SERVICE MANUAL Suzuki DT50, DT60 & DT65 (Prior to 1985)

SUZU KI DT50, DT60 AN 0 DT65

(Prior to 1985)

CONDENSED SERVICE DATA

NOTE: Metric fasteners are used throughout outboard motor.

TUNE·UP TIGHTENING TORQUES

Hp/rpm: Cylinder Head:
DT50 ."." .............. " ....... " .50/4801)..5500 6mm ............... _.......... " _...... 8·12N-m
DT60 .... """,, ..... " . " . " ....... 60/4800·5500 (6·9 ft.·lbs.)
DT65 .. " .... " ...................... 65/4800·5500 10mm ............................... AO·60N-mt
Bore: (29-44 ftAbs.)
DT50 (Prior to 1984) ......................... 80mm Crankcase .............................. .40·60 N -mt
(3.15 in.) (29-44 ft.·lbs.)
DT50 (1984), DT60 & DT65 .................... 84 mm ExhaustCover ............................. 8·12N·m
(3.31 in.) . (6-9 fUbs.)
Stroke ...................................... 72mm FlywheelNut ........................... 200·210N·m
(2.83 in.) (145·152 ft.·lbs.)
Number of Cylinders ............................... 2 GearcasePinionNut ....................... 31)..40 N'm
Displacement: (22-29 ft.·lbs.)
DT50 (Prior to 1984) .......................... 723 cc Propeller Shaft Nut ........................ 50·60 N· m
(44.12 cu. in.) (36-44 ft.·lbs.)
DT50 (1984), DT60 & DTS5 .................... 798 cc Standard Screws:
(48.69 cu. in.) Unmarked or Marked "4"'
Spark Plug; 5mm ................................... 2·4N·m
:>rGK ..... " ............................... B8HS' (2·3 ft.·lbs.)
Electrode Gap ............. " ............ 0.8-0.9 mm 6mm ................................... 4·7N·m
(0.031·0.035 in.) (3·5 ft.·lbs.)
Ignition 1)'P" ............................ Breakerless 8mrn ................................. lO·16N-m
Carburetor: (7·12 ft.·lbs.)
Make ...................................... Mikuni 10mm ................................ 22·35N"m
Model ..................................... B40·32 (16·26 ft.·lbs.)
Fuel:Oil Ratio ........ " ....................... 50;1 t Stainless Steel
'1984 DT50 models use NGK B8HS·1O spark plugs with an 5mm ................................... 2·4N·m
electrode gap of 1 mm (0.040 in.). (2·3 ft.·lbs.)
t1984 DT50 and 1983 and 1984 DT60 models are equipped 6mm .................................. 6·ION-m
with oil injection. (6-7 ft.·lbs.)
gmm ................................. 15·20N-m
SIZES-CLEARANCES (11·15 ft. ·lbs.)
Piston Riug End Gap ....................... 0.2·0.4 mm lOmm ................................ 34·41N·m
(0.008-0.016 in.) (25·30 ft. ·lbs.)
Piston Pin Diameter ................. 19.995·20.oo0mm Marked "7" or SAE Grade 5
(0.7872·0.7874 in.) Omm ................................... 3·6N·m
Piston to Cylinder Wall Clearance: (2·5 ft.·lbs.)
DT50 (Prior to 1984) .................. 0.097·0.112 mm 6mm .................................. g·12N·m
(0.0038·0.0044 in.) (6·9 ft.·lbs.)
DT50(1984),DT60&DT65 ............ 0.112·0.127 mm 8mm ................................. 18·28N·m
(0.0044-0.0050 in.) (13·20 ft.·lbs.)
Max. Cranksbaft Runout at Main 10mm .................... '" ......... 40-60N·m
Bearing Journal ........................... 0.05mm (29-44 ftAbs.)
(0.002 in.)
Max. Connecting Rod Small End
Side Shake ................................. S.Omm tTorque values should be 46·54 N • m (34·39 ft. ·lbs.) on DT50
(0.20 in.) (1984) and DT60 models.
 I

Suzuki OT50, OT60 & OT65 (Prior to 1985) OUTBOARD MOTOR

LUBRICATION SPEED CONTROL LINKAGE. The
carburetor throttle valves must be oor-
The power head is lubricated by oil rectly synchronized to open as the igni-
mixed with the fuel. On models with· tion is advanced to obtain optimum per-
out oil it\iection! fuel:oH ratios should
be 30:1 during break-in of a new or
t
A
formance. To adjust the speed control
linkage, it is necessary to first check
rebuilt engine and 50:1 for normal servo (and adjust if required) the ignition max-
ice when using a NMMA certified TC- imum advance as outlined in the IGNI·
WII two-stroke engine on or Suzuki TION TIMING section. Disconneet car·
"CCI" oiL When using any other type buretor link (C~Fig. SZl4-l1) and
of two-stroke engine oil, fuel:oil ratios rotate speed control lever (L) toward
should be 20:1 during break-in and 30:1 maximum speed position until it con·
for nonnal service. On models equipped tacta maximum speed stop. Set car-
Fig. $%14-2-1«,.,., to htd tOt float ,.~ lA>
with oil injection, for the first 5 hours ,pec#flc.Uoos, burewr throttle plates completely open
of operation, mix fuel with oil in fuel then vary the length of carburetor link
tank at a ratio of 50: 1 if Suzuki "CCI" (C) until ball joint connector will just at·
oil or a NMMA certified TO-Wll two- tach. Move speed control lever to full
strokE' oil is used. Mix fuel:oil at a ratio retard position. Clearance (A) at car·
of 30: 1 if any other type of two-stroke should be used. Gearcase capacity is ap· buretor throttle shaft actuating levers
oil is used. Switch to straight fuel in fuel proximately 650 mL (22 oz.) of gear oil should be 0.5·1.0 mm (0.020,0.040 in.).
tank at the completion of the 5 hour and should be drained and refilled after
break-in period. Manufacturer recom- the first 10 hours of use and then after REED VALVES. The inlet reed
mends regular or no-lead automotive every 50 hours of liSe. Reinstall vent and valves (Fig. SZI4·3) are located on a
gasoline having an 85·95 octane rating. fill plugs securely. using a new gasket if reed plate between inlet manifold and
Gasoline and oil should be thoroughly needed, w ensure a watertight seal. crankease. The reed petals should seat
mixed in fuel tank when u.'ied on models very lightly against the reed plate
without oil injection and when used FUEL SYSTEM throughout their entire length with the
during break-in period on models least possible tension. 'rip of reed petal
equipped with oil injection. CARBURETOR. Mikuni type B40-32 must not stand open more than 0.2 mm
The lower unit gears and bearings are carburewrs are used on all models. (0.008 in.)from contact surface. Reed
lubricated by oil contained in the gear· Refer w Fig. SZ14·1 for exploded view. stop opening should be 7.6·8.0 mm
case. SAE 90 hypoid outboard gear oil Initial setting of pilot air screw (7) from (O.3().O.31 in.) on DT50 models and
a lightly seated position should be PI, 7.55·7.95 mm (0.30·0.31 in.) on DT60
w 2'/. turns on DT50 models prior w 19l14 and DT65 models.
and DT65 models and 1'Is to 2'/, turns Renew reeds if petals are broken,
on'i984 DT50 models and DT60 models. cracked, warped, rusted or bent. Never
Final carburtetor adjustment should be attempt w bend a reed petal or to
made with engine at normal operating straighten a damaged reed. Never in-
temperature and running in forward stall a bent or damaged reed. Seating
gear. Rotate timing adjustment screw surface of reed plate should be smooth
(B~Fig. SZ14·11) in small incrementa
until engine idles at approximately
650· 700 rpm. Adjust pilot air screw so
engine idles smoothly and will accelerate
cleanly without hesitation. If neeessary,
readjust timing adjustment screw to ob-
tain 650-700 rpm idle speed.
Main fuel metering is controlled by
main jet (10). Standard main jet size for
e' """"'1
normal operation is number 165 on
DT50 models prior to 1984, number 155
on 1984 DT50 models, number 160 on
DT60 models and number 167.5 on
DT65 models.
To cheek float level, remove float bowl
and invert carburetor. Distance (A - Fig.
SZ14·2) between main jet and bottom of
14·--4K float should be 16.5-18.5 mm (0.65-0.75
15 in.) on DT50 models prior to 1984 and
DT65 models, 16.5-18 mm (0.65·0.71 in.)
on 1984 DT50 models and 16-18 mm
(0.63-0.71 in.) on DT60 models. Adjust
Fig. SZ14·1-ExpIoded view of Mlkuni cal'bur. float level by bending float tang.
tors fyl1ical of ,,11 models.
To synchronize throttle plate opening 6
1. Body
2. Throttle stop serew
lL Spring
9. Main nouIe of top carburetor with bottom car· 1
3. Spri.'lg 10. Main jet buretor, use Suzuki carburetor balancer
4. PilotjM 11, lnkt valve Fig. SZ1.f..3- Exploftd yl.1M of Int.", nMn1iold
5. ThroW", llhaft 12. Float pin 09913·13121 or equivalent and make ad- lHld rHd valv. ....mbly.
connector 13.. FIQ8,t justment at throttle shaft connector 1. Manifold 4. Reed pet.als
6, Choke shaft <:OClneetol' 14. Gasket 2. Gasket 5. Reed stop
7. r'-IPt air screw 15. Fknit bow! (5-Fig. SZI4-1). :'t Reed plate 6. Gaskill:
SERVICE MANUAL Suzuki 0150, 0160 & 0165 (Prior to 1985)

Fig. SZ14.s- Use 011 pump .Ir biNd screw fA) to

bleed trapped air from 011 supply line or pump.

Flo. SZ1..... -lnlet manifold cap SCMW. should

be tightened In the HqU4»lc. shown above.
Fig. SZ14-S-Exploftd vSew of diaphragm type

and flat. When installing reeds or reed 2,

'"*1 pump and fuel flit., assemblies.
1. Cnwr
Dlaph""",, 9.Fuel filter body
I~'-LI
stop, make sure that petals are centered 3. Body 10.Packing

~c
4. Dmphragrn 11."0" ring
over the inlet holes in reed plate. and 5. SPring 12.Filter
that the reed stops are centered over Ii. Body 13.Bowl
reed petals, Apply a suitable high
temperature grease to inlet manifold
cap screw threads, then using sequence
1.
8.
"O~ rillgl>
lnsulator bhxk
1. 1Mt
O. OIIt:et
I[
shown ill Fig, SZ14-4 tighten cap approximately five minutes, then stop
screws, engine. Disconnect oil pump control L
'L.I
S,\ \ <"'\
\\
cable (C - Fig, SZI4-7) at carburetor <; \
FUEL PUMP. A diaphragm type fuel throttle lever, Detech oil supply line at ,
pump is mounted on the side of power oil tank outlet, Connect oil gage
:,~
head cylinder block and is actuated by 09900-21602 to oil supply line, Fill oil
pressure and vacuum pulsations from gage with a recommended two-stroke oil
the engine crankcases, Refer to Fig, unit even with an upper reference mark.
SZ14-5 for exploded view of fuel pump With oil pump control cable (C) in re-
assembly, leased position, start engine and main~
When servicing pump, scribe @I
taln engine speed at 1500 rpm, Allow
reference marks aeross pump body to engine to run for five minutes. After five
aid in reassembly, Defective or ques- minutes, stop the engine and observe oil Fig_ SZ14-1-11lsconn.ct 011 pump conftol c.ble
tionable parts should be renewed, Dia- gage. Recommended oil consumption is (e) at carburetor thrQttle lev., and ,eler to fe.t
phragm should be renewed if air leaks or for checking 011 pump output
2,7-3,5 mL (0.09,0,12 oz,) in five minutes
cracks are found, or if deterioration is at 1500 rpm.
evident. To check oil pump at maximum output
position, repeat previous procedure ex- while the stator plate is fIxed on models
FUEL FILTER. A fuel filter (9 cept use a suitable tool and hold oil pump with electronic advance. Refer to Fig,
through 13- ~1g, SZ14-5) is mounted on control cable (C) in fully extended posi- SZ14-8 for a typical wiring diagram of
the side of power head cylinder block on tion, Recommended oil consumption is models with independent ignition.
all models, Filter should be disassembled 4,6-5.6 mL (O.16-l),19 oz,) in five minutes Models with simultaneous ignition
and cleaned after every 50 hours of use. at 1500 rpm, systems are similar.
Renew ·0" ring (11) if required. If the obtained oil consumption
measurements are not within the recom- IGNITION TIMING. On independent
OIL INJECTION mended limite. then oil pump must be ignition models, ignition timing should
renewed. he 4· ATDC at 1000 rpm and 21 0 BTDC
Models So Equipped on DT60 models and 25° BTDC on all
IGNITION other models at 5000 rpm. On
BLEEDING PUMP. To bleed simultaneous ignition models with
trapped air from oil supply line or pump. All models are equipped with either an mechanical advance, ignition timing
firs! make sure outboard motor is in an independent or simultaneous pointless should he 3° ATDC at 1000 rpm and 25°
upright position and oil tank is full. Open electronic ignition system, Simultaneous BTDC at 5000 rpm, On simultaneous ig-
oil pump air bleed screw (A - Fig. ignition system models are identified by nition models with electronic advance
SZ14-S) three or four turns to allow oil the use of one ignition coil while two ig- (fixed stator plate), ignition timing
to seep out around screw threads, After uition coils are used on models with an should be go BTDC at 1000 rpm and 25°
five seeouds or when no air bubbles are independent ignition system, Simultane- BTDC at 5000 rpm,
noticed, close air bleed screw (A), ous ignition models may have Iuitial setting of ignition timing on all
mechanical or electronic advance, Stator models with mechanical advance may be
CHECKING OIL PIJMP OUTLET. plate is movable on simultaneous igni- accomplished as follows: Set throttle at
Start engine and allow to warm·up for tion models with mechanical advance full advanL'C position, then align mark
Suzuki DT50, DT60 & DT65 (Prior to 1985) OUTBOARD MOTOR

C3 Bl

Fig. SZ14~- Typical wlrlrJ{l dJ.gram 101 models with independent Ignition. Other moftla
ItJ "Down~ solenoid
.r. similar,
GR. Gray
L Ignition switch 6. Overheat buuer 1l. Choke $(>lenO'id hi. Starter mowr LtBL Light blue
7. TIlt and trim 12. Regulator
~:~~
2. Emergency swp 17. Starter 5Olenoid 22. Battery
!;witch ~itch 13. Reetif'w 18. Spark plugs B. Blad:
3. Hour roetlJt 8. 1'ilt and trim 14. CD iguitinn 19. Overheat sensor BL. Blue R a.d
4. Volt meter ~tm mod... 26, Neutral switch BR. Browll W, White
5. Tachom~tel' !f. ~Up" oolenoid 15, Stator 2}, 2U amp fuse G. Green Y. Yellow

(.\I-Fig. SZ14-9) on stator plate with vance ignition timing. run engine at rep<:>sitioning stator plate. On models
stationary mark (S) on upper seal hous- wide open throttle and note timing with electronic advance, reposition
ing. Loosen nut (N) on stator plate link marks. stator plate to adjust ignition timing.
to rep<Jsition stator plate. On models with mechanical advance,
Initial setting of ignition timing on all full reterd timing may be adjusted by TROUBLE-SHOOTING. If ignition
models with electronic advance may be turning bolt (B-Fig. SZl4-l1j in or out malfunction t){.'Curs, use only approved
accomplished by aligning mark (M - Fig. as requirad and full advance timing may procedures to prevent damage to the
SZ14-10) on stator plata with center of bo adjusted by loosening nut (N) and
stator plate retaining screw hole (H).
Final ignition timing check can be
made using a suitable power timing M
light. Immerse lower unit of outboard
motor in water and connect timing light
to upper spark plug. Set engine throttle
at full retard position and start engine.
Refer to ignition timing specifications
stated previously and check alignment
of flywheel timing marks with index
mark on electric starter cap on models
with mechanical ad1la.IlCe or v.ith index Fig. 5214-9-0n model. with meclulnlc.1 ad· Fig. SZ14·10-0n moeN/' ",Jth ./ecfronlc ad-
~anc., s.t Ignition ttmlng statically by 111I9nlnll fanee, Ht IfnWon timing .odlcally by aligning
mark on flywheel housing on models
with electronic advance. To check ad·
mark (AI) on st.ttor plahl with ,t.tlonary mark (S)
whe" ,,,,attl.
1$ In the full Itd~ance position.
m.rt (II) on .t.tor pl.,. wtth
hoi. (11).
ten"" of screw
SERVICE MANUAL Suzuki DTSO, DTGO & DTGS (Prior to 1985)
components. The fuel system should be -h.t4lr ChMlIl! Pubor Ground Stop :Iqtlj~;on To check condition of ignition coil,
checked first to make certain that faulty "'Tenter:
:l!tlu'l
8 1uel Wt.:tel Blue! : Black! separate the black/white wire connector
Black
running is not .caused by incorrect mix- le.d
'''' Rod
'''' : Whitt at coil and remove high tension wires
ture or contaminated fueL Make sure A A from spark plugs. Attach tester positive
malfunction is not due to spark plug, lead to black/white wire and nElb",tive
wiring or wiring connection failure. B B lead to coil ground. Primary coil re-
Trouble-shoot ignition circuit using C A sistance reading should be within the
Suzuki pocket tester number 09900- limits of 0.076-0.104 ohms. Attach a
25002 or ohmmeter as follows: A tester lead to each high tension wire.
C Secondary coil resistance reading should
Simultaneous Ignition Models_ On be within the limits of 2980-4030 ohms.
simultaneous ignition models with elec- Fig. SZ14·13-U.. chaff shown above and To check condition of CD ignition
tronic advance (fixed stator plate), check v.luesllsted In FiU. $Z14·12 to t.st condition of module, use tester or ohmmeter in con-
CD Ignition module used on s/multanltOVs Igni.
condition of low-speed capacitor charge tlon models with mechanical sdYance.
junction with test chart shown in Fig_
coil by separating the redlblack wire SZ14·13. Renew CD ignition module if
eonnector at stator and attach a tester required.
lead. Attach the other tester lead to
engine ground. Low-speed charge coil charge coil may be considered satisfac- Independent Ignition Models_ On in-
may be considered satisfactory if tory if resistance reading is within the dependent ignition models, check condi-
resistance reading is within the limits of limits of 1.62-1.98 ohms. tion of capacitor charge coil by
112-149 ohms. Check condition of high- To check condition of ignition coil, separating the green wire connector and
speed charge coil by separating the separate the white/black wire connector black wire connector at stator and at-
redlblack wire connector and blue/red at coil and remove high tension wires tach a tester lead to each wire. Charge
wire connector at stator and attach a from spark plugs. Attach tester positive coil may be considered satisfactory if
tester lead to each wire. High-speed lead to white/black wire and negative resistance roading is within tbe limits of
lead to coil ground. Primary coil re- 225-275 ohms.
sistance reading should be within the Check condition of pulser coils by
limits of 0.28-0.38 ohms. Attach a tester separating the gray wire connector,
lead to each high tension wire. Second- pink wire connector and black wire con·
ary coil resistance reading should be nectar at stator. Attach tester positive
within the limits of 2980-4030 ohms. lead to black wire. Attach negative lead
To check condition of CD ignition to gray wire and note tester reading,
module, use tester or ohmmeter in con" then attach negative lead to pink wire
junction with test chart shovm in Fig_ and npte tJ;Ster reading. Resistance
SZ14-12. Renew CD ignition module if reading for each pulser coil should be
required. within the limits of 180-220 ohms.
On simultaneous ignition models with Check condition of each ignition coil as
mechanical advance, check condition of follows: Separate the orange wire con-
capacitor charge coil by separating the nector and blar.kiwhite -wire connector
blue/red connector and black wire con- at coil for top cylinder, then attach a
nector at stator and attach a tester lead tester lead to each wire and note tester
to each wire. Charge coil may be con- reading. Separate light blue wire con-
sidered satisfactory if resistance nector and black/white wire connector
reading is within tbe limits of 135-165 at coil for bottom cylinder, then attach a
ohms. tester lead to each wire and note tester
Check condition of pulser coil by reading. Primary coil resistance reading
separating the white/red wire connector should be within the limits of 0.87-1.17
and black wire connector at stator and ohms for each coil. Diseonnect high ten-
Fig. SZ14-U-VI.w
und on models with mechanical
0' .pHd contro'mane
"oleag.
•.
attach a tester lead to each wire. Pulser sion wires from spark plugs. Attach
coil may be considered satisfactory if tester positive lead to high tension wire
Mod./s with .'ectronlc advanc. ("xed stator
pl.f.) are slmll,r.
resistance reading is within the limits of and negative lead to black/white wire.
7.29-8.91 ohms.
~I~",;"
lee.d Pu """'go «000'1'''''''''
KI' St.p
fJ~ 1Whit.,

~
-+'r.... tu Sklel Rldl 8",.;
I
C.,.'O- Pulttr Ground Stop I.,ltion
hac'! R«I 81ae1c I 61.clo: A«I l.ad -..-Pink
CNir-ue Slut!
&pulw' ~td
I
~ 8 A A .._-
A
+T •• ter
lell<l Green Gr.... .,"" Glue
Rod Or• •
Light
blue
8111Ckl
Whltlt

ChM~' RedT
~ ..~....
G,_
C I~ A A A Ch.r~ A A B C C C
."'."'"" p- I ..... ..~

.. C B A A "- artv B ~. B B B B B B
Grounoli Fig. SZ1.f.14-Use chart ad-
\'VhiU/ Jac.ttt and values tlsled In
Itnition
'" C B C ~ C Fig. SZf4·12 to fest cotrdl·
pi!'1k
B 8 "- B B B B B
I ~""I flon 01 CD illn't/on module
Stop
Rod A B A A ~ UNd on Independelff Ignl-
GJ:OtIn(! St""
.,,..} A A ~ A C C C
Fig. SZ14·12- U..
chart .how" aboN and
tts/un listed below to tft! condition of CD Ignl·
flon model.. s.... .od I B B B ~ B 8 B
tl<tn module und on .imulfaM0U4 ignition 0 .."" i
B B B B I B I~ 8 B
mQdBls with electronic . . .no..
C" Tester Medle alAAlld
I~ition
.....
litht
B B B 8 B B "- B
A. lOOk ohms or leM
IIlmw deflection then
return tuwtlrtl inumtc .""'1
Whitt A A A A 8 A A ~
B. lOOk ooms Qr more remstalli*
Suzuki DT50, OT60 & OT65 (Prior to 1985) OUTBOARD MOTOR
Secondary coil resistance reading should
be within the limits of 5020-6790 ohms
for each coil.
To check condition of CD ignition
modu)e, use tester or ohmmeter in con·
junction with test chart shown in Fig. 2
15-~=~
SZ14-14. Renew CD ignition module if
required.
16~
COOLING SYSTEM Fig. SZ14·18-Exptoded
view 01 crankcase assembly
WATER PUMP. A rubber impeller fyplcal of all models.
type water pump is mounted between L Cylinder head COYl!r
2. Gasket
the drive shaft housing and gearcase. A 3. Cylinder hear.!
4. Thermostat
key in the drive shaft is used to turn the 5. Head gasket
pump impeller. If cooling system prob- 6, Vah'/:'
7. Spring
lems are encountered, check water in- 8. CYlinder block
take for plugging or partial stoppage, '9.CrankcaSE'
10. Ouwr exhaust rover
then if not corrected I remove gearcase 11. Gasket
as outlined in the appropriate section 12. Inner exhaust covet
13. Gasket
and check condition of the water pump, 14. Upper seal housing
water passages and sealing surfaces. 15.
16.
Gasket
Upper crankshaft seal
When water pump is disassembled, 17. Lower crankshaft sea!
check condition of impeller (4-Fig. 18. DriVe shaft ;;eal
19. Drive shaft 8%! hOWling
SZ14-15) and plate (5) for excessive
wear. Turn drive shaft clockwise
(viewed from top) while placing pump
housing over impeller. Avoid turning
drive shaft in opposite direction when
water pump is assembled.
THERMOSTAT. A thermostat
(4-Fig. SZ14·16) is used to regulate 10
operating temperature. The thermostat
should start to open within the temper-
ature range of 40°_44° C (104°·111°Fj. per cover and disconnect linkage, fuel recoil starter. Remove Wllmg COnnec~
Thermostat can be removed for insper· lines and wires which interfere with tion cover plate located above exhaust
tion or renewal by removing cylinder power head removaL Remove carbur- cover (10-Fig. SZI4-l6) on cylinder
head cover. etors and electric choke solenoid. block and separate all wire connections.
Remove plug from side of lower cover to Remove ignition module, ignition coil(s),
POWER HEAD obtain access to shift linkage. Unscrew fuel pump. fuel filter, shift and speed
REMOVE A~D REINSTALL. To nuts retaining shift arm (2-~'ig. control linkage, flywheel and stator
remove the power head, first remove up- SZ14-25) to shaft (4), then disengage plate assembly. Remove upper oil seal
shaft (4) from shift rod (9). Remove housing (14), outer exhaust cover (10),
screws securing power head assembly to inner exhaust cover (12), intake mani-
lower unit and lift off power head. fold and reed valves. Remove cylinder
Before reinstalling power head, check head cover (1) and cylinder head (3), then
condition of drive shaft seal (18- Fig. clean carbon from combustion chamber
SZI4-16). If seal renewal is required, it and any foreign material accumulation
will be necessary to separate crankcase in water passages. Withdraw spring (7)
(9) and cylinder block (8) as outlined in and valve (6) from cylinder block.
the appropriate following paragraphs. Unscrew crankcase retaining screws
Apply a suitable high temperature and separate crankcase (9) from cylinder
grease to lip portion of seal and install block (8). Remove lower oil seal housing
seal into seal housing (19) with open side (19). Crankshaft and piston assembly
towards lower unit. Make certain drive may now be removed from cylinder
shaft splines are clean then coat them block.
with a light coating of water resistant Engine components are now ready for
grease. Apply a suitable sealer to mating overhaul as outlined in the appropriate
surfaces of power head and lower unit following paragraphs. Refer to the fol-
and install a new gasket. Coat power lowing seetion for assembly procedure.
head to lower unit retaining \:<tp screws
adjacent to cap screw heads with ASSEMBLY. Refer to specific serv-
silicone sealer. The remainder of in- ice seetioos when assembling the crank·
stallation is the reverse of removal pro- shaft, conneeting rod. piston and reed
cedure. valves. Make sure all joint and gasket
FIg. SZl4+15-Exploftd vt.w of wat., pump surfaces are clean. free from nicks and
I'ss.mb'y. DISASSEMBLY. Disassembly and burrs and hardened cement or ""rbon.
L Wa!er tu3e 4. Impeller
2. Pump housing 5. Pla'A inspection may be aceomplished in the Whenever the power head is disassem-
3. Key 6. Gasket follo~ng manner, Remove electric or bled, it is r"""mmended that all gasket
SERVICE MANUAL Suzuki DT50, DT60 & DT65 (Prior to 1985)
engages groove in cylinder block. Install 7 5 3
drive shaft seal (18) into seal housing
11 (19) with open side towards lower unit. 14
Apply a sufficient amount of water-
resistant grease to seal housing (19) to 8
12 _r-'l-':' ~ fill area between lower crankshaft seal 11
and drive shaft seal, then install seal 12
13~~::fi.A housing to cylinder block. Apply a coat 8

15
of Suzuki Bond No.4 or a suitable sealer
to mating surfaces of crankcase and cyl-
inder block and position crankcase on
10 ~~13
16 cylinder block. Using tightening se-
17-~ quence shown in Fig. SZ14-19. tighten 17 4 15 2 16 6 18
the crankcase screws to 46-54 X' m FIg. SZ14-20- Cylinder head clip 'c,.,.., .hould
(34-39 ftAbs.) on DT50 (1984) and DT60 be tlghten.d In the ',",,,enee shown abov•.
R.f., to fu' 101 tightenIng torque 'Pfelfle.·
18-~e:::l models and 40·60 N 'm (29-44 ft.-Ibs.) on lion..
all other models. Install uppor crank-
shaft seal (16-Fig. SZ14-1S) into seal
19_~~ housing (14) with open side towards
cylinder block, then install seal housing
Fig. SZI4-17-Explodod <I... <If .,.nk,hatt to cylinder block assembly.
L Piston rings
0'
assembly typleal all m~
11. Ball bearing
Cylinder head gasket should he in-
2, Piston 12. Top crank hal! stalled without the application of 'a
3. Plston pin clip IS. Crank half gasket sealer. With valve (6) and spring
4. Piston pin 14. ThNflt nngs
5. Thrust washer 15 Labyrinth $l!aI (7) installed in cylinder block, position
6. Needle bearing lS. 'iY ring
7. Cun~tillg rod n Ball buaring cylinder head. cylinder head cover and
8. Crankpil1 lit UtwiCr crankshaft related gaskets on cylinder block then
9. Needle hearing l\lWy.
10. Thrust washer 19. Ball btlll'mg using tightening sequence shown in Fig.
SZ14-20, tighten the 6 mm screws to
8-12 N'm (6-9 ft.-lbs.) and the 10 mm
screws to 4(\.54 N'm (&4-39 ftAbs.) on
DT50 (1984) and DT60 models and 40-60
N 'm (29-44 ft.-lbs.) on all other models.
RINGS, PISTONS AND CYLIN- Fig. $%14-21- AfnJmum sld.-fo-'" .hak. (A)
DERS. The pistons are fitted with two .t ,mall'nd 01 connecting 100 should De S mm
piston rings. Piston rings are inter- (0.20 In.) or I•• s.
changeable in grooves but must he in-
stalled with manufacturers marking
toward closed end of piston. Piston ring mm (0.010 in.) and 0.50 mm (0.020 in.)
end gap should he 0.2-0.4 mm (0.008- oversizes. Cylinder should be bored to
0.016 in.) with a maximum allowable an oversize if cylinder is out-of-round or
FIg. SZ14·1B- VI.w 01 'nstall.d ctlnk$lutit ring end gap of 0.8 mm (0.031 in.). taper exceeds 0.10 mm (0.004 in.). In-
..sembi), .howll1g midn beerlng locat/n" notch· Piston to cylinder wall clearance should stall piston on connecting rod so arrow
. . (N). be 0.097-0.112 mm (0.0038-0.0044 in.) on on piston crown will point towards ex-
DT50 models prior to 1984 and haust port when piston is in cylinder.
0.112·0.127 mm (0.0044-0.0050 in,) on
surfaces and mating surfaces without all other models. Pistons and rings are CONNECTING RODS, BEARINGS
gaskets he carefully checked for nicks, available in standard size as well as 0.25 AND CRANKSHAFT, Connecting
burrs and warped surfaces which might rods, hearings and crankshaft are a
interfere with a tight seal. Cylinder pressed together unit. Crankshaft
head. head end of cylinder block and should he disassembled ONLY by ex-
some mating surfaces of manifold and 1 5 1 3 9 perienced service personnel and witb
crankcase should he checked on a sur- suitable servioo equipment.
face plate and lapped if necessary to pro- Caged roller bearings are used at both
vide a smooth surface. Do not remove large and small ends of the connecting
any more metal than is ne<!essary. rod. Determine rod bearing wear by
When assembling power head. first measuring connecting rod small end
lubricate all friction surfaces and hear- side-to-side movement as shown at
ings with engine oil. Place thrust rings (A-Fig. SZ14-21). Normal side-to-side
(14 - Fig. SZ14-17) in cylinder bloek. movement is 5 mm (0.20 in.) or less.
then install crankshaft assembly. Make Maximum allowable limit of crankshaft
certain main hearing loeating pins runout is 0.05 mm (0.002 in.) measured
engage notches (N-Fig. SZ14-18) in at hearing surfaces ",ith crankshaft ends
cylinder block. Apply a suitable high supported.
temperature grease to lip portion of When installing crankshaft. lubricate
crankshaft and drive shaft seals, then in- 10 4 2 6 8 pistons, rings, cylinders and bearings
stall lower crankshaft seal (17 - Fig. FIg. SZ14-1t-C,.nkcaH c.p ICN..S should". with engine oil as outlined in ASSEM-
SZ14-1S) ensuring seal flange properly t/ghtenR In the seqllfilctl shown above. BL Y section.
 ,
Suzuki OT50, 0160 & 0165 (Prior to 1985) OUTBOARD MOTOR
STARTERS sion on rewind spring than is necessary
to draw rope handle up against housing.
MANUAL STARTER. Refer to Fig.
SZ14·22 for exploded view of overhead ELECTRIC STARTER. Some
type manUlll starter assembly used on models are equipped with eleetric
some DT50 models. Starter may be dis- starter shown in Fig. SZ14-23.
assembled for overhaul or renewal of in· Disassembly is evident after inspection
dividUlll components as follows: Remove of unit and reference to exploded view.
engine top cowl and three cap screws Starter brushes have a standard length
securing starter assembly to power of 16 mm (0.63 in.) and should he re-
head. If stamr spring remains under newed if worn to 9.5 mm (0.37 in.) or
tension, pull starter rope and hold rope less. After reassembly. hench test
pulley (10) with notch in pulley adjacent starter hefore installing on power head.
to rope outlet. Pull rope back through
outlet so that it engages notch in pulley LOWER UNIT
and allow pulley to slowly unwind.
Remove cap serew (21) and disassemble PROPELLER AND DRIVE
unit. Be careful when removing rewind CLUTCH. Protection for the motor is
spring (8); a rapidly uncoiling starter built into a speeial cushioning clutch in
spring could cause serious injury. the propeller hub. No adjustment is
Rewind spring is wound in a counter- possible on the propeller or cluteh.
clockwise direction in starter housing. Three-bladed propellers are used. Pro·
Rope is wound on rope pulley in a pellers are available from the manufac·
counterclockwise direction as viewed turer in various diameters and pitches
with pulley in housing. Reassemble and should be selected to provide op-
starter assembly by reversing timum performance at full throttle
disassembly procedure. To place tension within the recommended limits of
on rewind spring, pass rope through 4800-5500 rpm.
rope outlet in housing and install rope FIg. SZf4-23-Expioded view ot .'ectrlc sfeff.,
mot'or.
handle. Pull rope out and hold rope L "C~ rillg R&R AND OVERHAUL. Refer to
pulley so notch on pulley is adjacent to 2. Stop 8. Brush astIy. ~'ig.SZ14-24 for exploded .;ew of lower
3. Spring 9. Rrullh c!}ver
rope outlet. Pull rope back through ... Drive 10. Tht-ust wastref unit gearease assembly used on all
:;, FramiJ head 11. "E~ cl!p
ouUet between notch in pulley and hous· 6, Armature 12. End .....ap
models. During disassembly. note the
ing. Turn rope pulley counterclockwise 7. Fraroo 13. Starter wl!moid location of all shims and thrust washers
four complete revolutions to place ten·
sion on spring. Do not p]ace more ten~
Fig. $Z14·24 - Exploded
riew of Iow.r unit ,,84tease
ess.mbly used on all
model..
1. Link
2. Shiftum
3. &mjngs
4, Shift shaft
5. :Dw>t twa!
{>. Rod iplide
7. ''O~ nng
8. "0'" ring
'9. Shift roo
HI. Pin
11. Magnet
12. Magnet hQ/.der
13. Pin
14. Shift r:am
15 . .Bearing housing
16. Seal
1'1.Drive shaft
180 Bearing
19. Thrust WMher
20. Spring
21. WWlher
22. Collar
23. Snap ring
24. Shim
25. Needle bearings
26.~
27, Vent plug
28. Oil level plug
29".Drain plug
30. Strip- seal
31. Pinkm gear
FIg. SZ14·22- Exploaad view ot or.mud ttarNr 32. Collar
33, Washer
ss••mb1t u,.d on 80m. mod• . 34, pjnioo nut
1, Rope handle 35, Taper hearing
2, iktaint't 36. Shim
3. Rope guide 37. Forward gear
4., Grommet 38. Thrust washer
,5. Spring 39'. Shift pin
6. Surter housing 4;}. Spring guidt! 47. 'l'h.ru.s.t washer
7, Rope 41. Ciukh 41t ReveT${' g<:!al'
8. Rewind spring 42. Ph; ,lit Shim
9-. Plate 43. Pin ,,*wner 5(L Bearing
10. lWpe pulley 44 Shift spring 5L "0" ring
II. Bushing 45. PrcI*fler shaft 52, End c.p
12. Guide 46.Shlm 53, Net!rlle hearings
SERVICE MANUAL Suzuki DT50, DT60 & DT65 (Prior to 1985)
to aid in reassembly. To remove gear· Inspect gears for wear on teeth and on spring (44). Spring free length should be
ease, first unscrew plug (29) and drain engagement doge. Inspect clutch (41) for 69 mm (2.72 in.) v,ith a minimum length
gear lubricant. Remove plug from side wear on engagement snriaces. Inspect of 67 mm (2.64 in.). All seals and "0"
of lower engine cover to obtain access to shafts for wear on splines and on friction rings should be renewed when unit is
shift linkage. Unscrew nuts retaining surfaces of gears and oil seals. Check reassembled.
shift arm (2) to shaft (4), then disengaj,'" shift cam (14) and shift pin (39) for ex· Backlash between pinion gear (31) and
shaft (4) from shift rod (9). Remove the cessive wear. Check condition of shift drive gears (37 and 48) should be
cap screws securing gearcase to drive 0.05·0.30 mm (0.002-0.012 in.) and is ad·
shaft housing and separate gearcase justed by varying thickness of shims (36
assembly from drive shaft housing. Re· and 49). Propeller shaft end play should
move water pump assembly (Fig. be 0.05·0.30 mm (0.002-0.012 in.) and is
SZ14·15). Remove propeller with related adjusted by increasing or decreasing the
components from propeller shaft. thickness of thrust washers (38 and 47)
Unscrew two screws retaining gearcase and shims (46).
end cap (52- Fig. SZ14·24), then attach Reassemble gearcase by reversing dis·
a suitable puller to propeller shaft (45) assembly procedure while noting the
and withdraw propeller shaft assembly following: Install clutch (41) on propeller
with gearcase end cap. Unscrew pinion shaft (45) so "F" marked side (see Fig.
nut (34) and remove pinion gear (31), SZ14·25) is towards forward gear (37-
then extract forward gear (37). Drive Fig. SZ14·24). Tighten pinion nut (34) to
shaft (17) and related components may
be withdrawn from gearcase after
v 30·40 N'm (22·29 ftAbe.). Apply water·
resistant grease to ·0" ring (51). Apply
removal of bearing housing (15). 2 1 silicone sealer to gearcase and bearing
Fig. SZ14·!1- VIHf 01 pump ...~y showing housing (15) mating surfaces and to
lOll potU (1.n.
10000tfon of 011 U" plUG (F). ,.1.." valr.IVJ and
2~
bearing housing and drive shaft housing
mating surfaces. Coat retaining cap
screws adjacent to cap screw ht'ads with
silicone sealer.
With gearcase assembly installed, ad·
41 just shift linkage as follows: Set shift
arm (2) exactly between "F" and "R"
positions, then adjust link (1) so protru·
sion (P-Fig. SZ14·26) on shift lever (L)
is centered over neutral safety interlock
45 switch. Fill gearcase with outboard gear
oil as outlined in LUBRICATION sec·
tion.

Fig. SZ14-25-11l6taII cIIItch (41) on prop<ll"" shllfl

(45) with "F" m,rklld $Ide toward forward gll.r.

l1~O~"
_ 10

" ~

~12

13~

~14
Fig. SZ14-"- &pIodfiJ view of power tilt and
trim electric motor and pump auambl,.
L End cap 8. Frame M
'.Spring •. Gukot
8. Bruah 10. ReIe1"VOiT FIll- SZI4-n- VI ... Ide.t/fyllll/ m•••., tal....
.. BaIl 11. Fill plug
FIfI. SZI4-:e - Prot,usJon (PI on .hltl 1._ ILl ,alnt 1/111. fm plug IFI .n" ....mm.""" ,.".
m_'.
6. Armature 12. V ring
should be CMnfe",d O'n neutral "'ely .wltch 6. 'l'hrtat waaher 18. Pump aMY. roI, all,..., (LI on POW"' 11I1.nd trim p.mp_
wllan Iowa, unit Ie In o.ut,.t. 'I. Guk6 14. Cap ~w 0It IIT1i1l (19/141"" 1IT60 (11183-19/14/.
Suzuki DT50, DT60 & DT65 (Prior to 1985) OUTBOARD MOTOR

POWER TILT AND TRIM with outboard motor in a vertical posi- disassembled for repair or renewal of in-
tion. Hydraulic tilt should be cycled dividual components, upon reassembly
Some models are equipped with a several times and oil level rechecked if use Ingilis Company EP630548 flat
hydraulically actuated power tilt and system has been drained or lost a large black neobase or equivalent to provide a
trim system. An oil pump driven by a amount of oil. watertight seal.
reversible electric motor provides oil If a malfunction occurs in tilt and
pressure. A rocker control switch deter- trim system, first make sure malfunc-
mines motor and pump rotation thereby tion is not due to wiring. wiring con-
retracting or extending tilt and trim nection or electric motor failure. To
cylinders. The pump is equipped with an check oil pressure, connect a 20.7 MPa NOTE: On Models OT50 (1984) and OT60
automatic and manual release valve (3000 psi) gage to port "I" on pump and (1983·1984), the pump Is equipped with e
(V -Fig. SZI4-27) that when set in the operate pump_ Hydraulic oil pres- manual releas. valve (M-Flg. SZ14·29)
manual position (vertical) enables move- sure at port "I" should be within that, when rotated two turns counterclock·
ment of trim and tilt cylinders if the elec- the limits of 6.9-17.25 MPa (1000-2500 wise, enables movement of trim and tilt
tric motor malfunctions. psi). Connect test gage to port "2" and cylinders If the electric motor malfunctions.
Recommended oil is SAE 20W or SAE operate pump. Hydraulic oil pressure Recommended 011 Is SAE 2OW, SAE
30W motor oil or Dexron automatic should be within the limits of 1.66-5.52 10W30 or SAE 10W40 motor 011 or Oe.ron
transmission fluid. Do not run pump MPa (240-800 psi). Oil pressure less than automatic transmission fluid. 011 level (L)
without oil in reservoir. Fill plug (F) is specified may indicate leakage, faulty should reach 1111 plug (F) hole threads with
located in side of pump reservoir. Oil pressure relief valves or check valves. outboard motor In a vertical position. Do
level should reach fill plug hole threads If electric motor and pump assembly is not run pump without 0111" reservoir.
SERVICE MANUAL Suzuki DT55 & DT65 (After 1984)

SUZUKI DT55 AND DT65

(After 1984)

CONDENSED SERVICE DATA

NOTE: Metric fasteners are used throughout outboard motor.

TUNE·UP TIGHTENING TORQUES

Hp/rpm: Cylinder Head Cover ........................ 8-12N·m
DT55 •...•..•...•..•..•..•...•..•.... 5514800·5500 (6·9 ft.-Ibs.)
DT65 ......................•...•....• 65/4800-5500 Cylinder Head ................. _.. _........ 20·26 N· m
Bore ........................................ 73mm (14-19 ft. ·lbs.)
(2.9 in.) Crankcase:
Stroke ....................... , .. , ........... 71 mm 6mm ................................... 8·12N·m
(2.8 in.) (6-9 ftAbs.)
Number of Cylinders ................. , ............. 3 lOmm ...................... .. . . .46054N·m
Displacement ................................. 891 cc (34·39 ft.-lbs.)
(54.4 cu. in.) ExhaustCover ........................... , .S·ION·m
Spark Plug: (607ft .•lbs.)
NGK ....................................... B8HS IIlywheel Nut ................... , ....... 200·210 N'm
Electrode Gap: (145-152 ft.·lbs.)
Prior to 1986 .. , ... , .... 0.9·1.0 mm {'",arease Pinion Xu! .. , .. , .. , ....... , .. , .. ,30-40 N'm
(0.035·0.040 in.) (22-29 ft.·lbs.)
After 1985 .... , , , , , , , , , , . , . , . , ...... 0.8·0,9 mm Propeller Shaft Nut ........................ 50-60 N' m
(0.031·0.035 in.) (36·44 ft.-Ibs.)
Ignition Type ............................ Breakerless Standard Screws:
Carburetor lI-lake ............................. Mikuni Unmarked or Marked "4"
5 mm ........ , ........... , ... ' .. ' ..... ' .2·4 N'm
SIZES-CLEARANCES (2-3 flAbs.)
Piston Ring End Gap ....................... 0.2·0.4 mm 6mm .................................. .4·7N·m
(0.008·0.016 in.) (3·5 it. .Ibs.)
Piston Pin Diameter ................. 19.995·20.000 mm 8mm, .......... , .. , .................. 10·l6N·m
(0.7872·0.7874 in.) (7-12ft.·lbs.)
Piston Pin Bore Diameter. . . . .. 19,998-20.006 mm 10mm .. , ........... , .................. 22-35N·m
(0.7873·0.7876 in.) (16·26 ftAbs.)
Piston-to-Cylinder Clearance: Stainless Steel
Prior to 1986 ' , ............... , ... 0.112-0.127 mm 5mm ................................... 2·4N·m
(0.0044·0.0050 in.) (2·3 ft. -100.)
After 1985 .................. ,"" ,0.099-0.114 mm 6mm ....... , ............... , .. , ..... , .6·l0N·m
(0.0039-0.0045 in.) (5-7 ft.-Ibs.)
Standard Piston Diameter, . . ., .72.893-72.908 mm 8mm ......................... , ....... 15·20N·m
(2.8698·2.8703 in.) (11·15 ft.·lbs.)
Cylinder Bore Diameter ... , , .73.000·73.015 mm lOmm ...................... , ......... 34·41 N'm
(2.8740·2.8746 in.) (25-30 ft. -lbs.)
Max. Cylinder Bore Wear ................ ,0,10 mm !\-larked "7" or SAE Grade 5
(0.0039 in.) 5mm ................................... 3·6N·m
Max. Crankshaft Runout at ~Iain (2-5 ft.·lbs.)
Bearing Journal ........................... 0.05 mm 6mm .................................. 8·12N·m
(0.002 in.) (6·9 ft.·lbs.)
Max. Connecting Rod Small End Side Bmm . ................... ............. IB-2BN·m
Shake ..................................... 5.0 mm (13-20ft.·lbs.)
(0.20 in.) lOmm .... , ........................... 40·60N·m
(29·44ft.-Ibs.)
Suzuki DT55 & DT65 (After 1984) OUTBOARD MOTOR

WBRICATION models and #155 on DT65 models after

1988.
The power head is lubricated by oil Standard pilot jet (2) size for normal
mixed with the fuel. All models are operation is #75 on IIT55 models prior
eqnipped with oil iI\jection. 'The recom-- to 1989, #77.5 on DT55 models after
mended oil is Suzuki Outboard Motor Oil 1988, #77.5 on DT65 models prior to
or a suitable equivalent .'IMMA certified 1989 and #80 on DT65 models after
TC-WII engine oiL The recommended 198B.
fuel is unleaded gasoline with a mini- Th check fioat level, remove float bowl
mum pump octane rating of 85. During and invert. carburetor. Distance (D-Fig,
break-in period (first 15 hours of oper- 8Z15-:3) between main jet and bottom of
ation on models prior to 1987_ or first l() float should be 10-12 mm (0.39-0.47 in.)
hours on later models), mix a recom~ on DT55 models and 17-19 mm (0.67-0.75
mended oil with fuel at a 50: 1 ratio and in.) on DT65 models. Carefully bend
use in combinatjon with the normal oil tang (T) on fioat lever to adjust fioat
injection system, Switch to straight level.
gasoline in the fuel tank after break·in 'lb t>ynchronize carburetor throttle
period. V'alves, first detach rod between throt-
The lower unit gears and bearings are tle shaft lever on middle carburetor and
lubricated by oil contained jn the gear~ throttle control lever. Loosen screw or
C(L<;e. The recommended oil is Suzuki screws (Ill-Fig. 8Z15-1) on top and bot-
Outboard Motor Gear Oil or a good qual- tom carburetors, Throttle lever return
ity SAE 90 hypoid gear oiL GearcaBe ca- spring pressure should cause respectIve
pacity is approximately 650 mL (22 ozs.). throttle valve to close. Visually verify all
Gear oil should be drained and refilled throttle valves are closed! then retight-
after the first 10 hours of operation and en screw or screws (16) un top and bot-
Fig. SZ15-1-Explod8d view of Mlkunl car- every 50 houI'S thereafter. Reinstall vent tom carburetors. Reconnect rod be-
buretor typlC,J of all models. and fiU plugs securely, using a new gas- tween throttle shaft lever on center-
L Body l( Nllildle ket if necessary. After operdting for a carburetor and throttle control lever,
2. Pf,ot jet 10. Main jet
3, Sptm~ 1), Float short time, recheck oil level and refill if then verify synchronization of throttle
4. Pilot a,r scn'W 12, Pin
5. Gasket 13, Float howl
necessary. valves between all three carburetors,
6. Main nozzle 14. spr.ng
7. Gasket 15. Drain plug
8, Seat If•. &ti'W SPEED CONTROL LINKAGE. 'The
FUEL SYSTEM throttle valves of all three carburetors
must be properly synchronized as out-
CARBURETOR. lvlikuni type BV82-24 lined in the CARBURETOR section. On
carburetors are used on DT55 models models prior to 1989, a tbrottle valve
and Mikuni type BV· 40-32 carburetors switch assembly 18 used to register mid-
are used on DT65 models. Three carbu- dle carburetor throttle valve position.
retors are used. Refer to Fig, SZ15-1 for An idle switch and an acceleration
exploded view. Initial setting of pilot air switch make up throttle position switch
SCrew (4) from a lightly seated position assembly. Each switch has a roller
should be Ills to 15 / 8 turns on DT55 mounted on a lever that contacts the
models prior to 1986, I'/! to 2 turns on throttle shaft cam mounted on the mid-
I1I'65 models prior to 1986 and 11/4 to 13/4 dle carburetor, As the cam is rotated,
turns on all models after 1985_ Final car- the lever on each switch activates a
buretor adjustment shOUld be per- plunger, tnus sending an electrical sig-
formed with engine at normal operat- nal to the cm module by which the ig-
ing temperature and running in forward nition timing is altered to match throt-
gear. Adjust idle speed control knob (1- tle valve opening. When the throttle
FIg. sn5-2--AdJust Idle $peed control knob (/) to Fig_ SZI5-2) so engine idles at 650-700 valve is fully closed, the idle switch is
set engine Idle BpBfld. Note that em models alter rpm in forward gear. .'Iote that idle turned OK and the acceleration switch
1988, Idl. 8pHd control switch Is located on low-
er engine cover. speed control switch is located in the is turned OFF. When the throttle valve
lower engine cover on late modets. Each is opened, the idle switch is turned OFF
position of the idle speed switch and the acceleration switch is turned
changes idle speed approximately 50 ON.
rpm by changing ignition timing from
eight degrees ATDC (slow) to TDC (fast). NOTE: Throttle shalt cam used on Model
A<ljust pilot air screw (4-Fig_ SZI5-1) so 0155 differs from throttle shall cam used on
engine idles smoothly and will acceler- Model OT65, Backside 01 throttle shalt com
ate cleanly without hesitation. If neces- is Identified by a "B" on D155 models and
sary, readjust idle speed switch so en- by an "A" on OT65 models. Make sure cor-
gine idles within 650-700 rpm. rect cam Is used.
Main fuel metering is controlled by
main jet (10). Standard main jet size for On models after 1988, a throttle
Fig. SZ1$-3-Dlstsnce (DJ lor correct flo" ,• .",
normal operation is #117.5 on DT55 valve sensor that varies output voltage
should b.11·12 mm m.43·(J.47In.j OIl 0155 mod· models prior to 1989, #120 on DTS5 according to throttle valve position is
els and 17·19 mm 10.67·0.75 in.) o.n DT6S modfUs. models after 1988, #147.5 on DT65 used in place of the on/off type switch
Send ,ank (T) on float lever to adjust. models prior to 1988, #150 on W88 DT65 used on earlier models, The throttle po-
SERVICE MANUAL Suzuki DT55 & DT65 (After 1984)
sidon sensor is mounted to the center seconds or when no air bubbles are NOTE: Oil pump used on OT55 models is
carburetor and directly engages the car· noticed, close air bleed screw (A) and identified by blue pelnt on top cover of pump
buretor throttle shaft. The COl module reconnect oil supply line to oil tank assembly. 011 pump used on DT65 models
uses information from the throttle valve outlet. Is not painted.
sensor and the gear counter coil to de~
termine the optimum ignition timing for CHECKING OIL PUMP OUTPUT.
all throttle openin~'. Refer to the IGNI· Start engine and allow to warm·up for
TION section for testing and adjusting approximately five minutes, then stop
procedures. engine. Diseonnect oil pump control rod
(o-Fig. SZI5-6) from bottom carburetor
throttle shaft lever. Detach oil supply
REED VALVES. The inlet reed line at oil tank outlet and plug oil tank
valves (Fig. SZ15-4) are located on a outlet. Connect oil gage 099O!}.21602 to
reed plate between intake manifold and oil supply line. Fill oil gage with a ree· 3
crankcase. Each cylinder is fitted with a ommended engine oil until even with an
reed plate that contains two reed valve upper reference mark. Bleed alr from
assemblies. The reed petals should seat system as previously outlined, then re-
very lightly against the reed plate fill oil gage to an upper reference mark. FIg. SZ1f.4-Exploded "aw ot intake manifold
throughout their entire length with the With oil pump control rod (5) in released and rHd NIH 4I'S-sembly.
least possible tension. Tip of reed petal position, start engine and maintain en- 1. Intake IT.anifo:d a Rffll petals
gine speed at 1500 rpm. Allow engine 2. Rf.<!d ulatt' 4. Reed stop
must not stand open more than 0.2 mm
(0.008 in.) from contact surface. Reed to run for five minutes. After five
stop opening should be 7.6·8.0 mm minutes, stop engine and note oil gage.
(0.30-0.31 in.). Oil consumption at 1500 rpm in five
Renew reeds if petals are broken, minutes should be 2.3-3.1 mL (0.078-
cracked, warped, rusted or bent. Never 0.105 fl. oz.) on DT55 models prior 10
attempt to bend a reed petal or to 1986,2.0-3.2 mL (0.068-0.108 fl. oz.) on
straighten a damaged reed. Never in- DT65 models prior to 1986 and 1.9-3.2
stall a bent or damaged reed. Seating mL (0.064-0.108 fl. 0'.) on all models af·
surface of reed plate should be smooth ter 1985.
and flat. When installing reeds or reed Th check maximum oi~pump output,
stop, make sure that petals are centered repeat previous procedure except, hold
over the inlet holes in reed plate, and oil pump control rod (5) in the fully open
that the reed stops are centered over position. Start engine and maintaln 1500
reed petals. Apply Thread Lock "1342" rpm for two minutes. Maximum oil
or a suitable equivalent to threads of pump output at 1500 rpm in two
reed stop serews prior to installation. minutes should be 3.4-5.1 mL (0.115-
0.172 fl. oz.) on DT55 models and 4.0-5.9
FUEL PUMP. A diaphragm type fuel mL (0.135-0.199 fl. oz.) on DT65 models.
pump is mounted on the side of power
head cylmder block and is actuated by NOTE: 011 pump output may vary due to
pressure and vacuum pulsations from t....tlng ermr and ambl.nt t.mperatu..... Re'
the engine crankcase. Refer to Fig. peat test th.... or four tlme$ and determIne Fig, SZ15·$-Expl0d6d vi,w of dJ.phragm type
SZ15·5 for exploded view of fuel pump average oulput. ' fuel pump and I.,." flltor nnmbll...
assembly. I. COVIU'
2. ('oaskrt 7. Filter ba.;w
Defective or questionable parts should If oil pump output is not within the 3. Bodv 8. {'.ask'ft
be renewod. Diaphragm shOUld be specified limits, oil pump should be 4, DiaPhragm 9, "0" fbI!:
5_ IOPer platt' 10. Fij~r «<'men!
renewed if air leaks or cracks are found, renewed. S. Gaskott 11, Cup
or if deterioration is evident.

FUEL FILTER. Fuel filter (7

through 11- Fig. SZ15-5) is mounted on
the side of power head cylinder block.
Filter should be disassembled and
cleaned after every 50 hours of use. 1 0,.•.-6
Renew "0" ring (9) if required. \.:,i
,
Fig. SZ15-8-Exptoded vI.w A
01 011 In/Htion pump and
a
OIL INJECTION "".t~ component••

BLEEDING PUMP. To bleed

trapped air from oil supply line or pump,
first make sure outboard motor is in
A, Air bleed !iCl'(IW
1. Pump tlSSy.
2. G!lSket
3. Driven goor
4. Retainer
5. Control Md
J
upright position. Detach supply line 6. Cheek valve
from oil tank and plug oil tank outlet.
Open oil pump air bleed screw (A - Fig.
SZ15·6) three or four turns. Hold oil
filter level with outlet side on top. Pour
oil through oil supply line until oil seeps
out around screw threads. After five
Suzuki DT55 & DT65 (After 1984) OUTBOARD MOTOR
IGNITION show 190-270 ohms. Leave tester lead neet spark plug wires from coils. Th test
connected to green wire connector and primary windings, connect tester 00-
A capacitor discharge ignition (eDl) attach remaining tester lead to coil's hveen the following wires: Number 1
system is used, If engine malfunction is core, Tester should show an infinite coil-orange wire and black wire; num-
noted and the ignition system is suspect- reading, ber 2 coil-blue wire and black wire;
ed, make sure the spark plugs and all number 3 coil-gray wire and black
eleetrical wiring are in good condition PIJLSER COIL, 'Three pulseI' coils are wire. Primary winding resistance on all
and all electrical connections are tight used, Unplug wires at connectors lead- coils should be 0.5-0.8 ohm on models
before trouble·shooting the CD ignition ing from pulseI' coils. Attach one tester prior to 1988 and O.I.().3 ohm on models
system, lead to black ground wire and remain· after 1987. Renew coil(s) if primary reo
The standard spark plug is NGK B8HS ing tester lead to connet'tor leading to sistance is not as specified.
with an electrode gap of 0,9·LO mm pulser coil. Thster should show 170-250 Th test secondary windings, attach
(0,035.(),Q39 in,) on models prior to 1986 ohms. Repeat test for each pulser coil, one tester lead to each spark plug wire
and 0,8·0,9 mm (0,031·0,035 in,) on Disconnect tester leads and attach one terminal and remaining tester lead to
models after 1985, tester lead to mounting ear on pulser orange wire on number 1 coil, blue wire
coil and remaining tester lead to con· on number 2 coil and gray ",ire on num-
TESTING CDI SYSTEM AND BAT- nector leading to pulseI' coil, Thster ber 3 coil, Renew coil(s) if resistance is
TERY CHARGING COIL. Refer to Figs, should show an infinite reading, not within 4700-7000 ohms on models
8215·7, SZ15-8, SZ15·9 andSZ15·1O, and prior to 1988, 1700-2900 ohms on 1988
the follOwing sections for testing CD! BATTERY CHARGING COIL, Unplug models and 6000-9000 ohms on 1989
components and battery charging coil, wires at connectors leading from bat- models,
Use Suzuki Pocket Thster 09900-25002 tery charging coil. Att.ach one tester
or a suitable ohmmeter unless otherni.o;e l(>,ad to red wire connector and remain· COUNTER COIL, On models after
stated to test components. Renew the ing tester lead to connector of yellow 1988, a gear counter coil is mounted
component or components if not with- wire. Tester should show 0,2·0,6 ohms, along outer periphery of flywheel ring
in the specified limits_ Leave tester lead connected to red "ire gear. The CD! module process informa-
connector and attach remaining tester tion from the gear counter coil in com~
CONDENSER CHARGING COIL, Cn- lead to coil's core. Thster should show bination with the throttle valve sensor
plug wires at connectors leading from an infinite reading, to determine ignition timing. The gear
condenser charging coiL Attach one counter coil can be identified by a HC"
tester lead to green wire connector and IGNITION COILS. Three ignition coils stamped in side of coB. 1b test counter
remaining tester lead to connector of are used, Separate wires at connectors coil, separate connector leading from
black wire with red tracer, Thster should leading from ignition coils and discon· counter coil. Connect tester leads to or-
ange wire with green tracer and black
wire with green tracer. Counter coil can
be considered acceptable if resistance
is within 170·250 ohms, Air gap between
counter coil and flywheel ring gear
teeth should be 0,5 mm (0,020 in.),

NOTE: Air gap between eounler coli and

lIywheel ring gear teeth mU$t be sel to ex·
FIg. SZ/5'7-v/ow Identifying
loc.tlon of puis., coils (P), aclly 0.5 mm (0.020 In.) lor pro""r operation
",,_rchafll" coli (Cland of outboard motor. Make sure aIr gap Is
battery ch.rge coli (8) on properly adJu.ted.
mod,,1s prior to 1989. Refer to
Fig. SZ15~8 for dlag18m of Ig~
n/tlon ,ystem on models .fler
1988, THROTI'LE PLATE SWITCH (Models
Prior to 1989), Unplug wires at connec-
tors leading from throttle plate switeh
assembly, Attach one tester lead to
black wire connector and remaining
tester lead to connector of light green
wire with red tracer. With lever on idle
switeh (I-Fig. SZI5-11) depressed, tester
should show infinite resistance. With le-
ver released, tester should show zero
ohm. Leave the tester lead attached to
Fig, SZ/5-8-D/agram (t/ 19ni-
tion system compommts on the black wire connector and connect
_ sftor 1988, remaining tester lead to connector of
L COl mooul£ brown wire with yellow tracer to test
2" PulsEr eoils
3. Battery charging acceleration switch (A), Previous t.est
con procedure should be used and previous
4" Con4£l'\ser e}targi:n8
ron test results should be obtained,
5. Gear counter em!
6. Idle IIpNd switth
i" Ignition c!JIh THROTTLE VALVE SENSOR (Models
S" Throttle tmfOition after 1988), Th test throttle valve sen·
sensor
9. Coolant temperature sor (5-FiS. SZ15·12), remove alignment
IIwltch pin attached to black cover over throt-
 SERVICE MANUAL Suzuki OT55 & OT65 (After 1984)
tie valve sensor and insert alignment pin NOTE: The manufacturer mcotnl"f'lends u. should now he 2.6 volts or more. Do not
(1) into hole in sensor and sensor earn ing only a nonmetallic screwdriver to turn attempt to adjust wide-open throttle
(3). Align slot in carn (3) with throttle sensor adjusting screw or sensor voltmeter sensor voltage. If wide-open throttle
sbaft. Disconnect throttle valve sensor reading may not be valid. II metal screw- sensor voltage is not 2.6 volts or higher,
connector (4). Connect test harness driver must be used, remO\te screwdriver renew sensor.
09930-89530 or suitable jumper wires to from area of throttle valve senser after ad.. If throttle valve sensor is removed or
a battery as shown in Fig. SZ15-12. Bat- justment to prevent erroneous voltmeter renewed, install as follows: Insert align-
tery voltage must be nine volts or more. reeding. ment pin (1) as shown to align cam and
Connect positive ( +) lead of a suitable sensor shaft. Align slot in sensor cam
DIGITAL voltmeter to test harness light Ir sensor output voltage at closed with carburetor throttle shaft and in-
green wire with red tracer and volt- throttle is below 0.45 volt. idle speed ig' stail sensor on carburetor. Lightly tight-
meter negative ( ~ ) lead to battory nega- nition timing will be fixed at 5 degrees en mounting screws {7J to allow for ad-
tive ( ~ ) terminal as shown. With throt- BTDC; idle speed switch will he inoper- justment of sensor position on
tle fully closed. voltmeter reading ative. If sensor output voltage at closed carburetor. Connect test harness and
should be 0,45-0.55 volt. If not. remove throttle is above 0.55 volt. ignition tim- digital voltmeter as shown in Fig. SZ15-
ruhber cap (2) and tum a<\iustment ing at idle speed will be incorrect. Re- 12. Make sure battery voltage is nine
screw (under cap) as necessary to obtain rer to IDLE SPEED SWITCH section. volts or more. Sensor output voltage at
the correct voltage reading. Note that Once the specified voltage reading is dosed throttle should be 0.45-0.55 volt.
turning adjustment screw cIock;"ise ,,111 obtained at closed throttle, remove If not, move position of sensor on car-
increase voltage and counterclockwise alignment pin and open carburetor to buretor to obtain specified voltage and
will decrease voltage. wide-open throttle, Voltmeter reading securely tighten screws (7). Recheck

~,
.

(/)) 19
I
QUI
! '
y
B

t
j~

Fig. SZl5-9-wtrlng dlsgrsm typical of all model. prior to 1989. Model shown is equipped with power tnt BI1d trim system, Rfrler k> Fig. SZ'f5.fD for wiring
dlBg1'8m of 1989 models.
L ~jtiOll switcli 8. Choke lioli;>nnid 17. Thrllttle plate G. G~n Bf}'. E~k with y~ntw.' LglR Ll.i!ht green witl'.
2. (>rhHl.t & 011 9, Oil level liwitch !)witnh a.~sv. G,. Gray (""'" rOO trai*'
,. wammg 002ter
Neutralliwitch
4. Emerger,cy stvp
Hl. Spark plug,
1L ~tion enils
12. Lngwllto:r
18. COl module
19. Idle speed cmlUnJ
liwitc-h
Lt.BL
O.
P
Lght
Om_
Pink
hlue BlIR. Blue with
Imm
~

Br!W, Brown with ?'hire

RIB. P.t'd with black

""'"
RIW. Red with whtw
switch !Wl1$Uf 20. "''"''"Y mowr R Rffi tracer ,-,
5. P'JWer tilt & tt'.m
l' Stator plate assy,
Ref'tifier
21. Start.er
relay
W.
Y.
White
Yellow
Btl);' . Brown with
}~l!owL~r
WIS, Whitf' with blaek

I
switch
6. P<JWer tilt & trim "
15. lAw oil warning 22, Start.eT motor BlR Black with red G/Y, Green with yellQW
("""
WtR. Wh,t;:! with rt!d
"""',
~w,
7" Puw;;r tilt & tom
mot!)!' N'lap
,.. rmwt unit
Oil warning ~t
switCh
R Black
Bl. Blue
Br, Brown
"""',
BiW. Black with white
tracer
tracer
LglB. Light grHn with
hlack tracer
Y/G. y,,!low with
(-, grH1l
Suzuki OT55 & OT65 (After 1984) OUTBOARD MOTOR
voltage after tightening screws (7) and sor la operatIng properly and correctly aJust- take for plugging or partial restriction,
if necessary, remove cap (2) and turn ad- ed. Reier to THROTTLE VALVE SENSOR then if not corrected remove gearcase
j

justment screw to obtain 0.45-0.55 volt. aectlon. as outlined in tllc appropriate section
Be sure to reinstall cap (2). After obtain- and check condition of the water pump,
ing the correct voltage at closed throt- Note that each position of idle speed 'water pas.<iages and sealing surfaces.
tIel remove alignment pin and check switch should change ignition timing When water pump is disassembled,
st'nsuf output voltage at wide-open two degrees and change engine idle check condition of impeller (4-Fig.
throttle. Voltage should be 2.6 volts or speed approximately 50 rpm. If timing SZl5-13) and plate (5) for excessive wear.
higher. Do not attempt to a<\just wide- and engine rpm do not change with Turn drive shaft clockwise (viewed from
open throttle voltage. each switch position, idle speed switch top) while placing pump housing (2)
may be defective.
IDLE SPEED SWI'OCH. Idle speed
switeh (o-Fig. SZ15-8) malfunction can CD! MODULE. Use Suzuki tool 09930-
be quickly verified by checking ignition 99810 or 09930·99830 with test harness
timing and engine rpm while switching 09930-89450 to test CD! module.
position of idle speed switch. Make sure
engine is at idle speed when checking COOLING SYSTEM
timing.
WATER PUMP. A rubber impeller
NOTE: A defectIve or maladjusted throt- type water pump is mounted between
Ue valve eenaor may cause Idle speed switch the drive shaft housing and gearcase. A
to be Inoperative or Ignition timing at Idle key in the drive shaft is used to turn the
speed to be Incorrect. Prior to teatlng Idle pump impeller. If cooling system prob- Fig. SZf5-11-_ switch (II snd s _
speed switch, ma.... sure throttle valve ..n- tems are encountered. check water in- switch (A) USBd on modela prier to 1989.

Pig. SZ15~1()-Wltlng dhtgrttm typical of fTtOdHIlIftsr 1988 equipped with remote control and power tilt and trim.

Il ma~k Q,. firay o:¥, G(('f'fl with. IVi'. Red with yclww mill'. mUte with nod LtG Light gr~n
G Green 0, Orangi' yellow tt'l'ITer tracer tracer Ltllt Light bhle
p Pink U-'G Black With grel'n It'll, Red with black W'n. Whlte with hlark BlfW, Him] with white Fil3l Pink witl! blue
R uacer tracer
w. """
White
Y. Yellow
tracer
tlilt Hlw::k with hJd
traclPr
RIG, with green
tracer
WiN. White with red
tracer
Or,'W, HroWfl with
wiuw tracer
traeer
Pr/W. Puq:;l(' with
white tr~r
ilL Blue IJiW. Black with whue R'W, Red with white ylC Yf'llow wlth Dr/G, OrallSC with Lt(i'R. Light gr~n with
Brown green tnwer green tracer
"' trne('~

"""'" red trac"r

SERVICE MANUAL Suzuki DT55 & DT65 (After 1984)
over impeller: Avoid turning drive shaft POWER HEAD connect fuel supply line from connec-
in opposite direction after water pump wr in bottom engine cover. Disconnect
is reassembled, REMOVE AND REINSTALL. To re- shift and throttle linkage. Remove pilot
move the power head, first remove en- discharge water hose (ll-Fig. SZ15·14j
THERIIlOSTAT, A thermostat (i-Fig, gine cover, Disconnect wiring to oil from fitting in bottom engine cover. Re-
SZ15·14) is used to regulate engine opel" tank. Remove oil supply line from oil move cover to expose power head re-
ating temperature, The thermostat tank outlet and plug outleL Remove taining screws. Remove the nine screws
should start to open within the temper· sc-rews to withdraw oil tank. On models and lift power head assembly with reo
ature range of 40°·44° C (104°-111' F) equipped \"'lth power tilt and trim, re- lated engine components. from lower
on models prior to 1986 and 48°·52° C move relays from side of cylinder head. unit assembly,
(118°·126° F) on models after 1985, Remove CDI module. Detach wiring Before reinstalling power head, check
Thermostat can be removed for inspec- from electric starter and starter relay condition of drive shaft ""als (25-Fig,
tion or renewal after removing ther- that will interfere with power head SZ15-15). If renewal of seals is required,
mostat housing (9). removal. Remove engine flywheeL Dis- it is necessary to separate crankcase
(I-Fig, SZ15·14j from cylinder block (2)
as outlined in the appropriate following
paragraphs, Apply a suitable water-
6 5 2 7 resistant grease to Up portion of seal.;;.
and install seals into seal housing (26-
Fig, SZI5·15) with open side of seals to-
3 ward lower unit. Make certain drive
shaft splines are dean, then coat splines
Test Harness with a light coat of wat.er~resistant
09930-89530 grease. AppJy a suitable sealer to mat~
ing surfaces of power head and lower
unit and install a new gaskeL Coat area
of power head ret.aining screws acljarent
to screw heads with silicone sealer,
Tight.en the nine power head retaining
Lt G/R
screws to 18·28 N'm (13-20 ftAbsllle·
mainder of reinstallation is the revm'Sc
of removal procedure.
01-oi ta 1
Vo1t1"le':.er
DISASSEMBLY. Disassembly and in·
spection can be accomplished in the fol~
Fig. SZtSNt2-Refer to test for throttle vslve sensor testing and instafJatkm procedure, lowing manner. Remove ignition CQils,
I Ahgnmem pm
Cnp (adj\lstmf'nt
strew
, Cfmne~t{lr
5 Thrnttl" valvp
6 Carburet"r
7 Mounting ""r':'w
B:R. Black with red
trae",r
LtG.R. Light green witk
electric starter and bracket, and idle
speed adjusting switch and bracket. Re~
3 ~R<;or ('am sonor a.'I~y. Il mack red tr.a(er move throttle control arm and lever and

Fig. SZ15-14-ExpIoded view

of cylinder blOCk and crank·
2 case MSembly.
1. Crankt'aru: half
Z. Cylinder hlock
3. Cylinri(>c head gusket
4. Cylinder head
5. C'ylil1(Wr head {';tw'!" gm;kt't
5. Ci."lindi>r hud (w.er
4 7. 1'fwrn·""tat
$,. Gasse:
ft TrermoSltat huv;ing:
5 10. C(l<)ling" v.'at('r S('!)!<"r
11. PLitt dlschal"g(" wat"! hi,,,,,,

Fig. SZ1S..13-Explodttd view of water pump

assembly,
1, Wat.;>r tube 4. lrr.p€:lcr
2, Pump r.ousing S Plate
3, Key S. Gasket
Suzuki DT55 & DT65 (After 1984) OUTBOARD MOTOR
clutch control arm, Remove stator plate mostat, Remove spark plugs, cylinder sequence shown in Fig. SZ15-16, tight-
assembly. Remove oil ir\}ection pump head cover and cylinder head, then en the 6 mm crankcase screws to 8-12
(I~Fig. SZ15-6), retainer (4) and driven clean carbon from comhustion chamber N'm (71-106 in.-lbs.J and the JO mm
gear (3), Remove fuel pump and fuel fil- and any foreign material accumulation screws to 46-54 N'm (34·39 ft.-lb •. ).
ter assembly. Remove carburetors and in wa.ter passages. Unscrew crankcase Tighten cylinder head screws in se-
electric choke solenoid, Remove intake retaining screw'S and separate crankcase quence shown in Fig. SZ15-17 to 20-26
manifolds and reed valve assemblies. (1~Fig. SZ15-14) from cylinder block (2). N'm (14-19 ft.-lbs.).
Remove outer and inner exhaust covers, Crankshaft and piston assembly can
Remove cooling water sensor, Remove now be removed from cylinder block. RIXGS, PISTONS AND CYLINDERS.
thermostat housing and withdraw ther- Engine components are now aecessi~ The pistons are fitted "ith two piston
ble for overhaul as outlined in the ap- rings. The top piston ring is chrome plat-
propriate following paragraphs. Refer to ed. Piston rings must be installed with
the following section for assembly manufacturer's marking facing top of
procedures. piston, Rings are pinned in place to pre-
vent ring rotation. Piston ring end gap
ASSEMBLY. Refer to specific service should be 0,2-0.4 mm (0.008-0.016 in.)
sections when assembling the crank- with a maximum allowable ring end gap
shaft, connecting rod, piston and reed of 0.8 mrn (0.031 in.). Piston-to-cylinder
valves, Make sure all joint and gasket clearance should be 0.112-0.127 mm
surfaces are clean I free from nicks and (0.0044-0.0050 in.) on models prior to
burrs and hardened cement or carbon. 1986 and 0.099-0.114 mm (0.0039-0.0045
Whenever the power head is disas- in.) on models after 1985. Pistons and
sembled, it is recommended that all gas- rings are available in standard size as
ket surfaees and mating surfaees with- well as 0.25 mm (0.010 in.) and 0.50 mm
out gaskets be carefully checked for (0.020 in.) oversizes. Cylinder should be
nicks, burrs and warped surfaces that bored oversize if cylinder is out-of-
might interfere witb a tight seaL Cylin- round, tapered or worn in excess of 0.10
dcr head, head end of cylinder block mm (0.004 in.). Install piston on con-
and some mating surfaces of manifold necting rod 50 arrow on piston crown
and crankcase should be checked on a will face toward exhaust pert when pis-
surf""e plate and lapped if necessary to ton is installed.
provide a smooth surface. Do not re w

move any more metal than is neeessary. CONNECTING RODS, BEARINGS

When r"assembling pewer head, lubri- AND CRA.c'"'KSHAFI'. Connecting rods,
cate aU friction and bearing surfaces bearings and crankshaft are a pressed-
with a recommended engine oiL Apply together unit. Crankshaft should be dis-
a suitable high temperature grease to lip assembled ONLY by experienced serv-
portion of cranksbaft seal. Apply a ice personnel using the proper service
suitable water~resistant grease to lip equipment.
portion of drive shaft seals and instaU Caged roller bearing is used at top of
Fig. SZ15-15-ExplocJed view ()t crankshah seals into seal housing (26~Fig. SZ15-15) crankshaft and caged ball bearings are
ll$semb/y
13, Oil injedion pump
with open side facing lower unit. used at t.he center and bottom of crank~
L Sea; drive gear Place thrust rings (28) into cylinder shaft.. Determine rod bearing wear by
2, R"l:er hear.r:g 14. Key block, then install crankshaft assembly. measuring connecting rod small end
3. trpper cr.rnkl;haft 1[" rl-rust w",«hen
Hi. Crank pin Make certain main bearing locating pins
4. ~hearir,~ 17. C',nlletting TiKI
5. Lahyrinth ~t1l.1 JR. Needle he»'r\ng
engage notches in cylinder block.
6. l'Ihl<ile uanbha(t 19, Piston \.lin dips Flanges of labyrinth seals (5 and 9), seal 18
upper half
7. Mkldle <crankshaft
20. Piston pin
21. Thrust washers (24) and housing (26) must fit securely 14
lnW€T half 22. N"'E:'dl~ \mring in grooves of cylinder block. Apply a
8. Ball (lCatinK 23, Snap ring
9. Labytinth seal 24. Seal coat of Suzuki Bond No.4, or a suitable
sealer to mating surfaces of crankcase
10lS~~~
10. Lower crankshaft 25. Senls

11. a",
assy.
ho,n..
12. Thrust washera
26. Housing
27" Seal
28. Thrust ring~
and cylinder block and position crank-
case on cylinder block. Using tightening
6-;..:::r"\\
1_,,-,
J-;::iiOS::::::;~
5--+4~~~~
Fig. SZ1IMs.-:Tlgh'en .rW·
ease screws In sequenca
shewn. Tighten 6 mm screws
8 .-.."""':0--..
t. 8-12: N'm (71-106 lo.-lbs.)
and 10 mm $Crews to 46·54 12
N.". (34·39It.-lbs,).

Fig_ SZ15-17-11ghten cylinder heed screws in u-

quence shown to 20-26 N'm (14·19 ft.~Ibs..).
Suzuki DT55 & DT65 (After 1984) OUTBOARD MOTOR
separate gearcase assembly from drive ler shaft. Unscrew two screws retaining POWER TILT AND TRIM
shaft housing. Remove water pump as- gearcase end cap (49-Fig, SZ15-20),
sembly (Fig SZI5-13), Remove propeller then attach a suitable puller to propel- Some models are equipped witb a
with related components from propel- ler shaft (43) and withdraw propeller hydraulically actuated power tilt and
shaft assembly with gearcase end cap trim system. An oil pump driven by a re-
(49), Unscrew pinion nut (32) and re- versible electric motor provides oil pres-
move pinion gear (29), then extract for- sure. A rocker control switch deter-
ward gear (35). Drive shaft (19) and re- mines motor and pump rotation,
lated components can be withdrawn retracting or extending tilt and trhn
from gearcase after removal of bearing cylinders, The pump is equipped with a
housing (15), manual release valve (M-Fig, SZI5-22).
Inspect gears for wear on teeth and on Rotating manual release valve (M) two
engagement dogs. Inspect dog clutch turns counterclockwise enables manu~
(37) for wear on engagement surfaces, al movement of trim and tilt cylinders
Inspect shafts for wear on splines and if electric motor malfunctions.
on friction surfaces of gears and oil Recommended power trim!tilt oil on
seals. Check shift cam (12) and shift pin models prior to 1987 is SAE 20, SAE
(39) for excessive wear, Check condition IOW-30 or SAE IOW-40 motor oil, or
of shift spring (42). Spring free length Dexron automatic transmission fluid.
should be 73 mm (2.9 in,). All seals and Recommended oil on models after 1986
"0" rings should be renewed when unit is Dexron II or equivalent. Do not run
is reassembled, pump without oil in reservoir, Oil level
Backlash between pinion gear (29) should be even with hottom of fill plug
and drive gears (35 and 45) should be hole, Power tilt system should be cycled
0.1-0,2 mm (0,004-0.008 in,) and is ad- several times and oil level rechecked if
justed by varying thickness of shims (34 system has been drained or lost a large
and 46). Propeller shaft end play should amount of oiL
be 0.2-0.4 mm (O.OOS·{l016 in.) and is ad-
! justed by increasing or decreasing the NOTE: On models prior to 1987, outboard
FIg. SZ15-21-Explohd view of " " _ trIm/!/U thickness of thrust washer (44). Reas- molor must be In lull down posnlon when
.nec:trlc motor and pump usembly USN on semble gearcase by reversing disassem~ checking oil level. On models after 1986, mo-
mod.,J. prior to ,.87. Lar"r models .,.. ,Imlhtr.
\. End cap
bly procedure while noting the follow- tor must be tilted fully up to check 011 level.
2. Gasket 6, ~~r\lt>ir ing: Install dog clutch (37) on propeller
3, Ele('tric motor assy 7, "O~ ring shaft (43) so "REV" marked side is to- If power trim/tilt malfunction occurs,
4. Gm,ket 8. Pump & valve
5, rill plug hndy nssy, ward reverse gear (45), Tight.en pinion make sure malfunction is not due to wir~
nut (32) to 30-40 N'm (21-29 ft,-lbs,), Ap- ing, connections or electric motor fail-
ply water-resistant grease to "0" ring ure. To check oil pressure! connect a
(48), Apply silicone sealer to gearcase 34.5 MPa. (5000 psi) pressure gage to port
and bearing housing (15) mating sur- (I-Fig, SZI5-22) on pump and operate
faces and to bearing housing and drive pump in the UP direction, Hydraulic oil
shaft housing mating surfaces. Coat re- pressure at port (1) should be within
taining cap screws ru:ijacent to cap screw 13,000-17,000 kPa. (1885-2465 psi), Con-
heads with silicone sealer. nect test gage to port (2) and operate
Engage shift shaft (2) in shift rod (3) pump in the DOWN direction. Hydrau-
eyelet and attach shift arm (I), Serure lic pressure should be within 2800-5600
with nut. Fill gearease with outboard kPa. (406-812 psi). Oil pressure less than
gear oil as outlined in LUBRICATION specified may indicate leakage, faulty
section. pressure relief valves or check valves,
The manufacturer recommends renew w

ing pump and valve body assembly to

service low pressure condition,
Fig. SZt5--22-Vlew of pump BSMmbly identifying
"'st ports (1 and 2) .nd manu", rehl... wt/ltW (MJ
on model. prior to 1987. uter mod.I, II,. similar.
R.fer to Fig. SZ15-23 to identify early and III,.
models pump ••sembl/e••

FIg, $Z'5-23-_ _lIty-

Ing ...rly (prlOT to 198T) and
I.t., (atter 1986) POWIt'
trlml1ll1 pump """"""'""

Prior to 1987 Allor 198&

SERVICE MANUAL Suzuki OT55 & OT65 (After 1984)
side-to-side movement as shown at (A- ELECTRIC STARTER propellers are used. Various propellers
Fig, SZ15-18), Nonna! movement (A) is are avallable from the manufacturer, Se-
5 mm (0,20 in,) or less, Maximum allow- Models are equipped with the electric lect a propeller to provide optimum per-
able crankshaft ronout is 0,05 mm (0,002 starter shown in Fig. SZI5-19. Disassem- formance at full throttle within the rec-
in.) measured at bearing surfaces with bly is evident after inspection of unit ommended speed range of 4800-5500
crankshaft ends supported, and reference to exploded view. Start- rpm.
When installing crankshaft, lubricate er brushes have a standard length of 16
pistons, rings, cylinders and bearings mm (0.63 in.) and should be renewed if R&R AND OVERHAUL. Refer to Fig,
with engine oil as outlined in ASSEM- worn to 11.5 mm (0.45 in.) or less. After SZ15-20 for exploded view of lower unit
BLY section. reassembly, bench test starter before in- gearcase assembly used on all models.
stalling on power head. During dlsas.'iembly, note the location of
all shims and thrust washers for refer-
LOWER UNIT ence during reassembly, Th remove gear·

"1 ,'~.'
"
PROPELLER AND DRIVE CLUTCH.
Protection for the motor is built into a
case, first unscrew plug (69) and drain
gear lubricant. Remove engine cover:
Unscrew nut retaining shift ann (1) to
"" special cushioning dutch in the propel- shaft (2), then disengage shaft (2) from
.
,"" ler hub. No a<\iustment is possible on the shift rod (3). Remove the screws secur-
,,:' propeller or clutch. Three-blade ing gearcase to drive shaft housing and

Fig. SZts-.18-MsXimum .1fcwabJ6 ~t04"

_ (A) _ 01 .en_llng rod _11_
/0 5.0 min (0,20 In.) cr 10...

Fig. SZ1fi..2t'J-ExpJoded vtsw of Iowar unit g&MCftB assembly used on IIJllhfJdels.

1. Shift nrm
2. SI-.ift shaft 17. Rearing 32. Nut 41. BeiL>1ng
3. Shilt tad 18. Thrust washer a.'1. Rearing 4S. ~O" ring
4. Dubt seal 19. Drive shaft 34. Shim 49, End cap
'.!W"""", 20. Spring 35. Fnrwaro gear 50, Needle b<:armgl>
6.. "(f' nng 21. Thrust washer 36. Thrust war;her 5L Sea]s
7. ~O~ rings 22. WruJtler 37. Dog dutch 52. Snap rir:g
S. Pin 23. Collar "'Pin 53, Spac~
9, Magnet holder 24, Snap ring 59. Shift pin 54, PJ'Xlp<!llcr
Fig. 5215w19-£XplOd&tJ "lew of eJectrJc mrttJr Ii) Mag'l\ll't 25. Nmml!? bearing 40. Spring guide 55. Sparer
motor, lL Pin 26. Seal 4 L Pin retainer 56. Tab washff
1. "C" ring 6. Throat wttSncn 12. Shift cam 27, Gearease 42. Shift spring 57. Nut
2. Stop 7 AITtIAture 13. DeWflt ball 28, Shim>. 43. PropeJler shaft 58. Cotter pin
3. Spring fL Frame 14. Spring 29. Pinkm gear 44. Thrust washer 59. Dtain plUit
4. Drive [} BI't1$h assy 15. Bearing flDUliing' 00. CHllar 4:i Reverse gear 00. Level plug
~. Frame head Ht End hoosing 16. St'Al 31. Washer 46. Shim 6L Vent p1UV
Suzuki DT55 & DT65 (After 1984) OUTBOARD MOTOR
separate gearcase assembly from drive leT shaft. Unscrew two screws retaining POWER TILT AND TRIM
shaft housing. Remove water pump as- gearcase end cap (49-Fig. SZI5-20),
sembly (Fig. SZI5-13). Remove propeller then attach a suitable puller to propel- Some models are equipped with a
with related components from propel- ler shaft (43) and withdraw propeller hydraulically actuated power tilt and
shaft assembly with gearcase end cap trim system. An oil pump driven by a re-
(49). Unscrew pinion nut (32) and re- versible electric motor provides oil pres-
move pinion gear (29), then extract for- sure. A rocker control switch deter-
ward gear (35). Drive shaft (19) and re- mines motor and pump rotation,
lated components can be withdrawn retracting or extending tilt and trim
from gearcase after removal of bearing cylinders. The pump is equipped with a
housing (15). manual release valve (M-Fig. SZI5-22).
Inspect gears for wear on teeth and on Rotating manual release valve (M) two
engagement dogs. Inspect dog clutch turns counterclockwise enables manu-
(37) for wear on engagement surfaces. al movement of trim and tilt cylinders
Inspect shafts for wear on splines and if electric motor malfunctions.
on friction surfaces of gears and oil Recommended power trim/tilt oil on
seals. Check shift cam (12) and shift pin models prior to 1987 is SAE 20, SAE
(39) for excessive wear. Check condition IOW-30 or SAE lOW-40 motor oil, or
of shift spring (42). Spring free length Dexron automatic transmission fluid.
should be 73 mm (2.9 in.). All seals and Recommended oil on models after 1986
"0" rings should be renewed when unit is Dexron II or equivalent. Do not run
is reassembled. pump without oil in reservoir. Oil level
Backlash between pinion gear (29) should be even with bottom of fill plug
and drive gears (35 and 45) should be hole. Power tilt system should be cycled
0.1-0.2 mm (0.004-0.008 in.) and is ad- several times and oil level rechecked if
justed by varying thickness of shims (34 system has been drained or lost a large
and 46). Propeller shaft end play should amount of oil.
be 0.2-0.4 mm (0.008-0.016 in.) and is ad-
justed by increasing or decreasing the NOTE: On models prior to 1987, outboard
Fig. SZ15-21-Exploded view of power IT/mit/it thickness of thrust washer (44). Reas- motor must be In full down position when
electric motor and pump assembly usect on semble gearcase by reversing disassem- checking 011 level. On models after 1986, mo-
models prior to 1987. Lster model• • re similar.
1. End cap
bly procedure while noting the follow- tor must be tilted fully up to check 011 level.
2. Gasket 6. Reservnir ing: Install dog clutch (37) on propeller
3. Electric motor ass,v. 7. "0" ring shaft (43) so "REV" marked side is to- If power trim/tilt malfunction occurs,
4. Gasket S Pump & valve
5. Fill plug bodyassy. ward reverse gear (45). Tighten pinion make sure malfunction is not due to wir-
nut (32) to 30-40 N'm (21-29 ft.-lbs.). Ap- ing, connections or electric motor fail-
ply water-resistant grease to "0" ring ure. Th check oil pressure, connect a
(48). Apply silicone sealer to gearcase 34.5 MPa (5000 psi) pressure gage to port
and bearing housing (15) mating sur- (I-Fig. SZI5-22) on pump and operate
faces and to bearing housing and drive pump in the UP direction. Hydraulic oil
shaft housing mating surfaces. Coat re- pressure at port (1) should be within
taining cap screws adjacent to cap screw 13,000-17,000 kPa (1885-2465 psi). Con-
heads with silicone sealer. nect test gage to port (2) and operate
Engage shift shaft (2) in shift rod (3) pump in the DOWN direction. Hydrau-
eyelet and attach shift arm (1). Secure lic pressure should be within 2800-5600
with nut. Fill gearcase with outboard kPa (406-812 psi). Oil pressure less than
gear oil as outlined in LUBRICATION specified may indicate leakage, faulty
section. pressure relief valves or check valves.
The manufacturer recommends renew-
ing pump and valve body assembly to
service low pressure condition.
Fig. SZ15-22-Vlew of pump assembly Identifying
test ports (1 and 2) and manua' re'.8.e wIve (M)
on models prior to 1987. Later models ere similar.
Refer to Fig. SZ1s..23 to Identify early and late
mod.l. pump assembll...

on till plug.

Fig. SZ15-23-VI.w Id.ntlfy-

Ing .arly (prior to 1987) and
I.t.r (aft.r 1986) pow.r
trlmltllt pump ....mbll.s.

PrIOr to 1987 After 1986

 SERVICE MANUAL Suzuki DT75 & DT85

SUZUKI DT75 AND DT85

CONDENSED SERVICE DATA

NOTE: Metric fasteners are used throughout outboard motor.

TUNE·UP TIGHTENING TORQUES CONT.

Hp/rpm: Cylinder Head (After 1982) .................. 46-54 N· m
DT75 ............................... . 75/4800-5500 (34-39 ft.-lbs.)
DT85 ............................... . 85/4800-5500 Crankcase:
Bore ........................................ 84mm Prior to 1983 ............................ 40-60 N· m
(3.31 in.) (29-44 ft.-lbs.)
Stroke ...................................... 72 mm After 1982 .............................. 46-54 N· m
(2.83 in.) (34-39 ft.-lbs.)
Number of Cylinders ............................... 3 Exhaust Cover ............................. 8-12 N· m
Displacement ................................ 1197 cc (6-9 ft.-lbs.)
(73.04 cu. in.) Flywheel Nut ........................... 200-210 N· m
Spark Plug: (145-152 fUbs.)
NGK ....................................... B8HS Gearcase Pinion Nut:
Electrode Gap ........................... 0.8-0.9 mm Prior to 1983 ............................ 60-70N·m
(0.031-0.035 in.) (43-50 ft.-lbs.)
Ignition Type ............................ Breakerless After 1982 .............................. 70-80 N· m
Carburetor Make ............................. Mikuni (50-58 ft.-lbs.)
Fuel:Oil Ratio ............................... 50:1' Propeller Shaft Nut ........................ 50-60 N· m
>IoAll models after 1985 and some earlier models are (36-44 ft.-lbs.)
equipped with oil injection. Standard Screws:
.Unmarked or Marked "4"
SIZES-CLEARANCES 5mm ................................... 2-4N·m
Piston Ring End Gap ....................... 0.2-0.4 mm (2-3 ft.-lbs.)
(0.008-0.016 in.) 6mm ................................... 4-7N·m
Piston Pin Diameter ................. 19.995-20.000 mm (3-5 ft.-lbs.)
(0.7872-0.7874 in.) 8mm ................................. 10-16N·m
Piston-to-Cylinder Clearance: (7-12 ft.-lbs.)
DT75 (Prior to 1987) .. ..... 0.077-0.093 mm 10mm ................................ 22-35 N·m
(0.0030-0.0037 in.) (16-26 ft.-lbs.)
DT85 (Prior to 1988) And DT75 (1987) .0.112-0.127 mm Stainless Steel
(0.0044-0.0050 in.) 5mm ................................... 2-4 N·m
All Models (1988) . . . ............. 0.135-0.165 mm (2-3 ft.-lbs.)
(0.0053-0.0065 in.) 6mm .................................. 6-10N·m
All Models (1989) .. . .............. 0.12-0.15 mm (5-7 ft.-lbs.)
(0.0047-0.0059 in.) 8mm ................................. 15-20N·m
Max. Crankshaft Runout at Main (11-15 ft.-lbs.)
Bearing Journal ........................... 0.05 mm 10mm ................................ 34-41 N·m
(0.002 in.) (25-30 ft.-lbs.)
Max. Connecting Rod Small End Marked "7" or SAE Grade 5
Side Shake ....•............................ 5.0 mm 5 mm ................................... 3-6 N·m
(0.20 in.) (2-5 ft.-lbs.)
6mm .................................. 8-12N·m
TIGHTENING TORQUES (6-9 ft.-lbs.)
Cylinder Head (Prior to 1983): 8mm ................................. 18-28N·m
6mm ................................... 8-12N·m (13-20 ft.-lbs.)
(6-9 ftAbs.) 10mm ................................ 40-60N·m
10mm ................................. 40-60N·m (29-44 ft.-lbs.)
(29-44 ftAbs.)

, WBRICATION During engine break-in (first 10 hours Recommended oil for all models is
of operation) on models equipped with Suzuki Outboard Motor Oil or an equiva-
The power head is lubricated by oil oil injection, a 50: 1 fuel and oil mixture lent NMMA certified TC-WII engine oil.
mixed with the fuel. On models with- should be used in the fuel tank in com- Recommended fuel is regular or unlead-
out oil injection, fuel:oil ratio should be bination with the oil iI\iection system to ed gasoline with a minimum pump oc-
30:1 during break-in (first 10 hours of ensure adequate power head lubrica- tane rating of 85.
operation) of a new or rebuilt engine tion. After break-in period, switch to The lower unit gears and bearings are
and 50:1 for normal service. straight gasoline in the fuel tank. lubricated by oil contained in the gear-
Suzuki DT75 & DT85 OUTBOARD MOTOR
case. Suzuki Outboard Motor Gear Oil or Idle sp....d change per each position of
a SAE 90 hypoid outboard gear oil switch.
should be used. Gearcase capadtyis ap~
proximately 700 mL (23.7 oz.) of gear oil On all models, adjust pilot air screw
and should be drained and refmed af· SO engine idles smoothly and accelerates
ter the first 10 hours of use and then af· cleanly without hesitation. If necessary,
ter every 50 hours of use. Reinstall vent readjust timing screw (models prior to
and fill plug. securely. using a new gas· 1988) to ohtain 6(){)-700 rpm idle speed.
ket if needed, to ensure a watertight Main fuel meteriug is controlled by
seal. main jet (5). Standard main jet size for
normal service is #140 on all DT75
models except 1987 models, #135 on
FUEL SYSTEM 1987 DT75 models. #162.5 on DT85
models prior to 1987 and #157.5 on DT85
CARBURETOR. Mikuni Model B32-28 models after 1986.
carburetor is used on DT75 models and Standard pilotjct (12) size for normal
Mikuni Model B40-32 carburetor is used service is #80 on DT75 models prior to
on DT85 models. Refer to Fig. SZ16-1 for 1987, #87.5 on DT75 models after 1986.
exploded view of carburetor. Initial set- #75 on DT85 models prior to 1987 and
ting of pilot air screw (3) from a lightly #80 on DT85 models after 1986.
seated position should be 1 to 1'1, turns Th check float level, remove float bowl
on DT75 models prior to 1987, 1314 to 21/4 and invert carburetof" Distance CD-Fig.
turns on DT75 models after 1986, 1'f. to SZ16-2) between main jet and bottom of
2'1, turns on DT85 models prior to 1988 float should be 12.5-14.5 mm (0.49-0.57
and 1~/8 to 2'/8 turns on D1'85 models af~ in.) on DT75 models prior to 1987. 10-
ter 1987. Final carburetor a<\justment 12 mm (0.39·0.47 in.) on DT75 models af·
should be made with engine running in ter 1986. 17.5-19,5 mm (0.69-0.77 In.) on
forward gear at normal operating tem~ DT85 models prior to 1987 and 17-19 rum
perature. On models prior to 1988. ro- (0.67-0.75 in.) on DT85 models after
tate timlug a<\just screw (B-Fig. SZI6- 1986. Adjust float level by bending float
3) in small increments until'engine idles tang (T).
at approximately 600-700 rpm in for· Th synchronize carburetor throttle
ward gear. valves on models prior to 1988, use
Fig. SZ16·1-l!xploded new 0'
buTfltors typIcal 01 atl mod.".
Mlkunl car-
NOTE: On modols after 1987, an Idle speed
Suzuki carburetor balancer 09913-13121
or equivalent and make adjustment at
1. Bodv 9_ Float adju$lment switch located In the lower on- throttle shaft connectors (14-Fig. SZ16-
2. Sprfng lO. GliSkd
3, P:lot air screw IL Float hr,wl glne cover I. used. Each poslUon of the Idle 1) with engine running at 1000 rpm. 'fu
4. Main !¥1ule 12. Pi:ot jet speed switch chang•• ignition timing two synchronize throttle valves on models
5. Main jet 13. Jam nut
6. GasKet t4. CClnnedor degrees resulting In approximately 50 rpm after 1987, loosen the throttle valve ad·
7. Seedle & seat 15. Throttle sWp screw
B. Pin 16. Spring

Fig. SZ1/l-lI-VIew of speed 0

control Dnlalge typical Df all
models prior to 1988. Models
lifter 1987 lW similar. Refer to
Fig. SZ16..f, RekJr to text for
Identification of compOMnts
and adjUStment procedure.

FIg. SZ1fJ..2-Dfatance (D) for correct float IBwJJ

should be 12,5·14.5 mm (0.49.(J.57 In.) on D175
models prior to 1987, 10-12 mm (tJ.39-D.47 In.) on
DT75 models alttlr 1986, 17.5-19.5 mm (O.(J9..fJ.T7
In.) on 0T85 models prior to 1987 and 1;~19 mm
(o.fI1..o.75 In.) on DT85 models after 1986.
 SERVICE MANUAL Suzuki 0T75 & OT85
justment screws (I-Fig. SZ16-4) located attempt to straighten or repair a dam- right position and oil tank is full. Open
on throttle levers of top and bottom aged reed petal. Never install a bent or oil pump air bleed screw (A-Fig. SZI6-
caburetors. Ensure that all throttle damaged reed petal. Seating surface of 6) three or four turns to allow oil to seep
valves are completely closed, then reed plate should be smooth and flat. out around screw threads. After five
retighten screws (I). When installing reeds or reed stop, make seconds, or when no air bubbles are no-
sure that petals are centered over the ticed, close air bleed screw (A).
SPEED CONTROL UNKAGE. The inlet holes in reed plate, and that the
carburetor throttle valves must be cor- reed stops are centered over reed petals.
rectly synchronized to open as the ig- Apply Suzuki Thread Lock 1342 or a CHECKING OIL PUMP OUTPUT.
nition is advanced to obtain optimum suitable equivalent thread locking com- Start engine and allow to warm-up for
performance. To adjust the speed con- pound to threads of reed stop screws approximately five minutes, then stop
trol linkage, it is necessary to first during reassembly. engine. Disconnect oil pump control rod
check, and adjust if required, the igni- (5-Fig. SZI6-6) from bottom carburetor.
tion maximum advance (models prior to FUEL PUMP. A diaphragm type fuel Detach oil supply line at oil tank outlet
1988) as outlined in the IGNITION TIM- pump is mounted on the side of power and plug oil tank outlet. Connect Suzu-
ING section. Disconnect carburetor link head cylinder block and is actuated by ki Oil Gage 09900-21602 to oil supply
(C-Figs. SZ16-3 or SZI6-4) and rotate pressure and vacuum pulsations from line. Fill oil gage with a recommended
speed control lever (L) toward maximum the engine crankcase. Refer to Fig. SZI6- engine oil until even with an upper ref-
speed position until lever (L) contacts 5 for exploded view of fuel pump as- erence mark. If necessary, bleed system
maximum speed stop on crankca..o;e. Set sembly. as previously outlined and refill oil gage.
carburetor throttle valves completely When servicing pump, scribe refer- With oil pump control lever in the
open, then vary the length of carbure- ence marks across pump body to aid released position (minimum output),
tor link (C) until ball joint connector will reassembly. Defective or questionable start engine and run at 1500 rpm for ex-
just attach. Move speed control lever to parts should be renewed. Diaphragm actly five minutes. After five minutes,
full retard position. Clearance (A-Fig. should be renewed if air leaks or cracks stop engine and note oil gage. Oil con-
SZI6-3) at carburetor throttle shaft ac- are found, or if deterioration is evident. sumption at 1500 rpm in five minutes
tuating levers should be 0-1 mm (0-0.39 should be 3.7-5.6 mL (0.12-0.19 fl. oz.) on
in.). FUEL FILTER. A fuel filter (9 models prior to 1986 and 2.2-3.7 mL
through 13-Fig. SZI6-5) is mounted on (0.07-.12 fl. oz.) on models after 1985.
REED VALVES. The intake reed the side of power head cylinder block Th check pump maximum output, re-
valves are located on a reed plate be- on all models. Filter should be disassem- peat previous procedure except hold
tween intake manifold and crankcase. bled and cleaned after every 50 hours pump control lever in the fully open po-
The reed petals should seat very light- of use. Renew' '0" ring (11) if required. sition and run engine at 1500 rpm for
ly against the reed plate throughout exactly two minutes. After two minutes,
their entire length with the least possi- stop engine and note oil gage. Maximum
ble tension. Tip of reed petal must not OIL INJECTION oil pump output at 1500 rpm in two
stand open more than 0.20 mm (0.008 minutes should be 5.9-8.9 mL (0.20-0.30
in.) from contact surface. Reed stop Models So Equipped fl. oz.) on IYf75 models prior to 1986 and
opening should be 7.6-7.9 mm (0.30-0.31 all DT85 models. and 5.0-7.5 mL (0.17-
in.). BLEEDING PUMP. To bleed trapped 0.25 fl. oz.) on IYf75 models after 1985.
Renew reeds if petals are broken, air from oil supply line or pump, first
cracked, warped, rusted or bent. Never make sure outboard motor is in an up-

c
Fig. SZ16-4-Vlew of throttle
linkage used on all models af-
ter 1987. Refer to text for ad-
Justment procedure.

• Fig. SZ16·5-Exploded view 0' diaphragm type

'uel pump and 'uel filter assemblies.
I. Cover
2. Diaphragm Fuel filter body
9.
3 Body 10.
Packing
4. Diaphragm 11"0" ring
S. Spring Filter
12.
6. Body Bow!
13.
7. "0" rings 1Inlet
"- Insulator blo(,k 0 Outlpt
SERVICE MANUAL Suzuki OT75 & OT85
rpm, The idle speed switch is the only gine at wide-open throttle and note tim- leading from condenser charging coil(s),
provision for adjusting idle speed on ing marks, On models prior to 1988, attach tester
models so equipped. Note that carbure- Full retard timing can be adjusted by between black wire with red tracer and
tor throttle valves must be fully closed turning screw (B) as necessary, Adjust red wire with white tracer (low speed
for idle h'Peed switch to function, Full full retard timing so motor idles at 600- charge coil), Resistance should be 680-
advance timing on models after 1987 700 rpm in forward gear regardless of 831 ohms on 1986 and earlier models.
should be 18 degrees mDC at full throt- actual timing noted with timing light, and 600-900 ohms on 1987 models,
tle and is controlled automatically by Leave tester connect"d to red wire with
the Ie ignition system. TROUBLE-SH()(1fING, If ignition white tracer and attach remaining
On models prior to 1988, initial setting malfunction occurs, use only approved tester lead to black wife (high-speed
of ignition timing can be accomplished procedures to prevent damage to the charge coil). Resistance should be 114-
as follows: Set throttle at full advance components, The fuel system should be 140 ohms on 1986 and earlier models
position, then align mark (M-Fig. SZI6- checked first to make sure that faulty and 100-150 ohms on 1987 models,
3) on stator plate with stationary mark running is not the result of incorrect On models after 1987, attach tester
(8) on upper seal housing. Loosen two fuel mixture or contaminated fuel. between black and green charge coil
screws (T) on maximum advance stop Make sure malfunction is not due to wires. Resistance should be 170-25()
plate (P) and position plate to lightly spark plugs, wiring or connections. ohms.
contact advance lever (D), Trouble-shoot ignition system using
Maximum advance timing check can Suzuki Pocket Tester 09900-25002 or a
be made using a suitable timing light, suit.able ohmmeter. PULSER COIL. On models prior to
Immerse lower unit of outboard motor 1987, two pulser coils afe used, One
in water and connect timing light to up- CD::mENSER CHARGING COIL, On pulser coil triggers cylinders 1 and 3 and
per spark plug lead. Refer to ignition models prior to 1988, two condenser the remaining coil triggers cylinder 2,
timing specifications previously stated charge coils are used, low speed and On models after 1986, tIlfee pulser coils
and check alignment of flywheel timing high speed, Models after 1987 are are used, one for each cylinder, Th test
marks \\;th index mark on electric start- equipped with one condenser charge pulser coils, disconnect wires between
er cap. 1b check advance timing, run en- coil. Disconnect wires at connectors CD! module and pulser coils,

i' ~-_~ ",'V",",,,,,,'''

.... ::'.:I"-11o-.. d--<:.,
.•
-~.
o
~.
~_~...E:~.:':-' • -'!I'O _';.7" - -e'-~'"

..:;:
t~"
,~

::
:~
r!
;~

FIg. Sl'fU-Wlrlng diagram typlcsl of modeIlI after 1987 tX/UlppMi with power frlmltllt and bstt9ry ch8rglng coil.
R:Y Roo with yellow
B. Black Or. Onmgt: LtG. U,gltt gret'n tracer I.iR.ht blu{>
G~ Green R'R Black with rw Ria, Ite<! with black Wilt White with black YiG. Yellow WIth OrUl~ Wlth
p Piuk trl.l£ef tracer tracer gret't\ naff'r green trl'!.Cf:'f
5, ll«l BlW. Black with white RiG, Red with green W!R White with re<l ISltR Blue with rod F!B!. Pmk wtth blUf'
W, White tfflcer tracer ,~. uat..-r tracer
y Yellow Gm, Green with red RfW" Red with whitf' YIH. Yeil»w with Dr!W. Brown with LtG"R. ught gti'en with
G•. Gray tracer ,~, black trarer white tracer redt~r
Suzuki DT75 & DT8S OUTBOARD MOTOR
On modeL,; prior to 1987, connect ground, Primary resistance should be 'fHRaITLE VALVE SENSOR (Models
tester bet ween green wire and yellow 0.21-0.29 ohm on models prior to 1987, after 1987). 1b test throttle valve sen-
wire with red tracer. Note reading and 0.2-0.5 ohm on 1987 models and 0.2-0.3 sor (5-Fig. SZI6-1O), remove alignment
connect tester between pink wire and ohm on models after 1987. lest coil pin attached to black cover over throt~
white wire with red tracer. Resistante S€C'ondary winding resistance between tle valve sensor and insert alignment pin
of both coils should be 320-391 ohms. coil primary and secondary terminals, (1) into hole in sensor and sensor cam
On 1987 models, connect tester be- Secondary resistance should be 2130- (3). Align slot in cam (3) v.ith thrott.le
tween engine ground and alternately 2880 ohms on models prior to 1987, shaft. Disconnect throttle ·valve sensor
between green, pink and yellow wire 4700-7000 ohms on 1987 models and connector (4)" Connect test harness
with red tracer. Resistance should be 1800-2800 ohms on models after 1987. 09930-89530 or suitable jumper wires to
290-420 ohms at all test connections. a battery as shown in Fig. 3Z16-1O. Bat-
On models after 1987, connect tester NOTE: On models after 1987, Ignition coli tery voltage must be nine volts or more"
between ground and alternately be- secondary Jeads are equipped with a Connect positive (-) lead of a suitable
tWe€n red wjr~ with black tracer, white resistance-type spark plug cap. Resistance DIGITAL voltmeter to t.est harness light
wire with blue tracer and red wire with 01 resistance sparl< plug cap should be green wire with red tracer and volt-
white tracer. Resistance at an test con~ 101000 ohms. Be sure to add this value to meter negative ( -) lead to battery nega-
nections should be 160-240 ohms. con secondary resistance If checking coli tive ( - ) terminal as shown. With throt.-
and secondary lead as a unit. tle fully closed, voltmeter reading
BATTERY CHARGING COIL. Discon- should be 0.45-0.55 volt. If not. remove
nect wires leading from battery charg- COUNTER COIL. On models after rubber cap (2) and turn adjustment
ing coiL On models prior to 1988, con~ 1987, a gear counter coil is mounted screw (under cap) as necessary to obtain
neet tester uct ween red wire and yellow along outer periphery of flywheel ring the correct voltage reading, Not.e t.hat
wire, Resistance should be O.54~O,66 gear. The CDI module proce&-<;es infor- turning adjustment screw clockwise will
ohm on models prior to 1987 and 0.4-0.8 mation from the gear counter (~oil in increase voltage and counterclock",'1se
ohm on 1987 models. Next., connect combination with the throttle valve sen- will decrease voltage.
tester between red wire and red wire sor to detennine ignition timing, Th test
with yellow tracer. Resistance should be counter coil, separate connector lead- NOTE: The manufacturer recommends u&-
0.36-0.44 ohm on models prior to 1987 ing from counter coil. Connect tester ing only a nonmetallic screwdriver to turn
and 0.2-0.6 ohm on 1987 models. leads between orange WIre with green sensor adjusting screw or sensor voltmeter
On models after 1987~ connect tester tracer and ground, Counter coil can be reading may not be valid. If metal screw·
between red wire and yellow wire. Re- considered acceptable if resistance is driver must be used, remove screwdriver
sistance should be 0.25-0.35 ohm. within 160-240 ohms. Air gap between from area of throttle valve sensor after ad·
counter coil and flywheel ring gear justment to prevent erroneous voltmeter
t.eeth should be 0.5 mm (0.020 in.). reading,
IGNITIOK COILS. Three ignition coils
are used on all models. Disconnect wires NOTE: Air gap between counter coil and If sensor output voltage at closed
leading from ignition colls and secon~ flywheel ring gear teeth must be set to ex~ throttle is below 0.45 volt. idle speed ig-
dary leads from spark plugs. lest coil actly 0.5 mm (0.020 In.) lor proper operation nition timing will be fixed at 5 degrees
primary winding resistance between of outboard motor. Make sure- air gap is BTDC; idle speed switch will be inoper-
coil primary terminal and engine properly adjusted. ath-e. If sensor output voltage at closed
throttle is above 0.55 volt. ignition tim-
ing at idle speed will be incorrect. Re-
"X1HltR fer to IDLE SPEED SWITCH section.
, HAD CHARGE PULSER IGJUHQft STili' Once the specified voltage n-ading is
.lmER$"-" "',
LEAD
Inllc,<-! ~ed!
Wlnte
!!lij(~ Green 11< n~ "i-<lte/ ~:I10<1 Orange
~('j IiO
l i9h!
Bllle
Grf>j'
Black!
White
obtained at closed throttle, remove
alignment pin and open carburetor to
~
lack/
R" A A A A A A B B B A wide-open throttle. Voltmeter reading
R~d/
-. should now be 2)5 volts or more. Do not
CUARGE
iiI1ite B ~ B 8 3 8 B 8 B 8 8 attempt to adjust wide~open throttle
Bla;:~
B B I~~ A A A A C C C B &ensor voltage. If \vide~open throttle
sensor voltage is not 2.5 volts or higher,
, '~
:;reef1 B B A A : A A C C C 8 renew sensor.
If throttle valve sensor is removed or
Ptr.k B 8 8 B '.,'" :3 8 8 8 B 8 renewed, install as follows: Insert atign-
PULSEf!.

,,'
WflHe/
8 8 A A A I',,· A C C
,
C 8
ment pin (1) as shown to align earn and
sensor shaft. AJign slot in sensor cam
Ye1lo ..!
, 8 8 A A A
.
A
~ C C C 8 wit.h carburetor throttle shaft and in-
'" . stall sensor on carburetor, Lightly tight~
{I~<lrge C C C B B C C ~ B 8 C en mounting screws (7) to allow for ad-
IGHI- light
Ic , , C
c ~
justment of sensor position on
,I
TIOPI Slue C C B 8 B 8 C
carburetor, Connect test harness and
Grey : C C C B 8 C C B 8 ~ C digital voltmeter as shown in Fig. SZ16-
10" Make sure battery voltage is nine
~
Slack/
ST1ll' I.nit.,. A A A A A A A C C C volts or more, Sensor output voltage at
closed throttle should be 0.45-0.55 volt.
Fig. SZ16-9-USe above ch8Jt snd vaJlJe$ listed below tQ test condltlcm of CDI module on models
If not, move position of sensor on car-
prior to 1987.
C" Tf'sWf needle sr,oulrl buretor to obtain speCified voltage and
deiieet. then return seeurely tighten screws (7). Recheck
A. lOOk ;1hm" or 1(fflS towaro lnfimt«
Il lOOk oh11'ls or more voltage after tightening screws (7) and
SERVICE MANUAL Suzuki OT75 & OT85
if necessary, r"move cap (2) and tum ad- lead alternately to each ignition coil pri· Thermostat can be removed for inspec-
justment screw to obtain 0.45-0.55 volt. mary terminal while running engine at tion or renewal after removing ther-
Be sure to reinstall cap (2). After obtain- 1000 rpm. CD! module output should be mostat housing (5).
ing the correct voltage at closed throt· 160 volts or more at each test con-
tIe, remove alignment pin and ch""k nection. POWER HEAD
sensor output voltage at wide-open On models after 1987, set PRY to posi-
throttle. Voltage should be 2.5 volts or tive ( t) 500 range. Connect PRY black REMOVE AND REINSTALL. Th re-
higher. Do nol attempt to adjust wide- test lead to engine ground, Disconnect move the power head, first remove en-
open throttle voltage. ignition coil primary wires from coils. gine cover. Detach battery cahles. Re-
Connect red test lead alternately to move fuel filter and disconnect fuel
IDLE SPEED SWITCH. Idle speed each ignition coU primary wire. Crank supply line from connector in lower enw
switch malfunction can be quickly veri~ engine at each connection. CD! module gine cover, Disconnect shift and throt·
fied by checl<ing ignition timing and en- output should be 96 volts or more at tle linkage. Detach any wiring that will
gine rpm while switching position of each connection. If not renew CD! interfere with power head removal. Re-
idle speed switch. Note that carburetor module. move covers to expose power head re-
throttle valves must be fully closed for taining screws and nuL Remove the
idle speed switch to function. COOLING SYSTEM screws and nut, then lift power head as-
sembly with related components from
NOTE: A defective or maladjusted throt· WATER PUMP. A rubber impeller' lower unit assembly.
tle valve sensor may ...... Idle speed swlt\:l1 type water pump is mounted between Before reinstalling power head, check
to b. Inoperative '" Ignilion I1mlng at Idle the drive shaft housing and gearease. A condition of drive shaft seal (15-~'g,
sp•• d to be Ineorrect. Prior to testing Idle key in the drive shaft is used to turn the SZHH3). If seal renewal is required, it
speed switch. make sure throttle valve sen~ pump impeller, If cooJing system prob- will be necessary to separate crankcase
lOr Is operating properly and """"ctly .Just. lems are encountered, check Vt"ater in- (I-Fig SZI6·12) from cylinder block (2)
ed. Refe. 10 THROTTLE VALVE SENSOR take for plugging or partial stoppage, as outlined in the approprinte following
_tlon. then if not corrected, remove gearcase paragraphs, Apply a suitable water·
as outUned in the appropriate seetion resistant grea.'5e to lip area of seal and
Note that each position of idle speed and check condition of the water pumpl install seal into seal housing (IB-Fig.
switch should change ignition timing water passages and sealing surfaces. SZ16-13). Make certain drive shaft
two degrees and change engine idle When water pump is disassembled, splines are dean, then coat splines with
speed approximately 50 rpm. If timing check condition of imneller (4-Fig. a light coating of water~resistant grease.
and engine rpm do not change with SZl6-11) and plate (5) for excessive wear. Apply a stiltable sealer to mating sur·
each switch position, idle speed switch 'fum drive shaft clockwise (,iewed from faces of power head and lower unit and
may be defective. top) while placing pump housing (2) install a new gasket. Coat the area next
over impeller. Avoid turning drive shaft to heads of power head to lower unit reo
CD! MODULE. On models prior to in opposite direction after 'water pump taining screws with silicone sealer.
1987, use Suzuki Pock Tester 09900- is reassembled. Tighten the power head retaining
25002 or a suitable ohmmeter and re- screws and nut to 15,20 N'm (11-15 ft.-
fer to chart in Fig. SZ16·9. On models af· THERMOSTAT. A thennostat (7-Fig. Ibs.), The remainder of installation is the
ter 1986, test CDI module using Stevens SZl6-12) is used to regulate engine oper- reverse of removal procedure.
Model CD-77 peak reading voltmet;>r ating temperature, The thermostat
(PRV). should start to open within the temper' DISASSEMBLY. Disassembly and in-
On 1987 models, set PRY to the nega· ature range of 48°,52° C (118°-126° F) sp<>Ction can be accomplished in the fol·
tive (- ) 500 range. Connect PRY black on 1987,1989 DT75 models and 40°_44° lowing manner. On models equipped
test lead to engine ground and red test C (1040 .111° F) on all other models. with oil injection! disconnect wiring to

6 5 2 1

3
Test Harness
09930,89530

Digital
Voltmeter

Fig. SZ16-10-Refer to text for fhrottle valve Sf!lnSDr testing and Installation procedul't).
Fig. SZ16-11-Exploded view of water pump as--
l. Ahgnmem pin
2 Cap (adjwlftnertt
screw)
.,
5. Throttle valve
sensor a:wy.
Carburetor
BIR. Black with red
tra<;'f'[ " Water tube
ombly.
4" Impeller
,
3. 54>ma'f ram
Connector
7. Mounting;;crew
fl. Black
LtG/R, Light green with
r(>d tra<:er
2 Pump housing
3. Key
5" Plate
6. Gasket
Suzuki DT75 & DTa5 OUTBOARD MOTOR
,
oil tank. Remove oil supply line from oil
tank outlet and plug. Remove cap
screws to withdraw oil tank. On models
equipped with power tilt and trim, re-
move relays from side of cylinder block.
Remove carburetors and electric choke
solenoid. Remove fuel pump assembly.
Remove oil if\iection pump (I-Fig. SZI6-
Fig. SZ16-12-Exploded view
of cylinder block assembly
6), retainer (4) and driven gear (3). Re-
typical of ai/ models. move ignition coils, electric starter,
1. Crankcase half starter motor relay, rectifier and CDI
2. Cylinder block module. Remove speed control linkage.
3. Gasket
4. Cylinder head Remove flywheel and stator plate as-
5. Thermostat housing sembly. Remove electric starter motor
6. Gasket
7. Thermostat bracket and any remaining wiring that
8. Valve will interfere with cylinder block and
9. Spring
10. Gasket crankcase separation. Remove intake
1L Inner exhaust cover manifolds and reed valve assemblies.
12. Gasket
13. Outer exhaust cover Remove outer and inner exhaust covers.
Remove thermostat housing and with-
draw thermostat. Remove spark plugs,
cylinder head, spring (9-Fig. SZI6-12)
and valve (8), then clean carbon from
combustion chamber and any foreign
material accumulation in water pas-
sages. Unscrew crankcase retaining
screws and separate crankcase (1) from
cylinder block (2). Crankshaft and pis-
ton assembly can now be removed from
cylinder block.
Engine components are now accessi-
ble for overhaul as outlined in the ap-
propriate following paragraphs. Refer to
the following section for assembly
procedures.

ASSEMBIX. Refer to specific service

sections when assembling the crank-
24 shaft, connecting rod, piston and reed
valves. Make sure all joint and gasket
Fig. SZ16-13-Exploded view
of crankshaft assembly typi-
surfaces are clean, free from nicks and
cal of all models. burrs and hardened cement or carbon.
1. Seal Whenever the power head is disas-
2. Roller bearing
3. Pin sembled, it is recommended that all gas-
4. Top crankshaft upper half ket surfaces and mating surfaces with-
5. Top crankshaft lower half
6. Roller bearing out gaskets be carefully checked for
7. "0" ring nicks, burrs and warped surfaces that
8. Bearing ring
9. Labyrinth seal ring might interfere with a tight seal. Cylin-
10. Labyrinth seal der head, head end of cylinder block
11. Middle crankshaft half
12. Lower crankshaft half and some mating surfaces of manifold
13. Roller bearing and crankcase should be checked on a
21 14. Seal
15. Seal surface plate and lapped if necessary to
16. Seal housing provide a smooth surface. Do not re-
17. Crankpin
18. Thrust washer move any more metal than is necessary.
~~1 19.
20,
Needle bearing
Conneding rod When assembling power head, first

8~~7
21. Thrust washers lubricate all friction surfaces and bear-
22. Needle bearing
23. Piston ings with engine oil. Apply a suitable

9~~10
24. Piston pin clips high temperature grease to lip area of
25. Piston pin
26. Piston rings crankshaft seal. Apply a suitable water-
resistant grease to lip area of drive shaft
~12 seal and install seal into seal housing
(16-Fig. SZI6-13). Place bearing retain-

15~13
ers (8) and seal rings (9) into cylinder
block, then install crankshaft assembly.

16~ 14 NOTE: labyrinth seal (10) Is not used on

~
models after 1987. Later models are
equipped with a metal slip-ring type seal.
SERVICE MANUAL Suzuki 0T75 & OT85
Make certain main bearing locating bottom of crankshaft. Determine rod to shift linkage. Unscrew nuts retaining
pins engage notches in cylinder block. bearing, connecting rod and crankpin shift arm (2) to shaft (4), then disengage
Apply a coat of Suzuki Bond No.4 or a wear by measuring connecting rod small shaft (4) from shift rod (5). Remove the
suitable equivalent sealer to mating sur M
end side~to-side movement as shown at screws securing gearcase to drive shaft
faces of crankcase and cylinder block, (A- Fig. SZ16·16). "'ormal movement (A) housing and separate gearcase assembly
then position crankcase un cylinder is 5 mm (0.20 in.) or less. Maximum al· from drive shaft housing. Remove wa z

block, Tighten crankca.;5e scre\vs in se~ lowable crankshaft rnnout is 0.05 mm ter pump assembly (Fig. SZ16·1I). Re·
quence shown in Fig. SZ16·14. Refer to (O.002 in.) measured at bearing surfaces move propeller with related compo-
CONDENSED SERVICE DATA section with crankshaft ends supported. nents from propeller shaft. On models
for tightening specifications. When installing crankshaft, lubricate prior to 1983, remove seal ring (65-Fig.
pistons, rings! cylinders and bearings 8Z16·18), washer (64) and snap ring (63)
RINGS, PISTONS AND CYLINDERS. with a recommended engine oil as out~ retaining gearcase end cap (58).
The piston are fitted with two piston lined in ASSEMBLY section.
rings. Piston rings must be in._lIed with
manufacturer's marking facing piston ELECTRIC STARTER
crown, Rings are pinned in place to pre~
vent ring rotation. Piston ring end gap Models are equipped with electnc
should be 0.2-0.4 mm (0.008-0.016 in.) starter shown in Fig. SZ16·17. Disassem-
with a maximum allowable gap of 0.8 bly is evident after inspection of unit
mm (0.031 in.). Piston-to-cylinder clear· and reference to exploded vi<'W. Stan-
ance should be 0.077-0.093 mm (0.0030· dard hrush length is 16 mm (0.63 in.).
0.0037 in.) on DT75 mod..ls prior to 1987, R<'new brushes if worn to 11.5 mm (0.45
0.112-0.127 mm (O.004HW050 in.) on in.) or less. After reassembly. bench test
1987 DT75 models and DT85 models pri· starter before installing on power head.
or to 1988, O.10l5·0.165 mm (0.005'3-
0.0065 in.) on all 1988 models and 0.12- LOWER UNIT
0.15 mm (0.0047-0.0059 in.) on all 1989
models. Piston and rings arc available in PROPELLER. Protection for motor is
standard size a& well as 0.25 mm (0.010 provided by a special cushioning clutch
Fig. SZ16-1S-Idaximum slde-fo-side movement
in.) and 0.50 mm (0.020 in.) oversize. budt into the propeller hub. Three-blade fA} at connectfng rod small end should be 5 mm
Cylinder should be bored to the next propel1ers are used, VarJous propellers (0.20 In.) or less.
oversize if cylinder bore is tapered, out~ are available from the manufacturer. Se-
of-round or worn in excess of 0.10 rom lect a propeller that will allow the out-
(0.004 in.). Install piston on connecting board motor to run at the speed range
rod so arrow on piston crown will face of 4800-5&00 rpm at full throttle.
exhaust port when piston is in cylinder.
R&R AND OVERHAUL, Refer to Fig.
CONNECl'ING RODS, BEARINGS SZ16-18 for exploded view of lower unit
AND CRANKSHAFT. Connecting rods, gearease assembly used on all models.
bearings and crankshaft are .a pressed- During disassembly, note the location of
together unit. Crankshaft should be dis- all shims and thrust washers for refer·
assembled ONLY by experienced serv- ence dming re~~mbly. 10 remove gear-
ice personnel using the proper service case, first unscrew plug (34) and drain
equipm~mt, gear lubricant, Remove plug from side
The crankshaft is supported by a of lower engine cover to obtain access
caged roller bearing at the top and
caged ball bearings at the center and

11 14
8

4
6
2

1 1~~18
12 Fig. SZ16-17-Expioded view of el«tri<: $lBrter
motor.
L "C~ r:llg
2. Stop g. Brugh assy.
3.. Sr-rlng 9 Gllilket
4. Drive 10. Ell'; h(;u8ing
FIg. SZ16--14-Tlghten crtmkcsse screws In "" Fig. SZ16·15-TIghten cylJnder hetfd $Clews in se- 5. Fran:e head 11. TrJUi'.t washer
quence shown, ReM to CONDENSED SERVICE quence shown. Refer tD CONDENSED SeRVICE 6. Armat'.lre 12. ~E" e]p
DATA for torque vatu.. DATA for torque values. 7. Frarne 13. Bra;::ke:
Suzuki DT75 & DT85 OUTBOARD MOTOR
NOTE: On mOdel. afler 1982, gearcasa rings should be renewed when unit is re- 18). Tighten pinion nut to 50-70 ?-I'm (44-
end cap (58) I. "'!alned to g.orca08 by two assembled. 51 ftAbs.) on models prior to 1983 and
screws. Backlash between pinion gear (49) 70-80 N-m (51-58 ftAbs.) on models af-
and drive gears (41 and 53) should be ter 1982. Apply water-resistant grease
Use a suitable puller and withdraw 0.05-0.30 mm (0.002-0.012 in.) on models to "0" ring (57). Apply silicone sealer
propeller shaft assembly with gearcase prior to 1983 and 0.1-0.2 mm (0.004- to gearcase and bearing housing (18)
end cap. Unscrew pinion nut (50) and 0.008 in.) on models after 1982. Backlash mating surfaces and to bearing housing
remove pinion gear (49), then extract is adjusted by varying thickness of shims and drive shaft housing mating surfaces.
forward gear (41). Drive shaft (20) and (40 and 54). Propeller shaft end play Coat retaining screws in area next to
related components can be withdrawn should be 0.05-0.30 mm (0.002-0.012 in.) screw head with silicone sealer.
from gearcase after removal of bearing on models prior to 1983 and 0.2-0.4 mm Engage shift shaft (4) in shift rod (5)
housing (IS). (0.008-0.016 in.) on models after 1982. eyelet and attach shift arm (2). Secure
Inspect gears for wear on teeth and on Propeller shaft end play is adjusted by with nuts. Fill gearcase with outboard
engagement dogs. Inspect dog clutch increasing or decreasing the thickness gear oil as outlined in LUBRICATION
(45) for wear on engagement surfaces. of shim (51). section.
Inspect shafts for wear on splines and Reassemble gearcase by reversing dis-
on friction surfaces of gears and oil assembly procedure while noting the POWER TILT AND TRIM
seals. Check shift cam (14) and shift pin following: Install dog clutch (45) on pro-
(43) for excessive wear. Check condition peller shaft (56) so "F" mark (Fig. SZ16- Some models are equipped with a
of shift spring (4S). All seals and "0" 19) is facing forward gear (41~Fig. SZI6- hydraulically actuated power tilt and
trim system. An oil pump driven by a Fe-
\"'€'rsible electric motor provides oil pres-
sure, A rocker control switch deter-
mines motor and pump rotation thereby
retmcting or extending tilt and trim
cylinders.

Early lYpe

The pump is equipped with an auto-

matic and manual release valve (V~Fig.
SZI6-20) that, when set in the manual

45

5i

Fig. sntJ.19-lnstaIl dog clutch (45} on propeller

shaft (56) with "F" ItIIIrked s~ ...,Iog Iorwanl
_(41).

FIg. SZ16-1f'-ExpIodod"'" oflyp/r;tll_ unit g_~'- on "" _ _ On models

BfIM 1982. ~. end C4p (58} Is retained to ~ by two screws.
L Link sa, Reverse gear
2. Shift arm t9. Bearing 36. Pin 54. Shim
3. Grorlmets 2(t Drive shaft 37. Bearing 5f). Bearit1£'
4. Shift shaft 2L Pm 38. ThMUlt bearing 56, Propdfcr :;haft
5. Shift tnd 22. Sr.im 39. Thrust washer 51. "O~ ring
6. Pin 23. Thrust washer 40. Shim 58. End cap
7. ~t.$ ....nl 24. Thrust bearing 41. Forward gear 59. Pin
8. 0 rmg 25. Spring 42. Thrust washer £0. Need~ bearing
9 Rod guide 26. (-nllar 43. Shift pin 61. Sea!
HI. "O~ ring
11. "n~ ring
12. Magr.et
21. Thrwllt washer
2R Thrust wR--~r
29. N~k bearings
44. Spring gujde
4.,). Dog dutch
4~t Pin
62, Snap ring
63, Snap ring
64, WWlher
v
Ut Magnet hoMer 30. V\Jut plug 47. Pm retajner 6&, Seal ring
U. Shift cam 31. Seal ring 48. Shift spring 66. Sparer
Hi. Pins 32. Level plug 49. Pinkm gear 67. Propeller Fig. SZ16-20-Vlew of early type pump assembly
16. Snap ring 33_ eearcase housing 50. Nut 68. Spaeff
n Seal 34. Drain plug 51. Shim 69. Tab "'"Moor showing IccBtion of 011 ffJl plug (F), f9Iease vatVIS'
18. &?anmr hrmsin)! 35 Gwket 52. Thl"Ust washer 70. Nut (V) and /<>Sf ports (1 and 2).
SERVICE MANUAL Suzuki DT75 & DT85

position (vertical), enables manual sion fluid. Do not run pump without oil pump assembly prior to 1987 and after
movement of trim and tilt cylinder.s if in reservoir. Fill plug (F) is located in 1980. When checking or filliug reservoir
the electric motor malfunctions. side of pump reservoir, Oil level should oil level on models prior to 1987, out-
Recommended oil is SAE 20 or SAE 30 reach fill plug hole threads with out- board motor must be trimmed fully
motor oil or Dexron automatic transmis~ board motor in a vertical position. Hy- down. When checkiug or filliug reser-
draulic tilt should be cycled several voir on models after 1986, outboard mo-
times and oil level rechecked if system tor must be tilted fully up.
has been drained or lost a large amount Pump on all models is equipped with
of oil. manual release valve (M-Fig. SZI6-23).
If malfunction oCCurs in tilt and trim If electric motor malfunction occurs!
system, first make sure malfunction is open manual release valve a maximum
not due to wiring, wiring connection or of two turns counterclockwise to ena-
electric motor failure. 1b check oil pres- ble manual movement of trim and tilt
sure, connect a 20.7 MPa (3000 psi) gage cylinders.
to port "I" on pump and operate pump. Recommended oil for models prior to
Hydraulic oil pressure at port "1" 1987 is SAE 20, SAE IOW-30 or SAE
should be within the limits of 6.9-17.25 lOW-40 motor oil, or Dexron automatic
MPa (1000-2500 psi). Connect test gage transmission fluid. Recommended oil for
to port "2" and operate pump. Hydrau- models after 1986 is Dexron automatic
lic oil pressure should be within the transmission fluid only. Do not run
limits of 1.66-5.52 MPa (240-800 psi). Oil pump without oil in reservoir. Fill plug
pressure less than specified may indi- (5-Fig. SZ16-22) is located in side of
cate leakage, faulty pressure relief reservoir. Oil level should reach fill plug
valves or check va1ves. hole. Hydraulic tilt should be cycled
If electric motor and pump assembly several times to bleed air and oil level
are disassembled for repair or renewal recheeked if system has been drained or
of individual components, upon reas- lost a large amount of oil.
sembly use Ingilis Company EP630548 If trim/tilt system malfunction occurs,

Fig. SZ1~21-Exp/odf1d view ol_y 'Y!'"

IrimllJlt _
L End ~ap
motor and pump ,.."""uuy.
_r
B. Frarn(f
flat black neobase or equivalent to pro-
vide a watertight seaL

Late 1}tpe
make sure problem is not due to wiring.
wiring connections Of electric motor
failure. 1b check oil pressure, connect
a 34.5 MPa (5QOO psi) gage to port (1-
Fig. SZI6-23) on pump and operate
2:. Spring 9, ("..w:et
3. BT"U'Sh Ht ReOOl'Votr Two designs of late model pump are pump in the UP direction. Hydraulic oil
,t Bali 1L Fill plug
5. Ar:n!lwre Ut "0" ring used. Refer to Fig. SZ16-24 to identify pressure at port (1) should be within 13-
6.
7.
Thl'USt washer
wket
lK Pump aMoS
14. Cap &ett'w
17 MPa (1885-2465 psi). 1b check down
pressure, connect test gage to port (2)
eI. and operate pump in the DOWN direc-
tion. Hydraulic oil pressure should be
within 28-56 MPa (406-812 psi). Oil pres-
sure less than specified may indicate
leakage, faulty pressure relief valves or
check valves. The manufacturer reeom w

mends renewing pump and valve body

assembly to service low pressure,

Fig. SZ16~23-VJew of lat. type pump assembly

identifying test ports (1 and 2) and manua' relNH
valve (If). Refer to text.

OW flu plUg 0I1t11 plugs ~~=l

'",,~;t-:--::J FIg. SZtIl-24-VI.w ldentlly-

Ing later et'yl# POW#f ttlmItIlf
pump_.
FIg. SZ1~i!2-Exp/odf1d . _ of 1111. Iy!'" _
IrimllJU _ . "",tor and pump ~
1. End tap
2. Gasket I}, ~rv<)it
3, Electrie motor assy . 7, "O~ ring
.t Gasket g, Pump &- valVi' body
fL FiJI plug ails)'.