SERVICE MANUAL Suzuki OT30 (Prior to 1988)

SUZUKI SUZUKI AMERICA CORPORATION

3251 E. Imperial Highway P.O. Box 1000

Brea, California 92621

SUZUKI DT30 (Prior To 1988)

CONDENSED SERVICE MANUAL

NOTE: Metric fasteners are used throughout outboard motor.

TUNE-UP Hp/rpm . . . . ......... ... . .... . ...... 30/4800-5500 Bore .............. . ......................... 71 mm

(2.80 in.) Stroke ....... . .......... . .. . ....... . . .. ..... 63 mm

(2.48 in .) Number of Cylinders ....................... ....... . 2 Displacement .......... .. . .. . . .. . . ... ......... 499 cc

(30.45 cu. in .) Spark Plug:

NGK ......... ..... .... ........... ........ BR7HS Electrode Gap ............. . ...... ....... 0.9-1.0 mm

(0.03!)-O.0:39 in.) Ignition Type ...... . ......... ................... CD! Carburetor l\!ake .. .. . .. . ....... . ............. Mikuni Idle Speed (in g-ear) ......... . . ........ .... 6!)0-700 rpm Fuel:Oil Ratio .................................. 50: 1

SIZES-CLEARANCES Piston Ring- End Gap ...... ...... . .......... 0.2-0.4 mm

(0.008-0.016 in.) Piston-to-Cylinder Cleanlnce:

Prior 1,) 1987 . . . . . . . . .. . ..... 0.067-0.082 mm (0.0026-0.00:32 in.)

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

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

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

(0.002 in.) Max. Connecting Rod Small End

Side Shake ................... .............. 5.0 mm (0.020 in.)

TIGHTENING TORQUES Power Head Mounting Screws ............... 15-20 N· m

(11-14 ft.-Ibs.) Crankcase:

6mm . . ... . .......... ................... 8-12N·m (6-8 fUbs .)

8mm .. .. ............... ..... .. . ...... . 20-26N·m (14·19 ft.-lbs. )

TIGHTENING TORQUES CONT. Flywheel Nut ................. ... . ...... 130-150 N'm)

(94-108 ft.·lbs.) Cylinder Head Screws:

'6 mm ................ . . ................. 8-12N·m (6-8 ft.-Ibs .)

8mm ......... .. ....................... 20·26N·m) (14-19 ft.-Ibs .)

Gearcase Pinion Nut ... .. ____ . .. .. ......... 18-22 N' m (13-16 ft.·lbs.)

Propell er Shaft Nut ....... .. ............... 27-30 N' m (19-21 ft.-Ibs.)

Standard Screws: Unmarked or Marked "4"

5 mm ................... . . .. ........... . 2-4 N'm (2-3 ft.-Ibs.)

nmm ............. .. . ... ...... . ......... 4-7N·m (3-5 ft. -Ibs.)

8mm . .. ......... . ... . . . . .. ....... .... l0-16N·m (7-12 ft.·lbs.)

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

Stainless Steel 5mm ............. .. __ ........... . ...... 2-4N·m

(2-3 ft.-Ibs.) 6mm .... _____ ........................ . 6·10N·m

(5·7 ft.-Ibs.) 8mm ................................. 15-20N·m

(11-15 ft.-lbs.) 10mm ..................... . .......... 34-4 1N·m

(25-30 ft.-lbs.) Marked "1" or SAE Grade !)

5mm ..... .................. .... ........ 3-6N·m (2-5 fUbs.)

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

8mm ................................. 18-28N·m (13-20 ft.-Ibs.)

10 mm .... .. . . .. . . ........ ............ 40-60 N'm (29-44 ft.-Ibs.)

Suzuki DT30 (Prior to 1988)

LUBRICATION

The power head is lubricated by oil mixed with the fue l. On models prior to 1987, fuel :oil ratio should be 30:1 dur­ing break-in (first five hours of opera­tion) of a new or rebuilt engine and 50:1 for normal service. On models a fter 1986, fuel :oil ratio during engine break­in should be 25:1 and 100: 1 for normal service. Recommended oil is Suzuki Out­board Motor Oil or a suitable equivalent N~I~IA (formerly mAl certified TC-WlI oi l. Recommended fuel is regular or un­leaded gasoline with a minimum pump octane rating of 85.

The lower unit gears and bearings are lubricated by approximately 230 mL (7.77 ozs.) of SAE 90 hypoid outboard gear oi l. Reinstall vent and fill plugs se-

Fig. SZl1-1-Exploded .I.w 01 Mlkunl 832·28 carburetor.

l. Body 2. 101 .. speed tl( n.ow ". \1",,, noz;r.k 3 . Spri~ 10. ~njet .. Pi lot I I. f loat 5, Sp'nnv. 12. !'in b. P1IQ\ a.ir lICl"eW 13. G;U.k~t

' . G;uke~ 14. F1(.13.t bo .... ,1 8 N~c &:K'at 15. COOke kmb

Fig. SZl1-2-01,'ance (0) lor co"ecl 1100' le.el should be 1()'12 mm (0.394.j).412 In.~

curely using a new gasket, if necessary, to ensure a water-t.ight seal.

FUEL SYSTEM

CARBURETOR. A Mikuni B32-28 car­buretor is used. Refer to Fig. SZll-1 for exploded view. Initial set.ting of pilot air screw (6) from a lightly seated posi tion should be II.:, to 1 'I~ turns open on models prior to 1987 and II!, to 2 turns open on models after 1986. Final carbu­reto r adjustment should be made with engine at normal operating temperature and running in forward gear. Ad,just idle speed screw (2) so engine idles at ap­proximately 650-700 rpm. Adjust pilot air screw so engine idles smoothly and will accelerate cleanly without hesita­tion. If necessary, readjust idle speed screw to obtain 650-700 rpm idle speed.

Main fuel metering is controlled by main jet (10). Standard main jet size for normal operation is 11160. Standard pi­lot jet (4) size is 1177.5 on models prior to 1987 and #81) on models after 1986.

1b check float level, remove float bowl (14) and im'ert carburetor body (I). Dis­tance (D-Fig. SZl1-2) between main jet and boltom of float should bE! 10-12 mm (H i" to " I" in .). Bend float tang to ad­just float level.

FUEL FILTER. A fuel filter assembly is used to filter the fuel prior to entering the fuel pump assembly. Periodically unscrew cup (5 - Fig.

Fig. SZf1-3-Exploded "ew 01 luel IIIler ass.mbly.

I . RA..,((, 2. ~C'll 3. "0" ri nr.

., E I~rr.('nt

5. C""

OUTBOARD MOTOR

SZll-3) from base (I) and withdraw filter element (4). Clean cup (5) and filter element (4) in a suitable solvent and blow dry with clean compressed air. Inspect filter element (4). If excessive blockage or damage is noted, then the element must be renewed.

Reassembly is reverse order of disas­sembly. Renew "0" ring (3) and, if need· ed, seal (2) during reassembly.

FUEL PUMP. A diaphragm fuel pump (Fig. SZll-4) is mounted on the side of power head cylinder block and is actuated by pressure and vacuum pulsa­tions from the engine crankcase.

When servicing pump, scribe ref­erence marks across pump body to aid in reassembly. Defective or questionable parts should be renewed. Diaphragm should be renewed if air leaks or cracks are found, or if deterioration is evident.

REED VALVES. The reed valves are located on a reed plate that is located behind the intake manifold. The intake manifold must be removed in order to remove reed plate and service reed valves.

Renew reed valves (2 - Fig. SZll-5) if petals are broken, cracked, warped, rusted or bent. Tip of reed petal must not stand open more than 0.2 mm (0.008 in .) from contact surface. Reed stop

Fig. SZ11·4-Exploded "ew 01 diaphragm Iy". luel pump.

1. Uwtr 2. o;.phmgm 3. GWft 4. Valv(' bodv .'). PIl\~ .

fi . Casket 7. Spring R Spring ~l 9. Ch~)': v(t!ve

1

o

Fig. SZ11·5-VI ... Idenllfying re.d p/ele (1~ reed .01 ... (2) and reed Slops (3~ R.ed .,op opening

(0) should be 5.0·5.4 mm (0.24-0.25 In.~

SERVICE MANUAL

opening (0) should be 6.0-6.4 mm (0.24-0.25 in.).

SPEED CONTROL LINKAGE. Place twist grip in the full closed posi­tion. Stator plate stopper (P- Fig. SZ11-8) should be in contact with cylinder block boss (D). Adjust rod (A - Fig. SZl1-6) length until mark (M) on throt­tle cam (C) is centered with roller (R). Rotate twist grip to the full throttle position. Stator plate stopper should be in contact with cylinder block boss. Ad­just rod (B) length until throttle limiter (L) contacts stopper (S) on bottom engine cover.

IGNITION

A breakerless, capacitor discharge ig­nition system is used. Refer to Fig. SZl1-7 for wiring diagram.

Full throttle and full ignition advance should occur simultaneously . Ignition timing is mechanically advanced and must be synchronized with throttle opening.

To check ignition timing, first im­merse lower unit of outboard motor in water. Connect a suitable tachometer to engine. Connect a power timing light to upper spark plug. Start engine and al­low it to run until it reaches normal operating temperature. Shift into for­ward gear and note ignition timing. Tim­ing pointer (T-Fig. SZll-8) should be aligned with 2 degree A TOC mark (A) on flywheel. Loosen locknut and rotate screw (S) until idle speed timing is as recommended. Maximum advance tim­ing should be 25 degrees BTOe (M) at 5000 rpm. Stop engine and loosen cap screws (e) and slide stator plate stopper (P) in slots to adjust maximum advance timing. Retighten cap screws (e ) after recommended maximum advance tim-

A

Fig. SZl1·6-Vlew 01 .peed conl,olllnkege. Ad· Just components 8S outlined In text.

A. Rod B. R.>d C. Thrnul" cam 1... Throule limiter

~d . r-.t.ltk R. Rullcr :=;. gtnppcr

ing is obtained . Reset idle speed timing as previously recommended.

If ignition malfunction occurs, check condition of spark plugs, and all wires and connections before trouble­shooting ignition circuit. Using Suzuki pocket tester 09900-25002 or a suitable ohmmeter, refer to the following test specifications and procedures to aid trouble-shooting.

To check secondary coil resistance of COl unit, detach spark plug wires at spark plugs. Connect a tester lead to ter· minal end of each spark plug wire. Secondary coil resistance should be 2136-3204 ohms at 20°C (68°F).

Remove top cover of electrical parts holder for access to wire connectors. Remove top three· wire coupler and separate. To check charge coil (Fig. SZl1· 7), connect a tester lead to black wire with red tracer and black wire of three· wire connector leading to stator plate. Charge coil can be considered satisfactory if resistance reading is within the limits of 102·154 ohms at 20°C (68°F).

To check pulser coil, connect a tester lead to red wire with white tracer and black wire of three-wire connector leading to stator plate. Pulser coil can be considered satisfactory if resistance reading is within the lii'nits of 27.9·41.9 ohms at 20°C (68°F).

Check condition of battery lighting coil by separating connectors of yellow wire and red wire. Connect a tester lead to terminal end of wires leading to stator plate. Lighting coil can be con· sidered satisfactory if resistance reading is within the limits of 0.24·0.36 ohms at 20°C (68°F).

Start Swlt c. h C(~~:::t-~--'

E,q. , !'I e 0 g LIA D:::LJ!II It

St OD ~'-___ -'-____ "'~<:b-s ... , tc h ." ~:, ~ ... G .• __ . ~,'

J , .. :.:.;~-:.~~. _ ~L I • • • !. - .~- .... .. -

EmE rgency Stop S ~'i tch

Suzuki DT30 (Prior to 1988)

If no component is found faulty in the previous tests, then the CD! unit must be renewed.

COOLING SYSTEM

WATER PUMP, A rubber impeller type water pump is mounted between the drive shaft housing and gearcase. A key in the drive shaft is used to turn the pump impeller, If cooling system prob· lems are encountered, check water in· takes for plugging or partial stoppage. If water intakes are clear, remove gear· case as outlined under LOWER UNIT and check condition of the water pump, water passages and sealing surfaces.

When water pump is disassembled, check condition of impeller (8 - Fig. SZl1-19) and plate (9) 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.

Fig. SZl1·8-Adju.r Idle .peed liming and me.· Imum IIdrllnce timing liS outlined In fexf.

A. 20 ATDC m:tr-k P. Sr<ttlJr pLlI t(" stoppt'r C. Cap ::C rcWIi S. Idl(' speed tl min,l( D. CY!Ir:dcr block bo~ adju:5t me-l"I1 l'ICn..v,-

~1. 2~" BTOC mnk T Timing point(·t

-- -----i , -:.~ -.

l ___ .

1;'0 1t~ge

r--~.., Re9vLttor -!..

COl Unit

l~~~~~~ __ J !.11th 19n1t10n Call

Fig. SZl1·7-WI,/ng dleg,am 01 e/ecl,lca/syslem on model. w/lh elecl,'c 'Ia"e,. B. BI""k G. Grt.'t!n R. R,,>d

\~' . " 'hile Br. Brown y. )',,!low B/R. BI~k ..... jth n.-d tracer R/W. Red with ....,h)te t~r BI. Blue BllR. Blut' wilh red l.I'acer Y/G. Yellow with ~t'I IJ'3C('r

Suzuki DT30 (Prior to 1988)

THERMOSTAT. A thermostat (7-Fig. SZll·14) is used to regulate oper· ating temperature. Thermostat should start to open within the temperature

4--'-

Fig. SZI1·9- T/ght.n crenkc .... cr .... In th. sequ.nc •• h ... n. R.,., t. CONDENSED SERVo

ICE DATA '.r .cre .. t.rques.

Fig. SZI1·10-T/ght.n cyllnd., h •• d .cre ... In •• qu.nc •• h ..... R.,., t. CONDENSED SERVo

ICE DATA '.r .cre .. t.rqu ••.

range of 48.5 °.51.5° C (119°.125° F). Thermostat can be removed for inspec· tion or renewal by removing cylinder head cover (6).

POWER HEAD

REMOVE AND REINSTALL. To remove the power head, first remove engine's top cover, Disconnect throttle cables, throttle limiting rod, fuel inlet hose at lower engine cover connector, choke knob and wires which will in· terfere with power head removal. Label wires, if needed, for later reference, Remove and carburetor's air intake cover, carburetor, rewind starter, starter motor relay and electric starter motor. Remove eight screws which secure power head assembly to drive shaft housing and lift off power head.

Before reinstalling power head, make certain drive shaft splines are clean then coat them with a light coating of water resistant grease. Install power head on drive shaft housing. Coat threads of retaining cap screws with silicone sealer and tighten screws to 15·20 N'm (11·14 ft.·lbs.). The reo mainder of installation is the reverse of removal procedure. Refer to SPEED CONTROL LINKAGE for synchroniz· ing throttle opening .... -ith ignition ad· vance.

DISASSEMBLY. Disassembly and inspection may be accomplished in the

Fig. SZ1",2-Explod.d .1... 0' pl.t.n .nd crank.h.ft .... mbly.

1. Seal 2. B."lll hcarin~ 3. Cmnk half .'- Crank h.taI f 5. IAbyrinth!ll'al 6, Wuhtr 1. s...J 8. Seat!l 9. Crnnk pin

10. Thru.~t V.'Q.dlCN. 11 . RoIIl'r~ng 12. Conn~tlng rod 13. Tnr\L"It w~n 14 . R,Qllcl" bearing 15. Cin:lip~ . 16 Pi!$to n pi n 17. Pi$ton I S. Pi~tfln rin..,

OUTBOARD MOTOR

following manner. Remove electric starter bracket, exhaust tube, fuel filter and fuel pump. Remove flywheel and key, stator plate with pulser, charge and lighting coils, Remove electrical parts holder, speed control linkage, upper oil seal hall sing and stator retainer ring, Remove intake manifold , reed valve plate, exhaust cover and exhaust plate with gaskets. Remove cylinder head and cover with gaskets. Remove the twelve crankcase cap screws, then separate crankcase from cylinder block. Lift crankshaft assembly with pistons and connecting rod assemblies from cylinder block.

Engine components are now accessi· ble for overhaul as outlined in the ap· propriate following paragraphs, Clean carbon from cylinder head and combus· tion chambers and remove any foreign material accumulation in water pas· sages. Inspect components for damage and renew if needed. Refer to the follow­ing section for assembly procedure.

ASSEMBLY. Refer to specific servo ice sections when assembling the crank­shaft, connecting rods, pistons and reed valves. Make sure all joint and gasket surfaces are clean and free from nicks and burrs. Make sure all carbon, salt, dirt and sand are cleaned from the com· bustion chambers, exhaust ports and water passages.

Lublicate crankpin bearings a nd cyl· inder walls of cvlinder block with Suzu· ki engine oil or" a suitable NMMA certi· fied two·stroke engine oiL Install crankshaft assemblv in crankcase. Make sure flange of lo~er oil seal (7 - Fig. SZll·12) and middle labyrinth seal (5) fits properly in crankcase grooves. Make sure bearing pins engage notches in crankcase, Spread a coat of Suzuki Bond No. 1215 or a suitable equivalent on the mating surfaces of the crankcase and the cylinder block. Posi tion crankcase half on cylinder block and tighten the crankcase screws in the sequence shown in Fig. SZ11·9 to torques sho'9l in CON· DENSED SERVICE IWn ... Tighten the cylinder head screws in thc sequcnce shown in Fig. SZ11·10 to torques shown in CONDENSED SERVICE DATA, Tighten the intake manifold screws in the sequence shown in Fig. SZ 11·1 L

PISTONS. PINS. RINGS AND CYLINDERS, Each piston is fitted with two piston rings. Piston ring end gap should be 0.2·0.4 mm (0,008-0.016 in.) with a maximum allowable ring end gap of 0.8 (0.031 in.), Piston rings are reo tained in position by locating pins. Standard piston pin diameter is 17,995-18.000 mm (0,7085·0.7087 in.). Install marked side of piston ring toward top of piston. Piston to cylinder

SERVICE MANUAL

wall clearance should be 0.067·0.082 mm (0.0026·0.0032 in.). Piston and rings are available in standard size as well as 0.25 mm (0.010 in.) and 0.50 mm (0.020 in.) oversizes. Cylinders should be bored to an oversize if either of the cylinders is out·of·round or taper exceeds 0.10 mm (0.004 in.). Install pistons on connecting rods so arrow on piston crown points toward exhaust port side of cylinder bore.

CONNECTING RODS. BEARINGS AND CRANKSHAFT. Connecting rods. bearings and crankshaft are a press together unit. Crankshaft should be disallsembled ONLY by experienced service personnel and with suitable service equipment.

Caged roller bearings are used at both large and small ends of the connecting rods. Determine rod bearing wear from side to side as shown in Fig. SZll·I3. Normal side to side movement is 5.0 mm (0.20 in.) or less. Maximum limit of crankshaft runout is 0.05 mm (0.002 in.) measured at bearing surfaces with crankshaft ends supported.

--I'

Fig. SZ11·13-Mo •• conn.ct/ng rod .m.II .nd sid. to sid. to determine conn.ct/ng rod, b •• ,·

Ing .nd crank pIn .... .,. R.ler 10 t •• ,.

Apply Suzuki Super Grease "A" or a suitable high temperature grease to lip portion of lower crankshaft seal prior to installation.

MANUAL STARTER

Refer to Fig. SZll-I5 for an exploded view of manual starter assembly. Starter may be removed as a complete unit by detaching the neutral start cable and removing the three cap screws securing starter assembly to power head. To disassemble starter, proceed as follows : Remove starter handle (I6-Fig. SZll-I5) and allow starter rope (14) to slowly wind onto pulley (4). Detach neutral start components. Invert starter housing (1) and remove cap screw (17). Withdraw plate (10) and spring (9).

Remove drive pawl (6) and return spring (5). Remove snap ring (8). Lift pulley (4) with starter rope (14) from starter housing. Use suitable hand and eye protection, and withdraw rewind spring (2) from starter housing (1). Be careful when removing rewind spring (2); a rapidly uncoiling starter spring could cause serious injury.

To reassemble, coat. rewind spring area of starter housing (1) with a suitable water resistant grease. Install rewind spring (2) in starter housing. Re­wind spring (2) must wind in a counter­clockwise direction from the outer end. Wrap starter rope (14) in a clockwise direction 21f2 turns onto pulley (4) when viewed from the flywheel side. Reassem­ble starter assembly by reversing disassembly procedure making certain rewind spring's hook properly engages groove in pulley (4). Apply water resis­tant grease to friction side of drive plate (10). Make sure slot (S-Fig. SZll-I6) in

FIg. SZ11·14-E.plod.d ., .... 01 cylinder block .nd

crankcase .558mb',. 1. Crankc;u;c 2. Cvlinder bl(~k 3. Ga..~k~l ·1. Cyli nder head 5. Gi\ . .'>.ket 6. Cvlinder head ('OWf

7. Ttum nO'St:\t 8. Ga.~et 9. Exhaust pl:\te

10. GMket 11. Exhau~t ower 12. Upper oil seal housing 13. G;\.<;k~t

Suzuki 0130 (Prior to 1988)

drive plate properly engages tab (T) on starter housing boss and spring (9) fits into groove (G) in pulley (4).

To place tension on rewind spring (2-Fig. SZll-I5), pass starter rope (14) through rope outlet in hOl.(sing (1),

Fig. SZ11·15-E.plod.d .I.w 01 m.nu.' .t.rter • .. embly.

1. HouS'ing 2. Rewind sprin~ 3 Bushjn~ 4. Pulley 5. R(lturn ~ring 6. Drive pi .... 1 7. Spacer 8 Snap rinJ.':' 9. S~ring

10. Pl:l.l(" 1<1. Sprin&

g: ~~:(e 14. S~r ""'pt '1 5. Clip 16. H:lndle 11. C:tp ~n.'W

Fig. SZ11-16-Dur/ng ,. •••• mbly •• 'ot (S) In dr/ •• pl.t. mu.t properly .ng.g. t.b (T) on .t.rter hou./ng boss .nd sprJng (9) mu.t lit Into

groo •• (G) /.I!J>d"'y (4~

FIg. SZ11·17-For proper n.ut,., .t.rt c.bI •• d· lu.tm.nt, mark (M) In I ••• r (L) must ". bot .... n m.,ks (X .nd y) on .tarter hou.'ng (1) wh.n goar sllitt 'ewlt Is In i'Forward" 01 .. R .... t'." position.

Suzuki DT30 (Prior to 1988)

spring (11), rope guide (12), rubber plate (13) and install rope handle (16). With starter rope (14) inserted in slot of pulley (4), rotate pulley 4 turns counter· clockwise when viewed from the fly­wheel side. Secure pulley, then release starter rope (14) from slot in pulley and allow starter rope to slowly wind onto pulley. Do not place any more tension on rewind spring (2) than is necessary to draw rope handle up against housing.

Remount manual starter assembly and reassemble neutral start cable and associated components. With the gear shift lever in the "Forward" or "Reverse" position, mark (M - Fig. SZl1·17) in lever (L) must be between marks (X and Y) on starter housing (1). Adjust the length of the neutral start cable to obtain the correct adjustment.

ELECTRIC STARTER

Some models are equipped with elec­tric starter shown in Fig. SZ 11·18. Disassembly is evident after inspection of unit and reference to exploded view. Standard commutator outside diameter is 30 mm (1.18 in.) and should be re­newed if worn to a diameter of 29 mm (1.14 in.) or less. Starter brushes have a

13

Fig. SZII·18-Exploded .Iew of electric sta" mOlor.

I . Rct,ainN 2. Stop 3. Sprin~ 4. Drive 5. Frame heM 6. Fn.me 1. Brosh

8. Sprinf{ 9. Bru!:lh holder

10. ArmatuF'e' 11. Thrust W83het 12. Frame end 13. Through-bolt

standard length of 12.5 mm (0.492 in.) and should be renewed if worn to 9 mm (0.354 in.) or less. During reassembly, make sure upper and lower alignment marks on frame (6-Fig. SZl1-18) align with notches in frame head (5) and frame end (12). After reassembly, bench test starter before installing on power head.

OUTBOARD MOTOR

LOWER UNIT

PROPELLER AND RUBBER DAMPER. A ratchet hub (50-Fig. SZ 11-19) is used to provide shock pro­tection for lower u nit gears and shafts. Three-bladed propellers are used. Standard propeller has a 260.3 mm (101/.

in.) diameter and a 304.8 mm (12 in.)

r.r 1

' . ,

v 'iJ

so

Fill. SZII·19-Exploded ,lew of lower unit gearcase assembly. 1. Grommet 15. Drive shaft 42. RcvC'~ gear 2. Water tube 16. Washer 29. Shim 43. Shim 3. Grommet 17. S~ring 30. Forward g-ear 44. "0" rin~ • . &.1 rube 18. Trust wa.. .. het 3L Shim 45. Bcaring 5. Grommet 19. W<lSher 32. Spring RUidc 46. Bt!1V'ing carrier 6. Wa~r pump housing 20. Coli.,. 33. Pin "7. B('aring 7. Kev 21. Snap ring 34. Dog dutch 48. ~al, 8. ImPeller 22. Bearing 35. RC'ta.iner 49. Spa.c:cr 9. Platl! 23. Level plug 36. Spring 50. Ratchet hub

10. Gasket 24. Gasket 37. Propeller shJ\lt 51. PropellC'r II. Upp.!r bearing housing 25. Drain plu~ 38. Shim 52. S~r 12. s",u 26. Hou!'ri n~ 39. Pinion gear 53. Wa.o;her 13. Bearing 27. B(>:uing '0. Nut 54. Nut 1·1. '"'0" ring 2lL Rod ". Shim 55. C<lttcr pin

SERVICE MANUAL

pitch on short shaft models and 279.4 mm (11 in.) pitch on long shaft models. Optional propellers are available from the manufacturer and should be selected to provide full throttle operation within the recommended limits of 4800-5500 rpm.

R&R AND OVERHAUL. Refer to Fig. SZl1-19 for exploded view of lower unit gearcase assembly. During disassembly. note the location of all shims and ;"'ashers to aid in reassembly_ To remove gearcase. first remove drain plug (25) and level (vent) plug (23) and drain gear lubricant. Loosen shift rod locknut (9 - Fig. SZ 11-22 and turn ad­justment nut (8) until upper and lower shift rods are separated. Remove cotter pin (55 - Fig. SZl1-19). nut (54), washer (53). spacer (52) and withdraw propeller (51) with ratchet hub (50). Withdraw spacer (49). Remove six lower unit cap screws_ Withdraw lower unit assembly from drive shaft housing.

Remove bearing carrier (46) retaining screws. Being careful. use a suitable slide hammer and extract bearing car­rier with propeller shaft assembly. Disassemble water pump assembly. Remove pinion nut (40) and withdraw pinion gear (39) and shim (38). Remove cap screws securing upper bearing hous-

J J

Fig. SZ11-20-Us. two 5 mm J.ckscr.ws pos/· !lon.d as shown to wllhdr.w upper b •• r/ng

housing wllh drl •• sh." compon.nts_

34

31

F/g_ SZ11-21-lnst.1I dog clutch (34) on prop.lI.r shart (37) so "F" mark Is toward forw.rd g •• r_

ing. then use two 6mm cap screws posi­tioned as shown in Fig. SZl1-20 and tighten screws in equal increments to withdraw upper bearing housing with drive shaft components_ Remove for­ward gear (30- F~g. 8Z11-19) shim (29) and bearing (27). Remove screw from side of gearcase securing guide holder (13 - Fig. SZl1-22) and withdraw lower shift linkage components.

Inspect all components for excessive wear and damage. Apply a water resis­tant grease to lip portion of all seals. All seals and "0" rings should be renewed when unit is reassembled.

Reassemble lower unit by reversing disassembly procedure while noting the following: Install dog clutch (34 - Fig. 8Z11 -2 1) on propeller shaft (37) so "F" marked side is toward forward gear. Tighten pinion nut (40- Fig. SZl1-19) to 18-22 N-m (13-16 ft.-lbs .)_ Tighten water pump housing (6) cap screws to 6-10 N'm (4-7 ft.-Ibs_). Tighten bearing carrier (46) cap screws to 6-10 N'm (4-7 ft.-Ibs.) . Tighten propeller retaining nut to 27-30 N'm (19-21 ft.-Ibs.). Assembled backlash between pinion gear (39) and forward gear (30) should be 0.1-0.2 mm (0.004-0.008 in.). Adjust thickness of shim (38) or shim (29) until recommend­ed backlash is obtained. Recheck mesh

Suzuki OT30 (Prior to 1988)

pattern between pinion gear and for­ward gear to determine if correct tooth contact is being made. Adjust pinion gear shim (38) or forward gear shim (29), if needed. to obtain correct mesh pattern_ Assembled propeller shaft end play should be 0.2-0.4 mm (0.008-0.016 in.). Adjust thickness of shim (41) until recommended end play is obtained. Ap­ply silicone sealer to lower unit and drive shaft housing mating surfaces. Tighten lower unit cap screws to 15-20 N· m (11-15 ft.-Ibs.).

Adjust shift rod adjustment nut (8- Fig. SZl1-22) until the proper engagement of "Forward." "Neutral" and "Reverse" is obtained_ Tighten locknut (9) to secure adjustment nut (8) position. Fill gearcase with approx­imately 230 mL (7.77 ozs_) of SAE 90 hypoid outboard gear oil.

Fig. SZ11-22-E.p/odod .,.w of shIN control IInkeg. compon.nt •.

I. Shift IC\-'('r 2. Cam 3. Det(' nt ball 4. Detel'lt !'pring 5. RQd 6. Shaft i . UPJ)tr shift rod 8. Adu.etment nut 9. I..«knut

10. Lower shift rod

11 . Du."I.t ~Al 12. Rod (lUid. 13. Guide holder 14. "0" r inK 1.'5. wO~ rinp 16. Guide 17.~r 18. PIn 19. Shift cnm

Suzuki DT30C (After 1987) OUTBOARD MOTOR

SUZUKI DT30C (After 1987)

CONDENSED SERVICE DATA

NOTE: Metric fasteners are used throughout outboard motor.

TUNE-UP Hp1rpm ...

Number of Cylinders .... . . . _ .... _ .. - .. .

.30/5000-5600 rpm (18.6 kW)

... 3 . . 62 mm (2.44 in .)

.... 60 mm (2.36 in.)

.... 543 cc (:3:3. 1 cu. in.)

.. .. NGK B7HS-1O . .0.9-\.0 mm

Dore . . ..... ___ ___ __ . ___ __ - .

Stroke

Displacement ... _ . . ______ .. __ __ . _ ..

Spark Plug _ . . _ .. Electrode Gap

Ignition . _ . . Carbure tor:

Make ..... Model ..

Fuel:Oil Ratio .

SIZES-CLEARANCES

(0.035-0.0:39 in .) ..... CD!

.Mikuni . _ .... B26-20

... ... _ ... Automatic Metering

Piston Ring End Gap . .. ___ . ..... . ..... 0.1:'5-0.35 mm (0.006-0_014 in.)

. _ .. 0.8 mm (0_0:30 in_)

... _ . 15.995-16.000 mm (0.6297-0.6299 in.)

... ... .. 15.9S0 mm (0_6291 in.)

... 16_002-16.010 mm (0.6300-0.6303 in.)

. .. . _ . .. . .... 16_030 mm (0_6311 in.)

. . . . 61.920-61 .935 mm (2.4378-2 .4384 in.)

Wear Limit

Piston Pin Diameter

\Vear Limit

Piston Pin nore Diamete r ...

Wear Limit

Standard Piston Diame ter

Standard Cylinder nore Diameter .. ... . .. 62_000-62.015 mm

(2.4409-2.4415 in.) Piston-to-Cylinder

Clearance ..

Wear Limit ...

... ... _ . _ .... _ ..... 0.072-0.087 mm (0.0028-0.0034 in.)

. . _ . 0.167 mm (0.0066 in.)

lI-1ax. Crankshaft Runout at Main _Journal .. 0.05 mm

(0_002 in.)

SIZES-CLEARANCES CONT_ Max. Connecting Rod Small

End Side Shake .. .. . . . . __ . _____ __ ..... 5.0mm

TIGHTENING TORQUES Cylinder Head:

(0_20 in_)

6 mm_ . .. . _. _. _. . _ . _ .. . ______ .. . .. S-12 N'm

8 mm.

Crankcase: 6 mm ...

8 mm

Flywheel Nut

Stand ard Screws-

(6-9 ft.-Ibs.) . .... 21-25 N'm

(15-18 ft.-Ibs_)

_ ... _ . , . . . _ ... , , . . . . .. _ 8-12 N'm (6-9 ft.-Ibs.)

. . . _ . , _ . _ . . _ . __ .. _ . .. . .. 20-26 N'm (15-19 ft.-Ibs.)

. _ . __ ... .. 130-150 N'm (96-111 ft.-Ibs_)

Unmarked or Marked "4" : 5,mm

6 mm .

.. 2-4 N'm (IS-:35 in.-Ibs_) ... __ .4-7 N'm (35-62 in .-Ibs_)

8 mm ... ___ . _ . . . ______ . __ , __ __ _ ....... 10-16 N'm

10 mm .

~nless Steel: 5 mm _ .... . .. " ____ . _____ __ . - - - . .

6 mm .

Smm .... ___ _ .. ___ , _ ... __ , ___ ._ .

10 mm .

Marked "7": 5 mm . _. _ .. , ___ __ , _, _____ , _,. _.

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

(7-12 ft.-Ibs.) ... 22-35 N'm (16-26 ft.-Ibs.)

. . 2-4 N'm (18-35 in.-Ibs.)

.6-10 N'm (53-88 in .-Ibs.)

· _15-20 N'm (11-15 ft. -Ibs.)

.. .. . 84-41 N'm (25-30 ft.-Ibs.)

· _ .. 3-6 N'm (27-53 in _-Ibs_)

· . . 8-12 N'm (6-9 ft.-Ibs.)

8 mm ... .. ____ _ . , ____ . _ . _ , , . . . _ . . ... _ . 18-28 N'm

10 mm ...... .... _ .. (13-21 ft. -Ibs.)

.40-60 N'm (29-44 ft.-Ibs.)

LUBRICATION

The power head is lubricated by oil mixed with the fuel. Model DT30C is equipped with automatic oil injection . Recommended oil is Suzuki Outboard .Iotor Oil or a good quality NMMA cer­tified TC-Wll engine oil. Recommended fuel is regular or unleaded gasoline hav­ing an 85 minimum octane rating. Man-

ufacturer does not recommend llsing gasoline containing alcohol additives. Howeve r, unleaded gasoline containing ethanol (grain alcohol) may be used providing ethanol content does not ex­ceed five percent and minimum octane rating is 85.

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

NOTE: Manufacturer recommends NOT using any gaSOline containing methanol (wood alcohol),

SERVICE MANUAL

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

FUEL SYSTEM

CARBURETOR. Three Mikuni B26-20 carburetors are used. Refer to Fig. SZII­:35 for exploded view. Initial setting of pilot air screw (12) is 1'/, to 2 turns out from a lightly seated position. Final ad­justment should be made with engine at normal operating temperature and run­ning in forward gear. Adjust idle speed with idle speed switch located on out­side of lower cover so engine idles at ap­proximately 650-700 rpm. Adjust pilot air screw so engine idles smoothly and will accelerate cleanly without hesita­tion. Readjust idle speed to 650·700 rpm is necessary.

Main fuel metering is controlled by main jet (5). Standard main jet for nor­mal operation is #125. Standard pilot jet (II) for normal operation is #70 on 1988 models and #67.5 on 1989 models.

Fig. SZIl-35-EJr.ploded view of Mlkunl 826·20 car-buretors used.

I. l1od~

2 Ga:-:.ket 3. IIigh !lP'I~ Mu.ll' 4. Chf)k~ ,rod 5. Mllinjct 0. 1-100. t 7. F[l'»t t bo ..... 1

8. ~in!O(;r:o:!. ..... Q. Float pin

10. N('('(fl~ .... 1\'(' t l. PUiO()!t -I2. Pilet ~rt"w 1:3. Throttle control

ro(h;

Th check float level, remove float bowl (7) and invert carburetor body (I). Mea'i­ure float level from float bowl mating surface to bottom of float at 180 degrees from needle valve as shown in Fig. SZII· 36. Float level should be 16.5·18.5 mm (0.65-0.73 in.). Bend tang on float to ad-

• just float level.

FUEL FILTER. A fuel filter assembly is used to filter the fuel prior to enter­ing the fuel pump. Periodically unscrew bowl (5-Fig. SZII-37) and withdraw fil­ter element (4). Clean bowl and filter el­ement in a suitable solvent and blow dry with clean compressed air. Inspect fil­ter element for excessive blockage or other damage and renew if necessary. Reassemble in reverse order of disas­sembly. Renew "0" ring (3) and seal (2) upon reassembly.

FUEL PUMP. A diaphragm-type fuel pump is used. Refer to Fig. SZII-38 for exploded view. Fuel pump is mounted on the side of power head cylinder block and is actuated by crankca'ie pulsations.

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

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

Renew reed valves (2-Fig. SZII·39) if petals are broken, cracked, warped, rusted or bent, or if tip of petal stands open in excess of 0.2 mm (0.008 in.) from seat area. Do not attempt to bend or straighten a damaged reed petal. Reed stop opening (0) should be :3.8 mm (0.15 in.). When reassembling reed valve as· sembly, apply Suzuki Thread Lock 1342 or a suitable equivalent thread locking compound to threads of screws (4).

SPEED CONTROL LINKAGE. To ad­just speed control linkage, loosen throt­tle lever adjusting screws (I-Fig. SZII-' 40) on top and bottom carburetors and rotate throttle levers (2) counterclock­wise to full closed position. Hold levers (2) closed and retighten screws (I). Ad­just throttle link (4) so throttle arm (3) is against stopper (5) and clearance (C) is 0.5-1.5 mm (0.020-0.060 in.) with throttle in fully closed position. Make sure throttle plates are synchronized at full closed and full open positions.

If throttle cables reqnire adjnstment, loosen cable adjustment nuts and adjust cables so core wires are tight with no free movement in drum (6). Make sure arm (3) contacts stopper (5) when throt-

Suzuki DT30C (After 1987)

Fig. SZII-36-MeBsure floBllevel from fioBI bowl mating surface to bottom of float 180 degress 'rom needle valve as shown. Bend tang on floBt

10 ad/uSI "OBI level.

Fig. SZII-37-Exploded view of fuel filler BS­sembly.

I B.a_'1 .... 2. S(' l:il :3. "0·· ring

4. Filter o. Bo ..... 1

Fig. SZII-3B-Exploded view of fuel pump BS­sembly.

1. Cover 2. Diaphragrn 6. Ga..'ikC't 3. Ga..<.;kC't 7. Sprin~ 4. Valve body 8. Spring seat 5. Plate 8. Check valve

Suzuki DT30C (After 1987)

tie is fully closed . Oil injection pump cont rol linkage should be checked and!or adjusted after speed control link­age adjustment. RefPr to OIL IN.JEC­TION section.

OIL INJECTION

CONTROL LINKAGE AD.JUST­MENT. ;"Iake sure speed control linkage is properly 'H\justeri. Initial length of pump control rod (5-Fig. SZll-41) shoulri be 77.i5 n1ln (3'()5 in .) as shown . With throttle in fully closed position, clea rance (e) between lever stopper (6) and boss ii) on pump housing should be I mm (O.04f) in.) or less, but stopper (6) should not contact boss (7). To adjust , loosen nuts (4) and adj ust length of rod (5) as necessary. Make sure nuts (4) are securely tightened after adjustment. !l.f-

4

Fig. SZ11-39-Cross-sectionsl view of reed block and valves assembly.

I It<,\'11 bi fid. 'l . RC'~d f.W'lal .) Ret4:1 ~l l lp

4. &r.,..". U. Heed SlflP o j>l' Tl in,IJ

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

OIL FLOW SENSOR_ Inline filter C'onta ined in oil flow sensor should be periodica{ly removed and cleaned in a su itable nonflammable solvent. ;"Ianu­facture r recommends renewing filt e r if excessive plugging or contamination is noted.

To test oil flow sensor, remove sensor and connect a suitable ohmmeter be­t,,'een sensor red wire with blu e tracer and black wire. Plug sensor inlet and connect a vacuum sou rce to sensor ont­let. WiLh vacLlum applied, ohmmete r should show continu ity. Remove vacu­LIm source and sensor should show in ­fin ity.

BLEEDING PUMP. To bleed tnlpped ai r from oil supply lines or pump, pro­ceed as follows: Fill fuel tank with a 50: I mixture of recommended gasoline and oil. Fill oil tank with a recommended oi l. Loosen bleed screw (n - Figs. SZI I-41 or SZll-42) two or three turns. Start engine and a llow to idle at 61;0-700 rpm until no air bubbles are noted at bleed screw (8).

CHECKING OIL PUMP OUTPUT. Start en/,tine and a llow to warm-up for approximately five minutes. St.op en­gine, disconnect oil pump control rod from carbure tor and remove oil tank . Connect oil gage 09900-2020;; or a su ita­ble equivalent to oil pump supply hose. Fill oil gage with a recommended oil un-

)

Fig. SZII,40-Vlew of speed control linkage. Ad/ust link­

age as described in lext. 1 s<:rew 2. ThrfJlth' Io-v"f :). ThmttlC' a rm 4 Link tfKI

Slo)lPN I •. GJi b l(' (!ruIn

OUTBOARD MOTOR

til oil is even with an upper reference mark . m eed system as previously de­scribed. With oil pump control rod in fully closed position, start engine and allow to run at 1;;00 rpm for five minutes. Oil consumption should be 1.0-1.9 mL (0.035-0.065 oz.) in five minutes at 1500 rpm. Mm'e oil pump control rod to fully open position, resta rt engine and allow to run at 1500 rpm for two minutes. Oil consumption should be 1.2-1.7 mL (0.04-0.06 oz.) in two minutes at HiOO l1)m . Renew oil pump assembly (2-fig. SZI1 -42) if pump output is not as specified . After reinstalling oil tank, bleed air from oil injection system as p reviously described.

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

COOLING SYSTEM

WATER PUMP. A rubbe r impeller­type water pump is mounted between the drive shaft housing a nd gearcase. Key (7-fig. SZI1-43) in the drive shaft is used to tum the impeller (6). If cool­ing system malfunction b encountered . check water imakes for plugging or par­tial rest riction. If water intakes are clear, remove gearcase as outlined in LOWER UN IT section and check condi­tion of water pump, water passages and sealing su rfaces.

When water pump is disassembled, in­spect impelle r (6) and plate (8) for ex­cessive wear or other damage. Tum

B

Fig. SZII-41-View of ollinjecr/on pump and co".. fro/linkage. Refer to text for contro/llnkage lid·

justment. I Thr(,uk IC''' l 'r •. Centrol rod 2. Pump &.-fOs.y. 6. Stopper .1. Pump I("\'(" r 7. Ik ....... 4 . l \rt,iU:'III1l('nl nUL..; U. DI~d s<'r('w

SERVICE MANUAL

drive shaft clockwise (viewed from top) while placing pump housing (5) over im­peller. Avoid turning drive shaft in op­posite direction after water pump is re­assembled.

THERMOSTAT. A thermostat is used to regulate operating temperature. Test thermostat by submersing in heated wa­ter with a suit.able thermometer. Ther­mostat should start to open at 48°-52° C (118°-126° F). Thermostat can be re­moved for inspection or renewal after removing thermostat cover located in cylinder head.

ENGINE TEMPERATURE SENSOR. Engine temperature sensor is located at lower side of engine block. Sensor is normally open and changes to closed circuit when engine temperature reaches 32°-38° C (89.6°-100.4° P) on 1988 models and :36° -44° C (97°-111° F) on 1989 models. When sensor is open, ignition timing is automatically ad­vanced approximately five degrees which increases idle speed and allows engine to warm-up quicker. When sen­sor closes, ignition timing and idle speed return to normal idle set.ting.

WATER FLOW SENSOR. Water flow sensor is located in cylinder head cov­er. Water flow sensor is designed to warn operator should cooling water flow to engine become insufficient. Th test sensor, remove sensor from cylinder head cover and make sure sensor float moves freely. If not, remove pin secur­ing float and carefully clean float and pin with water. Note that one side of pin hole in sensor is smaller than other side. Drive pin out toward larger hole. Con­nect a suitable ohmmeter between sen­sor wires and move float up ~nd down. Ohmmeter reading should be zero ohm with float in down position and infini­ty with float in up position.

IGNITION

A breakerless, integrated circuit, ca­pacitor discharge ignition system is used. Refer to Fig. SZII-44 for wiring di­agram. An integral ignition control mod-

ule monitors throttle valve position (throttle valve sensor) and flywheel po­sition (counter coil) and calculates and automatically a~justs ignition timing for optimum performance at all speeds above idle. Refer to Fig. SZII-4.5. With thmttle valves fully closed (idle speed), timing and idle speed are controlled by idle speed switch. Refer to IDLE SPEED SWITCH section.

TROUBLE-SHOOTING. If igllition malfunction occurs, check condition of spark plugs, and all wires and connec­tions before trouble-shooting ignition system. Use only approved procedures to prevent damage to the components. The fuel system should be checked first to make certain that faulty operation is not the result of incorrect fuel mixture or contaminated fuel. Use Suzuki Pock­et 'lester 09900-2.5002 or a suitable ohm­meter to test ignition components and circuits. Referto Figs. SZII-44 and SZI\-46 when trouble-shooting ignition system.

CONDENSER CIIARGING COIL. Fly­wheel must be removed for access to condenser charging coil. Make sure a suitable puller is used to remove fly­wheel. Disconnect condenser charging coil (5-Fig. S211-46) and connect tester between black wire with red tracer and green wire. Resistance should be 170-250 ohms. Renew condenser charging coil if resistance is not as specified.

PULSER COIL. Three pulser coils (2 , 4 and 6-Fig. SZII-46) are used, and if removed, must be reinstalled in original position on stator or engine will not start. Note color of pulser coil wires or mark coils for reference. Pulser coils-to­flywheel air gap should be 0.75 mm (0.03 in.) on 1988 models and 0.5 mm (0.020 in.) as shown in Fig. SZl1-47.

Th test pulser coils, separate connec­tors leading from pulser coils. Attach one tester lead to a good engine ground and remaining tester lead to red wire with black tracer on number 1 coil, white wire with black tracer on num­ber 2 coil and red wire with white trac­er on number 3 coil. Renew pulser

Fig. SZII-42-Exploded view of 011 In/ectlon pump 85-

sembly. I. G''-.',kl'l 2. Pump a. ........ y. :), Pump lcw' r 4 . ;\djll~tinR nUl 5. Control rod 6. Rebin('r 7. Dri\'('n gear

Suzuki OTlOC (After 1987)

coil(s) if resistance is not within 170-250 ohms.

COUNTER COIL. Separate connector leading from counter coil (7-Fig. SZI\-46). Connect tester leads to orange wire with green tracer and black wire (1988 models) or black wire with green trac­er (1989 models). Counter coil can be considered acceptable if resistance is within 160-240 ohms. Air gap between counter coil and flywheel ring gear teeth should be 0.5 mm (0.020 in.).

NOTE: Air gap between counter coil and flywheel ring gear teeth must be set to ex­actly 0.5 mm (0.020 In.) for proper operation of outboard motor. Make sure air gap Is properly adjusted.

IGNITION COILS. Three igllition coils are used. Refer to Fig. S211-46. Separate wires at connectors leading from igni­tion coils and disconnect spark plug wires from coils. Th test primary wind­ings, connect tester between the follow­ing wires: Number I coil-orange wire and black wire; number 2 coil-blue wire and black wire; number 3 coil­gray wire and black wire. Primary wind­ing resistance on all coils should be 0.1-0.4 ohm. Renew coil(s) if primary resis­tance is not as specified.

Fig. SZII-43-Exploded vIew of waler pump assembly.

I. Grtlrnm Ct G. Impe>l1cr 2. Wal te r tube 7. Key :) . Grommt:'t ~ . Pla te 4. Grommet H. G:.a. .. kl'( G. lIou~mR 10. $wd

Suzuki DT30C (After 1987)

1b test secondary windings, attach one tester lead to each spark plug wire terminal and remaining tester lead to orange wire on number 1 coil. blue wire on number 2 coil and gray wire on num­ber 3 coil. Renew coil(s) if resistance is not within 1900-2700 ohms.

THRO'ITLE VALVE SENSOR. 1b test throttle valve sensor (5-Fig. SZll -48) , remove alignment pin attached to cov­er over throttle valve sensor and insert alignment pin (lJ into hole in sensor and sensor cam (:3). Align slot in cam (3) with throttle shaft. Disconnect throttle valve sensor connector (4). Connect test har­ness 09930-89530 or suitable jumper wires to a battery a~ shown in Fig. SZll-48. Ilattery voltage must be nine volts or more. Connect positive ( + ) lead of a suitable digital voltmeter to test harness light green wire with red tracer and voltmeter negative ( - ) lead to battery

negative (-) terminal as shown. With throttle fully closed, voltmeter reading should be 0.45-0.55 volt. If not, remove rubber cap (2) and turn adjustment screw (under cap) as necessary ~o obtain the correct voltage reading. Note that turning adjustment screw clockwise will increase vo!t<lge and counterclockwise will decrease voltage.

NOTE: The manufacturer recommends us­ing only a nonmetallic screwdriver to turn sensor adjusting screw or sensor voltmeter reading may not be valid. If metal screw­driver must be used, remove screwdriver from area of throllie valve sensor aller ad­Justment to prevent erroneous voltmeter reading.

If sensor output voltage at closed throttle is below 0.45 volt, idle speed ig­nition timing will be fixed at 5 degrees BTDC and idle speed switch will be in-

EnQln. Temp Sensor

OUTBOARD MOTOR

operative. If sensor output voltage at closed throttle is above 0.55 volt , igni­tion timing at idle speed will not be cor­rect. Refer to IDLE SPEED SWITCH section.

Once the specified voltage reading is obtained at closed throttle, remove alignment pin and open carburetor to wide-open throttle. Voltmeter reading should now be 2.7 volts or more. Do not attempt to adjust wide-open throttle sensor voltage. If wide-open throttle sensor voltage is not 2.7 volts or higher, renew sensor.

If throttle valve sensor is removed or renewed. install as follows: Insert align­ment pin (1) as shown to align cam and sensor shaft. Align slot in sensor cam with carburetor throttle shaft and in­stall sensor on carburetor. Lightly tight­en mounting screws (7) to a llow for ad­jus tment of sensor position on carburetor. Connect test harness and

011 Level Switch Od Flow

SaMer

Oil aW01er Warnm9 Lamp

Idle Speed Switch

Throttle Valy!! Stns.or

8r

Fig. SZII-44-Wlring dlagrsm of eleelrical 'yslem on modol. equipped with eleelrlc ,'arter. ~. B11u:k G. Grecn Pro Purpk' P. Pink WG. lJIa.J:: k ..... ith IVB . He'd ..... Ith blade W,lJ. Whit~ with Bl IB. IHu(.' with black Or:(~ . Or ..... n~l· with R. "'-'" ~rC'C'n trHCl'r lra('~ r black t r;tc,~ r lntr<'r ~J'(~ n lr;u:cr r . Y('lIow IYR. Uhu;k with red R.G. lled with green W;R. While w ilh rt'd Bl iP, UI .... : with pink P UI. Pink with bluf' W. While tracer trac:,~r trattr tra(,\:,( t flu·!,.' r 81. Blue Il ' 1,\" . Blad w ith IV"",' , ROO Wi th white 'i, 1} ,:{('lIow,",'H h IW R. Uluc with red Pr,W. Purple with Br. Drown white- 1 ~C'('r tmccr black trnt !,.·r traC;N white- trA('Cr Gr. Gray (i ,1t G r r.~_·n with n ;tl IL-Y. Red with ydlflw Y:G. Yellow with m,w Hlu!'" with white tl G/R. U!1ht )O'('l'n Or. Oran ~c U"',wer tnlt:c r IVl'CIl trae,,'r (r3r cr with rf'd l rI'lC,'(

SERVICE MANUAL

digital voltmeter as shown in Fig. SZl1-48. Make sure battery voltage is nine volts or more. Sensor output voltage at closed throttle should be 0.45-0.55 volt. If not, move position of sensor on car­buretor to obtain specified voltage and securely tighten screws (7). Recheck voltage after tightening screws (7) and if necessary, remove cap (2) and turn ad­justment screw to obtain 0.45-0.55 volt. Be sure to reinstall cap (2). After obtain­ing the correct voltage at closed throt­tle, remove alignment pin and check sensor output voltage at wide-open throttle. Voltage should be 2.7 volts or higher. Do not attempt to adjust wide­open throttle voltage.

IDLE SPEED SWITClI. Idle speed switch (8-Fig. SZ11-46) malfunction can be quickly verified by checking ignition timing and engine rpm while switching position of idle speed switch. Make sure engine is at idle speed when checking timing.

NOTE: A defective or maladjusted throt­tle valve sensor may cause Idle speed switch to be inoperative or Ignition timing at Idle speed to be incorrect. Prior to testing Idle speed switch, make sure throttle valve sen­sor is operating properly and correctly ad­Justed. Refer to THROTTLE VALVE SENSOR section.

Ignition timing at idle speed should be as shown in Fig. SZII-49. Note that each position of switch should change engine idle speed approximately 50 rpm. If tim· ing and engine rpm do not change with each switch position, idle speed switch is defective and must be renewed.

To test idle speed switch with Suzuki Pocket Tester 09900-25002 or a suitable ohmmeter, disconnect idle switch and connect tester bet ween black wires with white tracer (Fig. SZll-44). Switch resistance on 1988 models should be as follows: Position (A-Fig. SZl1-49)-zero ohm; position (B)-2200 ohms; position (C)-4700 ohms; position (0)- 13,000 ohms; position (E)-infinity. Switch reo sistance on 1989 models should be as folio .... ,: Position (A-Fig. SZl1-49)-zero ohm; position B-11,OOO ohms; position C-22,OOO ohms; position 0-68,000 ohms; position E-infinity. Renew idle speed switch if resistance values are not as specified.

If no components are found to be defective in the pre\·ious tests and ig· nition system malfunction is still sus· pected , install a known good COl mod· ule and recheck engine operation.

CHARGING SYSTEM

BATTERY CHARGING COIL. Refer to Fig. SZII-44. Flywheel must be reo

moved for access to battery charging coil. lle sure to use a suitable flvwheel puller to remove flywheel. To t~st coil, separate wires at connectors leading from battery charging coil. On manual

Fig. SZII-45-Chart showing Ignlllon riming In re/ar/on ro

throttle valve position.

c:

'"

Suzuki DT30C (After 1987)

start models, connect one lead of Suzu­ki Pocket Tester 09900-25002 to termi­nal of yellow wire with red tracer and remaining tester lead to terminal of yel­low wire. On models equipped with

25

2 0

5

10

5

0

5-:/

/ 17'

./ -ir .//

/

/ /

o 5 10 15 20 25 30 35 90 Throttle Valve Position (Degrees)

Fig. SZl1-46-Dlagram of Ignlr/on sysrem componenrs. 1. COl mooul(o '2 . Number 2 pul~cr

('QII

'3. Baltcr), charginf/: C")i l

1. Sumh.-.. r :) pUI~N CQi l

.5. Condl!n~{'r cha~in~ (~IJ iI -

ti. Numb('f I pulscr clJ iI

7. Co unter coil 8. Idll- ~peN s ..... itch

Fig. SZII-47-Alr gap be­IWfHln pulser cofls and fly­wheel should be 0.75 mm (0.029 In.) on 1988 models and 0.5 mm (0.020 In.) on

1989 models mea.urfld.

9. Number 1 ignition coil

10. NumbN 2 i.'Ulirion coil

11. Numb('r:3 i,l(llition coil

Flywheel

12. Throttle vah·e sensor

1:3. Engin. .. t(·m~rif.ture sensor

Ring Gear

0.5 mm (0.020 1n.)

Suzuki DT30C (After 1987)

electric start, connect one tester lead to red wire and remaining tester lead to yellow wire. Battery charging coil can be considered acceptable if resistance is within 0.2-0.6 ohm.

RECTIFIER. Use Suzuki Pocket Tester 09900-25002 or equivalent ohm­meter to test rectifier: Refer to Fig. SZl!-50 for view of rectifier assembly and to chart in Fig. SZII-.51 for rectifier test data. Renew reclifier if test results are not as shown in chart.

POWER HEAD

REMOVE AND REINSTALL. To re­move power head, remove engine cov­er, disconnect neutral start interlock ca­ble from lever and remove rewind starter assembly. RemO\'e electric parts holder cover and rectifier cover. Discon­nect battery cables, disconneet CD! module wires, and remove CD! module and electric parts holder. Remove oil tank and disconnect throttle valve sen­sor, choke solenoid, warning lamp, idle speed switch and fuel hose. Disconnect ignition coil wires, remove silencer cov­er and disconnect choke lever. Remove

6 5 2 7

eight cap screws and separate power head from drive shaft housing.

Before reinstalling power head, make certain drive shaft splines are clean, then apply a light coat of water­resistant grease to shaft splines. Install power head on drive shaft housing while rota ting propeller shaft to assist alignment of drive shaft and erankshaft splines. Apply a suitable silicone sealant to threads of retaining screws, then tighten screws to 15-20 N'm (11-15 ft.­Ibs.). Remainder of installation is the re­verse of removal procedure. Refer to SPEED CONTROL LINKAGE for adjust· ment procedure.

DISASSEMBLY. Disassemble power head as follows: Remove exhaust tube, carburetors, throttle control lever. rec­tifier, starter relay and starter motor. Remove fuel filter, fuel pump, oil pump, oil hoses. choke solenoid and intake manifold screws. Carefully pry off in­take manifold using a screwdriver or suitable tool. Use caution not to dam· age mating surfaces. Remove rewind starter mounting brackets, ignition coils, engine temperature sensor, counter eoil and starter pulley. Use a suitable puller and remove flywheel. Remove'stator as-

Fig. SZ1'-48-Refer to text for throWe valve sensor testfng and Installation procedure. 1. Ali,lUlnll'nt pin 4 Connl'Ctl)r 7. :\llJuntmg :-.cr('w 2, Cap (I'dju$[mem 1',. Throttle valv(" n. lll,a('k ~tew) ~n~r L"";y . BlR. 1J1ack ""ith n'd ltG· B.. Li~ht gJ'('('n with

:.1. $.enStl r ('3m G. C.rb~Hl~{or f.r11("('r rcd t raC(' r

9° AlOe

'-E

Idle Speed Switch

Fig. SZI 1-49-lgnlllon timing at Idle speed shOUld be a. shown at the corresponding Idle spHd Switch position •.

OUTBOARD MOTOR

sembly, cylinder head, exhaust cover, thermostat cover and thermostat. Re­move 14 crankcase screws and careful­ly separate erankcase from cylinder block. Crankshaft a<;sembly can now be removed from crankcase.

REASSEMBLY. Refer to specific serv­ice sections when reassembling the crankshaft, connecting rods, pistons and reed valVes. Make sure alljoint and gas­ket surfaces are clean and free from nicks and burrs. Cylinder head and block mating surfaces should not. be warped in excess of 0.30 mm (0.012 in.). Cylinder head and block mating sur­faces may be lapped using 11400 or finer emery paper. Use caution when lapping to not remove any more material than necessary to true mating surfaces. Make sure all carbon, sait, dirt and sand are cleaned from the combustion chambers, exhaust ports and water passages. Lubricate crankpin bearings and cylin­der walls with Suzuki Outboard Motor Oil or a suitable NMMA certified TC-WII engine oil. Coat crankcase-to-cylinder block mating surface with Suzuki Bond 1207B or suitable equivalent sealant. Tighten crankcase screws in sequence shown in Fig. SZII-52 . Tighten 6 mm screws to 8-12 N'm (6-9 ft.-Ibs.) and 8 mm screws to 20-26 N'm (15-19 ft.-Ibs.). Make sure two long clamps (L) are mounted on crankca~e where shown. Rotate crankshaft after reassembling crankcase to check for locking or abnor­mal noise. If locking or abnormal noise is noted, crankcase must be disassem­bled to determine cause and repaired. Tighten cylinder head screws in se­quence shown in Fig. SZU-53. Tighten 6 mm screws to 8-12 N'm (6-9 ft .-Ibs.) and 8 mm screws to 21-25 N'm (15-18 ft.­Ibs.). Install clamps (C) where shown. Make sure mating surface of flywheel is clean prior to installation. Tighten fly­wheel nut to 130-150 N'm (96-1ll ft.-lbs.) using appropriate tools. Refer to CON· DENSED SERVICE DATA for other fas­tener tightening values.

PISTONS, PINS, RINGS AND CYLINDERS. Refer to CONDENSED SERVICE DATA for pistons, pins, rings

B

Rg. SZII-50-Vlew of rectifier assembly. Refer to chart In FIg. SZI I-51 to t".t reetlller.

SERVICE MANUAL

and cylinder service specifications. Each piston is fitted with two piston rings. Pistons are equipped with locat­ing pins in ring grooves to prevent pis­ton ring rotation . Measure piston diam­eter 23 mm (0.9 in .) up from bottom of skirt at a right angle to piston pin bore. Pistons and rings are available in stan­dard size and 0.25 mm (0.010 in .) and 0.50 mm (0.020 in.) oversize. Install pistons on connecting rods so arrow on piston crown will face exhaust ports upon reassembly. All cylinders should be bored to next oversize if any cylinder is out-of-round or tapered in excess of 0.10 mm (0.004 in .).

CRANKSHAFT, CONNECTING RODS AND BEARINGS. Connecting rods, bearings and crankshaft are a press together unit. Crankshaft should be disassembled ONLY by experienced service personnel using appropriate service equipment.

Determine connecting rod bearing wear from side-to-side movement as shown in Fig. SZll -55. Normal side-to­side movement (A) is 5.0 mm (0.197 in.) or less. If movement exceeds 5.0 mm (0.197 in.), connecting rod, crankpin and crankpin needle bearing should be re­newed . Maximum allowable crankshaft runout is 0.05 mm (0.002 in.) measured at bearing surfaces with ends of crank­shaft supported in V-blocks.

Apply Suzuki Super Grease "A" or a suitable equivalent to seal lips. When in­stalling crankshaft assembly into cylin­derblock, make sure seals properly en­gage grooves in block. Make sure bearing pins properly engage notches in cylinder block .

MANUAL STARTER

Refer to Fig. SZll-56 for exploded view of manual rewind starter assem­bly. To remove starter assembly, remove screw (18) and clamp (19), detach neu­tral start cable (12) and remove three screws securing starter assembly to power head . 1b disassemble startel~ re­move cotter pin (1:3), washer (14), arm (15), spring (16) and lever (17). 1b relieve rewind spring tension , invert starter housing and grasp a section of rope, place rope into notch (N-Fig. SZll-57) provided in rope pulley (7). Holding rope as shown, allow pulley (7) to rotate

~ 8 L EAD OF TESTER

---------Blo ck Wh ile Yell 0 ...

clockwise relieving rewind spring ten­sion . Remove screw (2-Fig. SZll-56), plate (3) and friction spring (4). Remove pawl (5) and spring (6), then carefully lift out rope pulley (7) making sure re ­wind spring (8) remains in housing (11). Using suitable hand and eye protection, carefully remove rewind spring (8) from housing (11).

Inspect all components for excessive wear or other damage and renew as necessary. Reassemble starter in the re­verse order of disassembly noting the following: Starting with inner coil, wind rewind spring into housing in clockwise direction. Apply a suitable water­resistant grease to rewind spring. Wind rope onto pulley (7) 2'1, turns in coun­terclockwise direction (viewed from fly­wheel side) and install pulley (7) into housing. Make sure pulley properly en­gages hook on inner coil of rewind spring. Apply water resistant grease to both sides of plate (3) . 1b preload rewind spring, place rope into notch of rope pulley as shown in Fig. SZll-57 and ro­tate rope pulley four turns counter­clockwise. Release rope and allow re­maini.ng rope to wind onto pulley. Install starter assembly on power head and connect neutral start cable. With clutch lever in neutral position, slol (S-Fig. SZll-.58) should align with mark (N) on housing (11) . With clutch lever in for-

L

FIg. SZII-52-Tlghten crankcBSfI screws In se­quence shown. TIghten 6 mm screws to 8-'2 N'm (6-9 ft.-Ibs.) and 8 mm screws to 2()'26 N·m (t5-19 ft.-Ibs.). Makfl sure long clamps (L) are posl.

tloned as shown.

Red

"- Block ~ ocr w

5 ,500-85000 ~r~?'~n H88n. FIg. SZII-51-Refer to FIg.

SZI I-50 and U$6 chart shown to test rwctlffer assembly.

0>-WhIle = -------

CO CO . ,," WW -'>- = 2,200 -

-------CO CD Yellow 32000

Red = k,.~ggn CO

-----

Suzuki DT30C (After 1987)

ward or reverse gear, slot (S) should be centered between marks (M). Loosen screw (18) and move cable (12) to adjust. Make sllre starter will operate only in neutral position .

Fig. SZl 1-53-Tlghten cylinder head screws In se­quence shown. Tighten 6 mm screws to 8·12 N'm (6-9 ftAbs.) and 8 mm screws to 2t-25 N'm (15-

tB ft.-Ibs.). Note location of clamps (e).

FIg. SZI 1-54-Exploded vIew of pIston and crank­shaft assembly.

I . Sca l 2. )Iain ix-ari nH :1 . Crank hlllf 4. Crank half ;) . )(aJn beanng 6. C('ntt'f crnnkshaft

Il.<;sy . 7. )[:lin b(':tri n~ F:. S4'al 9 . Lnwcr rmnkshaCt

I\. ....... y . Ifl. )Iain h .. 'arin~

11. 011 pump dr ive p:cnr l ~. S<:al 18. Crank pin 14. Thru.\t wuhcr 1;). Need~ btarinK In , Connecting rOO 17. Needle bt-ar'np: 1!1. Rer.aJner I ~ . Pi~lnn pin 20. Pbton 2 1. Pi:ston rin$C!5

•

Suzuki DT30C (After 1987)

Fig. SZI'-55-Move connecllng rod small end slde·to·slde to determine connecting rod, bearing and crankpin wear. Maximum allowable small end

play (A) Is 5.0 mm (0. 197 In.}.

FIg. SZl1-56-Exploded view of "'-.1 slarter assembly.

I . Cup .} Sf:n .'\\' ;). Phlt .: ·1. Fric tion "Prl ll,l{ .J, 1)I.".d

u. SvnnJ( 7. UII1)(' IH,II",y fl . n~~wiRl.J sprinlot ~I. ftnl"-' ~"fdt,

](I. UO[l('

N

I L II,,~,_'U "I( 12. NeutrAl lfl<t" ('ahh' U. lAKli'r pin 1-& . W, !lh'Jr n . Ann ,''1. S,Jollng 11 . 1A.' \ ' C!r IR . Str .. ", l ~'. UallllIJ

FIg. SZI'-57-To reI/eve rewind spring lenslon, grasp rope (IO) as shown, place rope Inlo nOlch

(N) and allow pul/ey (7) 10 rolale clockwise.

ELECTRIC STARTER

Refer to Fig. S211-59 for exploded view of electric starter assembly used on models so equipped. Disassembly is evident after inspection of unit and referral to exploded view. Standard commutator outside diameter is 30 mm (1.18 in .) . Renew armature (6) if commu­tator is worn to less than 29 mm (1.14 in.). Standard undercut between com­mutator segments is 0.5-0.8 mm (0.020-0.031 in.) with a minimum allowable un­dercut of 0.2 mm (0.008 in.). Renew brushes (8) if worn to 9 mm (0.354 in .) or less. During reassembly, make sure upper and lower alignment marks on frame (7) align with notches in end frames (5 and 10). Tighten through-bolts (11) to 15-20 N'm (11-15 ft.-Ibs.). Bench test starter prior to installing on power head.

11 Fig. SZl1-5B-Wlth clutch lever In neutral pos/­lion, slot (S) In arm (15) should align with mark (N) on housing (11). With clUlch lever In forward or reVBrstI gell', slot (S) should be In cent., of maries (foIj. Loo&an screw (IB) and move cable (12)

J toed/us!.

OUTBOARD MOTOR

LOWER UNIT

PROPELLER AND DRIVE CLUTCH. Protection for the motor is built into a special cushioning clutch in the propel­ler hub. No ac.ljustment is possible on the propeller or clutch. Three-blade propellers are used. Propellers are avail­able from the manufacturer in various diameters and pitches and should be selected to provide optimum perform­ance at full throttle within the recom­mended limits of 5000·5600 rpm.

R&R AND OVERHAUL. Refer to Fig. S211-60 for exploded view of lower unit gearcase assembly. During disas.~embly, note the location of all shims and wash­ers to aid in reassembly.

Th remove gearcase, first remove drain plug (25) and level plugs (23) and drain gearcase lubricant. Loosen shift rod locknut (6-Fig. S211-6l) and turn ad­justment nut (5) until upper and lower shift rods are separated. Remove six screws and separate gearcase assembly from drive shaft housing. Remove pro­peller and two screws securing beal;ng carrier (36-Fig. SZI1-60) to gearcase (27). Using a suitable slide hammer type puller. carefully extract bearing carrier and propeller shaft assembly. Remove water pump housing (4), impeller (6), key (5), plate (7) and gasket (8). Install drive shaft holder 09921-29610 or equivalent on upper spline of drive shaft (14), then remove pinion gear nut (30) by turning drive shaft. Remove two remaining screy,,-s securing bearing hous­ing (9) to gearcase. Use two 6 mm screws positioned as shown in Fig. SZl1-62 and tighten screws in equal increments to

Fig. SZII-59-Exploded view of electric stsrter sS$Smbly.

1. Il, ·t.\im-r 2 . Stop :3. Spring ·1. Otl\'c n.""'Y. rl, ~nd frum e­t; ,\rnHl.turC' i . Fr:tm(' 8 . Bru,"Ihl'S fl. Brtl.sh holder

10. End (ram\.' 11. Throu~h ·ho1t

SERVICE MANUAL

withdra'" upper bearing housing and drive shaft components. Heach into gearcase and remove pinion gear (29-Fig. SZ 11-60). shim (28). forward gear (54), shim (55) and bearing (57). Refer to Fig. SZII-63 and remove screw secur­ing shift rod guide holder (lO-Fig. SZII-61). Lift lower shift rod a,sembly out top of gearcase.

Inspect all com ponents for excessive wear or other damage. Apply a suitable water-resistant grease to lip area of all seals. Henew all seals. gaskets and " 0" rings upon reassemhly_

Reassemble lower unit in n~verse or­der of disassembly noting the following: Install dog clutch (.:il-Fig. SZI H i4) on propeller shaft (47) so side marked "F" is toward forward gear (?;4 - Fig. SZII-60). If removed. install pinion bearing (22) into gearcase using a suitahle dri\': er. Be su re lelte red side of hearing (22) faces up. Apply Suzuki Thread Lock 1:342 or a suitable eqUivalent to threads of pinion llu l (30) and tighten nut to 27-:30 N'm (20-22 ft.-Ihs.). Forward gear-to­pinion gcar backlash sholild he 0.1-0.2 mm (0.004-0.008 in .). A<\just thickness

Fig. SZ11-60-E.xploded view of lower unit gearcase assembly. I (i l"" "lnl .. ~t 2. W.[LT('r w i)(> :~ (f rommt·' ·t W!ltt' r pumJl

hnu~inl(

!\.('\' G Imi)('II('r

PI{l r,· G :Il:Sk~l

Beilrin~ hnu'in': HI Se\ll l II U-e8ri n~ 12 "0" .-illl( 1:3 Bushhl/l: 1-1 Om'l.: .. haft

1f, . Wa. .. h('r hi . .sprln }:l 17. Thru!il w.1sl\O: r II( W M)wt HI . f'on;., 21t. [}~r ri er

2 1. Sna p nn,l( 22. tkfui nM 2;), u..q ·1 plll~ :N . (f a.:ik .·l 25. D1'";t~n phi";' :W. (i :1:>k t·! ~7 . G\·arcu...~I· :!~. ~hilll :!!I. Pin lOll ~t':n'

:)4 1. ~ lIl

:31. Sh Ull :)2. np\"f· r...<: ~l';l r

3:J. Shim :l-1. " 0" rl n,..: :lS . Iknrill ,l-( ~j; , U l.'tJ fi n ,J( Cllffll'f

:H. Bt·:mn,lt :j~ M' ;11 :3fl, Sor-Al . 1/1 . Spa c-c-r ,II . UUShUljJ, ,12. Prolwllt'r ~:3 . :-i1';!C"l'r

,1 ·~ W :I~h('r

·IG. Nul ·11 ;. (,un" r pl11 ... ";" . I'rnpdkr "h;,fl Jjfj. Sjlr;n~

~!t I~pr :l lIlt' l

rd •. I'in :-01 , [klR duf<"h 5J P1l1 5:3 . T1lrU~l w :bh.-.r ~1 '1 . \o\uV, :1ffl ,r.( C' rt f

r,.·l. Shlnl !"J.l i . r'u~h rod 57 B('n ril1g

Suzuki DT30C (After 1987)

3---V 4~!

I •

~,

j Fig. SZ11·61-Exploded view of shift contra/link·

age components. I . Sh ift h'\'l ' r _. 1 .... ·\"l .. r

1'.("" t 'Pl" ' f "hlft HOfI .\ JjV" I I11t·nl Il1l1

(; . I.ucknu l I..."\~· • .' r ... Iun f1 Mi

!-I PII"I ~ ! . 1\: "II

J

I ii . t ; lIldc' IlIoIdr'r 11 . (;ul!.k U "(l"' rln~', 1: \ " r ) .. rlll~

II. :-; 1':1 ("1'1' I .PI ;t..l ilj.t I1I ·'

IL. shlft (" !) IH

I, 1'111

J

Fig. SZII-62-Use Iwo 6 mm Jackscrews (J) 10 withdraw upper bearing housing with drive shaft

components.

Shift Rod ,.., Assembly

Sc rew

Fig. SZ11·63-To remove lower shiff rod assem· blr, remove screw securing shih rod guide holder

and pull shift rod out top of gearcase.

Suzuki DT30C (After 1987)

of shims (28 and 55) to obtain specified backlash. After obtaining the proper backlash, check pinion gear-to-forward gear mesh pattern . Add and subtract equally from shims (28 and 55) to obtain correct mesh pattern while maintaining the correct forward gear-to-pinion gear backlash. Assembled propeller shaft end play should be 0.2-0.4 mm (0.008-0.016 in.). Adjust ~hickness of shim (31) to obtain the specified propeller shaft

end play. Recheck pinion gear backlash. If necessary, adjust thickness of reverse gear shim (33) so backlash is the same as previously adjusted forward gear-to-

51

Fig. SZl1-64-lnstall dog clutch (51) on propelle, sha" (47) so the " F" ms,k Is facing forward.

OUTBOARD MOTOR

pinion gear backlash setting. Tighten propeller shaft bearing carrier (36) screws to 15-20 N'm (11-15 ft.-Ibs.).

Adjust shift rod adjustment nut (5-Fig. SZIl-61) until the proper engage­ment of "Forward." " Neutral" and "Reverse" is obtained. Tighten locknut (6) to secure adjustment nut. Refer to LUBRICATION section and fill gearcase w;th the appropriate type and amount of lubricanl.

SERVICE MANUAL

SUZUKI DT40 (Prior To 1984)

Suzuki OT40 (Prior to 1984)

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

TUNE-UP DT40 TIGHTENING TORQUES Cylinder Head: Hp ........... . . . . . . . . ...... . .. . . . .. . ... . ....... 40

Bore ....................................... 76mm 6mm .................. . ................ 8-ION·m Stroke ................. .. .. ... .... .......... 68 mm 8mm ............ .. ............. .. ..... 20-23N·m Number of Cylinders ...... . .. . . . .. ... . .. . . . ........ 2 Crankcase: Displacement .............. . .................. 617 cc 6mm ................................... 8-12N·m Spark Plug: 10mm ........ ...... .... ..... .. ........ 40-60N·m

NGK ........... . .. . . . . . . ..... . .. . . ......... B8HS Exhaust Cover .................... ... ...... 8-10 N'm Electrode Gap . ............. ..... . ....... 0.8-0.9 mm Flywheel Nut . . ........ ......... .. ..... ..... 200 N'm

Magneto: Gearcase Pinion Nut ... . . .. . .. ................ :35 N· m Breaker Point Gap . ... . . . .. .. . .. .. .. ... . Breakerless Propeller Shaft Nut ............ .... .... .. ..... 50 N· m

Carburetor: Standard Screws: Make ...................................... Mikuni Unmarked or Marked "4" Model ........... ... . .. ............ . . . .... B401-32 5 mm ...................... ···· ..... ·· .. 2·4 N'm

Fuel:Oil Ratio ........................ . ...... ... 50: I 6mm .......... ............. . .. . . . ...... 4·7N·m 8 mm .... .. . .... ......... .. ........... 10-16N·m

SIZES-CLEARANCES 10 mm ... .... . . . . .. .. . ................ 22·35 N'm Piston Ring End Gap ....................... 0.2·0.4 mm Marked "7" Piston Pin Diameter ................. 17.995·18.000 mm 5 mm ....... ..................... . ····· .3·6N·m Piston to Cylinder Wall . 6mm ............ . ............ ......... 8·12N·m

Clearance ................. ... . . .... 0.061·0.082 mm 8 mm ................. ···· ............ 18·28 N'm Max. Crankshaft Runout at 10 mm ..................... . .. . ....... 40·60 N'm

l\'1ain Bearing .Journal ....................... 0.05 mm Max. Con. Rod Small

End Side Sh~ke ............................. 5.0 mm

LUBRICATION

The power head is lublicated by oil mixed with the fuel. Fuel:oil ratios should be 30: I during break-in of a new or rebuilt engine and 50: I for normal service when using an NMl\IA certified TC-WII , two-stroke engine oil or Suzu­ki "CCI" oil. If using any other type two-stroke engine oil. fuel:oil ratios should be 20: 1 during break-in and 30: 1 for normal service. Manufacturer recommends regular or no-lead automo­tive ga~oline with octane of 85-95. Gaso­line and oil should be thoroughly mixed.

The lower unit gears and bearings are lubricated bv oil contained in the gear· case. SAE 90 hy-poid outboard gear oil should be used. The gearcase should be drained and refilled after every 50 hours of use with 480 mL of gear oil. Reinstall vent and fill plugs securely, using a new gasket if necessary, to ensure a water tight seal.

FUEL SYSTEM

CARBURETOR. A Mikuni, type B401·32 carburetor is used . Refer to

Fig. SZ12-1 for exploded view. Initial setting of pilot air screw (6) should be two turns out from a lightly seated posi· tion. Final carburetor adjustment should be made with engine at normal operating temperature and running in forward gear. Adjust throttle stop screw (4) so engine idles at approximate' Iy 650· 700 rpm. Adjust pilot air screw so engine idles smoothly and will accelerate cleanly without hesitation. If necessary, readjust throttle stop screw to obtain 650-700 rpm idle speed.

Main fuel metering is controlled by main jet (10). Standard main jet size for normal operation is #200 on all models.

To check !loat level, remove !loat bowl and invert carburetor. Distance (A - Fig. SZI2·2) between main jet and bottom of !loat should be 16.7·18.7 mm. Adjust !loat level by bending !loat arm tang.

SPEED CONTROL LINKAGE. Igni­tion timing advance and throttle open­ing must be synchronized so that throt­tle is opened as timing is advanced.

To synchronize the linkage, first make certain that ignition timing is correctly set as outlined in IGNITION TIMING

Fig. SZ12·1- E.plod.d .1 ... 01 M'ku"' c.~ bu",Ior Iyplc.' 01 ." models.

1. Body 2. Pilot ;l't 3. Air jet ~. Thr~){t l (' slop scrl' ..... .,. Spnng G. Pilot air screw 7. Spring

8. In!et ... :11\,,-: 9. MlUn Mule

to. }tain jet 11 . Flo:..t 12. Float pin 13. Ga.o:kl·t l4 . FlO'll bowl

Suzuki DT40 (Prior to 1984)

section. Determine type of ignition system used, as noted in IG:-.IITIO:-.l sec­tion, then refer to Fig. SZ12-3 and ad­just the length of ~tator link (S). car­buretor link (C) and lower link (L) using \'alues listed in the following table. Measure link rod lengths between ad­justing nuts as ~hown on lower link (L).

Independent Ignition Stawr rod (S)

C"rbureto l' rod (C) Lower r"d (LI

Simultaneous Ignition Sta tor rod (S) Carburetor rod (C) Lower rod (LI

Rod Length 30 mm

155.5mm 91 mm

Rod Length :3i mm

1 5~ mill 92 mm

REED VAL VES_ The inlet reed valves are located on a reed plate be­tween inlet manifold and crankcase. The reed petals should seat very lightly against the reed plate throughout their entire length with the least possible ten­sion. Tip of reed petal must not stand open more than 0.2 mm from contact surface. Reed stop opening should be 9.9 mm.

Renew reed, if petals are broken , cracked, warped. rusted or bent. Never attempt to bend a reed petal or to

I A

Fig. SZI2·2-Float 1 ••• , (A) should ba 16.7·18.7 mm.

Fig. SZI2·3- Vie .. 01 speed control IInhg • . Stator link (5) should b. Insl.lIed., posit/on (1) tor independent Ignition and position (2) for simultaneous Ignition. Refer to text for adjust·

ment procedure.

straighten a damaged reed. Never in­stall -a bent or damaged reed. Seating surface of reed plate should be smooth and flat. When installing reeds or reed stop, make sure that petals are centered over the inlet holes in reed plate, and that the reed stops are centered over reed petals.

FUEL PUMP. A diaphragm type fuel pump is mounted on the side of power head cylinder block and is actuated by pressure and vacuum pulsations from the engine crankcases. Refer to Fig. SZ 12-5 for exploded view of fuel pump assemblv.

-Wh e n serv Ic In g pump, sc ribe reference marks across pump body to aid in reassembly. Defective or ques­tionable parts should be renewed. Dia­phragm should be renewed if air leaks or cracks are found . or if deterioration is evident.

IGNITION

All models are equipped with either an independent or simultaneous, pointless electronic ignition system. One ignition coil is used on models with a simul­taneous ignition system while two igni­tion coil s are used on models with an in­dependent ignition system. Refer to Fig. SZ12-6 for wiring diagram used on in­dependent ignition models. Models with simultaneous ignition systems are similar.

2 3 4 9 Fig. SZI2·4-Exploded .1 ... 01 In lake manilold

and reed 'fal.,8 assembly. I. Gasket 2. ~1 i\11ira!d 3. Gaslc:et .j fU!ed plntc 5. ~ ~tal!.

6. Reed ,top 7. Lubnr.1J.t ro ti \':l !V('

8. Valve stolP 9, G3@.kel

OUTBOARD MOTOR

3 Fig. SZI2·5- E.plod.d ., ... 01 diaphragm type

'ue' pump assembly. 1. Cuvt"r 2 Diaphl"J4rYl :~. G;~ht .1. ROOy :"i. rum p pla,('!

H, Dinpn r~m 7. Spring 8. SJ:rrinJ::'!ellt 9. RI\.~

10. G~kl!t

IGNITION TIMING. On independent ignition models, ignition timing should be 6° AT DC at 1000 rpm and 25° BTDC at 5000 rpm. On simultaneous ignition models. ignition timing should be 2° ATDC at 1000 rpm and 25° BTDC at 5000 rpm. On all models, initial setting of ignition timing may be accomplished by centering mark (1\-1 - Fig. SZ 12-i) on stator plate with crankcase and cylinder block mating surfaces then adjust stator plate stop (S) so tab (T) just contacts boss on cyli nder block.

Final ignition timing check can be made using a suitable power timing light. Immerse outboard 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 flywheel cover . To check advance ig­nition timing, run engine at wide open throttle and note timing marks. Reposi­tion stator plate stop to adjust ignition timing.

TROUBLE-SHOOTING. If ignition malfunction occurs, check and make sure malfunction is not due to spark plug, wiring or wiring connection failure. If spark is absent at both cylinders, first check neutral start inter­lock (NSI) operation. Check neutral switch adjustment; switch should depress at least 1 mm when shift linkage is in neutral position. Check condition of neutral switch (17 - Fig. SZI2-6) using Suzuki pocket tester number 09900· 25002 or a suitable ohmmeter. Separate the wire connectors between switch (17) and NSI module (16) and attach a tester lead to each wire connected to switch. With shift linkage in neutral position, tester should read zero resistance. ;\-lov­ing shift linkage to "F" or "R" positions

SERVICE MANUAL Suzuki OT40 (Prior to 1984)

I BliR R

G 0 B/W

,BIW lTBL t

+18...\.-

R

G W BlfR BR

B l i S BR l :S

li G BR

fo: ~. - l/ G

17

Fig. SZIZ·6-Typical wlrlnl/ dial/ram for DHO mod./s wllh Ind.".nd.nllgnil/on. Olher mod./s or. similar. 1. Ignition s'A'itch 2. Emergency ~(OP 6. Overheat buzzer

s'4itch 7. Choke solenoid 3. Hour metN 8. B~lte!j' <. Volt meta:r 9. Starter moto r 5. Ta.chO~le'r 10. Starte r relay

should cause tester to jread infinite resistance. Renew neutr"! switch if re-quired. ..

To check condition of NSI module, use tester or ohmmeter in conjunction with test chart shown in Fig. SZ12-8. Renew NSI module if required .

Trouble-shoot ignition circuit using Suzuki pocket tester number 09900-25002 or ohmmeter as follows:

Independent Ignition Models, On in­dependent ignition models, check condi­tion of capacitor charge coil (2 - Fig. SZ12-9) by separating the blue/red wire connector and black wire connector at stator and attach a tester lead to each

S M I I

1- 1-1

Fig. SZI2-7-Sellgnll/on liming slsllcslly by cen­lering msrle (M) on slBlo' plsle wllh c,snkcase and

cyllnde, block mallng surfsce. Refe, 10 lex/.

11 . 20 IUllp ru~ If). S tatQr 12. Regulator 16. NS( modUle IS. fU."Ctifier 17. Nl'utra) ~""' itch 14. CD ignition 18. Spark pilii!'

modwl' 19. Overheat ~Jly,(J r

wire. Charge coil may be considered satisfactory if resistance reading is within the limits of 225-275 ohms.

Check condition of pulser coils (4) by separating the gray wire connector, pink wire connector and black wire con­nector at stator and attach tester positive lead to black wire. Attach negative lead to gray wire and note tester reading and then to pink wire and note tester reading. Resistance reading for each pulser coil should be within the limits of 180-220 ohms.

~ - Tester lead

~ Bluel Green Brown Yellowl '0 red green

"' ~ C1> Bluol A B C ..... red ... C1>

.oJ Green B ~ B C

OJ

~ C1> Brown A A C Eo<

+ Yellow/ C C B ~ green

F/I/. SZIZ·8- U •• chsrl shown abo •• and •• /ues 1I.led below 10 lasl condil/on of NSI module.

A. 200k IIhms I Ir It·~" R. :lOOk "hm~ "r nlort'

c. Teslf'r nt:'~I(' should sM"" dd1t.-ction th.:n rt:turn to~:ard infinite

B. Black L I .IU 1.ll{hl hlul' BL. Blut!' O. Oran~ BR. Brown R. Red G. Gr(>en \\' . White

GR. GrdY Y. Yello"\,.

Check condition of each ignition coil as follows: Separate the orange wire con­nector and black/white wire connector at coil for top cylinder, then attach a tester lead to each wire and note tester reading. Separate light blue wire con­nector and black/white wire connector at coil for bottom cylinder, then attach a tester lead to each" wire and note tester reading. Primary coil resistance reading should be within the limits of 0.87-1.17 ohms for each coil. Disconnect high ten­sion wires from spark plugs. Attach

F/I/. SZIZ·9- View of Independenllgnillon SIIlo, pl.,. components. 1. S[:HJlr pllltc 2. CapacitfJ r ('hUitt' cuil

:3. LI):!nt irll( COli .; PuJ~e- r ... "(Ii!

Suzuki DT40 (Prior to 1984)

'""" - Tester lead

I~ G, .... G,oy Pink 8'0<1< SI .... 1 0 .. "", ,.d

'0 G,.,n ~ A A A B C

III G .. y B ~ B B B B (IJ .-t

B B ~ B Pink B B H

C A ~ QJ 8'0<1< A A C +l

91 .... 1 ~ rn B B B B B QJ ...

E-t 0 .. ".. B B B B B ~ + li~1 B B B B B B blue

glrl/ A A A A A ..... h,r.

tester positive lead to high tension wire and negative lead to black/white wire. Secondary coil resistance reading should be within the limits of 5000-6800 ohms for each coil.

To check condition of CD ignition module, use tester or ohmmeter in con­junction with test chart shown in Fig. SZI2-10. Renew CD ignition module if required.

Simultaneous Ignition Models. On simultaneous ignition models, check con­dition of capacitor charge coil by separating the blue/red wire connector and gray wire connector at stator and attach a tester lead to each wire. Charge coil may be considered satisfactory if resistance reading is within the limits 135-165 ohms. .

To check condition Of"-ignition coil, separate the black/white wire connector at coil and remove high tension wires from spark plugs. Attach tester positive lead to black/white wire and negative lead to coil ground. Primary coil resistance reading should be within the limits of 0.08-0.10 ohms. Attach a tester lead to each high tension wire. Second­ary coil resistance reading should be within the limits of 3000-4000 ohms.

To check condition of CD ignition module, use tester or ohmmeter in con­junction with test chart shown in Fig. SZI2-11. Renew CD ignition module if required.

COOLING SYSTEM

WATER PUMP. A rubber impeller type water pump is mounted between the drive shaft housing and gearcase. A key in the drive shaft is used to turn the pump impeller. If cooling system prob­lems are encountered, check water in­take for plugging or partial stoppage, then if not corrected, remove gearcase as outlined in LOWER UNIT section and check condition of the water pump, water passages and sealing surfaces.

lictlt blu,

C B

C B B I~

A

Blldel 'tIIfhia

C B

C B B B ~

Fig. SZ12·10-Uso adlaconl chart and values listed below to test condition 0' CD ignition module used on independent ignition sys-

tems. :\. lOOk ohms lIr leIS B. lOOk oJJm!i I1 f moore C. 'Ci!'$wr needk !(hould :-;hbW de­

nectiQn then retu,rn toward in­fini{~r~sJ.s~

- Tester lead

I~ Green Grey Black/ Blue/ BlacK Whitt Red

'0

~ '" Green A B B A w .-<

~ ~ Grey C A B A " ., Blackl

~ ~ Whi1e C C B C

" ... Bluel

~ + Red A B B B Black C A A B ~

Fig. SZ12·11- Uso chari shown abo.o and .a/uos Ifslod bolow 10 lasl condilion of CD Ignl· tion module used on simultaneous Ignition

systems. C. Tester needle should

"how defl~tion then A. lOoK ohms or Il'~'" return t.ow;J.t"d infinitl' B. lOOK ohms or mort' resista.nce

Fig. SZ12·12-E.ploded .Iew of waler pump assembly.

1. Water tube 4. Impeller 2. Pump housing 5. Plate 3. Key 6. Gasket

OUTBOARD MOTOR

When water pump is disassembled, check condition of impeller (4 - Fig. SZI2-12) and plate (5) for excessive wear and damage. Reinstall plate (5) with side marked "UP" towards im­peller. 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 (3-Fig. SZI2-13) is used to regulate operating temperature. The thermostat is calibrated to control temperature within the range of 48.5°-51.5°C (119°-125°F). Thermostat can be re­moved for inspection or renewal by removing cylinder head cover.

POWER HEAD

REMOVE AND REINSTALL. To remove the power head, first remove up­per cover and disconnect linkage, fuel lines and wires which interfere with power head removaL Remove car­buretor, fuel filter, fuel pump, electric and/or recoil starter, ignition coil(s), ig­nition module, rectifier, neutral safety interlock switch, interlock rod, flywheel, and stator assembly before detaching power head from lower unit. Disconnect shift linkage at shift handle and at shift rod connector located below lower drive shaft housing mount (15 - Fig. SZI2-15).

12~ 13-~ 2

14~

I Fig. SZ12·13-E.ploded .Iow of cronkcasa

assambly Iyplcal of all models. 1 Cylinder Iwad cover 2 Gru;ket 3. Thermostat 4. Cylinder head 5. Head gasket 6. Cylinder block 7. Crank~ 8. Outer exhau3t c:ov .... r

9. Ga.<;.ket 10. Inner exhaust co .... er 11. Gasket 12. Uppt'r ~al hou!ling 13. Gao:;ket 14. Upper ctank!:lhaft seal 15. Lower crankshaft seal

SERVICE MANUAL

Fig. SZ12·14-Exploded .Iew 01 c,anksh.1f .... mbly Iyplcal 01 .11 mod.ls.

I. P'l$tof') rin~ 10. Thrwt ws.mer 2. F\sWI1 . II . Ball bearing :1. Piston pin dip 12. Top crank half 4. Piston pin 13. Crank half 5, Thru5t wuher 14. Labyrinth ~ 6. Neoc!dl~ bearing Ili &, 11 OOnllK 7. UJnoottil1jl rod 16. Lowtr cranbh"rl 8. Cmnkpin ~mblv 9. N~Je. Ix>:uing 17. BaH beinnR'

Remove screws securing power head assembly to lower unit and lift off power head.

Before reinstalling power head, check condition of drive shaft seal (I-Fig. SZI2·15). If seal renewal is required, ap· ply a suitable high temperature grease to lip portion of seal and install into seal housing (3) with open side towards drive shaft housing (10). Make certa,in drive shaft splines are clean then coarthem with a light coating of water resistant grease. Apply a suitable sealer to mating surfaces of power head and lower unit and install a new gasket. The remainder of installation is the reverse of removal procedure.

DISASSEMBL Y. Disassembly and inspection may be accomplished in the following manner. Remove upper oil seal housing, exhaust cover, intake manifold and reed valves. Remove cylinder head and clean carbon from combustion chamber and any foreign material accumulation in water passages. Crankcase (7 - Fig. SZI2·13) may be separated from cylinder block (6) and crankshaft and piston assembly reo moved after removal of crankcase reo taining cap screws.

Engine components are now ready for overhaul as outlined in the appropriate following paragraphs. Refer to the following section for assembly pro· cedure.

ASSEMBL Y. Refer to specific servo ice sections when assembling the crank­shaft. connecting rod, piston and

, , o

....-10

Fig. SZ12·15 - Explod.d .I.w 01 d,l.e .h./t hou.· Ing lind rei. fed compon.nts.

1. Dr1~ Ylaft ~I 8. Upper mount ,",ou.'Jinj.! 2. GW(f:t 9, Rubber mount 3. Sea! hOUSing 10. Driv~ l hatt hoU!ing 4. Ga.t.ket 12. Re"l'~ thru!l.t mounl 5. Exhaust tub«! 13. Side mQUnl 6. Plate t.t . Lo ..... C! r t hMJ !lt mOll,nl 7. UpPl'r thrust mount 15. Low('r mount co .... er

reed valves. Make sure all joint and gasket surfaces are clean. free from nicks and burrs and hardened cement or carbon.

Whenever the power head is dis· assembled, it is recommended that all gasket surfaces and mating surfaces without gaskets be carefully checked for nicks. burrs and warped surfaces which might interfere with a tight seal. Cylinder head. head end of cylinder block and some mating surfaces of manifold and crankcase should be checked on a surface plate and lapped if necessary to provide a smooth surface.

Suzuki DT40 (Prior to 1984)

G ' I N Fig. SZ12·16- VI.w 01 In.,alled c,ank.half •••• mbly .howlng ,.by,'nlh .e.1 locallng g,oo.e IG) end m.'n bea,'ng locating nolche.

IN),

Do not remove any more metal than is necessarv.

When 'assembling power head, first lubricate all friction surfaces and bear· ings with engine oil. Install crankshaft assembly. Make certain labyrinth seal engages groove (G-Fig. SZI2-16) and main bearing locating pins engage notches (N) in cylinder block. Apply a coat of Suzuki Bond No.4 or a suitable sealer to mating surfaces of cylinder block and crankcase and position crankcase on cylinder block. Using a crossing pattern. tighten the lO mm crankcase screws to 40·60 N· m and the 6 mm crankcase screws to 8-12 N· m. Cylinder head gasket should be installed with gasket sealer. Position cylinder head and gasket on cylinder block and tighten head screws in sequence shown in ·Fig. SZ12·17 to 20-23 N"m. Cylinder head cover cap screws (C) should be tightened to 8-10 N" m.

Install crankshaft seal (14 - Fig. SZ12·13) into upper seal housing (12) with open side towards cylinder block. Apply a suitable high temperature grease to lip portion of crankshaft seals (14 and 15), then install upper seal hous­ing and lower crankshaft seal in cylinder block assembly.

RINGS, PISTONS AND CYLIN­DERS. The piston is fitted with two piston rings. Rings are interchangeable in grooves but must be installed with manufacturers marking toward closed end of piston. Piston ring end gap should be 0.2-0.4 mm with a maximum allowable ring end gap of 0.8 mm. Piston to cylinder wall clearance should be 0.061·0.082 mm. Pistons and rings are available in standard size as well as 0.25 mm and 0.50 mm oversizes. Cylinder should be bored to an oversize if cylinder is out·of-round or taper exceeds 0.10 mm. Install piston on connecting rod so arrow on piston crown will point towards exhaust port when piston is in cylinder.

Suzuki DT40 (Prior to 1984)

CONNECTING ROD, BEARINGS AND CRANKSHAFT. Connecting rod. bearings and crankshaft are a pressed together unit. Crankshaft should be dis­assembled ONLY by experienced serv­ice personnel and with suitable service equipment.

Caged roller bearings are used at both large and small ends of the connecting rod. Determine rod bearing wear by measuring connecting rod small end side-to·side movement as shown at (A - Fig. SZI2-18). Normal side·to-side movement is 5 mm or less. Maximum allowable crankshaft run out is 0.5 mm measured at bearing surfaces with crankshaft ends supported.

When installing crankshaft, lubricate pistons, rings, cylinders and bearings with engine oil as outlined in ASSEMBLY section.

STARTERS

MANUAL STARTER. Refer to Fig. SZ12-20 for exploded view of overhead type manual starter assembly. Starter may be disassembled for overhaul or renewal of individual components as

Fig. SZ12-17-Cy/lnde, h.ad cap .c,. ... • hould ba IIghl.n.d In Ih. .equ.nc. sho .. n abo.a.

R.'e, 10 I.xl

FIg. SZ12·18-frlu/mum ./de-Io-s/d •• h.k. (A) ., .ma/l.nd 0' connecllng ,od should be 5.0 mm

or I •• s.

follows: Remove engine top cowl and three cap screws securing starter assembly to power head. If starter spring remains under tension, pull starter rope and hold rope pulley (10-Fig. SZ12-20) with notch in pulley adjacent to rope outlet. Pull rope back through outlet so that it engages notch in pulley and allow pulley to slowly un­wind. Remove cap screw (17) and disassemble unit. Be careful when removing rewind spring (9); a rapidly uncoiling starter spring could cause serious injury.

Rewind spring is wound in a counter· clockwise direction in starter housing. Rope is wound on rope pulley in a counterclockwise direction as viewed with pulley in housing. Reassemble s tarter assembly by reversing disassembly procedure. To place tension on rewind spring, pass rope through rope outlet in housing and install rope handle. Pull rope out and hold rope pulley so notch on pulley is adjacent to rope outlet. Pull rope back through outlet between notch in pulley and hous­ing. Turn rope pulley counterclockwise four complete revolutions to place ten­sion on spring. Do not place more ten­sion on rewind spring than is necessary to draw rope handle up against housing.

ELECTRIC STARTER. Some models are equipped with electric starter shown in Fig. SZ12-21. Dis­assembly is evident after inspection of

r ~7 ---I ,

3

~~~11 ___ 13

~14 ___ 15

@ 16

~:: Fig. SZ12·20- Explod.d .Ie .. 0' o .. ", .. d .,.rt.,

.... mbly. 1. Ropt.- handle 2. Retainer 3. Rope ~ide • . Grommet 5. Spring 6. StArter housing 1. Nut 8. Rope 9. Rewind "pring

10. Ro~ pullll:!'Y I I. Spring 12. Pa .... · j 13. Sprina-14. OriVl' p)<1le 15. SpaHr 16. Wa!ber 17. Cap!tCre .... · 18. Starter cup

OUTBOARD MOTOR

unit and reference to exploded view. Starter brushes have a standard length of 14 mm and should be renewed if worn to 9.5 mm or less. After reassembly, bench test starter before installing on power head.

LOWER UNIT

PROPELLER AND DRIVE CLUTCH. Protection for the motor is built into a special cushioning clutch in the propeller hub. No adjustment is possible on the propeller or clutch. Three-bladed propellers are used. Standard propeller has a 330 mm pitch and a 292 mm diameter. Optional pro­pellers are available from the manufac­turer and should be selected to provide full throttle operation within the recom­mended limits of 4800-5500 rpm.

R&R AND OVERHAUL. Refer to Fig. SZ12-22 for exploded view of lower unit gearcase assembly used on all

2--~-,

:a---3

4--~"

5

6

12

FIg. SZ12·21- Exploded ., ... 0' .'ecl,lc .IIrte, motor.

1. "C~ r ing 2. SlOp . 3. Spring

i . FNune K Bru..~h assy. 9. Thrust washers

4. Dm'e 10. Shim 5. rl"ll1r.e ht-ad 11 . Bru.th eo\-er 6. Armalu~ 12. Starter $Olenoid

SERVICE MANUAL

models . During disassembly, note the location of all shims and thrust washers to aid in reassembly. To remove gear· case, first unscrew plug (30) and drain gear lubricant. Disconnect shift linkage at connector (2) located externally on the drive shaft housing. Remove the cap screws securing gearcase to drive shaft housing and separate gearcase assembly from drive shaft housing. Remove water pump assembly (Fig. SZI2·12). Remove propeller with related components from propeller shaft. Unscrew two bol ts re­taining gearcase end cap (50 - Fig. SZI2-22), then attach a suitable puller to propeller shaft (44) and withdraw pro­peller shaft assembly with gearcase end cap. Unscrew pinion nut (33) and remove pinion gear (32), then extract forward gear (36). Drive shaft (20) and related components may be withdrawn from gearcase after removal of bearing housing (13). Unscrew shift cam retain­ing screw (12) from gearcase to remove lower shift rod assembly.

Inspect gears for wear on teeth and on engagement dogs . Inspect clutch (40) for wear on engagement surfaces. Inspect shafts for wear on splines and on friction surfaces of gears and oil seals. Check shift cam (11) and shift pin (38) for ex­cessive wear. Check condition of shift spring (43). Spring free length should be 69 mm with a minimum length of 67 mm. All seals and "0" rings should be renewed when unit is reassembled.

Backlash between pinion gear (32) and drive gears (36 and 46) should be 0.05-0.30 mm and is adjusted by varying thickness of shims (35) and thrust washer (47). Propeller shaft end play should be 0.05-0.30 mm and is adjusted by increasing or decreasing the thick­ness of thrust washers (37 and 45).

Reassemble gearcase by reversing dis­assembly procedure while noting the following: Install clutch (40) on propeller shaft (44) so "F" marked side (see Fig. SZI2-23) is towards forward gear (36-Fig. SZI2-22). Tighten pinion nut (33) to 35 N· m. Apply water-resistant grease to mating surfaces of gearcase end cap (50) and gearcase. Apply silicone

Fig. SZ12·22- E.ploded rlew ot lowe, unit oe.,c8se .ssembly used on _II

model •. L Nut 2. Conn~ctor 3. Du!tl seal " . Rod guid ... 5 ... O~ rlng 6. "O~ ri nK 7. LO ..... (' r !<hift rod 8. M~('t 9. "~E"t holder

10. Pin 11 . Shift cam 12. Cam reta inin~ !'ere .... · 13. BeannR hOUSing 14. Seal 15. Needle- bearing: 16. BearinK rnce 17. Shim 18. Thrust. beatinK race 19. Thru~t bearing 20. Dri ... e thalt 21. Pin 22. Spring 23. Ctlllar 24 . Thrust ..... a.sher 25. W a.<;h('r 26. Needlt' beuings 27. ~arca..~ 28. Vent plug 29. Oil l'-!ve l plug 30. Drain plUK 31 . Strip s('a1 32. Pin ion g ("ciT

33. Pinion nut 34. Taper bearin jl( 35. Shim 36, Forv.-ard gP.ar 37. Thru!;l ..... asher 38. Shift pin 39. Sprin,l( KUid p. 40. Clutch 41. Pin 42. Pin retainer 43. Shift spring 44. Propeller ghaft 45. Thrullt ..... a. .. h(! r

1-... 2~ 3~ 4-@ 5;;<t 8

Suzuki OT40 (Prior to 1984)

58

~/ 5\57\

52 54\ , 51 \ .' • ... 55

53

"

46. Rovene ~ar 41. Thru~t ..... a.~het 51. Nc-edle bcarin~ !is. Propeller 48. "0" ring 52. S<al 56. Spacer 49. Ball bearing 53. Spacer 57. LockwlLo;.h('t 50 . End cap 54. Wa~her 58. P ropt' ller nut

sealer to gearcase and bearing housing (13) mating surfaces and to bearing housing and drive shaft housing mating surfaces.

With gearcase assembly installed, ad­just shift linkage by first ensuring gear­case is in neutral. Adjust shift rod con­nector (2) so shift control handle is ex­actly between "F" and "R" positions, then tighten jam nut (1). Fill gearcase with outboard gear oil as outlined in LUBRICATION section.

44 40

Fig. SZ12·23 -Install . clulch (40) on propeller shall (44) wllh OF" marked .Ide loward. forward

gea,.

Suzuki DT35 (After 1986) & DT40 (After 1983) OUTBOARD MOTOR

SUZUKI DT35 (After 1986) AND DT40 (After 1983)

CONDENSED SERVICE DATA

TUNE-UP lip/rpm

Bore ...

.3514800-5500 40/4800-5500

.79.0 mm (3.11 in.)

Stroke . , ' .. , , , . . . . .. . , . . . .. . . .. , ,71.0 mm (2,80 in.)

Number of Cylinders ..... . ' . , . , . , . , .. , . , ,2 Displacement, , , , , . , . , . . ... , . . .. . .. . . , . ,696 cc

(42.47 cu, in.) , . , , .. , , NG K B8HS , . , .. , . ,0.8-0,9 mm

(0.031-0.035 in.)

Spark Plug, , , , Electrode Gap,

Ignition Type, . , Carburetor Make .. , , , . '

, ,Breakerless CDI , . , . , . ,Mikuni

. B40-:32 . ,650-700 rpm

Carburetor Model . , , , . , ' . , , . . . , .... ' Idle Speed , , , , , . . ' .. , ... , ..

SIZES-CLEARANCES Piston Ring End Gap . . , ........ , .... 0.2-0.4 mm

Wear Limit (0.008-0.016 in.)

..... 0.8 mm (0.031 in .)

Piston Pin Diameter ' . . .. . , . . . . . 19.995-20.000 mm

Wear Limit (0.7872-0,7874 in.)

.19.980 mm (0.7866 in,)

Piston Pin Bore Diameter, , , . _ . . . ... 19.998-20.006 mm

Wear Limit . . . . . ,", . ..... .

Piston-to-Cylinder Clearance

Cylinder Bore Wear Limit,

Max, Crankshaft Runout at Main Bearing .Journal . , '

(0.787:3-0.7876 in.) , ..... , .20.032 mm

(0.7887 in.) , ... ,0.099-0.ll4 mm

(0.0039-0,0045 in. ) .. 0,10 mm

(0.0039 in.)

....... 0.05 mm (0.0020 in.)

Max. Connecting Rod Small End Side Shake ...... .. . , .. , , , . , . , . , . , ... , , . , , .. 5.D mm

(0.20 in.)

TIGHTENING TORQUES Cylinder Head Cover , ...

Cylinder Head. , . ,

Crankcase: 6 mm ..

10 mm",." .... , . .. , .. . . , .....

.... 8-12 N'm (6-9 fUbs.) ,20-26 N'm

(15-19 ft.-Ibs.)

,8-12N'm (6-9 ft.-Ibs.)

.. .46-54 N'm (34-40 fUbs.)

Exhaust Cover, ... , . . , ........... . . ,., .... 8-12 N'm

Flywheel Nut

Gearcase Pinion Nut

Propeller Shaft Nut

Standard Screws-Unmarked or Marked "4": 5 mm .' ... , . .. . .

6 mm"., .. " . . .. .. , .. . .. .. .. .. . .

8 mm., .. . .. ,", . . ,

(6-9 ft.-Ibs.) ... 200-210 N'm (147-155 fUbs.) ... ,30-40 N'm (22-29 ft.-Ibs.)

.50-60 N'm (37-44 ft.-lbs.)

.. 2-4 N'm (18-35 in.-lbs.) . ... .4-7 N'm

(35-62 in.-lbs.) , ,10-16 N'm (7-12 fUbs.)

10 mm. , , ..... , , , . . .. _ .. . . ... _ . . _ .... ,22-35 N'm

Stainless Steel: 5 mm

6 mm.

(16-26 ft.-lbs.)

..... 2-4 N'm (18-35 in.-Ibs.)

.... , , .6-10 N'm (53-88 in.-Ibs.)

8 mm .. , .. , .. , . .... , .. . . , . . . . ' . .. ... . , 15-20 N'm

10 mm, ........ ,",.

Marked "1": 5 mm

6 mm ..

",., .".,\., .. , . .

8 mm .... . . ,., .. ,',

(11-15 ft.-Ibs.) .. 34-41 N'm

(25-;30 fUbs.)

.. 3-6 N'm (27-53 in,-Ibs.) .... 8-12N·m

(6-9 ft.-lbs.) ... 18-28 N'm (13-21 ft.-Ibs.)

10 mm. . , ... . .... ' . , . , . . , . . , , . . , . , .. .40-60 N'm (29-44 ft.-lbs.)

LUBRICATION

The power head is lubricated by oil mixed with the fu el. All models are equipped with automatic oil injection. The crankshaft driven oil pump varies the fuel:oil ratio depending upon carbu­retor throttle opening. Recommended oil is Suzuki Outboard Motor Oil or a good quality NMMA certified TC-WIJ en-

gine oil. Recommended fuel is regular or unleaded gasoline having an mini­mum octane rating of 85. Manufactur­er does not recommend using gasoline containing alcohol additives. However, unleaded gasoline containing ethanol (grain alcohol) may be used providing ethanol content does not exceed five percent and minimum octane rating is 85.

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

During break-in (fir:;t 10 hours of op­eration) of a new or rebuilt engine, mix a recommended oil with the fuel at a 50:1 ratio and use in the fuel tank in combination with the oil injection sys­tem to ensure adequate lubrication dur-

SERVICE MANUAL

ing break-in process. After initial 10 hours of operation, switch to straight gasoline in the fuel tank.

The lower unit gears and bearings are lubricated with oil contained in the gem·case. Recommended gearcase oil is Suzuki Outboard Motor Gear Oil or a suitable equivalent SAE DO hypoid gear oil. Gearcase capacity is approximately 610 mL (20.6 n. oz.). Lower unit oil should be changed after the first 10 hours of operation and after every 100 hours or seasonally thereafter. Reinstall drain and vent plugs securely, using a new gasket if necessary, to ensure wa­ter tight seal.

NOTE: Oil level in gearcase should be rechecked after running outboard motor a short time and topped off if necessary.

FUEL SYSTEM

CARBURETOR, Refer to Fig. SZI:3-1 for an exploded view of the Mikuni B4()-32 carburetor used on all models. Initial setting of pilot air screw (4) is 1 'I, to 2 turns out from a lightly seated position. Final adjustment should be made with engine at normal operating temperature and running in forward gear. A(\just pi­lot air screw so engine idles smoothly and will accelerate cleanly without hesi­tation. Adjust idle speed screw (lo'i) so idle speed is 650-700 rpm at normal operating temperat ure in forward gear.

Fig. SZI3-1-Exploded view of Ihe Mlkunl 840-32 carburetor used.

1. Uody 2. Piln t JN :3 Spring -1. Pik.t ;l ir ~(:r.·w :,. GIL~ket

ti. In le-t "!.lIn' ~'a( Inh't nct'dle "al\'('

8 Main 1ll)J':li l '

~ , MaIn Jet 10. ChOKe rou 11. Floal 12. Pin J:3 . Gi),skct 14 . ~'oat oowl Ii"!, 1(11(' sfJCt.·d ::>c:n'w

Suzuki OT35 (After 1986) & OT40 (After 1983)

High speed fuel meteting is controlled by main jet (9). Standard main jet for normal operation is 1118,) Ott models pri­or to 1987 and 11190 on 1987 and later models. Standard pilot jet (2) for normal operation is !l70 on models ptior to 1987 and #77.,) on models after 1986.

To check noat level, remove noat bowl (14) and invert carburetor body (1). Measure noat level (L-Fig. SZ1:3-2) from main jet (9) to no at (11) as shown. Take measurement 180 degrees from inlet valve. Float level (L) should be 16.:;-18,;) mm (0.6;';-0.73 in.) on models prior to 1987 and 17-19 mm (O.G7-0.7,) in.) on models after HJ86. Bend tang on noat to adjust noat level.

FUEL FILTER. A fuel filter assembly is used to filter the fuel prior to enter­ing the fuel pump. Periodically unscrew bowl (7-Fig. SZ13-3) and withdraw fil­ter element (G). Clean bowl and filter el­ement in a suitable solvent and blow dry with clean compressed air. Inspect fil­ter element for excessive blockage or other damage and renew if necessary. Reassemble in reverse order of disas­sembly. Renew "0" ring (5) and seal (4) upon reassembly.

FUEL PUMP, A diaphragm-type fuel pump is used. Refer to Fig. SZ1:3-:3 for exploded view. Fuel pump is mounted on the side of power head cylinder block

Fig. SZI3-3-Exploded view of fuel filter and fuel pump as­

semblies. l. 'Sut 2. W8.~hN

U"-'k' I St.' il l J, 'cr' nnR (i, f i llNI:-lt-I11('nl

CIII' k. C(I\'('r

~I. Dblphragm 1(1, G'lUk('t II lKld y l~. Dhl jJhragm 1:3. Sllrin~ 11 s.- · ~I t I::;. G~L!"kt· t

Ui \: ;'llvN

and is actuated by crankca5e pulsations. Wben servicing [lump, scribe refer­

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

REED VALVES. The reed valves are located behind the intake manifold (1-Fig. SZt:3-6). The intake manifold must be removed to access reed valve as­semblies.

Renew reed petals (:3) if petals are bro­ken, cracked, warped, rusted or bent, or if tip of petal stands open in excess

Fig. SZI3-2-Measure floal level (L) from main jel (9) 10 fioBI (II) BS shown. Refer 10 lexl.

)

7

/

-

Suzuki DT35 (After 1986) & DT40 (After 1983)

uf 0.2 mm (0.008 in.) from seat area. Re­fer to Fig. SZI3-6. Do not attempt tu bend or stnLighten a damaged reed. Opening between tip reed stup (4) and reed plate should be 7.6-8.0 mm (0.:30-0.:32 in.) on models plioI' to HJ87 and 6.0-6.4 mm (0.24-0.25 in.) on models after 1986. When reassembling reed valve as­sembly, apply Suzuki Thread Lock 1:342 or a suitable equivalent thread locking compound to threads of reed attaching screws (4).

SPEED CONTROL LINKAGE_ Throt.­tIe opening and ignition timing advance must be synchronized fur proper oper­ation . To adjust speed control linkage and ignition timing, procf~ed as fullows:

FIg. SZt 3-5-Exploded view of reed valves and re­lated components.

I. lnt8kl!!' mitnifnld 2. Iu,'(o(l plnh .-:1 Itl·(·tl l>ehlL"'I

·1 . Hf' c-d sl oll :") , ('nl nk(' JlS;;' :I.s....;,y.

2 Fig. SZ13-6-Clearance (e) between reed petal. (3) and reed plale (2) should nol exceed 0.2 mm

(0.008 In.).

With engine not running, shift outboard into forward gear. Loosen throttle cam screws (IO-Fig. S21:3-8) and open throt­tle until stator mark located at (A) is aligned with crankcase and cylinder bluck mating surfaces (6). Note that a hole is provided in f1ywheel to access screws (10). With mark (A) aligned with trankcase mating surfaces, slide throt­tle cam (I) against crankcase stopper (2) and retighten screws (10). Without dis­turbing position of stator (:3), loosen screw (13-Fig. SZI3-8). Rotate carbure­tor throttle arm (14) so throttle valve is fully open, then hold cam roller (II) against throttle tarn (1) and retighten screw (1:3).

Next , with engine not running, place outboard into forward gear. Rotate sta­tor so mark (B-Fig. S213-8) is aligned with crankcase-to-cylinder block mating surface (6). Loosen nut (8) and turn s<:rew (!J) so cap (7) contacts stopper (4), then retighten nut (8). Rotate throttle limiter (l7-Fig. SZI3-9) against stopper (18) and adjust the length of rod (16) so carburetor throttle valve is completely open , then retighten nut (15).

OIL INJECTION

The plunger-type oil pump is dliven by a drive gear on the bottom of the crankshaft. Depending upon carburetor throttle valve opening, the oil pump varies the amount of oil delivered to the engine resulting in fuel:oil ratios from approximately 1;;0: I at idle to approxi ­mately :)0:1 at full throttle. Oil is inject­ed down stream from the incoming fuel and air mixture. An ainoil mixing valve lo~ated in the cranktase, mixes oil from injection pump with small amounts of air from crankcase pulsations to help emulsify the oil il\jt'cted into the fuel and air stream. Hefer to Fig. SZI3-1O for an exploded view of oil pump and re­lated components.

BLEEDING PUMP_ If oil pump, reser­voir or oil lines have been removed, or if outboard motor has been in long tenn

Fig. SZI3-8-Reler 10 lext lor speed control adjustment

procedure. I ThruU]1' cam 'J Cnlnkl'aJiC ~ \/)pper

:L St."uor I. ('rflnkl:'1iSl' ~Vqlp~n

{i Cru.nkease-w -cylillilC'r bind.: mlllinR SlIr(11("('

7. G~IP R. ~lIl !I . Idlt, ri mJIl,IJ lOCH' .....

I" S('1'"('W~

.\. St tl t') r IImr!.: B. Sutlor mark

OUTBOARD MOTOR

storage, air should be purged from oil in­jection system. 'Ib bleed air from injec­tion system, first fill the oil reservoir. Open bleed screw (Fig. SZI:3-12) until oil escapes. Allow oil to nm out bleed screw for approximately five seconds, then retighten bleed screw.

CHECKING PUMP OUTPUT, Start engine and allow to warm-up for ap­proximately five minutes. Stop engine and disconnect oil pump control rod (6-Fig. SZI3-1O) from carburetor throt­tle lever. Disconnect the oil pump sup­ply line from oil tank, plug tank outlet and remove tank. Connect Suzuki oil gage 08900-21602 or a suitable calibnit­ed container to oil pump supply line. Fill oil gage with a recommended oil and bleed system as previously outlined. Re­fill oil gage, if necessary, to an upper ref­erence mark. With oil pump control le­vel' in the fully closed position (control rod pushed down), start engine and run at. 1500 rpm for exactly five minutes. On models prior to 1986, oil pump output should be 2.2-2.8 mL (0.07-0.08 fl. oz.) in five minutes at H'iOn rpm. On models after 1985, oil pump output should be 1.3-2.3 mL (0.044-0.08 fl. oz.) in five minutes at 1500 rpm. Next, move oil pump control lever to the fully open po­sition (<:ontrol rod pulled up). St.art en­gine and run at 1500 rpm for exactly two minutes. Oil pump output should be 3.2-4.0 mL (0.11-0.14 fl. oz.) in two minutes at 1500 rpm on models prior to 1986, or 2.9-4.4 mL (0.098-0.149 f1. oz.) in two minutes at 1500 rpm on models after 1985. Renew oil pump assembly (I-Fig. SZI:3-1O) if output is not as specified. When installing pump (I) be certain driven gear (4) properly engages crank­shaft drive gear and oil pump assembly. Bleed il\j~<:tion system as previously outlined )

NOTE: Results of oil pump outputteSl may vary according to weather conditions, test­Ing error or other conditions- The manufac­turer recommends repeating output test procedure two or three times to ensure the proper results are obtained.

I(3NITION A capatitor discharge ignition (CDI)

system is used. The primary ignition components are t.he f1ywheel, condens­er charge coil (1-Fig. S213-1:3), pulser coil (2) stator (3) and CDI module. The ignition toils are contained in the CD! module. The CDI module is also equipped with an oil warning cirtuit and an rpm limiter to prevent engine speed from exceeding 5!J00 rpm.

Ignition timing is advanced electron­ically by the CD! module and mechani­cally by rotation of stator assembly (3). Ignition timing should be 1-3 degrees

SERVICE MANUAL

ATDC at 1000 rpm and 24-26 degrees BTDC at 5000 rpm. Loosen screws (10-Fig. SZI3-8) and move throttle cam (1) to adjust full throttle timing advance. 10 adjust idle timing, loosen nut (8) and turn screw (9). Turning screw (9) clock­wise advances timing.

TROUBLE-SHO<YfING. Refer to Figs. SZI3-13, SZ13-15 and SZ13-16 for wiring diagrams typical of all models. Trouble­shoot ignition system using Suzuki Pock­et Tester 09900-25002 or a suitable equivalent ohmmeter.

NOTE: The resistance specifications for trouble-shooting Ignition system are based on measurements taken at 200 C (680 Fl. Ac­tual resistance values obtained while test­Ing may vary depending upon ambient tem­perature, temperature of component and tester manufacturer.

CONDENSER CHARGE COIL. Dis­connect charge coil connector and con­nect tester between green and black wires. Charge coil resistance should be 230-280 ohms on models prior to 1987 and 200-300 ohms on models after 1986. No continuity should be present be­tween green charge coil wire and engine ground or charge coil core.

PULSER COIL. Disconnect wires at connector leading to pulser coil. Con­nect tester between white/red and black wires. Pulser coil resistance should be 175-210 ohms on models prior to 1987 and 160-230 ohms on models after 1986. No continuity should be present be­tween pulser coil white/red wire and en­gine ground.

LIGHTING COIL. Disconnect Hghting coil and connect tester between red and yellow wires. Lighting coil resistance should be 0.20-0.25 ohm on models pri­or to 1987 and 0.2-0.6 on models after 1986. No continuity should be present between Hghting coil red wire and en­gine ground.

IGNITION COILS. Test ignition coil secondary winding resistance by con­necting tester between spark plug high tension leads. Resistance should be 2:300-:3100 ohms on models prior to 1987 and :3100-:3200 ohms on models after 1986. Renew CD! module if coil secon­dary resistance is not a~ specified.

cm MODULE. Suzuki CD! Tester 09930-99810 or 09930-99830 and test harness 09930-89440 are available from the manufacturer to test the CD! mod­ule. Follow instructions provided with the tester.

Suzuki DT35 (After 1986) & DT40 (After 1983)

COOLING SYSTEM

THERMOSTAT. A thermostat located in the cylinder head cover is used to regulate operating temperature. Test thermostat by immersing in heated wa­ter with an accurate thermometer. Thermostat should begin to open at 58.5°-61.5° C (137°-143° F). Renewther­mostat if it fails to open within the specified temperature range. When in­stalling thermostat, be certain bleed hole is facing direction shown in Fig. SZI3-17.

15-~

WATER PUMP. A rubber impeller type water pump is mounted between the drive shaft housing and gearcase. Drive key (6-Fig. SZI3-18) in the drive shaft turns impeller (5). When servicing water pump, inspect condition of water passages and sealing surfaces. Rotate drive shaft in clockwise direction when installing pump housing (4) over im­peller. Avoid turning drive shaft in op­posite direction after reassembling pump.

14 "I

L (

) (

1 Thrql,tk cam "J. STlltv r

10. Sc n'ws 11. Cam r(liler l~. I.,(' \'(·r 1:3. S!'r(".\" H. ThnlUle [PVt'r Fi ~ut 11). Hod 17. Thrnult' Ilmit('r 1::-> Crankc.ls{' stopp,-'r

Fig. SZI3-9-View 01 speed con/rolllnKage. ReIer /0 len lor ad/us/men/ procedure.

Fig. SZI3-10-Vlew 01 oll/n­fectlon pump and related

components. 1. Pump a~~y 2. Adapter :3. (Task,'t -1. Driv{'n gear

Check valv('s Control rorl

Suzuki OT35 (After 1986) & OT40 (After 1983) OUTBOARD MOTOR

F11. SZI3-12-Vlew of Injecllon pump bleed screw.

3

4 Fig. SZ13-13-Vlew showing location of con dens­er charge call (I), pulser call (2) and IIghling call

(4) on stator assembly (3).

POWER HEAD Be sure to properly route all wires and hoses to prevent interfering with mov­

REMOVE AND REINSTALL. Remove ing parts. engine co\·er. Disconnect neutral start interlock cable from throttle limiter (17-Fig. SZI!l-!-J). Disconnect and re­move oil tank , remove the rewind start­er and remove a ir box silencer. Discon­nect oil pump control rod from carburetor and remove choke knob. Dis­connect and remove carburetor. Remove throttle lever rod from throttle lever, disconnect battery cables from st.'lrter motor and remove two cables from st.arter relay. Disconnect brown and green/yellow wires from neutral start switch. Loosen electric pm1s holder at­taching screw and disconnect all inter­fering wires. Remove inlet hose from fuel pump. Remove flywheel using a suitable pulle r. Remove power head mounting sc rews and lift power head off drive shaft housing.

Before installing power head , be sure drive shaft sp ines are clean . Apply a light coating of water-resistant grease 1.0 drive shaf t splines. Apply Suzuki Sili­cone Seal 9!-JOOO-:3 1120 or a suitable equivalent to mating surfaces of power head and drive shaft housing and threads of power head moullting screws. Lower power head onto drive shaft housing while rotating power head slightly to engage crankshaft and drive sha ft splines. Remainder of reinstalla ­tion is the reverse of removal procedure.

DISASSEMBLY. Remove six screws and detach exhaust tube (23-Fig. SZI3-20). Remove starter motor and bracket, then disconnect wires inside the e lec­tric parts holder and CD! module holder. Remove stator assembly, upper oil seal housing (6) and stator retainer. Remove fuel pump and fuel filter. oil pump as­sembly, oil pump adapter and oil hoses. Remove 12 screws and detach intake manifold (I). Remove one screw secur­ing reed plate, then detach reed plate assembly. Remove exhaust cover screws and carefully pry off exhaust cover (17), then exhaust plate (16). Remove lower oil seal housing, thermostat cover and thermostat. Remove 13 cylinder head screws.

NOTE: Cylinder head screws are stamped with numbers 1 through 13. When removing screws, remove in order starting with num­ber 13.

Carefully separate cylinder head and cover by prying at the corners of head. Remove heat sensor from cylinder head. Remove two screws securing cylinder head cover to cylinder head and sepa­rate cover from head. Remove ten 14 mm and two 10 mm screws and careful­ly separate crankcase cover from cylin-

---]~ II r-----I ~jl :-~-.. -_ :~

~:

~.~ ~

: '--- ' ''~ -'''' ... ... -..... , . -----,

r,,:~.:;, ·· ... -1 .. -...- r~ ____ .J :'

I .,.

Fig. SZ13-15-Wlrfng diagram on models prior to 1987 equipped with e/«,rlc St8rt, remote control and optional voltage regulator. Refer to Fig. SZ13·16 for c%r code Identification.

SERVICE MANUAL Suzuki OT35 (After 1986) & OT40 (After 1983)

der block. Lift crankshaft, connecting rods and pistons assembly from cylinder block. Engine components are now ac­cessible for inspection and overhaul as outlined in the appropriate service sections.

REASSE~mLY. Refer to specific serv­ice sections when reassembling crank­shaft, connect ing rods and pistons. Re­new all gaskets and seals. Make sure all joint and gasket surfaces are clean and free of nicks or burrs and hardened sealer.

It is recommended that all gasket and mating surfaces be carefully checked for nicks, burrs and warped surfaces which might interfere with a tight seal. Cylin­der head , cylinder block, exhaust cov­er, crankcase cover and intake manifold mating surfaces should be checked with a suitable straightedge and feeler gage. If surfaces are not flat to within 0.03 mm (0.0012 in.), surface should be lapped to provide a smooth surface. Do not remove more metal than necessary to true surface.

Lubricate aU bearings and friction sur­faces with a recommended engine oil. Lubricate lip of seals (I, 6, 12 and 13-

8'::;><IT'~ l,",jT01

il ~ -.... .. . "-~

~ . . . . ,

ITOO' ... " . " ... T . _. f 1< ~ ; r)r:~

i '~'2 I i ; . i ! ~i

. .

Fig. SZ I3-21) with Suzuki Super Grease "A" (part 99000-25030) or a su itable equivalent water-resistant grease. Ap­ply Suzuki Silicone Seal (part 99000-31120) or a suitable equivalent to both sides of lower bearing housing gasket.

NOTE: Seal (6) on models prior to 1989 Is a labyrinth type seal. On models after 1988, a lip type seal is used, Lip type seal can be

Fig. SZI3-17-lnstall ther­mostat with bleed hole faCing

direction shown.

~ 'to" , .. , l e>( C~ OOO- .. ".a.I C~ ",,- nO"

I~ .

L ~

:() J .... MlU~

.11 1 1f

I -';lL i • .. :: '.:':.'J

LI-=-: ~ ::=;:: ~ : ;: ~ i 1

11 1 ! j . . .. . ~ .. .•

'" .;'~'-,~\ ..

~

~ .. , =-r·' =-1- ' ,I 1

~ ~~

:~ F F . Ir;:; = ~ 'r .

=~-l. .'

used on earlier models, however, labyrinth seal will not Interchange with later models.

Place thrust ring (5) into groO\'e in cyl­inder block, then install crankshaft a~­sembly. Make certain main bearing locating pins engage notches in cylinder block. Flanges of seals (6 and 12) must fit securely in grooves in cylinder block. Apply a coat of Suzuki Bond NO.4 (part

Bleed Hole

Fig. SZI3-16-Wlring diagram on modelS after 1986 equipped wllh electric .tart, remote control and power tift. P 1\1. Pmk wilh blue­

t racer U, Ul;((.:k W Wh ite Gr. G GrCt..:1l y , \\-lIo\\' Or, p, PInk [II 131m' RiG. n, Ih'd Br UMwn

CrllY R' Y. Il('d ..... ith yellow Orang.: (racC'r Hl-d ..... it h !tr r~('n W!1l. White with red tr'H'('t tracer

)' rG.

Bld1.

yello ..... with lUff n t r.leer l:J lu(" with rl,<1 lr~~r

uBI. Ught hhl\' LtG ' H. U!(tl1 Rr~.'n with

rf."d (raco: r

Suzuki DT35 (After 1986) & DT40 (After 1983) OUTBOARD MOTOR

99000-31030) to mating surfaces of crankcase cover and cylinder block an(1 position crankcase CO\'er on cylinder block. Using the tightening sequence shown in Fig. SZ1 3-22, tighten the 10 mm screws to 46-54 N'm (:l4-40 rt .. -Ibs.) and the 6 mm scre"''!:i to 8- 12 N'm (6-9 ftAbs.). After assembling crankcase, check crankshaft rol<1lion for binding or unusual noise. If binding or noise is not­ed, the reason must be determined and repaired before proceeding with assem­bly. t:sing the tightening sequence shown in Fig. SZI:j·2:3, tighten 8 mm cyl­imler head screws to 20-26 N'm (15-19 ft.- Ibs.) <lnd 6 mm screws to 8-12 N'm (6-9 fr.-Ibs.).

RINGS. PISTONS AND CYLINDER. Refer to CONDENSED SERVICE DATA for pistons, pins, rings and cylinder serv­ice specifications. Each piston is fitted wi th two piston rings. Top piston ring is chrome plated. Pistons are equipped with locating pins in ring grooves to pre­vent piston ring rotation. Install piston rings with marked s ide facing up and end gaps properly positioned around locating pins. ~Ieasure piston diameter 28 mm (1.10 in .) up from bottom of skirt at a right angle to piston pin bore. PislOns and rings a re a\'ailable in stan­dard size, 0.25 mm (0.010 in.) and 0.50 mm (0.020 in.) oversize. Install pistons on con necting roos so arrow on piston crown will face exhaust ports upon reas­sembly. AH cylindel'!:i should be bored to next. oversize if any cylinder is worn , out-of-round or tapered in excess of 0. 10 mm (0.004 in .).

CRANKSHAFT, CONNECTING RODS AND BEARINGS. Connecting

11

~. 10

rods, bearings and crankshaft a re a press together unit.. Crankshaft should be disassembled ONLY by experienced service personnel using appropriate service equipment.

Determine connecting rod , crank pin and bearing wear from side-to-side as shown in Fig. S21:3-24. Normal side-to­Side movement is 5.0 mm (0.197 in .) or less. If movement exceeds 5.0 mm (0.W7 in .), connecting rod, crankpin and crankpin needle bearing should be re­newed. Maximum allowable crankshaft runout is 0.05 mm (0.002 in.) measured at bearing surfaces with ends of crank­shaft supported in V-blocks.

Apply Suzuki Super Grease ' 'A" (part 99000-2iiO:30) or a su itable equivalent to seal lips. When instaHing crankshaft a~­sembly into cylinder block, make sure

flanges of seals (6 and 12-Fig. SZI:J-21) properly engage grooves in cylinder block. Make sure main bearing locating pins properly engage notches in cylin­der block.

MANUAL STARTER

To remove manual starte r assembly, disconnect neutral start cable (l-Fig. SZI3-26) and remove three screws secur­ing housing (9) to power heao . To disas­semble starter, remove cotter pin secur­ing a rm (2), then remove aml (2), spring (:3) and dog (6). Invert starter housing (9). Grasp rope and place rope into notch in outer diameter of pulley (14), then allow pulley to unwind in a clock­wise direction until tension on rewind spring is re lieved . Remove screw (21-

16

21

--23

17

Fig. SZI3·IS-Exploded .Iew of waler pump as· sembly. Fig. SZ13-20-Exploded view of crankcase. cylinder block snd related components.

I S<~al 7. P! ~ t -= 2. !:i,"al tub~' S G~k("t :1. Gr()mmN ~ . i3eanng re{aint'r

1. Intak(· lll J:tn lrr)ld 7. CyllndN blr)(:k 1:3. Thl'rmostat HI . . "ic1,J.1:t :2- R('~d PCtlllll R. Anoot' H . CtWN 20 , "0" rlng :) IkC'd !i1np n. O~~«.' l 1[ •. (i ;eok,'l 2 ) . 1..o'A'("r oil SC-~ I

4. IIQu:.in(t 10. Gromml't

" lmp('") l~r I!. Wlllc r IUi;)c .1. Ik("(1 p tat e 1(1. CvlinJ"r ht:ad lG. t:Xh3U~t pl;l((. htlU:ol In~ .J. Crank~ «)\'('r II . (i;u;kN 17. ExhAust (,un.'r 22 . r. 1t..;:\(~t

ti . Dri\'t" kr:oy I:!. Grommet Ii Oil !Of' ;11 hnu.!oltl ~! 12 . Cylind ('r hf"aJ covc r l ~ Ua.sk~t.<; 2:) . F.xhau.'t tub\!

SERVICE MANUAL

Fig. SZt:3-26) and drive plate (20), spring (16) and spring (19). Remove snap ring (IB) and washer (17). Carefully lift rope pulley (14) with rope from housing, mak­ing sure rewind spring remains in hous­ing. Using suitable hand and eye protec­tion, remove rewind spring (1:3) from housing.

Reassembly is the reverse of disassem­bly procedure noting the following: Ap­ply a suitable water-resistant grease to rewind spring (1:1), bushing (11) and washer (10). Starting with outer coil. wind rewind spring into housing in a counterclockwise ;jireetioll. Use caution not to allow rewind spring to fly out of housing. Tie starter rope onto pulley (14) and thread through rope guide in hous­ing (9). Install rope pulley by aligning slot in center hub with eye on inner coil of rewind spring, then place pulley into housing. Rotate pulley counterclock­wise slightly to ensure pulley and re­wind spring are properly engaged. Ro­tate pulley counterclockwise to wind rope onto pulley 2'1, turns. Place rope into notch in pulley, then while holding rope in notch (N), rotate pulley four turns counterclockwise to preload re­wind spring. Release rope and allow re­wind spring to wind remainder of rope onto pulley. Install neutral start cable and adjust length of cable so mark (M­Fig. SZI3-27) is located between marks (X and Y) on starter housing (9) with shift lever in forward or reverse posi­tion. Starter should only be operable with outboard in neutral.

ELECTRIC STARTER

AU models are equipped with the elec­tric stalter shown in Fig. SZI3-28. Dis­assembly is evident after inspection of unit and referral to exploded view. Frame (7) and end frames (5 and 9) are match marked for correct reassembly.

Standard commutator diameter is 30 mm (1.18 in.). Armature should be re­newed if commutator diameter is less than 29 mm (1.14 in.). Mica between commutator segments should be under­cut to 0.5-0.B mm (0.020-0.031 in.) with a minimum undercut of 0.2 mm (0.008 in.). Standard brush length is 12.5 mm (0.49 in.) and shOUld be renewed if wom to less than 9 mm (0.:35 in.).

PROPELLER. Protection for lower unit and motor is provided by a cushion­ing rubber hub built into the propeller. Various propellers are available from the manufacturer. Select a propeller to al· low outboard motor to operate within the specified speed range of 4BOO-5500 rpm at full throttle.

R&R AND OVERHAUL. Refer to Fig. SZI:l-:lO for exploded view of gearcase

Suzuki OT35 (After 1986) & OT40 (After 1983)

Fig. SZI3-21-Exploded view of crankshaft, connecting rods and pistons assembly. I . selOt l 2. nearing :) Crankwaft 'L'-~Y . .1. BtarinJl ;). Thru~t rlll~ (i . Sea l 7. Hearing ~. Vhl."h.' r !J, Key

10. Oil rump drin "(o;lr

11 . Washt·' I;!. Se-a l n. Seal 14. Crank pin I .). Wtt.'lht, t l(j, ~Mn~

17. W aJl her I ~ Cnnnl'('l lnA rod 1 f,l Snap rln,lo! 2('1 Pi ston pin ".! 1. Pisl!')n 22 Pi:-tOI\ ring."

3--1

15

3

9-~·1l ~. 10 (Q)'. 11 ~12 I§ 13

13

Fig. SZI3·22-Uslng the tightening sequence shown, tighten the 10 mm crankcase screws to 46-54 N'm (34-40 ft.·lbs.) and the 6 mm screws to

Fig. SZI3·23-Uslng the tightening s.quence shown, tighten 8 mm cylinder head screws to 20-26 N'm (15·19 ftAbs.) and 6 mm screws to 8·12

8-12 N'm (6·9 ft.·lbs.). N'm (6-9 ftAbs.).

Suzuki DT35 (After 1986) & DT40 (After 1983)

Fig. SZI3-24-Maxlmum allowable slde-Io-slde shake (A).' small end 01 connec1lng rod Is 5.0 mm

(0.20 In.) .

IS~

20

6~17 &-18 qJp -...--19

«> , ___ 21

Fig. SZI3-26-Exploded view 01 manual ,.wlnd stane"

I . N~utra l ~fl 11. Du.:.hlnlt intNiock eable 12 . UraCkt:t

2. StQJ)~r arm 13 . Iw ..... ind spring 3. Sprin~ 1·1. ftoJpt, pull __ 'Y ·1. Bu. .. h nfl 1.) , l'a"",l a. Spacer 16. Spri n~ 6. Pulltr dOl{ Ii . W.u.hcr ; Ur.u:'ht IS. Snap fin!,: S. Ropt' hllndlt· J!1 . Sponlt 9 . II(Ju:&inl( 211 , Drive platt.'

10 . Wu hcr 21. Screw

Fig. SZI3-27-For proper neutral stan cable ad­justment, mark (M) In arm (2) musl be between marks X and Yon slaner housing (9) when gear

shih lever Is In forward or reverse position.

assembly. During disassembly. note lo­cation of all shims and thntst washers for reference during reassembly.

To remove lower unit, first drain oil. Remove engine cover, loosen nut (7) and turn shift rod coupler (6) to separate up­per and lower shift rods. Hemove six screws securing gearcase to drive shaft housing, remove gearcase and place in a suitable holding fixture.

Remove the trim tab. Straighten tabs on lock washer (62), remove propeller nut (63), propeller, thrust hub (61) and bushing (60). Remove two screws secur­ing bearing carrier (55). Using Suzuki special tools (or equivalent) as shown in Fig. SZI3-31 , pull propeller shaft assem­bly from gearcase. Slide water tube seal collar (2-Fig. SZI3-I8) off drive shaft (31-Fig. SZI3-:30) and remove water pump assembly (Fig. SZI3-18). To re­move pinion gear (44-Fig. SZI3-30), fit Suzuki drive shaft holder (part 09921-29510) or equivalent splined tool, on top of drive shaft. Heach into gearcase and hold pinion nut (43) with the proper size wrench and rotate drive shaft to un­screw nut (4:3). After removing pinion gear (44), reach into gearcase and with­draw forward gear (39) along with shim

FIg. SZI3-28-Exploded v/.w 01 electric staner. I . Ik t;l l n<' r 7. f'ram~ 2. ~ tu p 8. Bru."Ihes &- holder 3. Sprin,K assv 4. Drl\'I" gear ,b :.)' . 9. End rram+: :; . J::nd r ra.m(: 10. Dampcl'" Ij .'\rmHt lJr'(> II. Throufi(h·b+',1t

OUTBOARD MOTOR

(38) and bearing (:37). Use two 6 mm jackscrews as shown in Fig. SZI:3-32 to separate upper bearing housing (24-Fig. SZI3-30) from gearcase. When hous­ing (24) is free, slide housing off drive shaft (31), then pull drive shaft assem­bly from gearcase. Remove collar (23) and washers (21 and 22).

Spring (20) can be removed from drive shaft (31) after removing pin (:32). Dog clutch (45), shift pin (41) and guide (42) can be remove from propeller shaft (49) after removing retainer (46) and driv­ing out pin (47).

Inspect gears for wear on teeth and on engagement dogs. Inspect dog clutch for wear on engagement surfaces. Inspect shafts for wear on splines and friction surfaces. Check shift cam (I7) and shift pin (41) for excessive wear. Standard free length of shift spling (48) is 69 mm (2.72 in.). Renew spring (48) if free length is less than 67 mm (2.64 in.) . Re­new all seals and' '0" rings during reas­sembly.

Backlash between pinion gear (44) and forward gear (39) should be 0.1-0.2 mm (0.004-0.008 in.) and is adjusted by varying thickness of pinion shim (28) and forward gear shim (38). To increa~e backlash, subtract equally from shims (28 and :38). To decrease backlash , add to shims (28 and 38) equally. Propeller shaft end play should be 0.2-0.4 mm (0.008-0.016 in .) and is adjusted by vary­ing thickness of thrust washer (50). Check pinion gear-to-forward gear mesh pattern using a suitable gear marking compound. Vary thickness of shims (28 and 38) to obtain the optimum mesh be­tween gears. After pinion and forward gear adjustment, and prior to installing propeller shaft and related components, check and record drive shaft end play. After installing propeller shaft assem­bly, recheck drive shaft end play. The second drive shaft end play measure­ment should not be less than when first cheeked . If so, subtract from shim (52) as necessary.

Reassemble gearcase by reversing dis­assembly procedure while noting the following: Thoroughly lubricate all fri c­tion and bearing surfaces. Install dog clutch (45) on propeller shaft (49) so mark (F-Fig. SZI3-33) is faCing forward gear (39). Apply a suitable thread lock­ing compound to threads of pinion nut (43) and tighten nut to 30-40 N'm (22-29 ft.-Ibs.) . Apply a suitable water­resistant grease to outer diameter of carrier (55-Fig. SZI3-30) and carrier " 0" ring (53). Tighten carrier attaching screws to 15-20 N'm (11-14 ft.-lbs.). Tighten propeller nut (63) to 50-60 N-m (37-44 ft .-Ibs.). Apply a light coat of water-resistant grease to drive shaft splines. Apply silicone sealer to mating surfaces of gearcase and drive shaft

SERVICE MANUAL Suzuki OT35 (After 1986) & OT40 (After 1983)

~ .-:'~jj .A!f!-I~}'" ~f 24

~~~ 8"1 / 9 25

t=--10 t 26 ~11 28 . 27

12 __ 29

- 30

Fig. SZI3-30-Exploded view of lower unit gearcase _1fIbIy _ .. Iff linkage and components. I . !':\h ifr Il"\'et ". I'm 2 . Pbte Li . ~b"nC't :) Ann W . Pin . ,. 000, ' 7. ~hift (;!-lnl

5. UPP<' t ~hlft rnf! I~ I~dl~

6. Coup lN 1fJ . Spring 7. .Il\mt. nut 20 . ::;pnnll ~ . St' :!1 21. Th ros.t wt\.-:.Iu.: r 9 . C;uidc 2') Was.ht;' r

In. " 0 " ranI( 2:J. Collar II . " 0 " ring 2;1. BtlLrinJ{ h f) u !(inl( 12 . "0" rln(Z 2::. Soots 1;1 r"" Wl'r "hlrt r,"[ 2ti, l}J"a.ring

27. Bu:.hinj( 28. Shim 40. Tb ru,,'t wa .... h(' r 2 j:l , nlru.~t wash<.-r 41. Shift pin J(I. Thr\l:i t bearing 42 . Sprin" lituid.~ :31. Drive ~hatt 4:.L Nnt :32 . Pin 44 . Pinion ,qc:lr J:l . Uearinlit ·1:; . 00100\ clutch 34 Cover 46 . Hetain(,t :.lot.. Gt'fll'C:a.'oc ,ti . Pin 36. Cover 'S- Spring :3i, l3e-arUl(l ,19, ProJ>\!ll('r ~ha(( 38 . ShIm ;jO , Thru~t w"-,,hl ' r :\9. Forward !tear ii l. R(·\'l'N' Rl'ar

Fig. SZI3-32-Use two 6 mm jackscrews positioned w/te", shown to withdraw upper bearing hOUSing with drive

shaft component",

Fig. SZI3-31-Removlng propeller shaff assem· bly using Suzuki propeller shaff ",mover 09950-

59310 and slide hammer 09930-30102.

:;2. Shim 5.:~ . " 0 " rjn~

64. Bcarlnj( 5 1;. ~'rtng carrier ¥J. Bc Ullin,ltS m. Sht .. . 8. ThnN hub .,g. Prnp<: Ut"t 60. Uushmft 6 1. Thru~t hub 6'" L.ockwa...; h~ r 63, Sut

housing and gearcase retaining screws. Tighten gearcase screws to 15-20 N'm (11-14 ft .-Ibs.). Adjust coupler (6) so shift lever (1) travels equal distance from neutral to forward position as from neu­tral to reverse position.

POWER TILT

All models are equipped with power tilt system. An oil pump driven by a re­versible electric motor provides oil pres­sure. A rocker control switch deter­mines motor and pump rotation , thereby retracting or extending tilt cylinders.

NOTE: All models are equipped with pow­er TILT only. Damage to the power tilt sys· tern may Occur if attempt Is made to use the system as power trim.

Power tilt pump assembly is equipped with manual release valve M-Fig. SZI3-:)(i) . Manual release valve (M) should in the closed position (clockwise) for nor­mal operation. If power tilt malfunction occurs, outboard motor may be raised and lowered manually by opening the manual release valve (M) two turns maximum (counterclockwise).

Recommended oil is Dexron 11 or a suitable equivalent automatic transmis­sion fluid. On early models (prior to seri­al number 613245), check oil level with the outboard motor in the fully down position. On later models (after serial number 613244), check oil level with the outboard motor tilted full y up. Refer to Fig. SZ13-35 to identify early and late pump assemblies. Oil leve l should be to bottom of fill plug hole on all models.

Bleed air from hydraulic system by tilting up and down through several cy­cles. Be sure to recheck oil level after several cycles and fill as necessary.

)

Suzuki DT35 (After 1986) & DT40 (After 1983)

F

45

49

Fig. SZI3-33-lnslall dog clulch (45) on propeller shaft (49) so mark (F) Is facing forward gear

(fronl).

If power tilt malfunction oceurs make sure malfunct ion is not due to wi ling, connections or electric motor failure. 1b check down circuit pressure. disconnect down tube (D-Fig. S213-:36) from pump and t ilt cylindel: Connect a :34.5 MP-a (5000 psi) pressure gage be tween pump and cylinder. Make sure manual release valve is fully closed (clockwise) . Oper­ate power til t switch in the down direc­tion until tilt cylinder rod is fully retracted . Down pressure should be 3000-7000 kPa (435-1015 psi). Remove test gage. reinstall down line (D) and

Fig. SZI3-35-Vlew shows difference between early (pri­or 10 1987) and lal. (alter 1986) power liII pump and

motOr assemblies.

Prior 10 serial II 613245 After serial # 613244

Pump and valve bodyassy,

M

Fig. SZI3-36-Vlew of pump 8ssembly identities manual release valve (Id), up circuit

(U) and down circuli (D).

OUTBOARD MOTOR

bleed air from hydraulk system making sure reservo ir is full of oil. To test up pressure, remove up line (U) from pump and c·ylinder. Connect test gage between pump and cylinder in up circuit (U) . Op­e rate tilt switch in the up d irection un­til c·ylinder rod is full extended . Up pres­sure should be 1:3.000-17.000 kPa (1885-2466 psi). Hemove test gage and reinstall up line (U). Making sure reser­voir is full of oil , bleed al\ air from hy­draulic system. Renew pump and valve body assembly if hydrauliC pressure is low or erratic.

! ~/