Suzuki Outboard Service and Repair Manual

This Clymer outboard shop manual covers Mariner 2-225 horsepower engines for the years 1985-1991 and includes Jet Drives.

Models Included are:
SUZUKI DT 100 (DT100)
SUZUKI DT 100 SUPER FOUR (DT100)
SUZUKI DT 115 (DT115)
SUZUKI DT 140 (DT140)
SUZUKI DT 15 (DT15)
SUZUKI DT 150 (DT150)
SUZUKI DT 150 SUPER SIX (DT150)
SUZUKI DT 175 (DT175)
SUZUKI DT 2 (DT2)
SUZUKI DT 20 (DT20)
SUZUKI DT 200 (DT200)
SUZUKI DT 200 EXANTE (DT200)
SUZUKI DT 225 (DT225)
SUZUKI DT 25 (DT25)
SUZUKI DT 30 (DT30)
SUZUKI DT 35 (DT35)
SUZUKI DT 4 (DT4)
SUZUKI DT 40 (DT40)
SUZUKI DT 55 (DT55)
SUZUKI DT 6 (DT6)
SUZUKI DT 65 (DT65)
SUZUKI DT 75 (DT75)
SUZUKI DT 8 (DT8)
SUZUKI DT 8 SAIL (DT8)
SUZUKI DT 85 (DT85)
SUZUKI DT 9.9 (DT9.9)
SUZUKI DT 9.9 SAIL (DT9.9)
SUZUKI DT 90 (DT90)

The Suzuki outboard manual by Clymer is a great  reference for repair and service information. This service manual is written for the do-it-yourselfer as well as the experienced mechanic.  The repair manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the engine. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail.  The shop manual will guide mechanics and owners through each service, troubleshooting and repair procedure possible.

---

The Suzuki outboard manual includes the following chapter information:

CHAPTER ONE | GENERAL INFORMATION
Manual organization | Notes, cautions and warnings | Torque specifications | Engine operation | Fasteners | Lubricants | Gasket sealant | Galvanic corrosion | Protection from galvanic corrosion | Propellers

CHAPTER TWO | TOOLS AND TECHNIQUES

CHAPTER THREE | TROUBLESHOOTING
Operating requirements | Starting system | Lighting system | Charging system | Ignition system | Breaker-point ignition component testing (1985-1989 DT 2) | Transistorized ignition system (1990-on DT 2) | Pointless electronic ignition (PEI) component testing | Integrated circuit (IC) and Micro Link ignition systems | Fuel system (carbureted models) | Engine temperature and overheating | Engine

CHAPTER FOUR | LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication | Storage | Complete submersion | Anti-corrosion maintenance | Galvanic protection and bonding wires | Engine flushing | Tune-up

CHAPTER FIVE | TIMING, SYNCHRONIZATION AND ADJUSTMENT
Engine timing and synchronization | Timing adjustment | Throttle adjustment | Throttle valve sensor adjustment | DT 225 EFI

CHAPTER SIX | FUEL SYSTEM
Loss of high speed rpm (all DT 15) | Off idle lean conditions (1988 DT 30 and 1989 DT 65) | Fuel pump and filter | Carburetor removal|installation | Carburetor overhaul|adjustment | Throttle plunger carburetor (DT 2) | Centerbowl carburetor (DT 4, DT 6; 1985-1987 DT 8) | Integral fuel pump carburetor (1988-on DT 8; 1985-on DT 9.9, DT 15) | Centerbowl single -throat carburetor (DT 20 through DT 85; DT115, DT140) | Centerbowl dual-throat carburetor (V4 and V6) | Carburetor cleaning and inspection | Reed valve assembly | Fuel tank | Fuel line, connector and primer bulb | Fuel injection system (DT 225 V6)

CHAPTER SEVEN | ELECTRICAL SYSTEMS
Electrical connectors | Battery | Lighting system (1985-1986 DT 9.9, DT 15, DT 40) | Battery charging system | Electric starting systems | Starter motor | Magneto breaker point ignition (1985-1989 DT 2) | Breakerless transistorized ignition (1990-on DT 2) | PEI ignition | Integrated circuit (I.C.) ignition system | Micro Link ignition system (V4 and V6) | Ignition coil (all models) | CDI unit (all models)

CHAPTER EIGHT | POWER HEAD
Engine serial number | Fasteners and torque | Flywheel | Power head

CHAPTER NINE | GEARCASE
Propeller | Water pump | Gearcase | Propeller shaft clutch | Pinion gear depth and forward|reverse gear backlash | Pinion gear adjustment (1986-on DT 115, DT 140; V4 and V6) | Propeller shaft end play (DT 8 through DT 65 models only) | Clutch pushrod dimension

CHAPTER TEN | AUTOMATIC REWIND STARTERS
Bendix starter | Overhead starter | Adjustment

CHAPTER ELEVEN | POWER TRIM AND TILT SYSTEM
Hydraulic pump | Troubleshooting | Pump oil pressure test | Component replacement

CHAPTER TWELVE | OIL INJECTION SYSTEM
System components | Operation | Low oil level warning light and buzzer | Oil flow sensor | Air|oil mixing valve | Oil pump service | Component replacement

CHAPTER THIRTEEN | JET DRIVES
Maintenance | Water pump | Jet drive | Bearing housing | Intake housing liner

INDEX

WIRING DIAGRAMS

---

Publisher: Clymer Manuals — 1992
Author: Ed Scott
Binding: Paperback — 8¼ x 10¾ inches
Pages: 628 — Hundreds of b&w photos and illustrations
ISBN: 0892875569

---

The Suzuki outboard service and repair manual applies to the following years:
1985, 1986, 1987, 1988, 1989, 1990, 1991

---