1988 Suzuki DT150 150 HP 2-Stroke Outboard Factory Service & Work Shop Manual

FOREWORD No models typify this commttment more than the revolution~ry V6 model1. The OT150 1nd the OT200 these 2.7·11ter 60° V's ftaturo hems th.lt have set standards for the outboard industry. Items suth IS SuuJkl's sophisticated IC Ignition system whh warning systems and monhor, Suzuki's pre·atomlzed oil Injection wilh oil flow sonwr as well as a staning system and unique shifting system. These Items plus more are covered In-depth in the follow ing text to assist you in glvtng ell StJzuki V6 customers the ultlmett In service_ The models OT150 and OT200 outbolrd motor in lhts manual is ol standlrd specifQtions and may dtffer in mmor rHpKtS from DT150 and OT200 motor actuallye~ltftdbyMt'Ydmen, Butsuchd ttfttencts. if anv.are of little or no eonttqutnce for the purpose of t«V'ic.ng end mainttnlnoe. Thts lef'i.ct manual 1'\ts been proOJced prlmanly for experltnced Suz.ukl mec:hentcs.. Apprentioe and do·tt your~elf mechanics willtlso find th1s manual to be an extremely useful rep11r gutde. nus maooal contains lhe most up.oto·da:te infoonatlon It •he time of publication. The rights are reserved to update or m1k1 correctlor'ls •o this manual at anv t•me. Plt~ttot read this manual and follow lu instructions care·fully. To emphMize speeial 1nfotmat10n, the words WARNING, CAUTION end NOTE carry specie1 metntngs and should bt' carefully rev~ WARNING •.••.. • The P«ton ... Afew of the uset' may be' tnvof\otd 01$t"egardmg this infOflNt•on could retult '" lf'IJU'Y to the own~ CAUTION •• , .•• , • ThHt jnJt~tlons point out speci" •rv•ce procedures or preca.Uions thet must be followed to avoid damaging the outboard motor. NOTE •.•••..•••..•• Spec:ial lnformttion to make maintenance easier or important instruCtiOns clearer. NOTE . This manuel is compiltd based 011 '86 (VGt models. C COPYRIGHT SUZUKI MOTOR CORPORATION 2001 SUZUt(l MOTOR CORPORATION Marine & Power ProductS Div1.Sion

D GENERAL INFORMATION ELECTRICAL AND IGNITION FUEL SYSTE =M .: .... ::.__ _______ ____j 0 OIL INJECTION SYSTEM POWER UNIT HOUSING AND BRACKET POWER TRIM AND TILT LOWER UNIT MOTOR SETTING AND OPTIONAL PARTS 1[1) TROUBLESHOOTING I Ill DT150 / 175 / 200 " VH " (' 87) MODEL I If) DT150/ 175/ 200 " VJ " (' 88) MODEL I IEJ DT150/ 175/ 200 " K" (' 89) MODEL I I DT150 / 175/ 200 " L, (' 90) MODEL

I il •• II li:J IN' •EX TLE DT150 175/200 "M" ('91) MODEL m "il DT225 "M" ('91 > MODEL 1m lfl DT200TC "R" ('94) MODEL 1m 1 DT150TC/ 150STC/ 200TC "W" ('98) MODEL m

GENERAL INFORMATION CONTENTS I FUEl RECOMMENDATI ON . . . . . .. , ..•.•.. , .•. , ... , , .•. ~.,....... . . . . . . . • • . 6 OIL R ECOMME ND ATION • , •• . ................................... 6 BAEAKING·I..N •. • ..... ... • ' ...................... ~.I ••••.•••••••••••••••••• 6 MAINTENANCE, INSPECTION ANO SERVICING •••• ., ...................... ,.. . .. 7 SPECIFICATION ., ••. , ................... .. ........ .... .. .. ...... .. . ~·····. 8 SERVICE DATA . , • • • • • • • • • • • • • • • • • .. , , , , • , .••• , •••• , •••...•• , •.• , .. '0 OIL SEAlS •••...•. , . .. . ........ . ........................................ 12 AVAJ LABLE SHIMS . •••.. . ••.••• -•. •••••••.•••••• .... ••••• , •••••••••••••• 13 TIGHTENING TO ROUE CHART • , , , ••.•• , , • • • •• , •• , •.•. , , ••••••• , •• , •••. , ••• 14 SPECIAL TOOLS ..... • .... ••.•••...••.•.• ..... •••... ~ .•.•• . .• . .•.••••..•• 15 Al'l'LICATION CHART Of MATERIALS REOUIREO ......................... . ...... 18 COOLING SYSTEM ••.• , • . . • • • • • • • . . • . • • . • • • • • ••••.•..• . ••• • • , .••.. . •...• 26 PREVENTION Of GALVANIC CORROSION ................. , .................... 30

6 GENERAL INFORMATION FUEL RECOMMENDATION Su1uki recommend~ Ulat vou usc unleiK1ed ga!ioHn~. cor,ta11ung "o _,.!oohol. WI Ill a1 lea~ 85 J)Ut'I"'(J oct..-ln~ • ~'..M. mt>thod) Aec,.~lar htaded gasoline. cootaloing 1\n •lcrJhol m1rV also be u~. OIL RECOMMENDATION U!IL! SUZUKI CCI oil or BIA fBoauno lndusuv Assoc-i.-mon) cenlfred lubm:ant. ILls a proprietary lubrfcant designed tO ensure rhe best tmgino per rurmance and to mlnimize con1buuion chembet di!P051l\~ ii\IOtd pretgmtion and prolonQ the- ~park plug lila. It SUZUKI CCI oil ot BIA eel11fidd lub,itam lS oot ov1Hible, ilf10ther hfgh·_grad~ OUT· BOARD MOTOR oil may bo usc'<f lMtotd. It it Wtlh the oil ~nt in 1he 'fuel that 'he runnmg partt of the engine are lubncau~d BREAKING - IN Tha firit 10 huutll Jl41 the 1110tt •mpnrtal'lt tn lilt! lift of your Mqlne Prop;.•r o~rdtlon dut~nt~ t111t brL-atc-tn Pt:rlod wUI help ;~fllure ma>:itnum life .md perlorrrmnce trom vour V..S engine. Th~ followlnSI CJUid0llnos e.xpiDtn ocooer brea .. In procet1u.rt-3 USE A 50 : I GASOLINEIOILMI)t.TUAEOUAING THE BREAK-IN PERIOD Eveo though y· our engtoe. utlltzes tin oil Injection system for lubr1eanu1'. vou should use a 50 , f gasollnl'/oll mixture in comblnatton with oil lnjec 1 lon during tJ\1! first 5 hours of eng1nr ~ration to l"!elp et1sure pr~r break~ln 8to. sum to use a SUZUKI CCI oil or BIA·certifted 011 in the tuel mll((ure After ella break ln perfod, uJ~ ur•lg!H 9iJ;Sotloe (Qr fueJ C MAXIMUM THROTTlE OPENING RECOMMEN DATION Ourtnq th& hrst 5 !'lours of engtne ope;rauon, the maxtmum throttlt! openmg you should UR! IS 1i2 thronle For the rem:tindr:r of the break·in period, ' 'Sit full 1h(otl1e ONl V to bring the boat to t11e pl.rmlotJ posiuon Reduce tliL' throttle ooenino .11 coon as the- boat k 10 the .,taning poSition. Oo not opcrare Utt-: engine oonunuoo!l.h,. At tull thronlo 1 fOr tnorp ttn1n 30 wconds. VAIW THE ENGINE SPEED nu.t tmQ~ne 'f)etd Vloufd be varied during the hn.o.ak·lh p~liod Thi' 11Uows U!e P~fU tO bC' ''loaclt!d" (aidmg t11~ miltlllg orocm) -aod thcrt .. unloadecl" lallowlng tht! parl$ to cool). Although n Is esttonUI.il Jh,.n -.om~ flres.:s be placed on lhf' 11ng1ne componentt dut!ng b,.....k m. vou must bf. t~reful not \0 excessh•t~lv load tile engine. ALLOW THE ENGINE TO WARM UP AfTER STARTING A.llow -sutftcumr idll"~ ttmt- for- lhP. e!lg!n'+ to w~nn up aht<r cold cngint!' '!tl!llmg CAUTION Fnllure to follow tho br.ea.k·Tn procedure. described abo\te com rf!$i.llt m severe engme demage.,

GENERAL INFORMATION 7 MAINTENANCE, INSPECTION AND SERVICING KeLrJ)If19 thi' outboard motor In th.P bel\ operable condition Sl ;~II umes Involves I"II!Uher cumbt!tsorm; me-asu~" nor costly exl)l'ft d1ft!OllOI'\ .. juu Cl!lrry OtJl $lmple ordinary SC!tVicers in a .$'fS\tH1l-IJIIC manner if re~lar !ntef'\1415 l''*' outboard motor user should be- advised to go by the following scllc-dule, which cs bMed on the con cepl of s-vsternahc: c:arc- . ,.,,,,, .• , hi 10 hrl I Ev•rr SO tus E"Wir'V 100 k!'l" I Otl Sf.nort h"n1 - 01 I MonU1 or 3 MQnttu Of 6 UIO!Hh~ J - C.rt)lJIC{OI I - I I - Pitton cylimNr ••d cvl.nOir Mild - - I - So.wk pi~Ji~S - - C&~ C81A - Puefll!l• I I - • I Fu~ l1lt9f - I - I - 0 1l CJUniP - - I - ~ ~ ~ O•lllf11!' lind. Wt(lt $ t:tM!c:k \'ai\·n) I I - I lubriC:OtiO" t I t - - I -- ~ ,. t .. W11e "'''""'' I I - l I • - Startfl rnot01 - - I I ~ i - -- Emet~ncv s.w!1eh I I L= I lgn1tJon twneh and storw nlw-ec I t I I ~B!nerv - I I - I I ,. . Rfmqtu a'lntral I - I I i t + Pu¥o•• tr+m and till I - I I + r ~ + PrOIJI!Hilf I I ~ - - ,. ,. frln\ t•b' tl!'ld PIOTI!C11Qn 11'1"-C - I - I - t- ... - ~~.:.,oil R - R R I • .. - Bolu. 1r1dnuu T - T T L - - W•\llr pump I IE'Itf"' one yur• ln.,~c1 m.J ct~n.!ldjl4tt. hlbliCilln or ftol•oe, '' n«nq...,. C Cht•\ A Alt)U.st T. Tlgnllln R Rfpllle~

8 GENERAL INFORMATION SPECIFICAnON [ """ on oo T or.,. DIMENSION a WEIGHT 0. .. 11! llo•I Q1h ''""'' , ... , , 1),\ Ul11 - Ow••tot .... "'' ...... tltll t.4G 1;"13• f- - - +- - o-wl ......... L -·-· !lOt ' ")I + UL ....... ,, ..... ,J 1 ......... L •tllbl -:m t-..1 J + UL -· llbl ~ 2U..,._t I- -· ~ - ,,,~ ............ , L '-" '"' ...... IIIIGtll-1 !fli:Nt Ill 1- """"I•" lfl,.! I IPO\• t•on) l - UL Qtil!l 111 PERFOHMANCE ~··""-' ... """ '"~ h ... '""' 110 11601 J t 4li10CH ''~C'f>.,lh"er.,... ··~ """' - - ...- ~ ,,.:;: ... ~ . ..., --- ~f:AHEAO ........... ~ ., .... ' f- - - f't•lflr• t t.>f t, I~ ·-· • t - ... '''"' I ft.! .,.. w li 1 -- + ... n-.. "'"'''"' 11 11 21 1- ~ - Tot- tit~,,.•....,_~ ,.,J lc" •I r- 1t10J ll ... ll t ~ - - ......, .. "*'. ..... •Mil e! .,...,0 - -- - ._,hl4'tW'U- ,_..,.. ....... 1- ~ - · ·~h'...., fh.... ,. ......... p._, 1- + - c..woo ..- ..... , .... , I- '" sr•~~'~~• r.•- .... _ l ·c - C11.41U ""~"" ., ... ~.til ''"'~~ ,, . ".., - + - - ~ Hll'lt!OI II ••••"'" ~ontoCJ -- ~ l f'l•l•t.n t'l'll .... It 'f'!•l+""

-----------= G ..::; EN = ER ~ A ..;:_ L INFORMATION 9 onto T -I o... FUU & OIL .... S,.su~· riiOO"T>•f"''ll"' Jl lflal tl.'lolt-.,. ...t"d ptlolln•~:l)tl~'!·nltllfl tlkor!"l. ttllh •I '•IIU lt6 ,..., II...: 1 a111 jR , Jl4 mllll'llfli, f~O'OIIVt todfl II•IWtiN._ ftll114111'11.1'1<1 ••r.r.•l<ll ...... ·l•tioO j.,\l,..d ~ -,hiWIIJ ''"It ~·-·c~•••.,. sutu~~tl Cc1 •• .. ••• ,,....~ , .... ,, .. ", .. A..oo.r.;;;7 - ,,..,.. ... ~ .. ,,,..., .... oe.ot I - OJ•~·~ L SUilllflo •tl ¥0 .. 5-i)f, - ....... ~<l~ ........ td ..... -.o ....... ::>Af.SIIQ) O..e4c-.a ... I .... U$1 ...... , '* rn !l.'Jf o• 8AACKET ''"" ...... .... " ><>' - - t' '"'""'" '"" Athohi4IIUI Pn ,.,,..,.. - - ,...~., .. , .. ,... •.•, ...p ..... ' ·"""' .. ,.. LOWER UNIT ..... ... ·~ ... . - ''rren tt ·- ,...,,,.~ .... .e .. ~ .. d Cl ... IYUfllll -- ·- - co- llltld ,.1 ~··· '""""' I "'OUOI:lotln '""•• N'•h et ... td'! - - "-•lll'll ... J • ···~ • •• Jft .. l~ • D•lm,li.,,l • t">~otl! J!n,jJ Mft.. •l41 ll•niP+t ""- ) • .•. , • ,. ' • ·~·· • " f- - l • .. • ,.. - • • .. ~ • lO ~ I • • •••• ll Ttlne spec:ihc:ations are S.UbJec1 to Ct1dn91 wtlhout notielt.

10 GENERAL INFORMATION SERVICE DATA ...... ._ I Df1IWI o. .. T -0-1100-- -1 POWER H EAD C.. ""~''' It drll•ctlft-. u ... u "'''' 1+1'1.1 l. f) 0\ II) OCI1! tal,, QO'j .. ! 't'C'tiO.C• ,_, "''"'"' . Ill tll 201 - .. ,, .... ._, .. 11GI'l- "'"' .... .. .. oOJD •noo''' ~ ~ D...,. dot•~ 1 ,__ _, .. , D..O»IIUIU!t\ - - , ...... '" ..... . ... I _ ... , II tJO- D 140 tDOOII - 0.80155l ,...,_ -..,..., _,.,..,.., _ ,., lO It 71 tr~ c-t'- ... '" e1W1 1- ~ ~ ·- 0, I• n•lof• llor' J?>•~ """'" ...-,!If\ I -lO II tilf-r;.l.-. .. lll!~w·••o - . . - w.... ,..,.,~11 .... b8fll ....... ,, """I·•• I -+ 010 10~1 I· • ,. ,, .... ''"' l!.i•t•!ltii>T 51P """ I••• I ll ,fl!tlt "' '7 OOU 10 OO,IQ ... UJEQH - - ~ .... 11 """' ,, .. , :ll 1110 10 ~&btl - + ''"'-'" ~ •·01• "'-·· no ~ .... .. n- 1 :n M:' • 72 n I 'l D IJ661 - 0 -illii6ol ~ 1- ·- 1 ,_, - floLf n OlO t61lGTl' r- ~ .. ..... _ . .,.. ...... lTD _ .. , 020 0 fiOIDA!al ~ O.DI& I 1- 1- - ...... - ~· 0.110 • ., • I ~ - - - - - "'"' .................... .... ,. _ Lo .. J , • 1029 r r t ~ - Aft4~ -l C!MfD~ l,..o.!'l'ltl I """ "'"I f 0.70 10 DUll - - f .. ll'lll!bflofl t~"IUI'I•tu•• IHII"U 101X1o!" Ill 'c 1 'FJ •u _.. .. t\OC ,. II ~ """"' .... ...,.,..,. _, .. , ....... ,tt'l GC* ...... l '"' '"''""""'' ••r-o" l.l·•tll + o..,.., ................ ~"" lf~l 4.1 - •1 !I'll ftll' ll"'ollllt••t 1 500 ftP'M 10TI50'DT~I + ''""~ 11 I • lllM llfll 1 ~~N~tott .. • I $10(1 fU'U t01'110f Q3- ••DII!U t01 :1 I"WWIoot• ~ 1 JDD aN IOTl!DOf CAAIUAETOR , .. WIJii.Uf'iJI Wf.q) .._ ,. 1 ..... ,_, -·- t,\j .... ,.l • ..... 181.5 t l '"'·q .. f ... . ....... , 11 1J p '1•1 ,., • 1>b .... • f"·i!)l 111 ~I ~~ ...... ,. " " 1- - I lA ,. . .., .,.,.., ' ,., .... .... , Aulf110" 1 l4 ".'2 ' V•t~••-" ·-· 10 1.0 t t ........... - ··· .S .. III u •15 1 ,.,., .. " '.031-0~1 ·-- I _ ., ., :no - no Jt0 - '231 ll)t) .. OC}tl t0.83 -OJH

1988 Suzuki DT150 150 HP 2-Stroke Outboard Factory Service & Work Shop Manual

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