1985-1998 Suzuki DT4 2-Stroke Outboard Service & Repair Manual

GROUP TITLE GENERAL INFORMATION ELECTRICAL AND IGNITION FUEL SYSTEM POWER UNIT LOWER UNIT HOUSING AND ' BRACKET MOTOR SETTING TROUBLE SHOOTING 23-32 33-4.0

CD Engine cover ® Starter grip ® Throttle control grip ® Engine stop switch ® Steering adjuster bolt ® Shallow drive arm (j) Water outlet ® Protection zinc ® Exhaust outlet NOMENCLATURE ® Clutch lever @ Starter knob @ Fuel connector plug @ Throttle knob @ Tilt stopper pin @ Tilt lock pin @ Clutch adjust hole @ Oil filler plug @ Oil drain plug @ Sub water inlet ® Anti-cavitation plate @ Water inlet @ Fuel tank ® Fuel gauge @ Air-vent screw @ Squeeze pump

GENERAL INFORMATION CONTENTS BREAKING-IN • _• • • • . • • • . • • • • . . • • • . • . • • • • • • • • • • • • . • • • • • • • • • • • • • • • • • • • • • • 6 MAINTENANCE, INSPECTION AND SERVICING .. .. • • .. • • • • .. .. • • .. .. .. .. .. .. .. • • 7 SPECIAL TOOL._ . • • . . . • . • • • • • . . • . • • • • • • . . • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 8 APPLICATION CHART OF MATERIALS REQUIRED ................................ 11 TIGHTENING TORQUE CHART •••.•••••• _ ••.•••••••••••••••••••••••••••••••• 18 COOLING SYSTEM .•..••• _. _ •••••.•••••••••••.••••••••.•••••••••••••••••• 19 SPECIFICATION .• _ •••••••••.•••.••••••.••••••••••.•••••••••••••••••••••• 20 SERVICE DATA ••.••••.•••.•••••••••.••.••• - •••••.•.•••••••••••••••••••• 22 ll

6 GENERAL INFORMATION BREAKING-IN Neglecting accurate breaking-in operation will have an adverse effect on the durability of the engine, eventually causing engine overheating. 5 Minutes 5 Hours Operating l•f-® ® I ·0-Hours-• I Premixing gasoline © &oil 5 Hours Fig. 1-1 Breaking-in period is initial 5 hours. This initial 5 hours of operation is the critical period. Adhere to the following treatment referring to the above table. ®During initial 5 minutes, operate the engine at trolling speeds. @During the first 5 hours, operate the engine with a partial throttle (within 3/4 throttle opening). Therefore, we hope that you will guide our users as instructed below. I I 5 10- I I @ Thereafter © During the first 5 hours: • 30 parts of gasoline to 1 part of SUZUKI CCI oil orB lA certified lubricant or • 20 parts of gasoline to 1 part of other outboard motor oi I. @After 5 hours of initial operating: • 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.

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. 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 1st 10 hrs Every 50 hrs Every 100 hrs Bolts and nuts Retighten Retighten Spark plug Clean and adjust BP6HS, 0.6- 0.7 mm plug gap. (0.024 -0.028 in.) Wire harness Check connec- Check connec- tions for tightness tions for tightness Ignition timing Check and adjust Carburetor Check and adjust Check and adjust Gear oil Change Change Hypoid gear oil, SAE # 90, 190 ml Piston, cylinder De-carbon Renew gasket when and head de·carboning Propeller, shear Check for damage Check for damage Grease propeller pin and cotter pin 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 out wear Handle Grease Adjust pre-load Grease Clutch lever Grease Starter rope Check for tear and wear Tilt Adjust pre-load

8 GENERAL INFORMATION SPECIAL TOOL Snap ring remover (opening type) 09900-061 07 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 Micrometer 25- 50 mm: 09900-20202 Dial gauge 1/1 ,000 mm: 09900-20602 1/100 mm: 09900-20606 Cylinder gauge set 09900-20508 Dial gauge chuck 09900-20701 Thickness gauge 09900-20803 Torque wrench 50- 450 kg-em: 09900-21101 100-900 kg-em: 09900-21103 500-2,800 kg-em: 09900-21104 Steel "V" block set Small ... . _.... 75 mm: 09900-21303 Large ,_,_,_,_, 100 mm: 09900-21304 Pocket tester 09900-25002

Engine tachometer (Analogue type) 09900-26003 Engine tachometer (Digital type) 09900-26005 Timing light (12V battery-operated) 09900-27301 Timing light (Dry-cell-operated) 09900-27311 GENERAL INFORMATION 9 Electro-tester 09900-28106 SUZUKI converter 09900-28603 Stud bolt installing tool 6 mm: 09910-10110 8 mm: 09910-10710 10 mm: 09910-11510 Oil seal remover 09913-50121 Bearing and oil seal installer 09914-79610 Outboard test wheel 09914-79850 Shifter lock pin remover 09922-89810 Flywheel rotor remover 09930-30713

to GENERALINFORMATION Flywheel rotor holder 09930-40113 CDI test cord 09930-89830 09930-99810 Oil leakage tester Go===:::::::=::t:::l Q) 09950-69511 ® 09821-00004 Gear adjusting gauge 09951-09510

GENERAL INFORMATION 11 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 OIL SUZUKI CCI OIL [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 0.5 L -050 99000-21640 1.0 L -100 (SHELL SEKIVU) 1.0 L 99000-21250 (NIPPON OIL) 99000-21260 4.0 L 99000-21270 200L

12 GENERAL INFORMATION ENGINE COVER, RECOIL STARTER, ROTOR, CARBURETOR, CRANKSHAFT, CYLINDER, FUEL PUMP /'>I-f}~ /o;-'":ll.~ / ..... (!)'Y ~ ·' :~~l • . . • Fig. 1-2 NOTE: Wipe off iron dust 1 oil, etc. using a cloth dipped with thinner. ·· ... - . .:-

1985-1998 Suzuki DT4 2-Stroke Outboard Service & Repair Manual

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