1983-1997 Suzuki DT8 DT9.9 DT15C 2-Stroke Outboard Repair Manual

CD Engine cover ® Clutch lever ® Oil filler plug @ Anti-cavitation plate @ Oil drain plug ® Starter grip (']) Choke knob ® Fuel connector plug NOMENCLATURE ® Throttle control grip @ Tilt release lever @ Clamp screw © Fuel gauge @ Fuel tank @ Air-vent screw @ Engine stop switch @ Starter button (Only for DT9.9E/DT15E) @ Water outlet @Tilt pin @ Water inlet ® Exhaust outlet @ Flush plug @ Pilot water hole

GENERAL INFORMATION CONTENTS MAIN SPECIFICATION •..•••.••..•••••.••••.•••.••••••.• ........ • .... ••..•. 6 BREAKING·IN .•••••••••••.•...•••••.••.•.•.•••••••...•• ..... • .... • ...... 7 MAINTENANCE, INSPECTION AND SERVICING •••••.•..• ..... •• .... •.•• .......... 8 SPECIAL TOOL •..• ............. ••..•.••••.•.•.••.• ..... •...•.•• ..... ••.•. 9 APPLICATION CHART OF MATERIALS REilUIRED. . • . • . • . . • . • . • . . . . . . . . . . . . . . . • . • 12 TIGHTENING TORilUE CHART • • • • • • • • • . . • • • • • • • • • • • • • . • • • • • • • • • • . • . . • • • • • . • 22 COOLING SYSTEM ..•.•.•••.••• ............. •.• .... •...• .... • ..... •..••.. 24 SPECIFICATION .•..••••.•.•••••.••• ....... •..•.•.•...•.••••.•••..••...•• 26 SERVICE DATA .•••••••.•••• ..... ••••••.•••.••.••••• ...... •..••••••.•••• 28 ll

6 GENERAL INFORMATION MAIN SPECIFICATION Tilt position: 5 stages Cooling system: Displacement type water pump Gear ratio: 1.92 (23:12) \ I Clutch type: Dog clutch Fig. 1-1 m horse nm'" 0 ''" DT9.9/9.9E: 7 15/15E: 11.0kW (1 Ignition system: Suzuki "PEl" BR7HS-10 ~ B7HS (For the markets motors are mostly used for comercial rpose) Displacement: ® 59 mm (2.32 in) @ 52 mm (2.05 in) © 284 cm 3 (17.33 cu. Exhaust system: Through prop hub exhaust Gear oil: 170 ml (5.7/6.0 US/Imp. oz)

BREAKING-IN Neglecting accurate breaking-in operation will have an adverse effect on the durability of the engine, eventually causing engine overheating. Therefore, we hope that you will guide our users as instructed below. Breaking-in period is initial15 hours. This initial 15 hours of operation is the critical period. Adhere to the following treatment referring to the below table. ® 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. 5 Minutes 10 Hours I Operating -® @ GENERAL INFORMATION 7 © 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 10 hours: 30 parts of gasoline to 1 part of SUZUKI CCI oil or BIA certified lubricant. ® After 10 hours of initial operating: 50 parts of gasoline to 1 part of SUZUKI CCI oil or BIA certified lubricant. 5 Hours © I I I 1 I Fig. 1-2 --------1-0-Hours-•-5----10----15----20- Premixing gasoline & oil , ' I l v 10 Hours

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 1 st 10 hrs Every 50 hrs Bolts and nuts Retighten Retighten Spark plugs Clean and adjust plug gap. Wire harness Check connec- Check connec- tions for tightness tions for tightness *Starting motor I brushes length Ignition timing ' Carburetor Check and adjust Check and adjust ·+---- . Gear oil Change Change ------ Pistons, cylinder De-carbon and head Propeller Check for damage Check for damage Choke Check for proper , Check for proper operation I operation Fuel tank Fuel strainer Check for clean- liness Check for fuel Check for fuel Fuel hoses leakage leakage and hose cracking Water pump Handle Grease Adjust pre-load 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. ** For the comercial market Every 1 OOhrs Remarks BR7HS-10 0.9 -1.0mm (0.035 - 0.039in.) **B7HS 0.6-0.7 mm (0.024- 0.028in.) Check brush for Limit: 4.5mm wear (0.177in.) Check and adjust Hypoid gear oil, SAE # 90 Renew gasket when de-carboning Grease propeller shaft Clean and check for crack and fuel leakage (Usually check) Check impeller Replace if worn and casing for out wear Grease

SPECIAL TOOL Snap ring remover (closing type) ·"'· 09900-06108 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 100 mm 09900-20102: Scale 200 mm GENERAL INFORMATION 9 Micrometer 50- 75 mm: 09900-20203 Cylinder gauge set 09900-20508 Dial gauge 1/1 ,000 mm: 09900-20602 1/100 mm: 09900-20606 Dial gauge chuck 09900-20701 Thickness gauge 09900-20803 Thickness gauge 09900-20804 Steel "V" block set y Small ......... 75 mm: 09900-21303 Large ......... 100 mm: 09900-21304 Pocket tester 09900-25002

10 GENERAL INFORMATION Engine tachometer (Analogue type) ~ §§ l!iJ ~~ 09900-26003 Engine tachometer (Digital type) 09900-26005 Timing light (12V battery-operated) 09900-27301 Timing light (Dry-cell-operated) 09900-27311 Electro-tester 09900-28106 Hydrotester 09900-28403 Converter 09900-28603 Torque wrench 50-450 kg-em: 09900-21101 100-900 kg-em: 09900-21103 Stud bolt installing tool 6 mm: 09910-10110 8 mm: 09910-10710 Oil seal remover 09913-50121 Outboard test wheel 09914-79840 C.D.L test cord 09930-8931 0

Propeller shaft housing installer 09922-59510 Shifter lock pin remover 09922-89810 Slide hummer 09930-301 02 Propeller shaft remover attachment 09950-59320 GENERAL INFORMATION 11 Gear adjusting gauge set 09951-0951 0 Flywheel holder 09930-49310 Oil leakage tester =o==~ "----------"'-------l ® CD 09950-6951 o ® 09821-00004

12 GENERAL INFORMATION APPLICATION CHART OF MATERIALS REQUIRED PART NAME SUZUKI SUPER GREASE "A" WATER RESISTANCE GREASE THREAD LOCK SUPER "1333B" THREAD LOCK "1342" SUZUKI CEMEDINE 366E PART NO. NET 99000-25010 450 g 1 carton 99000-25160 (12 tubes) 250g 1 carton 99000-25170 (12 tubes) 50 g 99000-32020 50 g ' I 99000-32050 I 50 g • 99000-31 090 180 ml PART NAME SUZUKI SILICONE SEAL SUZUKI BOND NO.4 SUZUKI OUTBOARD MOTOR GEAR OIL SUZUKI CCI OIL [Regular oil] [Super oil] PART NO. NET 99000-31120 50 g 99000-31030 200g 1 carton 99000-22540 (24 tubes) 400 ml 99000-21750 0.5 L 1.0 L 99000-21145 ISH ELL SEKIVU) 1.0 L 99000-21460 (MITSU· BISHI OIL) 99000-21021 4.0 L 99000-21150 200L 99000-21640 -050 0.5 L 99000-21640 1.0 L -100 (SHELL SEKIVU) 1.0 L 99000-21250 (NIPPON OIL) 99000-21260 4.0 L 99000-21270 200L

ENGINE COVER, RECOIL STARTER, MAGNETO, STATOR GENERAL INFORMATION 13 I &, ' .,@ L-~ (') ~ NOTE: Fig. 1-3 """ @) I Wipe off iron dust, oil, etc. using a cloth dipped with thinner.

1983-1997 Suzuki DT8 DT9.9 DT15C 2-Stroke Outboard Repair Manual

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