Suzuki DT2 User manual

SERVICE MANUAL

TUNE-UP

SUZUKI

SUZUKI AMERICA CORPORATION

3251

E.

Imperial

Way

P.O.

Box

1100

Brea, California 92621

SUZUKI DT2

1b

determine

model

and

year

of

manufacture

of

Suzuki

outboard

motors,

refer

to

numbers

located

on

motor

clamp

bracket.

The

first six

characters

indicate

the

model

and

second

six

characters

are

motor

serial number.

The

first

character

of

serial

number

indicates

year

of

manufacture.

The

years

1977, 1978

and

1979

are

identified

by

the

letters

"C,"

"D"

and

"F"

respectively.

Starting

with

1980,

the

first

number

in

serial

number

corresponds

with

model year. For example,

if

first

number

in

serial

number

is

1,

model

year

is

1981.

CONDENSED SERVICE

DATA

NOTE: Metric fasteners are used

throughout

outboard

motor.

Hp/rpm

.........................

,

...

.

.....

. 2/4500

SIZES-CLEARANCES

CONT.

Crankshaft

Runout

at

Main

Suzuki

OT2

Bore

.......................

.

...........

.41.0

mm

Bearing

Journal

(Max.)

........

_

..........

0.03

mm·

(1.614 in.)

Stroke

.........

.

.........................

37.8

mm

(1.488 in.)

Displacement

.........

.

......................

50 cc

(3.05 cu. in.)

Spark

Plug:

NGK

....................................

BR5HS

Electrode gap

......

.

..................

0.5-0.6

mm

(0.020-0.023 in.)

Magneto:

Breaker

point

gap

................

,

....

0.3-0.4

mm

(0.012-0.016 in.)

Carburetor:

Make

....................................

Mikuni

Model

............

...

......

.

....

.

......

VM-11-10

Fuel:Oil Ratio

.................

.

.....

. _

....

See Text

SIZES-CLEARANCES

Piston Ring

End

Gap

.......

.

..........

0.10-0.25

mm

(0.004-0.010 in.)

Piston to Cylinder

Clearance

..............

.

.........

0.053-0.060

mm

(0.0021-0.0024 in.)

Piston Pin

Diameter

...............

11.996-12.000

mm

(0.4723-0.4724 in.)

(0.0012 in.)

Connecting

Rod Small

End

Side

Shake

(Max.)

...........

.

......

,

.....

3.0

mm

(0.118 in.)

TIGHTENING TORQUES

Cylinder Head

............................

8-12 N'm

(6-9 ft.-Ibs.)

Crankcase

.......

.

.............

.

...

,

.....

8-12 N'm

(6-9 ft.-Ibs.)

Reed

Plate

............................

0.5-0.75 N'm

(4.5-6_6 in.-Ibs.)

Flywheel

Nut

...............

.

..........

ＮＴＰＭｾＰ＠

N'm

(30-37

ft.-lbs.)

Standard

Screws:

5

mm

.............

.

......

.

.............

2-4 N'm

(18-36 in.-Ibs.)

6

mm

.......

.

....

.

....................

· . .4-7 N'm

(36-62 in.-Ibs.)

8

mm

.......

_ .

........................

10-16 N'm

(89-141 in.-Ibs.)

10

mm

.......

..

....

.

..................

22-35 N'm

(195-310 in.-Ibs.)

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Suzuki

DT2

WBRICATION

The

power

head

is

lubricated

by o

il

mixed

with

the

fueL Fuel:o

il

ratio

should be

30:1 during

br

ea

k-in

of

a

new

or

rebuilt engine. Fuel:oil ratio for

nor

-

mal service

is

50: I

on

models

prior

to

1987

and

100:1

on

1987

and

later

models. Recommended oil is Suzuki O

ut

-

board Motor

Oil

or

a good quality

NMMA

certified

TC-W

oiL

When using any oth-

er

type

of

two-stroke engine oil, fuel:o

il

ratios should

be

20: I

during

break

-in

and

30:1 for

normal

service

. Manufac-

turer

recommends

regular

or

unleaded

automotive ga';oline having

an

85-95 oc-

tane

rating. Gasoline

and

oil

should

be

thoroughly mixed.

The lower

unit

gears

and

bearings

are

lubricated with SAE 90 hypoid outboard

gear

oil. Lower

unit

capacity

on

models

priorto

1987

is

approximately 40 mL

(1.3

oz.). Oil

capacity

on

lat

er

models

is ap-

proximately

70

mL (2.4 oz.) on

short

drive

shaft

models

and

120 mL

(4

.1 oz.)

on

long drive shaft. models. On

early

models (prior

to

1987). lay

motor

on

side

to

fill

with

oil.

Later

models

are

equipped

with

a

vent

/oil level

check

plug on side

of

gearcase. Reinstall plug

securely using a

new

gasket if necessary

to

ensure

a

water

tight

seal.

FUEL SYSTEM

CARBURETOR. A Mikuni sliding

valve float

type

carburetor

is

used

. Re-

fer to Fig.

S21-1

for

exploded

view. Idle

speed

should

be

adjusted

after

motor

has

reached

normal

operating

temper-

ature. Move speed control to slow

speed

stop

and

adjust idle

speed

screw

(14) to

obtain

idle

speed

of

800-900

rpm.

Note

that

on

1987

and

later

models,

carbure

-

tor

is

equipped

with a pilot

air

screw

(Fig.

SZI-2) for low

speed

mixture

ad-

ju

s

tment.

Carburetor

with

pilot

air

screw

can

be

identified by

the

presence

of

a float bowl drain plug. Initial

setting

of pilot

air

scre

w

is

two

turns

out

from

a lightly

seated

position. Final adjust-

ment

should

be

made

with

engine

at

ope

rating

temperature

and

running

in

forward

gear

. Adjust pilot

air

screw so

engine

idles

smoothly

and

accelerates

without

hesitation.

Main fuel

metering

is controlled by

main

jet

(20-Fig.

SZI-I).

Standard

main

jet

size is

1195

for

models

through

1986

and

1190

for 1987

and

later

models. Nor-

mal position for clip (9)

onjet

needle

(10)

is

third

notch

from

top

of

needle. If

midrange mixture

is

too lean

or

too lich,

minor fuel

mixture

adjustment

can

be

accomplished by

repositioning

clip

on

jet

needle. Moving clip

down

on

needle

richens fuel

mixture

while

moving clip

up

on

needle

leans

fuel

mixture.

Fuel

filter

(17)

should

be

cleaned

after

eve-

ry

50

hours

of

operation.

Th

check float level, remove float bowl

and

invert

carburetor.

With float in-

stalled

on

float

ann

(23), float

surface

nearest

main

jet

should

be

19-21

mm

(0.748-0.826 in.) away from

carburetor

gasket surface. Make

certain

flo

at

is

lev-

el

with

gasket

surface

when

measuring.

Adjust float level by

bending

float

arm

tang.

When installing

carburetor,

renew

"0"

ring (13)

as

required.

IGNITION SYSTEM

Breaker point gap should

be

set

to

0.3-

0.4 mm (0.012-0.016 in.)

at

maximum

opening.

Adjustment

may

be

accom-

plished

through

holes in flywheel. Fly-

wheel

must

be

removed

to

renew

break-

er

ｬＩｯｩｮｴＮｾ

Ｎ＠

Tighten flywheel

nut

to

40-50

N'm (30-37

fUbs

.).

Fig.

SZI-I-Exploded

view

of

c."'urelo,

used on

models

p,'o,

10

1987.

On

1987

snd

I.

Ie'

models,

CB"'urero, Is equipped wlrh • pI/or

.,,

screw (Fig.

SZ1-2)

fo,

'ow

speed

mixture sd/usrmen/.

1.

ｓｰｾｴＮＮﾷ､＠

co

ntr

ol

a.:;::;y.

13

"0"

ｲｴｮｾ＠

2.

CIlP

nut

14. Idle sp

eed

scrc

.....

3. Spring

tG

. Spring

1. Tube: 16.

ｃ

ｨｯｫｾ＠

a..-..,

..

y.

5. C

lip

17

.

FUf'J

(iller

fl

.

SprlnR

!l

C!l(

18

.

l-'uI

.'1

illiN

\.'

;]

\ve

1.

ｾ｡ｴ＠

Ｑｾ

Ｎ＠

:\11Iin

nO:t:l

lc

8.

Thr

ottle

rod 20.

:\1.'110

j

et

f)

Clip 21.

Float

10 .

.TN

n

..

'OOle

22. Float

bowl

11.

Throttle

valve

23.

FIOfll

ann

12. Dody 2

-1

.

Pi\'ot

OUTBOARD

MOTOR

After

adjusting

breaker

points,

check

ignition timing using a dial indicator

and

an

o

hmmeter

or

continuit.y

tester

.

Re

-

move

the

spark

plug

and

insert

the

dial

indicator.

Set

piston position

at

TOC,

then

zero

the

dial

indicator

. Disconnect

the

black

lead

to

stop

button

and

con-

ne

ct

the

ohmmet.er

or

continuity

tester

between

lead

from

magneto

and

ground.

Rotate

the

flywheel

clockwise

until

meter

or

continuity

tester

indi-

cates

that

points

have

just

opened.

Dial

indicator

should

read

0.804 mm (0.032

in.).

If

ignition timing

adjustment

is re-

quired,

remove

the

flywheel

and

loos-

en

magneto base plate

(7-Fig.

SZI-3) re-

taining

screws. Rotating

base

plate

clockwise

retard

s ignition timing

while

rotating

counterclockwise

advances

ig-

nition

t.iming.

COOLING SYSTEM

WATER PUMP. A

rubb

er impeller

type

water

pump

is

used

to

cool

the

Pilot

Ai

r Screw

.......

--_Plug

Fig.

SZI-2-lnltl.'

setting

of

pilot

.,,

screw

on

models

so

equipped Is

/WO

lums

our from

sllghr-

Iy

seared

position.

---

1

---2

ｾＺＮＭＭ］ＺＺＺＺＺＭＭ

3

Fig.

SZI-3-Exploded

vleMf

of

magnero.

t.

ｾｵｲ＠

2. Lo('KW3!ihN

3. K(')"

4.

ｆｉｙＢＢｨ

ｾＱ＠

;).

Ignition coil

6.

ｉｾｮｩｬ

ｩｯ

ｮ＠

bh'ilk(!r

po

inL"

lJ.a

..

">(!

pl;lle

B. S

top

ｾｷｩｴ｣ｨ＠

Download this Manual

Suzuki DT5, DT6 & DT8

from

the

flywheel

side. Reassemble start-

er assembly

by

reversing disassembly

procedure.

To

place tension

on

rewind

spring

(2).

pass rope

(12)

through rope

outlet

in

housing (I) and install rope han-

dle

(II).

Pull

rope

(12)

out and hold

pulley

(3)

so

notch

on

pulley

is

adjacent

to rope outlet.

Pull

rope back through

outlet between notch

in

pulley and hous-

ing. Turn pulley

(3)

counterclockwise six

complete revolutions to place tension on

rewind spring

(2).

Release

starter

rope

(12)

and allow rope to

wind

onto pulley

(3).

Do

not place more tension on rewind

spring than

is

necessary to draw rope

handle

up

against hou

si

ng.

GEAR TYPE STARTER_

On

models

with gear type starter, starter may

be

removed and disassembled for overhaul

or renewal of individual components as

follows: Remove engine's top cover.

then remove rope handle

(11-

Fig.

SZ4-IS) and allow starter rope

(10)

to

wind onto

starte

r reel

(8).

Remove the

nut and cap screw securing

starter

assembly to power head and withdraw

assembly.

Use a suitable punch and

drive o

ut

(9).

Slide starter pinion (1)

with spring c

lip

(2)

from

starter

reel

(8).

Remove snap ring

(3).

then carefully

withdraw reel

(8)

from housing

(5)

so

re-

wind

spring

(7)

will

not

uncoil

from hous-

ing; a rapidly uncoiling rewind spring

could

cause serious injury. Broken re-

wind

spring

or

rope may

be

renewed

at

this point.

Rewind spring

(7)

is

wound

in

clock-

wise

direction into housing

(5)

as viewed

from bottom side. Wind

starter

rope

(10)

onto starter reel

(8)

in

a clockwise direc-

tion as viewed fr

om

bottom side. In

sert

reel

(8)

into housing, engaging eye

in

end

of spring with notch

at

reel base. In

sta

ll

Fig. SZ4·

14

- Exploded

./ew

of

cylinder

block

and

cranlc·

cas

••

ssembly

on

DrS

and

DT8 mod.,s. Drs

mod.,s

are

similar.

1.

Cronk""",

2. Cylinder b

lo.!

k

3.

c..k.t

.1. Cylindltt

he:

....

5.

ｇ｡ｳｫｾ

ｬ＠

6.

ｅ

ｸｨ｡ｾｴ＠

pl

at.c

; .

Gaw;('\

8.

E:o:hau

::

t (

x)VC'

r

Fig.

SZ4-15-Explodod

.'ow

0'

o.emead Iypo

manual

sfarl.r.

1.

H

ousi

ng

2.

Rt.

>Wi

nd

ｾ

ｲｩｮｊＡ＠

3.

Pul

ley

.

..

Spri

ng

5. Spao:!r

6. fu.

>t

um

sprin)r

7. Dri

..

'e pawl

8. Drive plate

9. Washer

ｌｏＮｾ

ｬＧ＠

11.

HaOOIe

12.

Start.t.or

rope

13.

Ilop<

guide

14.

Plate

15.

Spring

16.

Retainer

snap ring

(3).

then place

starter

pinion

(I) with spring clip

(2)

on

shaft. Make

certain spring clip

is

centered over lug

on

housing. Install pin

(9).

Thread

start

-

er

rope

(10)

through

starter

housing

(5)

a

nd

attach rope handle (II). Ho

ld

sta

rt

er

reel

(8)

so notch on

starter

reel pulley

is

adjacent to rope out

le

t. Pull a l

oop

of

rope back through outlet between notch

in

pulley and housing. While grasping

rope,

tum

starte

r reel

(8)

one complete

revolution clockwise as viewed from

bot-

tom side to place tension on rewind

OUTBOARD MOTOR

1

10

11

"'"

:x

ｾ＠

Fig.

SZ4

·

15-Exploded

./ew

0'

goa, Iypo manu"

startef.

1. St.arter pinion

2. Spring

dip

3. S

"""

ring

4. Bushi

ng

i .

14....md

ｾｰｲｩｮｧ＠

8.

ｓｬＮＧＮｲｴｶｲｾ＠

9. Pin

5. Housi

n,R

10

.

Stoner

rope

6. B

u.1hi

n£

11.

HaOOlc

spring

(7).

Release

starter

rope

(10)

and

allow rope to wind onto

starter

reel

pulley.

Do

not place more tension

on

re-

wind spring than is necessary to draw

rope handle

(11)

up

against engine's bot-

tom cover.

LOWER UNIT

PROPELLER AND

SHEAR

PIN.

Pro-

peller for normal use has

three

blades

and

is equipped with a

shea

r pin to pre-

vent

damage to lower

unit

gears. Stan-

dard

propeller has a 200 mm (7-7/8 in.)

diameter

on

OT5

and

DT6

models and

215

mm

(8-112

in.) on Model

DT8.

Stan-

dard propeller has a pitch of

170

mm

(6

-

3

1

4 in.) on

1IIodeI

DT

5,

190 mm (7-1/2

in.) on Model

DT6

and 180 mm

(7-118

in

.) on

Mod

el

DTS

. Optional propellers

are available

fr

om

the

manufacturer

and should be sele

cted

to

provide full

throttle operation within

the

reco

m-

mended limits of 4800-5500 rpm on

DT5

models and 5200-5700 rpm on Models

DT6

and

DT8

.

R&R AND OVERHAUL. Refer to

Fig.

SZ4-17 for exploded view of lower

unit gearcase assembly. During

disas-

sembly. note the location of

all

s

him

s

and washers to aid

in

reassembl

y.

To

remove gearcase. first remove drain

-

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Suzuki DT2 User manual

Suzuki DT2 User manual

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