Suzuki Dt Outboard Workshop Repair Manual

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Suzuki Dt Outboard Workshop Repair Manual

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Service Manual Application: Suzuki Workshop Service Manual DT 2 THRU 225 HP 1988, 1989, 1990,

1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 DT Outboard Engines.

This workshop service repair manual gives step by step information on maintenance, repair and

mechanic overhaul. This manual is detailed with hundreds of photos, pictures and illustrations to help

guide you through repair procedures. It will help you understand, care for, and lower the repair and

maintenance cost for your Suzuki Outboard Engine (motor) for a overall improved satisfaction with your

ownership. MODELS & YEARS COVERED: DT2 (DT-2) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995

& 1996 DT2.2 (DT-2.2) 1997 DT4 (DT-4) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 &

1998 DT5Y (DT-5-Y) 1998, 1999, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1999, 2000, 2001 & 2002

DT6 ( DT-6) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 & 1997 DT8 (DT-8) 1988, 1989,

1990, 1991, 1992, 1993, 1994, 1995, 1996 & 1997 DT9.9 ( DT-9.9) 1988 thru 1997 DT15 (DT-15)

1988-1989 DT20 (DT-20) 1988 DT25 (DT-25) 1990-1991 DT30 (DT-30) 1989-1997 DT35 (DT-35)

1988-1997 DT40 (DT-40) 1988-1998 DT55 (DT-55) 1988-1997 DT65 (DT-65) 1988-1997 DT75 (DT-75)

1988-1997 DT85 (DT-85) 1988-2000 DT90 (DT-90) 1989-1997 DT100 (DT-100) 1989-1996 & 1996-2001

EFI DT140 (DT-140) 1988-1996 & 1996-2001 EFI DT150 (150) 1988-1994 & 1995, 1996, 1997, 1998,

1999, 2000, 2001, 2002 & 2003 EFI DT175 (175) 1988-1992 DT200 (200) 1988-1992 & 1993-2000 EFI



DT4/DT5Y 1999+ DT5 DT6 & DT8 1999+ DT25C DT30C (DT25-C, DT30-C) 1999+ DT75 & DT85 1999+

DT100TC 1999+ DT115STC & DT140TC EFI (DT115-STC, DT140-TC) 1999+ DT150 / 175 / 200 1999+

DT225 M Below is a SMALL sample of some of the chapters including some of the information contained

in each chapter. There are many more chapters and data in this manual. CHAPTERS GENERAL

INFORMATION How To Use This Manual: can you do it, where to begin, avoiding trouble, maintenance

or repair, directions and locations, professional help, purchasing parts, avoiding the most common

mistakes. Boating Saftey: regulations for your boat, documenting of vessels, registration of boats,
numbering of vessels, sales and transfers, hull identification number, length of boats, capacity

information, certificate of compliance, ventilation & systems, required saftey equipment, sound producing

devices and much more. Saftey In Service: dos & donts. TOOLS & EQUIPMENT Tools And Equipment:

safety tools, work gloves, eye/ear protection, work clothes, chemicals, lubricants & penetrates, sealants,

cleaners. Tools: hand tools, socket sets, wrenches, pliers, screwdrivers, hammers, other common tools,

special tools, electronic tools, gauges, measuring tools, micrometers & Calipers, dial indicators,

telescoping gauges, depth gauges. Fasteners/Measurements & Conversions: bolts, nuts & other threaded

retainers, torque, standard and metric measurements. Specifications Charts: conversion factors

MAINTENANCE Engine Maintenance: serial number identification, 2-stroke oil, oil recommendations,

filling, lower unit, draining & filling, fuel filter, relieving fuel system pressure, removal and installation,

fuel/water separator, trim/tilt pivot points, inspection and lubrication, propeller. Boat Maintenance: inside

the boat, fiberglass hulls, trim tabs, adodes and lead wires, battery/cleaning/checking specific

gravity/terminals/charging & safety/replacing battery cables. Tune-UP: introduction, tune-up sequence,

compression check, checking compression, low compression, spark plugs, spark plug heat range, spark

plug service, removal and installation, spark plug gap, spark plug wires, timing and synchronization, DT2

(DT2.2) ignition timing, idle speed, DT4, DT6, DT9.9 and DT15, DT-15. FUEL SYSTEM Fuel and

Combustion: fuel recommendations, octane rating, vapor pressure and additives, the bottom line with

fuels, high altitude operation, alcohol blended fuels, abnormal combustion, factors affecting combustion.

Fuel System: carburetion, general information, carburetor circuits, basic functions, dual throat

carburetors, removing fuel from the system, fuel pump. Troubleshooting: fuel system, logical

troubleshooting, common problems, fuel pump, fuel line, common broblems, combustion related piston

failures. Carburetor Service: DT2 & DT-2.2, removal, installation, disassembly, cleaning, inspection,

assembly, DT4 & DT5Y, DT6 (DT-6) and 1988 DT8 (DT-8), DT20 (DT-20) to DT85, DT115 (DT-115),

DT140 ( DT-140), V4 & V6 powerheads, DT4 THRU DT85, DT90 Thru DT200. IGNITION & ELECTRICAL

Understanding and Troubleshooting Electrical Systems: basic electrical theory, how electricity works,

water analogy, ohms, electrical components, power source, ground, protective devices, swithes & relays,

load, wiring & harnesses, connectors, test equipment, jumper wired, test lights, open circuits, short

circuits, wire and connector repair, electrical system precautions and much more. Breaker Points Ignition

(MAGNETO IGINITION): system testing, breaker points, point gap adjustment testing, condenser, ignition
coil testing/removal/installation and much more. Capacitor Discharge Ignition CDI System: description

and operation, single cylinder ignition, Suzuki PEI ignition, System testing procedure, pulsar, charging

gear counter coils, ignition coils, CDI unit and more. OIL INJECTION Oil Injection System: description and

operation, oil pump, air/oil mixing valve, troubleshooting the oil injection system, bleeding the oil injection

system, oil tank, oil pump, oil lines, oil pump discharge rate testing & adjustment, oil pump control rod

adjustment. Cooling System: water pump, thermostat, removal, installation, cleaning, inspection. Oil

Injection warning System: Low oil level, oil flow, troubleshooting the oil injection warning system, oil level

sensor, oil flow sensor. Overheat Warning System: overheat sensor, testing, removal, installation, light,

buzzer. POWER HEAD Engine Mechanical: the two stroke cycle, flywheel removal, installation,

inspection, powerhead, disassembly & assembly. Powerhead Reconditioning: determine powerhead

condition, primary compression test, secondary compression, buy or rebuild, powerheand overhaul tips,

tools, cautions, cleaning, reaping damaged threads, power head preparation, cylinder block and head,

general information, inspection, cylinder bores, pistons, piston pins, piston rings, connecting rods, the

crankshaft, bearings. Specifications Charts: Torque Specs, engine rebuilding specs & specifications.

LOWER UNIT Lower Unit: general information, shifting principles, standard rotating unit, counter roatating

unit, troubleshooting the lower unit, propeller removal & installation, lower unit, no reverse gear, lower unit

with reverse gear. Lower Unit Overhaul includes disassembly, cleaning, inspection, assembly, shimming

procedure: DT4, DT5Y, DT6, DT8, DT9.9, DT15, DT20, DT25, DT30, DT35, DT40, DT55, DT65, DT75,

DT85, DT115, DT140, V4 & V6, JET Drive TRIM & TILT Manual tilt, gas assist tilt, power tilt, power trim

tilt and more. Suzuki Workshop Service Manual, Owners Workshop Manual, Repair Guide, Repair

Manual, 2hp, 2.2hp, 4hp, 5hp, 6hp, 8hp, 9.9hp, 15hp, 20hp, 25hp, 30hp, 35hp, 40hp, 55hp, 65hp, 75hp,

85hp, DT-90hp, 100hp, 140hp, 150hp, 175hp, 200 hp, 225hp, 1988, 1989, 1990, 1991, 1992, 1993, 1994,

1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 00,

01, 02, 03

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