1985-1998 Suzuki DT40 DT40C 2 Stroke Outboard Service & Repair Manual

) I il II II II ' INI lEX l~[.j GROUP TITLE I D GENERAL INFORMATION I D .__E_L_EC_T_R_IC_A_L _AN_D_IG_N_I_T_IO_N ___ _____,J II _F_U_EL_S_Y._R_E_M ______________ ~II D POWERUNIT Ill _H_O_U_S_IN_G_A_N_D __ BR_A_C_K_ET ________ ~II _L_O_W_E_R_U_N_IT ______________ ~II MOTOR SETTING AND OPTIONAL PARTS D TROUBLESHOOTING II .__D_T_4_0W_'_'V_F_ 11 ~('_85~)_M_O_D_E_L _____ ~II .II~~~~D~T~4~0C~"V~H~'-'~('8~7~)~M~O~D~E~L _____ ~Iml ) Ill DT40C ''L'' ('90) MODEL lfJ DT40C/40W /40WK "'N" ('92) MODEL ! IEJ DT40TC "'R" ('94) MODEL 1m IIFI 1m

NOMENCLATURE ® ® CD Motor cover ® Shift lever ® Pilot water hole ® Anti-cavitation plate @ Tilt release lever ® Tilt tension nut CD Stern brackets ® Flush plug ® Oil filler plug ® Oil drain plug cv-___;::_-----ft- ®-----tf7'..,._..... , The other side '----- ® '---® The other side ® ® ®'-t=:LSL_.,..._~ @ @1---+-~S @ Fuel line coupler ® Air-vent screw @ Speed control grip @ Fuel tank @ Stop button ® Prime bulb @ Tilt adjusting rod ® Fuel line @ Water intake ® Remote control lever @ Gear case ® Remote control box @ Skeg ® Emergency stop switch ® Water discharge hole ® Lock -out button @ Trim tab @ Ignition switch ® Fuel gauge ® Warm-up lever ) )

( GENERAL INFORMATION CONTENTS MAIN SPECIFICATION .• •••••• •• •• •. •• • ••••••••••••••••••••••• • •••.•••••••• & BREAKING·IN •• •• .• •• ••••• •• •••• • •• •• •• •••••••• •• • •• •• • •••• •••• ••••••••• 7 MAINTENANCE, INSPECTION AND SERVICING ...... . ......... .... ............... 8 SPECIAL TOOL . • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 9 APPLICATION CHART OF MATERIALS REQUIRED ............... . ................ 12 TIGHTENING TORQUE CHART •• •••••••••••••••••••••••••••••••••••••.•••••• 22 COOLING SYSTEM . . . . . • . • • • • • . • • • • • • • • • • • • • . • . • • • • • • • . • • • • • • • • • • • . • • • • • • 23 ) SPECIFICATION • • • • • • • . • • • • • • • • • • • • • • • • • • • • • • • • • . • • . . • • • • • • • • • • • • • • • • • • • 26 SERVICE DATA ••••••••••••••••.••••••••••••••••••••••••••••••••.••••••• 28 ) ) )

6 GENERAL INFORMATION MAIN SPECIFICATION Intake system: Reed valve Fig. 1-1 Tilt position: 5 stages Maximum tilt up angle: 72 degree Cooling system: Displacement type water pump Gear ratio: 2.09(23:11) 4~- Maximum horse power: 29.4 kW (40PS) Ignition system: Suzuki "PEl" C.D.I. unit BBHS ~ ® 79 mm (3.11 in) @ 71 mm (2.80 in) © 696 cm 3 (42.46 cu.in) Gear oil: 610 ml (20.6/21.5 US/Imp. oz) 0 ) ) ) ) )

() 0 ) ) ) ) BREAKING-IN Breaking-in period is initial 15 hours. This initial 15 hours of operation is the critical period. Adhere to the following treatment referring to the table. In early stages of break-in operation, the separate fuel tank (23 liters) should be filled with a 50 : 1 gasoline-oil mixture and used in combination with the oil from the oil tank. ~ (Minutes) (Hours) 510 20 30 4,0 I 50 1 m Breaking-in period Operating It@ ® Premixing gasoline @ &oil Fig. 1-2 GENERAL INFORMATION 7 ®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. @ • 50 parts of gasoline to 1 part of SUZUKI CCI oil or BIA certified lubricant or • 30 parts of gasoline to 1 part of other outboard motor oil. ® Fuel and oil are separately supplied to the engine. ~ 1p 115 I I © I I ®

a GENERAL INFORMATION 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. This outboard motor user should be advised to go by the following schedule, which is based on the con- cept of systematic care: Item Servicing intervals Remarks 1 st 10 hrs Every 50 hrs Every 1 OOhrs Bolts and nuts Retighten Retighten Refer to Service Data. Spark plugs Clean and adjust B8HS 0.8 - 0.9mm plug gap. (0.031 - 0.035in.) Wire harness Check connec- Check connec- tions for tightness tions for tightness *Starting motor Check brush for Limit : 9mm brushes wear (0.354in.) Ignition timing Check and adjust ATDC2°- BTDC25° Carburetor Check and adjust Check and adjust Gear oil Change Change Hypoid gear oil, SAE # 90 610ml Pistons, cylinder De-carbon Renew gasket when and head de-carboning Propeller Check for damage Check for damage Grease propeller shaft Choke Check for proper Check for proper operation operation Clean and check for Fuel tank crack and fuel leakage (Usually check) Fuel strainer Check for clean- liness Check for fuel Check for fuel Fuel hoses leakage leakage and hose cracking Lubrication hose Check for crack Check for crack and breakage and breakage Check impeller Replace if worn Water pump and casing for wear out Handle Grease Adjust pre-load Grease Clutch lever Grease Starter rope Check for tear and wear Tilt Adjust pre-load *Neutral start Usually check "OFF" and "ON" interlock switch * Only for electric starter type. ) 0 ) ) )

) ) ) ) SPECIAL TOOL Snap ring remover (closing type) 09900-061 08 T-handle box wrench 8 mm: 09900-00302-015 10 mm: 09900-00302-017 12 mm: 09900-00302-018 14 mm: 09900-00302-019 Impact driver set 09900-09003 @Bit (medium): 09900-09204 @Bit (large): 09900-09205 Vernier caliper 09900-20101: Scale 150 mm 09900-20102: Scale 200 mm GENERAL INFORMATION 9 Micrometer 50- 75 mm: 09900-20203 Cylinder gauge set 09900-20508 Thickness gauge 09900-20803 Pocket tester 09900-25002 Dial gauge 1/1,000 mm: 09900-20602 1/100 mm: 09900-20606 Dial gauge chuck 09900-20701 Steel "V" block set Small ......... 75 mm: 09900-21303 Large .•••••••• 100 mm: 09900-21304 Gear adjusting gauge 09951-09510

10 GENERAL INFORMATION Engine tachometer (Analogue type) 09900-26003 Engine tachometer (Digital type) 09900-26006 Timing light {12V battery-operated) 09900-27301 Timing light (Dry-cell-operated) 09930-76420 Electro-tester D 09900-281 06 Hydrotester 09900-28403 Torque wrench 50-450 kg-em: 09900-21101 100-900 kg-em: 09900-21103 500"' 2,800 kg-em: 09900-21104 CCI oil measuring cylinder 09900-21602 SUZUKI converter 09900-28603 Outboard test wheel 09914- 79980 Drive shaft holder 09921- 29510 ) ) ) 09930-99810

) ) ) ) ) ) ) ® ® ~ ® Propeller shaft housing installer 09922-59410 @Bearing installer handle 09922·59420 Shifter lock pin remover 09922-89810 Sliding shaft 09930-30102 Propeller shaft housing remover 09930-30161 GENERAL INFORMATION 11 Rotor remover ®/~~ ~~ }® CD: Flywheel/propeller shaft housing remover plate. 09930·39411 ®: Flywheel remover bolts. 09930-39420 Flywheel holder 09930-39520 Oil leakage tester cv @· ~ ~ I#" ~ (J ]j \D 09950-69511 @ 09821-00004 C.D.I. test cord 09930-89440 )® ® @ © ~ ®0 @ i i ® Attachment @Plate <0 Shaft @Bolt (£) Nut Dial calipers 09951-19430 09951-39914 09951-59910 01107-08408 08310·12088 09900-20605

12 GENERAL INFORMATION APPLICATION CHART OF MATERIALS REQUIRED PART NAME SUZUKI SUPER GREASE "A" WATER RESISTANCE GREASE THREAD LOCK SUPER "13338" THREAD LOCK "1342" SEALING COMPOUND 366E PART NO. NET 99000-25010 450 g 1 carton 99000-25160 (12 tubes) 250g 1 carton 99000-25170 (12 tubes) 50g 99000-32020 50 g 99000-32050 50 g 99000-31090 180 ml PART NAME SUZUKI SILICONE SEAL SUZUKI BOND NO. 4 SUZUKI OUTBOARD MOTOR GEAR 01 L SUZUKI CCI 01 L [Regular oil] [Super oil) PART NO. NET 99000-31120 50 g 99000-31030 200g 1 carton 99000-22540 (24 tubes) 400ml 99000-21750 0.5 l 1.0 l 99000-21145 (SHELL SEKIYU) 1.0 l 99000-21460 (MITSU· BISHI OIL) 99000-21021 4.0 L 99000-21150 200l 99000-21640 ·050 0.5 L 99000·21640 (~._oE~L -100 SEKIYU) 1.0 L 99000-21250 (NIPPON OIL) 99000-21260 4.0 L 99000-21270 200L ) 0 ) ) )

1985-1998 Suzuki DT40 DT40C 2 Stroke Outboard Service & Repair Manual

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