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.)
Download this Manual
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＠
pin
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
pin
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
pin
(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
-
http://SelfFixer.com
Download this Manual
/