Suzuki 2-15HP outboard motors Service Manual
Contents
1. Download this Manual SERVICE MANUAL Suzuki DT2 SUZUKI SUZUKI AMERICA CORPORATION 3251 E imperial Way P O Box 1100 Brea California 92621 SUZUKI DT2 To determine model and year of manufacture of Suzuki outboard motors refer to numbers located on motor clamp bracket The first six characters indicate the model and second six characters are motor serial number The first character of serial number indicates year of manufacture The years 1977 1978 and 1979 are identified by the letters C D and F respectively Starting with 1980 the first number in serial number corresponds with model year For example if first number in serial number is 1 model year is 1981 CONDENSED SERVICE DATA NOTE Metric fasteners are used throughout outboard motor TUNE UP auae eee RE tr ee ee ee eee eee eee eee ETET 2 4500 BOG lt 6cccee ee 856 4 aes eR k Ins DTE ee eS OS 41 0 mm 1 614 in SORG 2 occu encuew momeen even nae memme snaa aa attri OLOL 1 488 in RU a ee 50 ce 3 05 cu in Spark Plug NGK avaemaverce g 5 6 8 ERG 8 8 BOYES ENE S 2G 8 DONE EB ERS BR5HS El CtrOd BaD o scence we een e e mein n ES 0 5 0 6 mm 0 020 0 023 in Magneto Breaker point gap x samma sesa sasa wasan es 0 3 0 4 mm 0 012 0 016 in Carburetor WARE 5 sera cc ce EOE EE EG GS SOS EER O99 6 SORES EE Mikuni PROUG aans mcoeomone weunensavseamievsbidiies VM 11 10 FUEC RAIO so 2 acne conse eee Me eA See Text SIZES CLEARANCES P2. asher 6 Ignition breaker points 3 Key 7 Base plate 4 Flywheel 8 Stop switch SERVICE MANUAL power head and lower unit Pump is lo cated in the gearcase and driven by the propeller shaft Water inlet should be inspected for plugging or partial restriction if cooling system malfunction is noted Refer to Fig SZ1 9 for exploded view of water pump To remove the impeller remove propeller propeller thrust pin and gear case end cap 1 then withdraw the im peller 2 Inspect impeller for cracks or excessive wear or scoring Power head should be separated from drive shaft housing and water passages thorough ly cleaned if large accumulations of for eign material are evident Turn propel ler shaft in a clockwise direction when inserting impeller in pump cavity POWER HEAD REMOVE AND REINSTALL To re move power head remove power head cover fuel tank control panel assembly and carburetor Remove recoil starter assembly flywheel and magneto base plate assembly Unscrew the six cap screws securing power head to drive shaft housing and separate power head from drive shaft housing Before reinstalling power head in spect water inlet and outlet passages in drive shaft housing and remove any for eign material Apply a coat of silicone sealer to mating surfaces of power head and drive shaft housing and install a new gasket Assemble power head on drive shaft housing and tighten retain ing cap screws to 6 10 Nem 53 88 i
3. cyl inder head gasket Align water passage holes in cylinder block with holes in head gasket and install cylinder head Tighten cylinder head bolts in a cross ing pattern to 8 12 N m 6 9 ft lbs Fig SZ1 4 Exploded view of crankcase and cyl inder assembly 1 Crankesase half 3 Cyhnder head 2 Cylinder block 6 Reed petal 3 Dawe 7 Reed stop 4 Head gasket 8 O ring 12 S 11 as 19S j E 3 eget por A 9 te C aes pa SW merd EINN 4 DaD am r a ST LU a a SF as Zs N we f j 11 5 C X 6 i 2 Ss t7 Fig SZ1 5 Exploded view of crankshaft piston and related components On 1988 and later models thrust rings 11 are full circle design 1 Piston rins 7 Bewring 2 Piston 8 Crankpin R Retainer ring n Crankshaft 4 Piston pin 10 Ball hearings 5 Bearing il Thrust rings 6 Connecting rod 12 Crankshaft seals Suzuki DT2 PISTON PIN RINGS AND CYLIN DER The piston is fitted with two pis ton rings Piston ring end gap should be 0 10 0 25 mm 0 004 0 010 in with a maximum allowable ring end gap of 0 60 min 0 024 in Piston rings are retained in position by locating pins Piston to cylinder clearance should be 0 053 0 060 mm 0 0021 0 0024 in Pistons and rings are available in standard size as well as 0 25 mm 0 010 and 0 50 mm 0 020 in oversize Cylinder should be bored to an oversize if cylinder is out of round or taper exceeds 0 10 mm 0 004 in In
4. e 20 1 during break in and 30 1 for normal service Manufac turer recommends regular or unleaded automotive gasoline having an 85 95 oc tane rating Gasoline and oil should be thoroughly mixed The lower unit gears and bearings are lubricated with SAE 90 hypoid outboard gear oil Lower unit capacity on models prior to 1987 is approximately 40 mL 1 3 oz Oil capacity on later models is ap proximately 70 mL 2 4 oz on short drive shaft models and 120 mL 4 1 oz on long drive shaft models On early models prior to 1987 lay motor on side to fill with oil Later models are equipped with a vent oil level check plug on side of gearcase Reinstall plug securely using a new gasket if necessary to ensure a water tight seal FUEL SYSTEM CARBURETOR A Mikuni sliding valve float type carburetor is used Re fer to Fig SZ1 1 for exploded view Idle speed should be adjusted after motor has reached normal operating temper ature Move speed control to slow speed stop and adjust idle speed screw 14 to obtain idle speed of 800 900 rpm Note that on 1987 and later models carbure tor is equipped with a pilot air screw Fig SZ1 2 for low speed mixture ad justment Carburetor with pilot air screw can be identified by the presence of a float bow drain plug Initial setting of pilot air screw is two turns out from a lightly seated position Final adjust ment should be made with engine at operating temperature and running in forward g
5. ear Adjust pilot air screw so engine idles smoothly and accelerates without hesitation Main fuel metering is controlled by main jet 20 Fig SZ1 1 Standard main jet size is 95 for models through 1986 and 90 for 1987 and later models Nor mal position for clip 9 on jet needle 10 is third notch from top of needle lf midrange mixture is too lean or too rich minor fuel mixture adjustment can be accomplished by repositioning clip on jet needle Moving clip down on needle richens fuel mixture while moving clip Dewralaaedlenieand del aixture Fuel filter 17 should be cleaned after eve ry 50 hours of operation To check float level remove float bowl and invert carburetor With float in stalled on float arm 23 float surface nearest main jet should be 19 21 mm 0 748 0 826 in away from carburetor gasket surface Make certain float is lev el with gasket surface when measuring Adjust float level by bending float arm tang When installing carburetor renew O ring 13 as required IGNITION SYSTEM Breaker point gap should be set to 0 3 0 4 mm 0 012 0 016 in at maximum opening Adjustment may be accom plished through holes in flywheel Fly wheel must be removed to renew break er points Tighten flywheel nut to 40 50 N m 30 37 ft lbs OUTBOARD MOTOR After adjusting breaker points check ignition timing using a dial indicator and an ohmmeter or continuity tester Re move the spark plug and inse
6. iston Kingi End Gap ccsss x ve v2 es vo sean 0 10 0 25 mm 0 004 0 010 in Piston to Cylinder Clearance naonana ene nanan amie 0 053 0 060 mm 0 0021 0 0024 in Piston Pin Diameter 11 996 12 000 mm 0 4723 0 4724 in SIZES CLEARANCES CONT Crankshaft Runout at Main Bearing Journal Max seww ags ss uas awaawa 0 03 mm 0 0012 in Connecting Rod Small End Side Shake CART ne mommeses nemana gaa 3 0 mm 0 118 in TIGHTENING TORQUES Cylinder Heat i 4486 KEIJ Raani 8 12 N m 6 9 ft lbs Crankcase 6 ccc x ano 6 poncmom eee ee eraro PAP 8 12 Ne m 6 9 ft lbs D I e eisa nee ee RNR 0 5 0 75 N m 4 5 6 6 in lbs Flywheel NAL os eee 2 sas ewcwu see saysa aoro 40 50 Nem Standard Screws SEU EOE ahd 2 a en ee a oe ek 2 4 Nem 18 36 in lbs NG sae wees os a ee KS oo ee es 4 7 Nem 36 62 in lbs Eni s cc uc eg 4 amp wee SEE 2 48 8 wane ee eK 10 16 N m 89 141 in lbs E n cicsvecss 60 4 6 Xo Hinde ow a4 00 Some 22 35 Nem 195 310 in lbs Suzuki DT2 LUBRICATION The power head is lubricated by oil mixed with the fuel Fuel oil ratio should be 30 1 during break in of a new or rebuilt engine Fuel oil ratio for nor mal service is 50 1 on models prior to 1987 and 100 1 on 1987 and later models Recommended oil is Suzuki Out board Motor Oil or a good quality NMMA certified TC W oil When using any oth er type of two stroke engine oil fuel oil ratios should b
7. n lbs Complete installation by reversing removal procedure DISASSEMBLY Disassembly and in spection may be accomplished in the fol lowing manner Remove cylinder head and clean carbon from combustion chamber and any foreign material ac cumulated in water passages Detach crankcase half 1 Fig SZ1 4 from cyl inder block after removing six crankcase cap screws Crankshaft and piston as sembly may now be removed from cyl inder block REASSEMBLY Refer to specific serv ice sections when assembling crank shaft connecting rod piston and reed valves Make sure all joint and gasket surfaces are clean and free of nicks and burrs Make sure all carbon salt dirt and sand are cleaned from the combus tion chamber exhaust port and water passages On early models place thrust rings 11 Fig SZ1 5 in cylinder block 2 Fig SZ1 4 then install crankshaft assembly On later models thrust rings are full circle design and must be assembled on Downteadriiis Mantalnstalling crank shaft Press crankshaft seals flush against thrust rings Install O ring 8 in cylinder block then apply a suitable water resistant grease to O ring and splined area of crankshaft Apply a suitable sealer to cylinder block and crankcase half mating surfaces and po sition crankcase half on cylinder block Using a crossing pattern tighten six crankcase screws to 8 12 N m 6 9 ft lbs Do not use sealer when installing
8. rt the dial indicator Set piston position at TDC then zero the dial indicator Disconnect the black lead to stop button and con nect the ohmmeter or continuity tester between lead from magneto and ground Rotate the flywheel clockwise until meter or continuity tester indi cates that points have just opened Dial indicator should read 0 804 mm 0 032 in If ignition timing adjustment is re quired remove the flywheel and loos en magneto base plate 7 Fig SZ1 3 re taining screws Rotating base plate clockwise retards ignition timing while rotating counterclockwise advances ig nition timing COOLING SYSTEM WATER PUMP A rubber impeller type water pump is used to cool the Fig SZ1 1 Exploded view of carburetor used on models prior to 1987 On 1987 and later modeis carburetor is equipped with a pilot air screw Fig SZ1 2 for low speed mixture adjustment l Speed control assy 13 O ring 2 Cap nut l Idle speed screw 3 Spring 15 Spring 4 Tube 16 Choke assy 5 Clip 17 Fuel filter fi Spring seat 18 Fuel intet valve 7 Seat pin 19 Main nozzle 8 Throttle rod 20 Main jet 8 Clip 21 Float 10 Jet needle 22 Float bow Li Throttle valve 23 Float arm 12 Body 24 Pivot pin Fig SZ1 2 Iinitial setting of pilot air screw on models so equipped Is two turns out from a light ly seated position a Lee Fig SZ1 3 Exploded view of magneto I Nut 5 Ignition coil 2 Lockw
9. stall piston on connecting rod so arrow on piston crown will point toward exhaust port CONNECTING ROD BEARINGS AND CRANKSHAFT Connecting rod bearings and crankshaft are a press to gether unit Crankshaft should be dis assembled ONLY by experienced serv ice personne using appropriate service equipment Caged roller bearings are used at both large and small ends of the connecting rod Determine rod bearing wear from side to side as shown in Fig SZ1 6 Nor mal side to side movement is 3 0 mm 0 118 in or less Maximum limit of crankshaft runout is 0 03 mm 0 0012 in measured at bearing surfaces with crankshaft ends supported Apply a suitable high temperature grease to lip area of crankshaft seals and install seals on crankshaft with open side toward bearings REED VALVE The reed valve is lo cated on the inside of crankcase 1 Fig SZ1 4 Power head must be removed and crankcase separated from cylinder block as outlined in the POWER HEAD section to service reed valve assembly Renew reed 6 if petals are broken cracked warped or rusted Tip of reed petal must not stand open in excess of 0 2 nim 0 008 in from contact surface Reed stop opening should be 4 0 mm 0 160 in Reed petal should be in Fig SZ1 6 Move connecting rod small end side to side as shown to determine rod bearing and crankpin wear Refer to text http SelfFixer com
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