1981-1992 Suzuki DT75 DT85 2 Stroke Outboard Service & Repair Manual

GROUP INDEX , ' No. GROUP TITLE PAGE I. MAIN SPECIFICATIONS FOR DT85 3- 4 2. GENERAL INFORMATION 5-'7 3. SERVICE DATA 19-27 4. APPLICATION CHART OF MATERIALS REQUIRED 29-37 5. OUTBOARD MOTOR SETTING AND ADJUSTMENT 39-48 6. ENGINE 49-73 7. COOLING SYSTEM 75-77 8. FUEL SYSTEM 79-89 9. SWIVEL AND STEERING 91 - 96 10. GEAR CASE 97-"8 ". POWER TRIM AND TILT SYSTEM 119 ...... 124 12. ELECTRICAL SYSTEM 125 ...... '37 '3. PROPELLER '39 ...... 141 14. TROUBLE SHOOTING ATTACHED IS. DT75 HQD" MODEL C83-MODEL) 143-170 16. DT85 HQD" MODEL C83-MODEL) 171-190 17. DT75/ 85 HVH" MODEL ('87-MODEL) 191- 231 18. DT75MQ/HQ/CQ/T/85CQ/T "VH" MODEL 233-275 19. DT75/85 HJ" MODEL ('88-MODEL) 277-326 20. DT75/85 HJ" MODEL ('88-MODEL) FOR USA 327-370

I " - ........... . -I, \ ) MAIN SPECIFICATIONS FOR DT85 CONTENTS MAIN SPECI FICATIONS FOR DT85 .... • ........... ••. •. ............... 4 , ,

4 MAIN SPECIFICATIONS FOR D185 Starter system: Electric starter BATTERY Ignition system: SUZUKI "PEl" Gear oil: 700 ml (23.7/24.6 US/lmp.oz.) Gear ratio: 13 : 27 ® CD n.o mm (2.83 in.) ® 84.0 mm (3.31 in.) ® 1.197 em' (73.04 cu.in. Standard spark plug and gap: NGK B8 HS 0.8-0.9 mm (0.031 - 0.035 in.) Cooling system: Displacement type water pump Exhaust system: Through prop hub exhaust

I GR~UP "'c------------------------'-, ---- GENERAL INfORMA rlON CONTENTS BREAKING-IN ................................................. 6 - 7 MAINTENANCE, INSPECTION AND SERVICING ......................... 8 SPECIAL TOOLS . .............................................. 9 - 10 OPTIONAL PARTS . ............................................ 11 - 17

6 GENERAL INFORMATION BREAKING-IN (For DT85 and DT85T) 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 -------J-0-Hours-.. -5----10----15----20- I I I I . Premixing gasoline & oil 10 Hours 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 above table. ~I During initial 5 minutes, operate the engine at trolling speeds. li During the first 10 hours, operate the engine with a partial throttle (within 1/2 throttle opening). In this period, operate the engine with fu II throttle for about 1 minute at every 10 minutes_ © For the hitter 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 (j)) During the first 10hours: * 30 parts of gasoline to 1 part of SUZUKI eel oil or BIA certified lubricant or • 20 parts of gasoline to 1 part of other outboard motor oi I. 'E After 10 hours of initial operating: * 50 parts of gasoline to 1 part of SUZUKI eel oil or BIA certified lubricant or • 30 parts of gasoline to 1 part of other outboard motor oi I. <. 'C) , .' - \

(For DT85TC) The Model DT85TC have employed the SUZUKI Oil injection System whereby the lubricating oil and gasoline are sent tothe engine separately. Furthermore, under this lubricating method, the lubricating oil feed rate for the engine will be automatically adjusted in accordance with the engine revolution speed so that optimum oil concentration ideally matched with the engine speed may be assured at all times. Nevertheless, it is necessary to supply the engine with lubricating oil necessary for satisfactory break-in during the first 15-hour (approximately) operation period after the new engine is put into operation for the first time. CAUTION: For improved break-in effect, make sure to see it that every user uses gasoline mixed with lubricating oil with a ratio of 50 : 1 during the first 5-hour operation period. (J>,-, During initial 5 minutes, operate the engine at trolling speeds. 1El' 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. © During the first 5 hours: * 50 parts of gasoline to 1 part of SUZUKI CCI oil or B IA certified lubricant or * 30 parts of gasoline to 1 part of other outboard motor oil. ® After 5 hours: The lubricating oil and gasoline are supplied to the engine separately. GENERAL INFORMATION 7 5 Minutes 10 Hours 5 Hours I -® @ © , , -0-Hours-.-5-----10----15 " , 5 Hours GASOLINE RECOMMENDATIONS Use automotive-quality gasoline with an octance number 85 to 95. OIL RECOMMENDATIONS Use SUZUKI CCI oil or Boating Industry Asso- ciation certified lubricant. It is a proprietary lubricant designed to ensure the best engine performance and to minimize combustion chamber deposits, avoid preignition and prolong the spark plug life. If SUZUKI CCI oil or Boat- ing Industry Association certified lubricant is not available, a high-grade OUTBOARD MOTOR oil should be used instead. SUZUKI CCI oil SUZUKI CCI oil (Only for U.S. Market)

B GENERAL INFORMATION MAINTENANCE, INSPECTOIN AND SERVICING • Since the DT85, DT85T and DT85TC are high-power engines, their lives will be greatly affected by daily care. Not only the periodic inspection but break-in operation is also very important in the life of the engine. Please familialize your customers with the correct procedures for break-in operation so the engine can be used in top working condition for a prolonged period of time. Item Servicing intervals Remarks 1st IOhrs Every 50hrs Every IOOhrs Bolts and nuts Retighten Retighten Refer to SERVICE DATA Clean and adjust Spark plug gap; Spark plugs spark gap 0.8 - 0.9 mm (0.031 - 0.035 in) Wire harness Check connections Check connections for tightness for tightness Starting motor brushes Check brush for wear Service limit: 12 mm (0.47 in.) Ignition timing Check and adjust ATDC7° - BTDC21.5° Carburetors Check and adjust Check and adjust Gear oil Change Change Hypoid gear oil SAE #90,700 ml Piston, cylinder and De-carbon Renew gasket when cylinder head de-carboned Replace or repiar Replace or repair Propeller badly bent or broken badly bent or broken propeller propeller Check and adjust Check and adjust Remote control linkage for proper linkage for proper control of clutch and control of clutch and throttle throttle Ignition switch Check for proper Check for proper and Choke solenoid operation operation Emergency stop switch Check "OFF" and Check "OFF" and "ON" "ON" Clean and check for Fuel tank crack and fuel leakage (Usually check) Inspect for fuel Inspect for fuel Fuel hoses leakage and hose leakage cracking •• I nspect for oil Oil injection system Inspect for oil leakage and oil leakage line breakage Inlet case hose I nspect for crack I nspect for oil and breakage and breakage Water pump Check impeller and Replace if worn casing for wear out Neutral start inter- Usually check "OFF" and "ON" lock switch • Check operation Power trim and tilt Check for oil leakage Check pipes for cracks For DT85T and DT85TC •• For DT85TC , , \ ) I

SPECIAL TOOLS P.T.T. oil pressure gauge (For DT85T, DT85TC) 09915-79410 P.T.T. cylinder cap remover and installer (For DT85T, DT85TC) 09944-09410 Test lead, C.D.I 09930-89510 EI ectro-tester (09900-28106) Bearing remover set 09913-69911 ©= I, ~ • D [,31 G)::=O Q) 1J) > SUZUKI converter 09900-28603 GENERAL INFORMATION 9 Pocket tester 09900-25002 Timing gauge A .. 09931-00112 ~ ~~~ CD Holder (09931-20120) ® Rod No. 1(09931-30120) ® Rod No. 2(09931-30130) Flywheel etc. remover CD m ® ® Carburetor balancer set 09913-13121 Oil seal remover 09913-50121 -- CD 09930-39410 ® 09930-39420 ® 09950-59520

'. , j 10 GENERAL INFORMATION Flywheel holder 09930-49410 Drive shaft holder 09950-79510 Hydrometer 09900-28403 CD Propeller shaft housing installer 09922-59410 ® Bearing installer handle 09922-59420 ~® ~C Rotor remove. slide shaft CD 09930-301 02 Attachment ® 09930-30161 Outboard test wheel 09914-79510 Engine speed tester CD 09900-26003 ® 09900-26004 CD ®~I Gl. ~ ~ o~~ "' ~"-' -"~ . ,,, ~.~1 c,:::~~ SUZUKI Timing light ID 09900-27301 ® 09900-27311 ~ /-' m~~~ @® Oil leakage tester CD 09950-6951 0 ® 09821-00004 <D «: : () r Beari ng oi I seal installer 09914-79610 r

/ f , \ I I OPTIONAL PARTS Meters As illustrated below, the optional speedometer, tachometer, voltmeter, hourmeter and trimmeter can be installed boat's dash board. Speedometer 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 as illustrated. Flash hose attachment (55181-95200) =D (55182-95200) GENERAL INfORMATION 11 Tachometer (34200-95500) Voltmeter (34600-95501 ) Hourmeter (34500-95501 ) Rectifier & regulator (32800-95820) f 30mm (1.2 in) Speedometer sensor

1981-1992 Suzuki DT75 DT85 2 Stroke Outboard Service & Repair Manual

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