 cu. in .) 6&8Hp . . .................................. 165cc (10.07 cu. in.) Spark Plug: NGK 0 BP6HS Electrode Gap 0.8·0.9 mm (0.031·0.035 in.) Ignition Type .......... 0 0 ••••••••••• CD! Carburetor Make Mikuni Idle Speed (in gear) .. ................... .. 600·650 rpm Fuel:Oil Ratio o ••••• 0 See Text LUBRICATION SIZES-CLEARANCES Piston Ring End Gap 0 0.10-0 .30 mm (0.004-0,Oi2 in . ) Piston to Cyli nd er Clearance 0.052·0.067 mm (0.0020-0.0026 in.) Piston Pin Diameter 11. 996·12 .000 mm (0.4723 0.4724 in.) Max. Crankshaft Runout at Main Bearing .Journal Max. Connecting Rod Small 0.0;; mm (0.002 in.) End Side Shake 0 0 .4.0 mm (0.160 in .) TIGHTENING TORQUES Power Head Mounting Screws .... . .. . 15-20 N'm (11·15 ft.-lbs .) Crankcase ........ . ..... .. . . ............. 8·12 N'm (6 9 ft.·lbs.) Flywheel Nut 60·70 N'm (44-52 ftAbs.) Cylinde r Head Screws 0 ••••••• 20-26 N'm Standard Screws: 5mm ... 6 mm • (15-19 ft.-lbs.) .... 2-4 Nom (1 -3 ft. lbs .) ... 4-7 N'm (3·5 ft.-Ibs.) 8 mm 0 0 0 0 0 0 " 10-16 N'm (7-12 ft.-Ibs.) 10 mm ... 0 0 ••••••••• 22-35 N'm (16-26 ft .- Ibs.)
SUZUKI DT9.9 & DT15 (1983-1987) AND DT15C (1988)
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
Suzuki DT9.9 & DT15 (1983-1987) & DT15C (1988) OUTBOARD MOTOR
TUNE-UP Hp/rpm ..... . .. . ........ .............. 9.9/450()'5300 1514700·5500 Bore 59mm (2.32 in.) Stroke 52 mm (2.05 in.) Number of Cylinders 2 Displacement 284 cc (17.33 cu. in ) Spark Plug : NGK BR7HS-1O Electrode Gap ........................... 0 .9-1.0 mm (0.035-0 039 in.) Ignition CD! Carburetor Make .... . .. ................... . .. Mikuni Idle Speed (in gear) 600·650 rpm Fuel:Oil Ratio See Text SIZES-CLEARANCES Piston Ring End Gap: D1'9.9 and DTl5 (to 1987) 0.15-0.35 mm (0.006·0.014 in.) Wear Limit .. .. ... .. .. .... ............. 0.7 mm (0.027 in.) DT9 .9 and DTl5 (1987) 0.20-0.40 mm (0.008·0.016 in .) We ar Limit 0.8 mm (0.03 1 in .) DT15C ... .... ... . .. . ............... 0 . 10-0 .25 mm (0.004-0.010 in ) Wea r Limit 0.8 mm Piston-to-Cylinder Clearance: (0.031 in.) DT9.9 and DT15 ... . . . ..... . ...... 0 .052-0.067 mm (0.0020-0.0026 in.) DT15C 0 042-0.062 mm (0.0016-0.0024 in.) Piston Pin Diameter 13 .995 - 14 .000 mm (0.5510-0.5512 in .) Maximum Crankshaft Runout at Main Be aring Journal Maximum Co nne c ting Rod Small End Side Shake: 0.05 mm (0.002 in.) DT9 .9 and DT15 4.0 mm (0.157 in .) SIZES-CLEARANCES CONT. DTl 5C 5.0 mm (0.197 in .) TIGHTENING TORQUES Power Head Mounting Screws 15-20 N'm (11 - 15 ft -Ihs .) Crankcase: 6 mm 8-12 N'm 8mm Cylinder Head Screws: (6-9 ft .- Ih s.) .20-26 N'm (15-19 ft .- Ih s ) DT9 .9 and DTl 5 . . . . . . . . . . . . ...... 20-26 N'm (15-19 ft .- Ih s .) DTl5C 2 1-25 N'm (16 - 18 ft. -Ihs .) Flywheel Nut . . . . . . . ...... . ........ 80-90 N'm Standard Screws(Marked "4"): 5 mm ..... ... . ............... . (59 -66 ft.-Ihs.) ..... 2-4 N'm (18- 35 in. -Ihs .) 6 mm 4-7 N'm (35-62 in. -Ihs .) 8 mm 10 -16 N'm (7·12 ft . -Ihs.) 10 mm .......... . .. . .... . . . .... ..... 22 -35 N'm (1 6-26 ft.-Ihs.) (Stainless Stee l) : 5 mm .... . ......... .. . . . . .. . .......... 2- 4 N'm (18 -35 in .- Ih s.) 6 mm 6-10 N'm (5 3-88 in -Ihs.) 8 mm ........... . .. . . .. . . ........... 15 -20 N'm 10 mm (Marked "7 00 ): (11·15 ft.-Ih s. ) 34-41 N'm (25- 30 ft.·lhs.) 5 film ,.,' , ,., , , , , •. , .3-6 N'm (26-53 in.-Ihs.) 6mm ",,8- 12N 'm (71-106 in .- Ihs .) 8 mm . , , .. , .. ' . ' , .. , . . , . . , . . , . . ..... 18 -28 N'm (1 3-2 1 ft, -Ihs .) 10 mm , , ' , , , ' , , .40-60 N'm (29-44 rUhs .)
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SERVICE MANUAL LUBRICATION
The power head is lubricated by oil mixed with the fuel. Recommended oil is Suzuki Outboard Motor Oil or a good quality NMMA certified TC- W twostroke engine oil. Recommended fuel is no-lead or regular automotive gasoline having an 85-95 octane rating. Fuel and oil shou Id be thoroughly mixed
On all models except OTI5C , fuel :oil ratio should be 30 : 1 during break-in of a new or rebuilt engine. On DT9.9 and OT15 models prior to 1986 , fuel ratio after initial \.5 hours of operation should be 50: I when using a recommended oil. On 1986 and later D1'9 9 and DT15 models , fuel ratio after initial 15 hours of operation should be 100 : 1 when using a recommended oil.
Model DTl5C is equipped with automatic oil il\iection. When breaking-in a new or rebuilt engine, mix a recommended oil with the gasoline at a 50 : 1 ratio in combination with the oil il\ieclion system to ensure sufficient lubrication during break-in Switch to straight gasoline after completion of the first tank of fuel.
Oil iI\iection system on Model DTl5C is equipped with a renewable oil filter between oil tank and oil pump. Renew filter after 50 hours of operation or after three months.
The lower unit gears and bearings are lubricated by approximately 170 mL (5.7 ozs.) of SAE 90 hypoid outboard gear oil. Reinstall vent and fill plugs securely using a new gasket, if necessary, to ensure a water tight seal.
FUEL SYSTEM
CARBURETOR. A Mikuni B24 - 15 carburetor is used on D1'9.9 models and Mikuni B24-18 carburetor is used on DTl5 and DT15C models. Refer to Fig. SZ6-1 for exploded view of carburetor
Initial setling of pilot air screw (2) from a lightly seated pOSition should be 1-114 to 1-3/ 4 turns on DT9.9 and OT15 models prior to 1987, 1-118 to 1- 5 / 8 turns on Model DT9.9 after 1986, 7 /8 to 1-3/8 turns on DTl5 models after 1986 and 1-l i2 to 2 turns on Model OTI5C
Final carburetor adjustment should be made with engine running at normal operating temperature in forward gear . Adjust idle speed screw (4) so engine idles at approximately 600-650 rpm Adjust pilot air screw so engine idles smoothly and will accelerate cleanly without hesitation. As adjustments affect each other, readjustment of idle s peed may be necessary.
Main fuel metering is controlled by main jet (13). Standard main jet size for normal operation is #110 on DT9.9 models, #122.5 on early DTl5 models
Suzuki OT9.9 & OT15 (1983-1987) & 0T15C (1988)
(prior to 1987) and #125 on late DTl5 and all OTI5C models. Standard pilot jet (6) size is #52 5 on DT9 9 models , #57 5 on OTI5 models and #65 on DTl5C models
To check float level, remove float bowl (10) and invert carburetor body (I) Base of float (9-Fig. SZ6-2) should
be a distance (D) of 23-25 mm (0.91-0 98 in.) from top of carburetor body flange on all models Adjust float level by bending float tang.
FUEL FILTER. A fuel filter assembly mounted on engine port side is used to filter the fuel prior to entering the fuel pump assembly. Periodically unscrew cup (5-Fig. SZ6-3) from base (1) and withdraw filter element (4). Clean cup (5) and filter element (4) in a suitable solvent and blow dry with clean compressed air. Inspect filter element (4) If excessive blockage or damage is noted , then the element must be renewed.
Reassembly is reverse order of disassembly. Renew . '0" ring (3) and , if needed, seal (2) during reassembly
FUEL PUMP. The fuel pump is an integral part of the carburetor. The fuel pump assembly can be overhauled without carburetor removal , proceed as follows : Remove engine top cover and disconnect the fuel tank supply hose at the outboard motor connector. Disconnect the fuel supply hose at the fuel pump inlet.
With reference to Fig. SZ6-1, disassemble the fuel pump assembly. Inspect all components for damage and excessive wear and renew if needed. Clean components as needed with a suitable cleaning solution. Blow dry with clean compressed air. If compressed air is not available, use only lint-free cloths to
1 Uody :.2 Pil o t air lIC t c :3. Spring ,1 Idl e :;.crcw 5 Spring ti Pilo tjt>t 7 Ga.!ikct fl Ne cdl<1:1 , FIQAt 10 r' loat bowl 11 Ga. kct 12 Sere,,· 13. Main j e t 14 C ho k e l<: vc r 15 Cho ke kMb 16 Gwokct 17 Diaphrllgm 18 Ch ec k " Idve a.. , y , 19 Diaphragm 20 Gasket 2 1. CO \ I t
Fig. SZ6-I-EJtploded .Ie .. of Wlltunl ry/H ""rburetor .nd fu.'
pump.
FIg. SZ6-2-For proper _ /e ••" _ of flost (9) should be. d/s/.nee (0) of 23-25 mm In.) y from top of c.rburetor body ".nge.
1
2 Seal 3
4 Element G Cup
Fig. SZ6-3-Exploded ./e of fUel filter -.rb/y.
&.'it!
"0" rillJC
