Suzuki Outboard DT8C, DT8C SAIL, DT9.9C, DT9.9C SAIL, DT9.9, DT16, DT20, DT25, DT25C Service Repair

SERVICE MANUAL

Suzuki DT8C & DT9.9C

SUZUKI DT8C, DT8C SAIL, DT9.9C and DT9.9C SAIL CONDENSED SERVICE DATA NOTE: Metric faateners ara uaad throughout outboard motor_

TUNE-UP Hplrpm ...

. .................... . 8/4700-5700 (6.0 kW) 9.9/5300-5700 (7.4 kW) Bore. . . . ............................. 54.0 mm (2.13 in.)

Stroke. . . . . . . . . . ................. .46.0 mm (1.81 in.)

Number of Cylinders ............................. 2 Displacement ............................... 211 cc (12.9 cu. in.)

Spark Plug .......................... NGK B6HS-1O Electrode Gap .......................... 0.9-1.0 mm (0.035-0.039 in.)

Ignition Type ................................. CDI Ignition Timing ............. 11 0 ATDC at 600 rpm (1) Maximum Timing Advance ..... 28 0 BTDC at 2000 rpm Carburetor Make ....................... Mikuni B24 Compression Ratio. . . . . . . . . . . . . . . . . . . . .. . .... 7.2:1 Idle Speed (in gear) .. 600-650 rpm Fuel:Oil Ratio ............................. See '!ext (I)-On 1988 DT9.9C models, ignition timing is 12 degrees ATDC at 600 rpm.

SIZES-CLEARANCES Piston Ring End Gap ................... 0.15-0.30 mm (0.006-0.012 in.)

Wear Limit . . . . . . . . . . . . . . . . . . . . . . . .. . ... 0.8 mm (0.030 in.)

Piston-to-Cylinder Clearance .................. . .0.052-0.067 mm (0.0020-0.0026 in.)

WBRICATION The power head is lubricated by oil mixed with the fuel. All models are equipped with automatic oil injection.

The recommended oil is Suzuki Outboard Motor Oil or a good quality NMMA certified TC-W oil. Recommended fuel is unleaded gasoline with a minimum octane rating of 85.

On a new or rebuilt engine, the first tank of fuel should be mixed with a recommended oil at a 50:1 ratio and used in addition with the oil injection system to ensure sufficient lubrication during engine break-in. Gasoline and oil should be thoroughly mixed in a separate container. After first tank of fuel is depleted, switch to straight gasoline in fuel tank.

SIZES-CLEARANCES CONT_ Wear Limit ...................... " .... 0.147 mm (0.0058 in.)

Piston Pin Diameter ............... 11.995-12.000 mm (0.4722-0.4724 in.)

Wear Limit ........................... 11.980 mm (0.4716 in.)

Cylinder Bore Diameter .. . . . . . . .54.000-54.015 mm (2.1260-2.1266 in.)

Piston Diameter ................... 53.940-53.955 mm (2.1236-2.1242 in.)

Allowable Crankshaft ........ 0'()5 mm Runout ....... .

(0.002 in.)

Allowable Connecting Rod Small End Side Shake ....... . . .. 4.0 mm (0.157 in.)

TIGHTENING TORQUES Crankcase Screws. . . . . . . . . . . . . . .

. .. 20-26 N-m (15-19 ft.-Ibs.) Cylinder Head Screws .................... 21-25 N-m (15-18 ft.-Ibs.) Flywheel Nut ........................... 80-90 N-m (59-66 (tAbs.) Standard Screws: ............ 2-4 N-m 5 mm (18-35 in.-Ibs.) ........................... .4-7 N-m 6 mm.

(35-62 in.-Ibs.) ..................... 10-16 N-m 8 mm ........ .

(7-12 ft.-lbs.)

10 mm ....... . .................. 22-35 N'm (16-26 ft.-\bs.)

Recommended lower unit lubricant is Suzuki Outboard Motor Gear Oil or a good quality SAE 90 hypoid gear oil.

Gearcase capacity is 175 mL (5.9 oz.).

Gearcase oil should be changed after initial 10 hours of operation and after every 100 hours of operation thereafter.

Reinstall drain and vent plugs securely, using new gaskets if necessary to ensure a watertight seal.

FUEL SYSTEM CARBURETOR. A Mikuni B24-15 carburetor is used on 8 hp models and a Mikuni B24-18 carburetor is used on 9.9 hp models. Refer to Fig. SZ7-1 for exploded view of carburetor assembly. Initial adjustment of pilot screw (2) from

a lightly seated position is 1-1/2 to 2 turns out on Model DTl3C and 1-3/4 to 2114 turns out on Model DT9.9C. Final adjustment should be made with engine at normal operating temperature and running in forward gear. Adjust idle speed to 600-650 rpm in forward gear.

Main fuel metering is controlled by fixed main jet (15). Standard main jet size for normal operation is #105 on Model DTl3C and #137.5 on Model DT9.9C. Standard pilot jet (5) size for normal operation is #85 on Model DTl3C and #65 on Model DT9.9C, 1b check float level, remove float bowl (10) and invert carburetor. Measure float level from carburetor body-to-float bowl mating surface to top of float at a point 180 degrees from inlet valve as shown in Fig. SZ7-2. Fioat level should be 23-

OUTBOARD MOTOR

Suzuki DT9.9 & DT16 (Prior To 1983)

SUZU KI DT9.9 AN 0 DT16 (PRIOR TO 1983)

CONDENSED SERVICE DATA NOTE: Metric fasteners are used throughout outboard motor.

TUNE·UP

DT9.9

Horsepower ....................... .

Bore .............................. .

Stroke ............................ .

Displacement ...................... .

Spark Plug: NGK ............................ .

Electrode gap .................... .

Magneto: Breaker point gap ................. .

Carburetor: Make ........................... .

Model ........................... .

Fuel:OiI Ratio ...................... .

9.9 56mm 52mm 256 cc

DT16 16 59mm 52mm 284 cc

B6HS 0.6·0.7 mm

B7HS 0.6-0.7 mm

Breakerless

Breakerless

Mikuni BV24·16 5.0:1

Mikuni BV24·19 50:1

SIZES-CLEARANCES Piston Ring End Gap ................ .

0.15-0.35 mm Piston Pin Diameter ................. . 13.995-14.000 mm Piston to Cylinder Wall Clearance ........................ . 0.042-0.058 mm Max. Crankshaft Runout at Main Bearing Journal. ............. .

0.05 mm Max. Connecting Rod Small End Side Shake ....................... .

4.0mm

0.15-0.35 mm 13.995-14.000 mm 0.042-0.058 mm 0.05 mm 4.0mm

TIGHTENING TORQUES Cylinder Head ...................... .

Crankcase: 6mm .......................... ..

8mm .......................... ..

Flywheel Nut ...................... .

Standard Screws: 5mm .......................... .

6mm .......................... .

8mm ........................... .

10mm .......................... .

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 and 50:1 for normal service when using a NMMA certified two-stroke engine oil or Suzuki "eCI" oil. When using any other type of two-

18-28 N'm

18-28 N'm

8-12 N'm 18-28 N'm 8()..90 N'm

8·12 N'm 18·28 N'm 80·90 N'm

2-4 N'm 4·7 N'm 10-16 N'm 22·35 N'm

stroke engine oil, fuel:oil ratios should be 20:1 during break-in and 30:1 for normal service. Manufacturer recom· mends regular or no-lead automotive gasoline having an 85-95 octane rating.

Gasoline and oil should be thoroughly mixed.

The lower unit gears and bearings are lubricated by oil contained in the gear-

2·4 N'm 4-7 N'm 10-16 N'm 22·35 N'm

case. SAE 90 hypoid outboard gear oil is recommended. Oil capacity of gearcase with integral exhaust outlet in the lower housing is approximately 220 mL. Oil capacity of gearcase with through· the-propeller exhaust is approximately 200 mL. Reinstall vent and fill plugs se· curely using a new gasket, if necessary, to ensure a water tight seal.

Suzuki DT20 & DT25 (Prior To 1983)

SERVICE MANUAL

SUZU KI DT20 and DT25 (PRIOR TO 1983)

CONDENSED SERVICE DATA NOTE: Metric fasteners are used throughout outboard motor_ TUNE-UP Hp ............................... .

Bore .............................. .

Stroke ............................ .

Displacement ...................... .

Spark Plug: NGK ............................ .

Electrode Gap .................... .

Magneto: Breaker Point Gap ................ .

Carburetor: Make ........................... .

Model ........................... .

Fuel:Oil Ratio ...................... .

DT20 19.8 64mm 61.5 mm 396 cc

DT25 25 68mm 61.5 mm 447 cc

B7HS 0.6·0.7 mm

B7HS 0.6·0.7 mm

Breakerless

Breakerless

Mikuni BV28-22 50:1

Mikuni BV32-28 50:1

SIZES-CLEARANCES 0.15-0.35 mm Piston Ring End Gap ................ .

Piston Pin Diameter ................. . 15.995·i6.000 mm Piston to Cylinder Wall Clearance ..... . 0.060·0.090 mm Max. Crankshaft Runout at Main Bearing J oumal .................. .

0.05 mm Max. Con. Rod Small End Side Shake ........................... .

5.0mm TIGHTENING TORQUES Cylinder Head ...................... .

Crankcase ......................... .

Exhaust Cover ..................... .

Flywheel Nut ...................... .

Standard Screws: 5mm .......................... .

6mm .......................... .

8mm .......................... .

10mm .......................... .

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 and 50:1 for normal service when using a BIA certified two· stroke engine oil or Suzuki ·CCI" oiL When using any other type of twostroke engine oil, fuel:oil ratios should be 20:1 during break-in and 30:1 for nor· mal service. Manufacturer recommends

0.15-0.35 mm 15.995·16.000 mm 0.060-0.090 mm 0.05 mm 5.0mm

18·28 N-m 18·28 N'm 8·12 N'm 1()()"110 N -m

18·28 N'm 18·28 N-m 8·12 N'm 100·110 N'm

2·4 N-m 4·7 N-m 10·16 N-m 22·35 N-m

2·4 N-m 4-7 N-m 10-16 N-m 22·35 N-m

regular or no·lead automotive gasoline having an 85·95 octane rating. Gasoline and oil should be thoroughly mixed.

The lower unit gears and bearings are lubricated by oil contained in the gear· case. SAE 90 hypoid outboard gear oil should be used. Gearcases with exhaust outlet in gearcase require 380 mL of gear oil while through·the·propeller ex· haust models req\lire 300 mL of 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 carburetor is used on all models. Refer to Fig. SZ8·1 for exploded view. Initial setting of pilot air screw (5) from a lightly seated position should be 1112.2 turns on DT20 models and 11/••13/. turns on DT25 models. Final carburetor adjustment should be made with engine at normal operating temperature and running in forward gear. Adjust throttle stop

-

Suzuki DT20 (1986-1988) & DT25 (1985-1988)

SERVICE MANUAL

SUZUKI DT20 (1986-1988) AND DT25 (1985-1988)

CONDENSED SERVICE DATA NOTE: Metric fasteners are used throughout outboard motor.

TUNE·UP Hp/rpm ......................... ' ....... 20/4800-5500 25/4800·5500 Bore: DT20 ...................................... 67mm (2.64 in.)

DT25 ..................................... 71mm (2.80 in.)

Stroke ...................................... 63 mm (2.48 in.)

Number of Cylinders ............................... 2 Displacement: DT20 ..................................... .444cc (27.10 cu. in.)

DT25 ...................................... 499cc (30.45 cu. in.)

Spark Plug: NGK ..................................... BR7HS Electrode Gap .......................... 0.8-0.9 mm (0.031-0.035 in.)

Ignition Type ................................. CD! Carburetor Make ........................... Mikuni Idle Speed (in gear) .................... 650·700 rpm Fuel:Oil Ratio ........................... , . See Text

SIZES-CLEARANCES Piston Ring End Gap ..... .

............ 0.2·0.4 mm (0.008-0.016 in.)

Piston-to-Cylinder Clearance: Prior to 1987 ...................... 0.067-0.082 mm (0.0026-0.0032 in.)

After 1986 ........................ 0.087-0.102 mm (0.0034-0.0040 in.)

Piston Pin Diameter ................. 17.995-18.000 mm (0.7085·0.7087 in.)

Max. Crankshaft Runout at Main Bearing Journal ................... , ... ".,0.05 mm (0.002 in.)

Max. Connecting Rod Small End Side Shake ................................. 5.0 mm (0.20 in.)

TIGHTENING TORQUES Power Head Mounting Screws ............... 15-20 N' m (11-14 ft.-lbs.1

LUBRICATION The power head is lubricated by oil mixed with the fuel. During break-in of a new or rebuilt engine, fuel:oil ratio should be 30:1 on 1985 D'I25 models and 25:1 on 1986 and later D'I25 and all D'I20 models. Fuel:oil ratio for normal service should be 50:1 on 1985 D'I25

TIGHTENING TORQUES CONT. Crankcase: 6mm ................................... 8-12N·m (6-8 ft. ·lbs.)

8mm .................................. 20-26 N'm (14-19 ft.-Ibs.) FlywheelNut ......... """, ........... 130-150N·m (94-108 ftAbs.) Cylinder Head Screws: 6mm ................................... 8·12N·m (6-8 ft.-lbs.)

8mm .................................. 20·26N·m (14-19 ft.-Ibs.) Gearcase Pinion Nut ....................... 18-22 N· m (13-16 ft.-lbs.)

Propeller Shaft Nut ........................ 27-30 N· m (19-21 ft.-Ibs.) Standard Screws: Unm.arked or Marked "4" 5mm ................................... 2-4N·m (2-3 ft.-lbs.)

6mm ................................... 4-7N·m (3·5 ft.-lbs.)

8mm ................................. 10-16N·m (7·12 ft.-Ibs.) 10mm ................................ 22-35 N'm (16·26 fUbs.) Stainless Steel 5mm ................................... 2-4 N'm (2-3 fUbs.) 6mm .................................. 6-10 N'm (5-7 ft.-Ibs.) 8 mm ................................. 15-20N'm (11-15 ft.-Ibs.) 10 mm ................................ 34-41 N'm (25-30 ft.-lbs.)

Marked "7" or SAE Grade 5 5mm ................. , ................. 3-6N·m (2-5 ftAbs.) 6mm .......... "" .................... 8-12N·m (6-9 in.·lbs.)

8mm ................................. 18·28N·m (13·20 fUbs.) 10mm ............................... .40·60 N'm (29-44 ft.-Ibs.)

models and 100:1 on 1986 and later D'I25 and all D'I20 models. Recommended oil is Suzuki Outboard Motor Oil or a good quality NMMA certified TeW engine oil. Recommended fuel is regular or unleaded gasoline having an 85 minimum octane rating. Manufacturer does not recommended using gasoline containing alcohol additives. However,

unleaded gasoline containing ethanol (grain alcohol) may be used providing ethanol content does not exceed five percent and minimum octane rating is 85.

NOTE: Manufacturer recommends NOT using any gllllOline containing methanol (wood alcohol).

OUTBOARD MOTOR

Suzuki DT25C

SUZUKI DT25C CONDENSED SERVICE DATA NOTE: Metric fasteners are used throughout outboard motor.

TUNE-UP Hp/rpm . .. . ..................... 25/5000-5600 rpm (18.6 kW) Number of Cylinders ............................. 3 Bore ..................................... 62 mm (2.44 in.)

Stroke .................................... 60 mm (2.36 in.)

Displacement. .............................. 543 cc (33.1 cu. in.)

Spark Plug .......................... NGK B7HS-1O Electrode Gap .......................... 0.9-1.0 mm (0.035-0.039 in.)

Ignition. . . . . . . . . . . ....................... CD! Carburetor: Make .................................... Mikuni Model ................................... B26-20 Fuel:Oil Ratio ................... Automatic Metering SIZES-CLEARANCES Piston Ring End Gap .................. 0.15-0.35 mm (0.006-0.014 in.)

Wear Limit .............................. 0.8 mm (0.030 in.)

Piston Pin Diameter ............... 15.995-16.000 mm (0.6297-0.6299 in.)

Wear Limit ........................... 15.980 mm (0.6291 in.)

Piston Pin Bore Diameter .......... 16.002-16.010 mm (0.6300-0.6303 in.)

Wear Limit ........................... 16.030 mm (0.6311 in.)

Standard Piston Diameter .......... 61.920-61.935 mm (2.4378-2.4384 in.)

Standard Cylinder Bore Diameter ....................... 62.000-62.015 mm (2.4409-2.4415 in.)

Piston-to-Cylinder Clearance ........................ 0.072-0.087 mm (0.0028-0.0034 in.)

Wear Limit. . . . . . . ............... 0.167 mm (0.0066 in.)

Max. Crankshaft Runout ............. 0.05 mm at Main Journal ....... .

(0.002 in.)

LUBRICATION The power head is lubricated by oil mixed with the fueL Model DT25C is equipped with automatic oil il'\iection.

Recommended oil is Suzuki Outboard Motor Oil or a good quality NMMA cer-

SIZES-CLEARANCES CONT_ Max. Connecting Rod Small End Side Shake ...................... , ... 5.0 mm (0.20 in.)

TIGHTENING TORQUES Cylinder Head: 6 mm ................................. 8-12 N-m (6-9 ftAbs.) 8 mm ................................ 21-25 N'm (15-18 ft.-lbs.)

Crankcase: 6 mm ................................. 8-12 N'm (6-9 ft.-Ibs.) 8 mm ................................ 20-26 N-m (15-19 ft.-lbs.)

Flywheel Nut. . . . . . . . . . . . . . . . . . .130-150 N-m (96-111 fUbs.) Standard ScrewsUnmarked or Marked "4": 5 mm ................................. 2-4 N'm (18-35 in.-lbs.)

6 mm ................................ A-7 N'm (35-62 in.-lbs.)

8 mm ......... , .................... 10-16 N'm (7-12 ft.-lbs.)

10 mm .............................. 22-35 N-m (16-26 fL-lbs.)

Stainless Steel: 5 mm ................................. 2-4 N-m (18-35 in.-lbs.)

6 mm ................................ 6-10 N-m (53-88 in.-lbs.)

8 mm ............................... 15-20 N-m (11-15 ft.-lbs.)

10 mm .............................. 34-41 N-m (25-30 ft.-lbs.)

Marked "7": 5 mm ................................. 3-6 N-m (27-53 in.-lbs.)

6 mm ................................ 8-12 N-m (6-9 ft..-lbs.)

8 mm ............................... 18-28 N-m (13-21 ft.-lbs.)

10 mm ........ , .................... AO-60 N-m (29-44 ftAbs.)

tified TC-W engine oiL Recommended fuel is regular or unleaded gasoline having an 85 minimum octane rating. Manufacturer does not recommended using gasoline containing alcohol additives.

However, unleaded gasoline containing ethanol (grain alcohol) may be used

providing ethanol content does not exceed five percent and minimum octane rating is 85.

NOTE: Manufacturer recommends NOT using any gaaollne containing methanol (wood alcohol).

Suzuki DT25C

SERVICE MANUAL During break-in (first 10 hours of operation) of a new or rebuilt engine, mix a recommended oil with the fuel at a 50:1 ratio in combination with the oil injection system to ensure adequate lubrication during break-in process. Be certain oil and fuel is thoroughly mixed in fuel tank. After initial 10 hours of operation, switch to straight gasoline in the fuel tank.

The lower unit gears and bearings are lubricated with oil contained in the gearcase. Recommended gearcase oil is Suzuki Outboard Motor Gear Oil or a suitable equivalent SAE 90 hypoid gear oil. Gearcase capacity is approximately 230 mL (7.8 ozs.). Lower unit oil should be changed after the first 10 hours of operation and after every 100 hours or seasonally thereafter. Reinstall drain and vent plugs securely, using a new gasket if necessary, to ensure water tight seal.

with idle speed switch located on outside of lower cover so engine idles at approximately 650-700 rpm. Adjust pilot air screw so engine idles smoothly and will accelerate cleanly without hesitation. Readjust idle speed to 650-700 rpm if necessary.

Main fuel metering is controlled by main jet (5). Standard main jet for normal operation is #125. Standard pilot jet (11) for normal operation is #70.

To check float level, remove float bowl (7) and invert carburetor body (1).

Measure float level from float bowl mating surface to bottom of float at 180 degrees from needle valve as shown in Fig. SZIO-2. Float level shOUld be 16.518.5 rom (0.65-0.73 in.). Bend tang on float to adjust float level.

FUEL SYSTEM CARBURETOR. Three Mikuni B26-20 carburetors are used. Refer to l''ig. S"llO1 for exploded view. Initial setting of pilot air screw (12) is 1-112 to 2 turns out from a lightly seated position. Final adjustment should be made with engine at normal operating temperature and running in forward gear. Adjust idle speed

Fig. SZ1CJ-Z-MtJIlBure flollt level from float bowl msllng surface to bottom of float 180 degrees from naad/a valve ss shown. Bend tang on flost to BdjuBt floet level.

FUEL FILTER. A fuel filter assembly is used to filter the fuel prior to entering the fuel pump. Periodically unscrew bowl (5-Fig. S"l10-3) and withdraw filter element (4). Clean bowl and filter el· ement in a suitable solvent and blow dry with clean compressed air. Inspect filter element for excessive blockage or other damage and renew if necessary.

Reassemble in reverse order of disassembly. Renew' '0" ring (3) and seal (2) upon reassembly.

FUEL PUMP. A diaphragm·type fuel pump is used. Refer to Fig. SZIO-4 for exploded view. Fuel pump is mounted on the side of power head cylinder block and is actuated by crankcase pulsations.

When servicing pump, scribe reference marks on pump body to aid alignment during reassembly. Defective or questionable components should be reo newed. Diaphragm should be renewed if air leaks or cracks are noted, or if deterioration is evident.

REED VALVES. The reed valves are located behind the intake manifold. The intake manifold must be removed to ac· cess reed block and valves assembly.

Renew reed valves (2-Fig. S"l10·5) if petals are broken, cracked, warped, rusted or bent, or if tiP of petal stands open in excess of 0.2 mm (0.008 in.) from seat area. Do not attempt to bend or straighten a damaged reed petal.

Reed stop opening (0) should be 3.8 mm (0.15 in.). When reassembling reed valve assembly, apply Suzuki Thread Lock 1342 or a suitable equivalent thread locking compound to threads of screws (4).

SPEED CONTROL LINKAGE. To adjust speed control linkage, loosen throt· tie lever adjusting screws (i-Fig. S"lIO· 6) on top and bottom carburetors and rotate throttle levers (2) counterclock-

6

3 1 Body 2. Gasket 3. HIgh speed nozzle 4, Chok(> rod fi. Main Jet 6. Float 7, Float bowl

8, 9.

10.

11

Drain screw Float pin Needle valve Pilot jet

12, Pilot screw 13, Throttle control rods

Fig. SZ10·3-Exploded view of fuel filter semb/y.

1. Base 2. Seal 3. "0" ring

4 Filter 5. Bowl

ss-

Fig. SZ1D-4-ExpIoded view of fuel pump _ sembly.

L 2.

3.

4.

5

Cover Diaphragm Ga<;ket.

Valve body Plate

6.

7.

8.

9.

Gasket Spring Spring seal CheCK valve

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Suzuki DT25C

OUTBOARD MOTOR

wise to full closed position. Hold levers (2) closed and retighten screws (1). Adjust throttle link (4) so throttle arm (3) is against stopper (5) and clearance (C) is 0.5-1.5 mm (0.020-0.060 in.) with throttle in fully closed position. Make sure throttle plates are synchronized at full closed and full open positions.

If throttle cables require adjustment, loosen cable adjustment nuts and adjust cables so core wires are tight with no free movement in drum (6). Make sure arm (3) contacts stopper (5) when throttle is fully closed. Oil iJ\jection pump control linkage should be checked and/or adjusted after speed control link age adjustment. Refer to OIL INJECTION section.

2

4~~---..l-J Fig. SZIO-S-Cross-sectlonal view of reed bloclc

and valves as_mbly.

1. Reed block 2, Rk-ed petal 3. Reed stop 4. &ww 0, Reed stop opening

OIL INJECTION CONTROL LINKAGE ADJUSTMENT. Make sure speed control linkage is properly adjusted. Initial length of pump control rod (5-Fig. SZI0-7) should be 77.5 mm (3.05 in.) as shown.

With throttle in fully closed position, clearance (C) between lever stopper (6) and boss (7) on pump housing should be 1 mm (0.040 in.) or less, but stopper (6) should not contact boss (7). To adjust, loosen nuts (4) and adjust length of rod (5) as necessary. Make sure nuts (4) are securely tightened after adjustment.

After adjusting pump control linkage, recheck speed control linkage and readjust if necessary. Refer to SPEED CONTROL LINKAGE section.

OIL FLOW SENSOR. Inline filter contained in oil flow sensor should be periodically removed and cleaned in a suitable nonflammable solvent. Manufacturer recommends renewing filter if excessive plugging or contamination is noted.

To test oil flow sensor, remove sensor and connect a suitable ohmmeter between sensor red wire with blue tracer and black wire. Plug sensor inlet and connect a vacuum source to sensor outlet. With vacuum applied, ohmmeter should show continuity. Remove vacuum source and sensor should show infinity.

BLEEDING PUMP. To bleed trapped air from oil supply lines or pump, proceed as follows: Fill fuel tank with a

50: 1 mixture of recommended gasoline and oil. Fill oil tank with a recommended oil. Loosen bleed screw (B-Fig. SZ10-7 or SZI0-8) two or three turns.

Start engine and allow to idle at 650-700 rpm until no air bubbles are noted at bleed screw (B).

CHECKING OIL PUMP OUTPUT. Start engine and allow to warm-up for approximately five minutes. Stop engine, disconnect oil pump control rod from carburetor and remove oil tank.

Conneet oil gage 09900-20205 or a suitable equivalent to oil pump supply hose.

Fill oil gage with a recommended oil until oil is even with an upper reference mark. Bleed system as previously described. With oil pump control rod in fully closed position, start engine and allow to run at 1500 rpm for five minutes. Oil consumption should be 1.01.9 mL (0.035-0.065 oz.) in five minutes at 1500 rpm. Move oil pump control rod to fully open position, restart engine and allow to run at 1500 rpm for two minutes. Oil consumption should be 1.21. 7 mL (0.04-0.06 oz.) in two minutes at 1500 rpm. Renew oil pump assembly (2-Fig. SZlO-8) if pump output is not as specified. After reinstalling oil tank, bleed air from oil iJ\jection system as previously described.

NOTE: Results of 011 pump output test msy vary according to weather conditions, testing error or other conditions. The manufacturer recommends repeating output test procedure two or three times to ensure the proper test results are obtained.

B

Fig. SZI0-6-Vlew of spMld comrol linkage. Adjust Hnkage lIS described In teld.

1. Screw 2. Throttle lever 3. Throttle ann 4, Link rod 5. Stopper 6. Cable drum

fig. SZI0-7-Vlew of 011 Injection pump andeen¡ trollinkage. Refer to text for controlllnkaga ad¡ justment.

1. Throttle lever 2. Pump ass}' 3. Pump lever 4. Adjustment nuL<;

G. Control rod Stopper 7. !los> B. Bleed SHeW

!j,