1988-1997 Suzuki DT25 DT35 2 Stroke Outboard Service & Repair Manual

FOREWORD GROUP INDEX This service manual has been produced primarily GENERAL INFORMATION for experienced Suzuki mechanics although others L------------------ may find it useful as a repair guide. This manual contains the most up-to-date information available ELECTRICAL AND IGNITION at the time of publication and all rights are reserved to update or make corrections to this manual at any ~------------------ time. FUEL SYSTEM The models in this manual are based on current L------------------ production of standard specification engines and may differ slightly from the model being repaired. OIL INJECTION SYSTEM Updated manuals should be purchased to cover later production models. .------------------- To emphasize special information, the words WARN- ING, CAUTION and NOTE carry special meanings and should be carefully reviewed. POWERHEAD HOUSING AND BRACKET WARNING ..... The personal safety of the user L------------------ may be involved. Disregarding this information could result LOWER UNIT in injury to the owner. CAUTION ..... These instructions point out special service procedures or precautions that must be fol- lowed to avoid damaging the outboard motor. NOTE ......... Special information to make maintenance easier or important instructions clearer. NOTE: This manual is complied based on '88 (VJ) models. SUZUKI MOTOR CO.,LTD. Service Publications Department Overseas Service Division ©COPYRIGHT SUZUKI MOTOR CO., LTD. 1988 I INSTALLATION AND OPTIONAL PARTS I TROUBLESHOOTING

GENERAL INFORMATION CONTENTS FUEl RECOMMENDATION • . . . . . . . . . . . • . . • . . . . . • • . • . . • • • • . . • . • • • • • . . . . • • • • . 4 Oil RECOMMENDATION . . . . • • . . . . . . . . . . . • . . . • . . . . . • . . • . • . . • . . . . . . . . . . • • • • 4 BREAK·IN . . . . • . . . . • • • . . . • • . . • . . • . . . . . . . . . • • • . • • . . • • . • . • . . • . . . . . . . . • . • . 4 MAINTENANCE, INSPECTION AND SERVICING . . . . . . . • . . . • . . . . . . . • . • • . • • . • . . . . . • 5 SPECIFICATIONS . . . . • . . • . . • . • • . • • . . . . . . . . . . . . . . . . . . . . . . . . . . • • • . • • . • . . . • . 6 SERVICE DATA • • • . . • • . • . • • • . . • . • . . • . . . . . • . . . • . • . . . . . . . . • . . . . . . . • . • . . . . • 8 TIGHTENING TOR!lUE CHART .• ............ ••...••• ............ •..•..••.•.. 11 SPECIAl TOOlS ••.•..•.••..••..•...• .... •..•..••.• ..... • ..... •••• .... ••. 12 APPliCATION CHART OF MATERIALS RE!lUIREO . . • • • • • . • • • . . • . • • . . • • . • . • • . . . • • • 14 Oil SEAlS .• ........ ••.• ........... ••.•...•.•...•..•..•.• .... • ..... •... 21 EXHAUST SYSTEM . . . • . . . . . • • • • . . • . . • . . • • • . • . • • . • . . . • . • . . • . . . . . • . . • • • • • . • 22 COOliNG SYSTEM ........... ••.••.••.••.•••.•.••..•.••.•..••••..•..•.•.. 23 PREVENTION OF GAlVANIC CORROSION .•...••...• ..... •.•• ..... •.• ..... ••..• 25

4 GENERAL INFORMATION FUEL RECOMMENDATION Suzuki recommends that you use unleaded gasoline containing no alcohol, with at least 85 pump octane (.BfMmethod). Regular leaded gasoline containing no alcohol, may also be used. OIL RECOMMENDATION Use Suzuki CCI oil or a Boating Industry Associa- tion (B lA) certified outboard motor oil. CAUTION: Do not mix different types of oil. Mixing different oil types can cause the oil to gel, resulting in damage to your outboard motor. BREAK-IN The first 10 hours of engine operation are the most important in the life of your engine. Proper operation during this break-in period will help ensure maximum life and performance from your engine. The following guidelines will explain proper break- in p raced u res. 1. Use a 50 : 1 gasoline/oil mixture during the first 5 hours of engine operation. Use this mixture in combination with the engine oil injection system to help ensure adequate lubrication for break-in operation. Be sure to use only Suzuki CCI oil or a BIA-certified oil in the fuel mixuture. After the break-in period, use straight gasoline for fuel. 2. Allow sufficient idling time (more than 5 minutes) for the engine to warm up after cold engine starting. 3. During the first 5 hours of operation, do not use more than 1/2 throttle. For the remainder of the break-in period, you may use full throttle, how- ever, do not operate the engine continuously at full throttle for more than 30 seconds at a time. CAUTION: Failure to follow the break-in procedures described above can result in severe engine damage.

GENERAL INFORMATION 5 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 services in a systematic manner at regular intervals. The outboard motor user should follow the schedule blow, which is based on the concept of systematic care: ~al 1st 10 hrs Every 50 hrs Every 100 hrs Off Season lte or 1 Month or 3 Months or 6 Months Carburetor I - I I Piston, cylinder and cylinder head - - I - Spark plugs - - C&A C&A Fuel line I I - I Fuel filter - I - I Oil pump - - I - Oil filter - R - I Oil line I I - I Lubrication - I - I Wire harness I I - I Starter motor - - I I Emergency switch I I - I Ignition switch and choke solenoid I I - I Battery - I - I Propeller I I - - Protection zinc and trim tab - I - I Gear oil R - R R Bolts and nuts T - T T Water pump I (Every one year) Remote control I - I I I: Inspect and clean, adjust, lubricate or replace, if necessary C:Ciean A: Adjust T: Tighten R: Replace

6 GENERAL INFORMATION SPECIFICATIONS Data Item Unit DT30MC DT30CR DIMENSION & WEIGHT Overall length (front to back) mm (in) 860 (33.9) Overall width (side to side) mm (in) 510 (20.1) Overall height s mm (in) 1 230 (48.4) L mm (in) 1 350 (53.1) Weight s kg (lb) 60 (132) 62 (137) L kg (lb) 61 (134) 63 (139) Transom height s mm (in type) [position] 424.5 (15) [3] L mm (in type) [position] 546.5 (20) [3] PERFORMANCE Maximum horsepower kW (PS) 22.1 (30) Recommended operating range r/min 5 000-5 600 Trolling speed r/min 650-700 POWER HEAD Engine type 2-stroke Number of cylinder 3 Bore ' mm (in) 62 (2.44) Stroke mm (in) 60 (2.36) Total displacement cm 3 (cu in) 543 (33.1) Compression ratio : 1 6.7 Standard spark plug BR7HS·10 Intake system Reed valve Exhaust system Through the prop Cooling system Water cooled Starting system Manual Electric Choke system Manual Electric Throttle control Twist grip Remote control Ignition system IC ignition

GENERAL INFORMATION 7 Data Item Unit DT30MC DT30CR FUEL& OIL Fue~ Suzuki recommends that you use unleaded gasoline containing no alcohol, with at least 85 pump octane (R ~ M method). Regular leaded gasoline containing no alcohol may also be used. Fuel to oil mixing ratio Automatic metering Fuel tank capacity I L (US/Imp. gal) 24 (6.3/5.3). 23 (6.1/5.1) ... For Canada Engine oil Use Suzuki CCI Oil or a Boating Industry Association (BIA) certified lubricant. Oil tank capacity I L (US/Imp. qt) 2.0 (2.11/1.76) Gear oil SUZUKI Outboard Motor Gear Oil (hypoid gear oil SAE # 90) Gearcase capacity I ml (US/Imp. oz) 230 (7.8/8.1) BRACKET Trim angle degree 4-20 Number of trim positions Adjustable 5 Maximum tilt angle degree 75 LOWER UNIT Reversing system Gear Transmission Forward- Neutral- Reverse Reduction system Bevel gear Gear ratio 2.09 (23/ 11) Drive line impact protection Rubber safety clutch Propeller Code number, Blade x Diam. (in) x Pitch (in) P901, 3 X 10-Y,.x 9 P911,3 x 10-Y.i x 9 (For Canada) P1001,3x 10-Y.x 10 .•. P1101,3x10-Y.x11 P1201, 3 X 1 0-Y. X 12 P1301, 3 X 10-Y,. X 13 "PS1300, 3 x 10-Y.x 13 P1401, 3 X 10-Y,. X 14 "PS: Stainless steel propeller P1501,3x 10-Y.x 15 These specifications are subject to change without notice.

8 GENERAL INFORMATION SERVICE DATA Data Item Unit DT30MC DT30CR POWER HEAD Crankshaft deflection Limit mm (in) 0.05 (0.002) Conrod deflection Limit mm (in) 5.0 (0.20) Cylinder head distortion Limit mm (in) 0.030 (0.00 1 2) Cylinder distortion Limit mm (in) 0.030 (0.00 1 2) Piston diameter STD mm (in) 61.920-61.935 (2.4378- 2.4384) Cylinder bore STD mm (in) 62.000-62.015 (2.4409- 2.4415) Piston to cylinder STD mm (in) 0.072-0.087 (0.0028-0.0034) clearance Limit mm (in) 0.167 (0.0066) Piston measuring position mm (in) 23 (0.9) from piston skirt end Cylinder measuring position mm (in) 28 (1.1) from cylinder top surface Wear on cylinder bore Limit mm (in) 0.1 0 (0.004) . Piston pin diameter STD ' mm (in) 15.995 _,16.000 (0.6297- 0.6299) u.:iJit i_ mm (id~ 15.980 (0.6291) . Piston pin hole diameter STD mm (in) 16.002-16.010 (0.6300-0.630J) Limit mm (in) 16.030 (0.6311) Piston ring end gap STD mm (in) 0.15- 0.35 (0.006- 0.0 14) Limit mm (in) 0.8 (0.031) Maximum reed stop opening mm (in) 3.8 (0.15) Reed seat clearance Limit mm (in) 0.20 (0.008) Thermostat operating temperature oc (oF) 48-52 (118-126) Amount of oil left in oil tank ml (US/Imp. oz) 500 (16.9/17.6) when oil level switch operates ,: . Oil pump discharge rate 5 minutes at 1500 r/min 1.0-1.9 ml and full closed /}'. 2 minutes at 1500 r/min 1.2-1.7ml and full open CARBURETOR Type (MIKUNI) 826-20 Main jet # 125 Main air jet ¢ (mm) 1.6 Pilot jet # 70 Pilot air jet ¢ (mm) 1.2 Pilot screw turns open Rotation 1]1,-2 Valve seat ¢ (mm) 1.2 Float height mm (in) 12- 14 (0.47- 0.55)

GENERAL INFORMATION 9 Data Item Unit DT30MC DT30CR ELECTRICAL Ignition timing ATDC 9•-ATDC 1°/650-700 r/min, BTDC 25°/5 000 r/min Condenser charge coil resistance a at 20°C 170-250 Pulser coil resistance a at 20°C 170-250 Gear counter coil resistance a at 20°C 160-240 Ignition coil resistance Primary a at 20°C 0.1-0.4 Secondary a at 2o•c 1900-2700 Battery charge coil resistance a at 20°C 0.2-0.6 Battery charge coil output w 12V 80 Standard spark plug Type NGK BR7HS-10 Gap mm !in) 0.9-1.0 (0.035-0.039) Fuse amp rating A 20 Recommended battery capacity Kc (Ah) 12V 126 (35) or over Choke solenoid resistance a at 2o•c 2.8-4.2 Starter relay resistance a at 20°C - I 3.5-5.1 OUTPUT SPECIFICATIONS USING A STEVENS tf::J77 METER (ALL MODELS) Crank the engine by means of the recoil starter. Condenser charge coil 120V or over (meter setting: POS 500) - Meter lead connection Red: Green Salek: Black/Red Pulsar coil 2.4V or over (meter setting: SEN 50) -Meter lead connection Red: Red/Biack(#1), White/Biack(#2), Read/White(#3) Black: Ground Gear counter coil 2.5V or over (meter setting: SEN 50) -Meter lead connection Red: Orange/Green Salek: Gray CDI to coil 1 05V or over (meter setting: POS 500) -Meter lead connection Red: Orange(#1), Blue(#2), Gray(#3) Black: Black

10 GENERAL INFORMATION Data Item Unit DT30MC DT30CR STARTING SYSTEM Battery rating Sec - 30 Battery output Kw - 0.6 Starter motor brush length STD mm (in) - 12.5 (0.49) Limit mm (in) - 9.0 (0.35) Commutator undercut STD mm (in) - 0.5-0.8 (0.02-0.03) Limit mm (in) - 0.2 (0.008) Commutator outside STD mm (in) - 30 (1.18) diameter Limit mm (in) 29 (1.14) - Allowable commutator STD mm (in) - 0.05 (0.002) taper Limit mm (in) - 0.4 (0.016) Pinion to ring gear gap mm (in) - 3-5 (0.12-0.20) These service data are subject to change without notice. I )

GENERAL INFORMATION 11 TIGHTENING TORQUE CHART Thread dia. Tightening torque Item N-m kg-m lb-ft Cylinder head bolt 6mm 8-12 0.8-1.2 6.0-8.5 8mm 21-25 2.1-2.5 15.0- 18.0 Crankcase bolt 6mm 8- 12 0.8- 1.2 6.0-8.5 8mm 20-26 2.0-2.6 14.5- 19.0 Flywheel nut 16 mm 130- 150 13- 15 94.0-108.5 Engine holder bolt 8mm 15-20 1.5-2.0 11.0- 14.5 Upper mount bolt 10 mm 34-41 3.4-4.1 24.5-29.5 Lower mount bolt 10mm 25-27 2.5-2.7 18.0- 19.5 Clamp bracket nut 22 mm 41-45 4.1-4.5 29.5-32.5 Gearcase mounting bolt 8mm 15-20 1.5-2.0 11.0- 14.5 Pinion nut 8mm 27-30 2.7-3.0 19.5-21.5 Propeller nut 14 mm 29-31 2.9-3.1 21.0- 22.5 Propeller shaft bearing housing bolt 6mm 6-10 0.6-1.0 4.5-7.0 Tightening torque for general bolt Types of bolt Thread Tightening torque diamter (mm) N·m kg-m lb-ft ~ ~ 5 2-4 0.2-0.4 1.5-3.0 6 4-7 0.4-0.7 3.0-5.0 8 10- 16 1.0- 1.6 7.0- 11.5 (Conventional of "4" marked bolt) 10 22-35 2.2-3.5 16.0- 25.5 ~ ~ 5 2-4 0.2-0.4 1.5-3.0 6 6-10 0.6-1.0 4.5-7.0 8 15-20 1.5-2.0 11.0-14.5 (Stainless steel bolt) 10 34-41 3.4-4.1 24.5-29.5 ~ ~ 5 3-6 0.3-0.6 2.0-4.5 6 8-12 0.8-1.2 6.0-8.5 8 18-28 1.8-2.8 13.0-20.0 (7 marked or,', marked bolt) 10 40-60 4.0-6.0 29.0-43.5

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1988-1997 Suzuki DT25 DT35 2 Stroke Outboard Service & Repair Manual

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