1985-1991 Suzuki DT55 DT65 3-Cylinder 2-Stroke Outboard Motor Service & Repair Manual
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l~t.H GROUP TITLE I
D GENERAL INFORMATION ID
_E_LE_C_T_RI_CA_L_AN_D_IG_N_IT_IO_N ___ ~D
_F_U_EL_S_Y_~_E_M ___________ ~II
I' POWER UNIT III
_H_O_U_S_IN_G_A_N_D_BR_A_C_K_ET ______ ~ II
LOWER UNIT II
------------~
MOTOR SETTING AND OPTIONAL PARTS II
TROUBLESHOOTING II
DT55/65 "VG" ('86) MODEL III
In. DT55/65 "VH" ('87) MODEL IIIiJ
)
III DT55/65 SERIES "J" ('88) MODEL 1m
If I DT55/65 SERIES "K" ('89) MODEL 1m
IF' DT55/65 SERIES "L" ('90) MODEL 1m
) It 1 DT55/65 "Mil ('91) MODEL lID
It' DT55/65 "Nil ('92) MODEL 1m
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GENERAL INFORMATION
CONTENTS
FUEL RECOMMENOATION '" ..•. .••. .• .. ... .. • ••• ••..•. .. •.• •. •. • ..•.. •.•. , 6
OIL RECOMMENOATION ... . .... .•. ..... ...•.. ............ . .... . ... ...• .... 6
BREAKING·IN ....... . .. . ... .. .. ..... . ..................... •. .• .. . ...... . 6
MAINTENANCE, INSPECTION ANO SERVICING ........... • ......... . .. • .... •.•... 7
SPECIFICATION .............. ..• .. .. ................ •..• ...... . ......... • 8
SERVICE OATA ................ . ........................ •... . .• ... ..•.. , 10
TIGHTENING TOROUE CHART .... ..... . ........................... • ........ 12
SPECIAL TOOLS ..... • ........ . •.. .. ........................... • ....... " 13
APPLICATION CHART OF MATERIALS REOUIREO ................... ... ..... . .. " 16
COOLING SYSTEM .......... . •. ... ........ .. . .• .......... ...•. . •.. .. ..... 23
PREVENTION OF GALVANIC CORROSSION .. . .. . .. ..... . .. , . . . ..... .. . , .. ... ... 26
D
6 GENERAL INFORMATION
FUEL RECOMMENDATION
Suzuki recommends that you use unleaded gasoline,
containing no alcohol, with at least 85 pump octane
(R; M method). Regular leaded gasoline, contain·
ing no alcohol, may also be used.
OIL RECOMMENDATION
Use SUZUKI eel oil or BIA (Boating Industry
Association) certified lubricant. It is a proprietary
lubricant designed to ensure the best engine per·
formance and to minimize combustion chamber
deposits, avoid preignition and prolong the spark
plug life. If SUZUKI eel oil or BIA certified lubri·
cant is not available, another high·grade OUT·
BOARD MOTOR oil may be used instead. It is
with the oil present in the fuel that the running
parts of the engine are lubricated.
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.
NOTE:
The early stages mean about 5 tanks.
® 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 eel
oil or B IA certified lubricant or
• 30 parts of gasoline to 1 part of other outboard
motor oil.
® Fuel and oil are separately supplied to the
engine.
~
(Minutes) (Hours)
Item 51020 30 40 50
,
1
" "
Breaking-in
I
period
Operating
~®
®
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©I
Premixing
gasoline @
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®
&oil
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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 services in a systematic manner at
regular intervals.
The outboard motor user should be advised to go by the following schedule, which is based on the con-
cept of systematic care:
~I
Initial 10 hrs Every 50 hrs Every 100 hrs Remarks
Item
Carburetor Check and adjust Check and adjust
--
Piston. cylinder
-- --
De-carbon Renew gasket when d ..
and cylinder head carboning
Water pump
-- --
Check impeller and Replace if worn out
casing for wear
Spark plugs Clean and adiust plug
--
Refer to SERVICE
--
DATA gap
Wire harness Check connections for Check connections for
tighteness tighteness
--
Starting motor
-- --
Cleek brush for wear Refer to page 63
brushes
Emergency switch Check "ON" and Check "ON" and
"OFF" "OFF"
--
Ignition switch and Check for proper Check for proper
choke solenoid operation operation
--
Remote control Check and adjust link· Check and adjust link·
Refer to page 138 -
age for proper control age for proper control
-- 139
of clutch and throttle of clutch and throttle
Power trim and tilt Check operation Cleek operation Refer to page 104
Cleek for oil leakage Check for oil leakage
--
Check tubes for cracks Check tubes for cracks
Propeller Check for damage Check for damage
--
Protection zinc --
Check for wear
--
Gear oil Change Change
--
Refer to SERVICE
DATA
Lubrication all Check and grease Check and grease
--
moving parts
Bolts and Nuts Retighten Retighten
--
Refer to TIGHTENING
TORQUE
Fuel tank Usually clean and check for cracks and fuel leakage
Fuel strainer
--
Check for cleanliness
--
Fuel hose. Check for fuel leakage Check for fuel leakage
and hose cracking
--
Oil tank Usually clean and check for cracks and oil leakage
Oil hose Check for oil leakage Check for oil leakage
--
and hose cracking
Oil pump -- --
Check and adjust Refer to page 78 - 80
Oil injection system Check for oil leakage Check for oil leakage
--
Refer to page 78
and air bleeding and air bleeding
Lubrication hose Check for crack and Check for crack and
breakage breakage
--
8 GENERAL INFORMATION
SPECIFICATION
)
Data
Item Unit
I
DTSSTC I I DT6STC DTS5C DT6SC
DIMENSION & WEIGHT
Overall length mm (in.) 6S0 (26.B) )
Overall width mm (in.) 365 (14.4) 4BO (IB.9) 365 (14.4) 4S0 (1S.9)
Overall height S mm (in.) 1290 (50.S)
L mm (in .) 1405 (55.3)
LL mm (in.) 14BO (5S.3)
-
UL mm (in .) 1530 (60.2)
-
- -
Weight S kg (I b) 97.0 (213.S) 103.0 (227.1) 97.0 (213.S) 103.0 (227.1)
L kg (lb) 99.0 (21S.3) 10S.0 (231.5) 99.0 (21S.3) 105.0 (231.5)
LL kg (lb) -- 101.0 (222.7) 107.0 (235.9)
UL kb (lb) 102.0 (224.9) 10S.0 (238.1) 102.0 (224.9) 10S.0 (238.1)
Transom height
S
mm (in. type)
402(15)
([Trim position]
[2]
L
mm (in. type) 517 (20)
[Trim position] [2]
LL
mm (in. type)
-- --
593 (23)
-
[Trim position] [2]
)
UL
mm (in. type) 644 (25)
-
-
-
[Trim position] [2]
PERFORMANCE
Maximum horsepower Kw (ps) 40.5 (55)
I
-
I 47.B (65)
I
-
Recommended operating range RPM 4800-5500
Trolling speed RPM 650 -700
POWER HEAD
)
Engine type Cycle 2
Number of cylinder Number 3
Bore mm (in.) 73 (2.9)
Stroke mm (in.) 71 (2.8) )
Total displacement em
3
(cu. in) 891 (54.4)
Compression ratio : 1 6.5
Standard spark plug (NGK) BSHS
Intake system Reed valve
)
Exhaust system Through prop hub exhaust
Cooling system Water cooled
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Item Unit
Starting system
Choke system
Speed control
Ignition system
FUEL & OIL
Fuel
Fuel tank capacity I L (US/Imp. gal)
Engine oil
Oil tank capacity I L (US/Imp. qt)
Gear oil
Gear oil capacity I ml (US/Imp. oz)
BRACKET
Trim angle Degree
Trim position Adiustable
Maximum tilt-up angle degree
LOWER UNIT
Reversing system
Transmission
Reduction sy.tem
Gear ratio
I mpact protection
Propeller
[COde number, ]
Propeller size (Blade x Oia. (in.) x Pitch (in.)
'SS: Stainless steel propeller
GENERAL INFORMATION 9
Data
OT55C DT55TC OT65C OT65TC
Electric
Electric
Remote control
IC ignition
Suzuki recommends that you use unleaded gasoline
containing no alcohol, with at lea.t 85 pump octane
(A; M method). Regular leaded gasoline containing
no alcohol may also be used.
23 (6.1/5.1)
SUZUKI CCI oil or BIA (Boating Industries Association)
certified lubricant.
3.0 (3.2/2.6)
SUZU KI Outboard motor ge.r oil (hypoid gear oil
SAE #90)
650 (22.0/22.9)
8-24 P.T.T.system 8 - 24 P.T.T. system
5 P.T.T. system 5 P.T.T. system
75
Ge.r
Forward - Neutral - Reverse
Bevel gear
1.917 (23/12)
Rubber safetY clutch
S 900, 3x 11lSx 9.0
S1000, 3x 11lSx 10.0
51100, 3x 11lSx 11.0
S12OO, 3x 11'I.xI2.0
S1301, 3xlllSxl3.0
S1400, 3x 11%x14.0
S1500,3xll14x15.0
S1600, 3x 11'/.x16.0
S1700, 3 x 11 x 17.0
'SS1300, 3xlllSx13.0
'SS1400, 3x 11%x14.0
'SS1600, 3 x 11'/. x 16.0
10 GENERAL INFORMATION
SERVICE DATA
Data
Item Unit
I
DT55TC I I DT65TC DT55C DT65C
POWER HEAD
Crankshaft deflection Limit mm (in.) 0.05 (0.002)
Conrad deflection Limit mm (in.) 5.0 (0.20)
Cylinder head distortion Limit mm (in.) 0.030 (0.0012)
Cylinder distortion Limit mm (in.) 0.030 (0.0012)
Piston to cylinder clearance mm (in.) 0.112 - 0.127 (0.0044 - 0.0050)
o
Piston diameter measuring point mm (in.) 35.0 (1.38) from piston skirt end
Cylinder bore measuring point mm (in.) 40.0 (1.57) from cylinder top surface
Wear on cylinder bore Limit mm (in.) 0.10 (0.004)
Piston pin diameter STD mm (in.) 19.995 - 20.000 (0.7872 - 0.7874)
Limit mm (in.) 19.980 (0.7795)
Piston pin hole diameter STD mm (in.)
19.998 - 20.006 (0.7873 - 0.7876)
Limit mm (in.) 20.030 (0.7886)
Piston ring end gap STD mm (in.) 0.20 - 0.40 (0.008 - 0.016)
o
Limit mm (in.) 0.80 (0.031)
Maximum opening for reed being bowed mm (in.) 7.6 - 8.0 (0.30 - 0.31)
Reed-to-seat clearance Limit mm (in.) 0.20 (0.008)
Thermostat temperature start to open
°c (oF)
48 - 52 (118 -126)
Amount of oil level switch to operate ml (US/Imp. oz) 500 (16.9/17.6)
Oil pump discharge rate (Full-open) 3.4 -5.1 ml for 2 minutes at 1500 RPM (DT55C. DT55TC)
4.0 - 5.9 ml for 2 minutes at 1500 RPM (DT65C. DT65TC)
(Full-close) 2.0 -3.1 ml for 5 minutes at 1500 RPM (DT55C. DT55TC)
2.0 - 3.2 ml for 5 minutes at 1500 RPM (DT65C. DT65TC)
CARBURETOR
)
Type (MIKUNI) BV32 - 24
-
BV40 - 32
-
Main jet # 117.5
-
147.5
-
Main air jet </J(mm)
1.4
-
1.0
-
Pilot jet # 70
-
75
-
)
Pilot air jet </J(mm) (j)2.0 ®1.5
- - -
Pilot air screw turns open Rotation 1'/. _1'/.
-
1% - 2
-
Valve seat </J(mm)
1.5
- -
-
)
Float level mm 10.0 -12.0 17.0 - 19.0
-
-
(in.) (0.39 - 0.47)
(0.67 - 0.75)
Trolling ,peed RPM 650 - 700
- - -
GENERAL INFORMATION 11
Data
Item Unit
DT55C DT55TC DT65C DT65TC
ELECTRICAL
Ignition timing RPM TOC - ATDC 6° 1650 - 700, BTDC 25° 13000
(J
Ignition coil resistance Primary n at 20°C 0.5 - 0.8
Secondary n at 20°C 4700 - 7000
Condenser charging coil resistance n at 20°C 190 - 270
()
Pulser coil resistance n at 20°C 170 - 250
Battery charging coil resistance n at 20°C 0.2 - 0.6
Battery charging coil output (12V) W 80 [180 . . .. option)
Spark plug Type (NGK) B8HS
Gap mm (in.) 0.9 - 1.0 (0.035 - 0.040)
Fuse A 20
Choke solenoid coil resistance n at 20°C 3.5 - 5.1
STARTING MOTOR
Rating Sec 30
( ) Output Kw 0.9
Brush length STD mm (in.) 16.0 (0.63)
Limit mm (in.) 11.5 (0.45)
Commutator undercut STD mm (in.) 0.5 - 0.8 (0.02 - 0.03)
Limit mm (in.) 0.20 (0.008)
Commutator outside diameter STD mm (in.) 33.0 (1.30)
Limit
mm (in.) 32.0 (1.26)
Difference between max./min. STD mm (in.) 0.05 (0.002)
diameter of commutator
Limit mm (in.) 0.40 (0.016)
Pinion/ring gear gap mm (in.) 3.0 - 5.0 (0.12 - 0.20)
Starting motor relay coil resistance n at 20°C 3.5 - 5.1
f
)
PTT MOTOR
Brush length STD mm (in.) 13 (0.5) 13 (0.5)
Limit mm (in.) --- 9 (0.35) 9 (0.35)
P.T.T. motor relay coil resistance n at 20°C 3.5 - 5.1 3.5 - 5.1
)
1 2 GENERAL INFORMATION
TIGHTENING TORQUE CHART
Item Thread dia.
Tightening torque
N·m
kg·m Ib·ft
Cylinder head cover bolt 6mm 8 -12 0.8 -1.2 6.0 -8.5
Cylinder head bolt 8mm 21 -25 2.1 - 2.5 15 . 0-18.0
Crankcase bolt 6mm 8 -12 0.8 - 1.2 6.0 - 8.5
10 mm 46 -54 4.6 - 5.4 33.5 - 39.0
Flywheel nut 200 -210 20.0 -21.0 144.5 - 152.0
Engine holder bolt 18 - 28 1.8-2.8 13.0 -20.0
Upper mounting bolt 34 -41 3.4 -4.1 24.5 -29.5
Lower mounting bolt 56-64 5.6 - 6.4 40.5 -46.5
Clamp bracket nut 41 - 45 4.1 - 4.5 29.5 - 32.5
Gear case bolt 8mm 15 -20 1.5 - 2.0 11.0 -14.5
10mm 34 -41 3.4 - 4.1 24.5 - 29.5
Pinion nut 30 -40 3.0 -4.0 21.5 - 29.0
Propeller shaft housing bolt 15 - 20 1.5 - 2.0 11.0-14.5
Propeller shaft nut 50 -60 5.0 - 6.0 36.0 -43.5
Water pump case bolt 15 - 20 1.5 - 2.0 11.0-14.5
Exhaust cover bolt 8 -12 0.8 -1.2 6.0 - 8.5
)
Exhaust tube and exhaust tube housing bolts 8 -12 0.8 -1.2 6.0 -8.5
Drive shaft housing bolt 15 - 20 1.5 - 2.0 11 . 0-14.5
Tilt cylinder cap 35 -60 3.5 - 6.0 25.5 - 43.5
Tightening torque for general bolt
TVpe. of bolt
Thread
Tightening torque
diameter (mm)
N'm kg·m Ib-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 or "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
)
IStainless 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 )
I
(7 marked or " marked bolt) 10 40 -60 4.0 - 6.0 29.0 - 43.5
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Thank you for considering this comprehensive Service Repair Workshop Manual for the Suzuki DT55 DT65 3-Cylinder 2-Stroke Outboard Motor from 1985 to 1993.
This manual encompasses all the necessary Service & Repair Procedures, making it an invaluable resource for both professional mechanics and DIY enthusiasts.
By utilizing this manual, you can significantly reduce expenses by performing your own repairs. The manual provides easy-to-follow, step-by-step instructions accompanied by illustrative pictures, covering all aspects of servicing and repairs.
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