Suzuki 50-85HP outboard motors Service Manual
Contents
1. 0 097 0 112 mm 0 0038 0 0044 in DT50 1984 DT60 amp DT65 0 02 00 0 112 0 127 mm 0 0044 0 0050 in Max Crankshaft Runout at Main Bearing Journal ccecvcsvssscaeeevevens 0 05 mm 0 002 in Max Connecting Rod Small End Side SHAKE s sreriseerrd teini eetnsedeueennsy 5 0 mm Download this Manual 9 20 n TIGHTENING TORQUES Cylinder Head OM 6 40 ona ox Re eee eee 8 12 N m 6 9 ft Ibs 3 TUMM Gyn aes 54 5 os eee ee buses bas 40 60 N mt 29 44 ft lbs Crankecase sesoraevrasarsereresesrev gt 40 60 Nemt 29 44 ft Ibs Exhaust Cover 0 0 ccc eee cee rece eees 8 12 Nem 6 9 ft Ibs Fiywheel Nut oi2s93454 6404or be vecaw ees es 200 210 N m 145 152 ft lbs Gearcase Pinion Nut 2 0 0 00 e cee eae 30 40 Nm 22 29 ft lbs Propeller Shaft Nut 2 0 0 0 0 0c ce eee enact 50 60 N m 86 44 ft Ibs Standard Screws Unmarked or Marked 4 DMN Eas 6 ats ech peed E GOS hae ea es 8 2 4 Nem 2 3 ft lbs GNU os besten ee ecw ends E ehns 4 7 Nem 3 5 ft lbs I sa eo oe E eee ees 10 16 Nem 7 12 ft lbs TAP Wik a ew eco ee eee owe 22 35 Nem 16 26 ft Ibs Stainless Steel El EEEE es Geek ewe eh eon ee 2 4N m 2 8 ft lbs i eu ee alee doe ew erase se eee chaues 6 10 Nem 5 7 ft lbs BiG ox en5 evan ease eae ae eee eae 15 20 N m 11 15 ft lbs ROSA coy od dunia cee cee ah eweeas otek 34 41 Nem 25 30 ft lbs Marked 7 or SAE Grade 5 DIO ceceeeeees 1saue sees eseeen ies anee2. SAE 90 hypoid outboard gear oil Fig 8714 1 Exploded view of Mikuni carbure tors tyvical of aii models R Spring 3 Main nozzle Spring id Main jet Pilot jel 1i inlet valve Throttle shaft 12 Float pin connector 13 Float 1 2 3 4 5 5 Choke shaft couneetor 14 Gasket D this Manual 15 Flost bow Fig SZ14 2 Rafer te teat for toat level A specifications should be used Gearcase capacity is ap proximately 650 mL 22 oz of gear ail and should be drained and refilled after the first 10 hours of use and then after every 50 hours of use Reinstall vent and fill plugs securely using a new gasket if needed to ensure a watertight seal FUEL SYSTEM CARBURETOR Mikuni type B40 32 carburetors are used on all models Refer to Fig 8214 1 for exploded view Initial setting of pilet air screw 7 from a lightly seated position should be 1 te 2 turns on DTS0 models prior to 1984 and DT65 models and 15 te 2 turns on 1984 DTS0 models and DT60 models Final carburtetor adjustment should be made with engine at normal operating temperature and running in forward gear Rotate timing adjustment screw B Fig Z14 11 in small increments until engine idles at approximately 650 700 rpm Adjust pilot air serew so engine idles smoothly and will aecelerate cleanly without hesitation If necessary readjust timing adjustment screw to ob tain 650 700 rpm idle speed Main fuel metering is controlled by main
3. buretor throttle shaft actuating levers should be 0 5 1 0 mm 0 020 0 040 in REED VALVES The imlet reed valves Fig 8214 3 are located on a reed plate between inlet manifold and crankcase The reed petals should seat very lightly against the reed plate throughout their entire length with the least possible tension Tip of reed petal must not stand open more than 0 2 mm 0 008 im from contact surface Reed stop opening should be 7 8 8 0 mm 0 30 0 31 in on DT50 models and 7 56 7 95 mm 0 30 0 31 in on DT60 and DT 5 models Renew reeds if petals are broken cracked warped rusted or bent Never attempt to bend a reed petal or to straighten a damaged reed Never in stail a bent or damaged reed Seating surface of reed plate should be smooth Fig 214 3 Exploded view of intake manifoid and reed vaive assembly 1 Manifold 4 Reed petals Gasket 5 Res stop 3 Reed piate 6 Gasket SERVICE MANUAL Fig S2144 inlet meniteid cap screws should be tightened in the sequence shawn aboye and flat When installing reeds or reed stop make sure that petals are centered over the inlet holes in reed plate and that the reed stops are centered over reed petals Apply a suitable high temperature grease to inlet manifold cap screw threads then using sequence shown in Fig SZI4 4 tighten cap acrews FUEL PUMP A diaphragm type fuel pump is mounted on the side of power head cylinder block and is actuated by pressure
4. SERVICE MANUAL Suzuki DT50 DT60 amp DT65 Prior to 1985 SUZUKI DT50 DT60 AND DT65 Prior to 1985 CONDENSED SERVICE DATA NOTE Metric fasteners are used throughout outboard motor TUNE UP Hp rpm DBO pape ee ier ere eeacaeanseeeehuraers 50 4800 5506 DVO e563 EEE E EE 60 4800 5500 Bik EEEIEE TETTE EE E E E ER 65 4800 5500 Bore DTO Prior to 1984 0 e cece ese c aes eraren 80 mm 3 15 in DT50 1984 DT60 amp DTS eee 84 mm 8 31 in na gig cdensiaets pel E cor eaeees anaes ss 72mm 2 83 in 2 Number of Cylinders 0 2 0 0 0 0 c cence erences Displacement DT50 Prior to 1984 2 6 4 esac cake ases cen siis 7123 ce 44 12 cu in DT50 1984 DT60 amp DT65 22 ee 798 ce 48 89 cu ind Spark Plug a E OTE sae eeeee ones eceeers B8HS Electrode Gap 6 6 eee 0 8 0 9 mm 0 031 0 085 in TENOR TYPE ons kak one 90e eset needs Breakerless Carburetor NMaleiccedacouene cs wae eee aceon e ese eee aed Mikuni MOBO cit perce techs TEETER TETEE TTT B40 82 PCV Rat s40ciet cals eak Canon aoa aaa dens ous 50 17 1984 DT50 models use NGK B8HS 16 spark plugs with an electrode gap of 1 mm 0 040 in 71984 DT50 and 1988 and 1984 DT60 models are equipped with oi injection SIZES CLEARANCES Piston Ring End Gap 00 0020 cee eee 0 2 0 4 mm 0 008 0 016 in Piston Pin Diameter 00 00 gt 19 995 20 006 mm 0 7872 0 7874 in Piston to Cylinder Wall Clearance DT50 Prior to 1984 00 0 00 0000
5. and vacuum pulsations from the engine crankeases Refer to Fig 214 5 for exploded view of fuel pump assembly When servicing pump scribe reference marks across pump body to aid in reassembly Defective or ques tionable parts should be renewed Dia phragm should be renewed if air leaks or cracks are found or if deterioration is evident FUEL FILTER A fuel filter 9 through 18 Fig Z14 5 is mounted on the side of power head cylinder block on all models Filter should be disassembled and cleaned after every 50 hours of use Renew O ring 11 if required OIL INJECTION Models So Equipped BLEEDING PUMP To bleed trapped air from oil supply line or pump first make sure outhoard motor is in an upright position and oil tank is full Open oil pump air bleed serew A Fig Zi4 6 three or four turns to allow oil to seep out around screw threads After five seconds or when no air bubbles are noticed close air bleed screw A Do PERO SRW warm up for Suzuki DT50 DT60 amp DT65 Prior to 1985 Fig Z14 5 Exploded view of diaphragm type fuel pump and fuel Hiter assemblies f Cover Ae inii Fuel filter body B y 16 Packing 4 Diaphragm ii O ring amp Spring 12 Filter 6 Body 13 Bowl 7 O rings _ L inket amp Insuinter biock amp Gutiet approximately five minutes then stop engine Disconnect oil pump control cable C Fig 8214 7 at carburetor throttle lever Detach oil suppl
6. jet 10 Standard main jet size for normal operation is number 165 on DT50 models prior to 1984 number 155 on 1984 DT50 models number 160 on DT60 modelis and number 167 5 on DT65 models To check float level remove float bow and invert carburetor Distance A Fig 8214 2 between main jet and bottom of float should be 16 5 18 5 mm 0 65 0 75 in on DT6 amp 0 models prior to 1984 and DT65 models 16 5 18 mm 0 65 0 71 in on 1984 DT50 models and 16 18 mm 0 63 0 71 in on DT60 models Adjust float ievel by bending float tang To synchronize throttle plate opening of top carburetor with bottom car buretor use Suzuki carburetor balancer 09913 13121 or equivalent and make ad justment at throttle shaft connector 5 Fig Z14 1 OUTBOARD MOTOR SPEED CONTROL LINKAGE The carburetor throttle valves must be cor rectly synchronized to open as the igni tion is advanced to obtain optimum per formance To adjust the speed control linkage it is necessary to first check and adjust if required the ignition max imum advance as outlined in the IGNI TION TIMING section Disconnect car buretor link C Fig 5214 11 and rotate speed control lever L toward maximum speed position until it con tacts maximum speed stop Set gar buretor thratile plates completely open then vary the length of carburetor link C until bail joint connector will just at tach Move speed contro lever to full retard position Clearance A at car
7. ss 8 6 Nem 2 5 it ibs 2111 a ee ee 8 12 Nem 6 9 ft lbs A yee cee oe ees eee ees 18 28 Nem 13 20 ft Ibs POY oi os wae oe ed os ak hee ben seen 40 60 N m 29 44 ft lbs Torque values should be 46 54 N m 34 39 ft Ibs on DTS0 1984 and DT6O models Suzuki DT50 DT60 amp DT65 Prior to 1935 LUBRICATION The power head is lubricated by oil mixed with the fuel On modeis with out oil injection fuel oil ratios should be 30 1 during break in of a new or rebuilt engine and 50 1 for normal serv ice when using a NMMA certified TC Wil two stroke engine oil or Suzuki CCT ail When using any other type of two stroke engine oll fuel oil ratios should be 20 1 during break in and 30 1 for normal service On models equipped with oil injection for the first 5 hours of operation mix fuel with oil in fuel tank at a ratio of 50 1 if Suzuki CCI of or a NMMA certified TC WIL two stroke oil is used Mix fuel oil at a ratio of 30 1 if any other type of two stroke oil is used Switch to straight fuel in fuel tank at the completion of the 5 hour break in period Manufacturer recom miends regular or no lead automotive gasoline having an 85 95 octane rating Gasoline and sil should be thoroughiy mixed in fuel tank when used on madels without oi injection and when used during break in period on models equipped with oil injection The lower unit gears and bearings are lubricated by cil contained in the gear case
8. tronic advance Refer to Fig 5214 8 for a typical wiring diagram of models with independent ignition Models with simultaneous ignition systems are similar IGNITION TIMING On independent ignition models ignition timing should be 4 ATDC at 1060 rpm and 21 BTDC on DT60 models and 25 BTDC on all other models at 5000 rpm On simultaneous ignition models with mechanical advance ignition timing should be 3 ATDC at 1000 rprn and 26 BTDC at 5000 rpm On simultaneous ig nition models with electronic advance fixed stator plate ignition timing should be 8 BTDC at 1060 rpm and 28 BTDC at 5000 rpm Initial setting of ignition timing on all models with mechanical advance may be accomplished as follows Set throttle at full advance position then align mark http SelfFixer com
9. y line at oll tank outlet Connect oil gage 09900 21602 to oil supply line Fill oil gage with a recommended two stroke oil unit even with an upper reference mark With oil pump control cable C in re leased position start engine and main tain engine speed at 1500 rpm Allow engine to run for five minutes After five minutes stop the engine and observe oil gage Recommended oil consumption is 2 7 3 5 mL 0 09 0 12 oz in five minutes at 1500 rpm To check oi pump at maximum output position repeat previous procedure ex cept use a suitable tool and hold oil pump control cable C in fully extended posi tion Recommended oil consumption is 4 6 5 6 mL 0 16 0 19 oz in five minutes at 1500 rpm if the obtained oi consumption measurements are not within the recom mended limits then oil pump must be renewed IGNITION All models are equipped with either an independent or simultaneous pointless electronic ignition system Simultaneous ignition system models are identified by the use of one ignition coil while two ig nition coils are used on models with an independent ignition system Simultane ous ignition models may have mechanical or electronic advance Stator plate is movable on simultaneous igni tion models with mechanical advance Fig 214 7 Disconnect oll pump control cable C at carburetor throttle lever and reter to text for checking off pump output while the stator plate is fixed on models with elec
Download Pdf Manuals
Related Search