1981-1992 Suzuki DT48 DT50 DT55 DT60 DT65 2 Stroke-Outboard Repair Manual
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GROUP INDEX
0
No. GROUP TITLE PAGE
I. MAIN SPECIFICATIONS FOR DTS0/65
3- 4
0
2. GENERAL INFORMATION 5-15
3. SERVICE DATA 17-24
4. APPLICATION CHART OF MATERIALS REQUIRED 25-36
)
5.
OUTBOARD MOTOR SETTING AND ADJUSTMENT 37-45
6. ENGINE
47-70
7. COOLING SYSTEM 71--72
a.
FUEL SYSTEM
73-81
9. GEAR CASE 83-102
)
10. SWIVEL, STEERING 103-108
I I. POWER TRIM AND TILT SYSTEM 109-,14
12. ELECTRICAL SYSTEM
, 15--13 I
13. PROPELLER 133--136
TROUBLE SHOOTING
ENGINE WILL NOT START UP, OR IS
)
14.
HARD TO START
ATTACHED
ENGINE STARTS BUT STALLS SOON
ELECTRICAL SYSTEM TROUBLE
) 15. DT60 "QD" MODEL ('83-MODEL) 137--160
16. DT50CI50TC "VE" MODEL ('84-MODEL)
J61-173
17. DT55M "VG" MODEL ('86-MODEL)
175~186
18. DTS0/60 SERIES "VH" MODEL ('87-MODEL)
187~237
)
19.
DTSSM/MQ/SOK/48M/MQ "L" ('90) MODEL
239-247
GROUP INDEX
No. GROUP TITLE PAGE
20. DT48M/55M/MQ/50KH "M" ('91) MODEL 249-259
21. DT48M/55M/50K "N" ('92) MODEL 260-278
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MAIN SPECIFICATIONS
FOR DTS0/65
CONTENTS
GROUP
1
0 MAIN SPECIFICATIONS FOR DT50/65 ......................... . ... . ..... 4
0
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4 MAIN SPECIFICATIONS FOR DTS0/65
Starter system:
Electric starter
( DT50/50W /50T /65/65T)
Recoil starter ( DT50M)
system:
Displacement
type water pump
Gear ratio
11 :24(DT50/50T)
12:23(DT50M/50W/
65/65T)
~-
Maximum horsepower
36.5kW(50PS) ... DT50
48.0kW(65PS) ... DT65
Ignition system:
SUZUKI "PEl"
Standard spark
plug and gap:
B8HS (*BRBHS)
(*for Canadian market)
0.8-0.9mm
(0.031 - 0.035in.)
Bore and stroke
® 72mm (2.83in.)
@80mm (3.15in.) ..... DT50
84mm (3.31in.) ..... DT65
©723cm
3
(44.12cu.in.) .. OT50
798cm
3
(48.69cu.in.) .. DT65
@
Exhaust system:
Through prop
hub exhaust
Gear oil:
650m I (22.0/22.9
US/Imp.oz)
@
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GENERAL INFORMATION
CONTENTS
GROUP
2
0 BREAKING-IN ...................... •• .... • ............... ,.,.,, ..•... 6
MAINTENANCE, INSPECTION AND SERVICING .............. • ....... •••••• 7
0
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SPECIAL TOOLS .................. •.. . ............... •..•.•.•• .... • 8- 9
OPTIONAL PARTS .• ............... . .......... •••..•..••...••... . 10- 15
6 GENERAL INFORMATION
BREAKING~IN
Neglecting accurate breaking-in operation will
have an adverse effect on the durability of the
engine, eventually, causing engine overheating.
5 Minutes 10 Hours
-...;;;
Operating
~®
®
Therefore, we hope that you will guide our users
as instructed below.
5 Hours
©
I I I I I
--------; -0- Hours -•-s-----10----15----20-
• J I I I
Premixing gasoline
&oil
@
10 Hours
Breaking-in period is initial 15 hours. This
initia115 hours of operation is the critical period.
Adhere to the following treatment referring to
the above table.
@During initial 5 minutes, operate the engine at
trolling speeds.
@During the first 10 hours, operate the engine
with a partial throttle (within 1/2 throttle
opening). In this period, operate the engine
with full throttle for about 1 minute at every
10 minutes.
© For the latter 5 hours, operate the engine
with a partial throttle (within 3/4 throttle
opening). In this period, also operate the
engine with full throttle for about 1 minute at
every 10 minutes.
10 Hours
@ During the first 10 hours:
* 30 parts of gasoline to 1 part of SUZU Kl CCI
oil or BIA certified lubricant or
* 20 parts of gasoline to 1 part of other out-
board motor oi I.
® After 10 hours of initial operating:
* 50 parts of gasoline to 1 part of SUZU Kl CCI
oil or BIA certified lubricant or
* 30 parts of gasoline to 1 part of other out-
board motor oi I.
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GENERAL INFORMATION 7
MAINTENANCE, INSPECTION AND SERVICING
Keeping this outboard motor in the best operable condition at all times involves neither cumbersome
measures nor costly expert attention: just carry out simple ordinary service in a systematic manner at
regular intervals.
Each DTS0/65 user should be advised to go by the following schedule, which is based on the concept of
systematic care:
Item
Servicing intervals
Remarks
1st 10 hrs Every 50 hrs Every 100 hrs
Bolts and nuts Retighten Retighten
Refer to SERVICE
DATA
Spark plugs
Clean and adjust 0.8-0.9 mm
spark gap. (0.031 - 0.036in.)
Wire harness
Check connections Check connections
for tightness for th ightness
*Starter motor
Check brush for wear
brushes
* Ignition timing Check and ac!l_ust
Carburetor
Check and adjust Check and adjust Necessary after each
balance balance disassembly or removal
Gear oil Change Change
Hypoid gear oil,
SAE # 90, 660m£
* Pistons, cylinder
De-carbon
Renew gasket when
and head de-carboning
Propeller Check for damage Check for damage Grease propeller shaft
Engine key and Check for proper Check for proper
choke operation operation
Clean and check for
Fuel tank crack and fuel leakage
(Usually check)
Fuel filter Check for cleanliness
Check for fuel
Check for fuel
Fuel hose
leakage
leakage and hose
cracking
Inlet case hose
Check for crack Check for crack
and breakage and breakage
*Water pump
Check impeller and
Replace if worn out
casing for wear
Steering handle Check for operation Check for operation
Clutch lever Grease
Starter rope
Check for tear and
Change once a year
wear
Tilt Adjust pre-load
Emergency switch
Check "OFF and Check "OFF" and
"ON". "ON".
Check and adjust Check and adjust
Remote control
linkage for proper linkage for proper
control of clutch and control of clutch and
throttle. throttle.
The* (asterisk) indicates that inspection and service should be done by the dealer.
8 GENERAL INFORMATION
SPECIAL TOOLS
PTT oil pressure gauge
(For DT50T, 65T)
09915-79410
PTT cylinder cap
remover and installer
(For DT50T, 65T)
09944-0941 0
C.D.I. test cord
09900-28604
EIectro-tester
09900-28106
Bearing remover set
09913-69911
>
SUZUKI converter
09900-28603
Pocket tester
09900·25002
Timing gauge F)
09931-00112 ~
~~~
CD Holder(09931-20120)
<Z) Rod No.1 (09931-30120)
@Rod No.2(09931·30130)
Flywheel etc. remover
CD
vvvv
®
Carburetor balancer set
09913-13121
Oil seal remover
09913-50121
CD 09930-3941 o
® 09930-39420
® 09950-59520
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Flywheel holder
09930-4941 0
Drive shaft holder
09921-29510
Hydrometer
09900-28403
Propeller shaft housing
installing tool
09922·5951 0
Rotor remove, slide shaft
CD 09930-301 04
Attachment
® 09930-30161
CD
Test wheel
09914-79980
GENERAL INFORMATION 9
Engine speed tester
<D (09900-26003)
® (09900-26004)
• =- "
~
~ 1
. ...... ~~
~
SUZUKI Timing light
09930-76420
®~
~®
Oil leakage tester
09950-69510
~
Bearing oil seal installer
09914-79610
10 GENERAL INFORMATION
OPTIONAL PARTS
METERS
As illustrated below, the optional speedometer, tachometer, voltmeter and hourmeter can be installed
boat's dash board.
Hourmeter
(34500-95501)
I
Speedometer
Tachometer
(34200-95500)
The speedometer cable conduit which is installed
on the dashboard should be routed to as much
higher position on the transom as possible. The
speedometer sensor should be mounted 30mm
below the bottom of the boat.
Speedometer set
(34100-95501)
Voltmeter
(34600-95501)
I
~
Voltage regulator
(32500-95721)
Flash hose
~
attachment
(55181-95200)
oOJ
sensor
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$31.99
$41.99
This manual covers all versions of the following machines:
- 1981 SUZUKI DT48 2-CYLINDER 2-STROKE OUTBOARDS
- 1981 SUZUKI DT50 2-CYLINDER 2-STROKE OUTBOARDS
- 1981 SUZUKI DT55 2-CYLINDER 2-STROKE OUTBOARDS
- 1981 SUZUKI DT60 2-CYLINDER 2-STROKE OUTBOARDS
- 1981 SUZUKI DT65 2-CYLINDER 2-STROKE OUTBOARDS
- 1992 SUZUKI DT65 2-CYLINDER 2-STROKE OUTBOARDS
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- Shocks
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