Suzuki 50-85HP outboard motors Service Manual

SERVICE MANUAL
Suzuki DT50, DT60 & DT65 (Prior to 1985)
SUZU KI DT50, DT60 AN 0 DT65
(Prior to 1985)
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
TUNE·UP
Hp/rpm:
DT50 ."." .............. " ....... " .50/4801)..5500
DT60 .... """,, ..... " . " . " ....... 60/4800·5500
DT65 .. " .... " ...................... 65/4800·5500
Bore:
DT50 (Prior to 1984) ......................... 80mm
(3.15 in.)
DT50 (1984), DT60 & DT65 .................... 84 mm
(3.31 in.)
Stroke ...................................... 72mm
(2.83 in.)
Number of Cylinders ............................... 2
Displacement:
DT50 (Prior to 1984) .......................... 723 cc
(44.12 cu. in.)
DT50 (1984), DT60 & DTS5 .................... 798 cc
(48.69 cu. in.)
Spark Plug;
:>rGK ..... " ............................... B8HS'
Electrode Gap ............. " ............ 0.8-0.9 mm
(0.031·0.035 in.)
Ignition 1)'P" ............................ Breakerless
Carburetor:
Make ...................................... Mikuni
Model ..................................... B40·32
Fuel:Oil Ratio ........ " ....................... 50;1 t
'1984 DT50 models use NGK B8HS·1O spark plugs with an
electrode gap of 1 mm (0.040 in.).
t1984 DT50 and 1983 and 1984 DT60 models are equipped
with oil injection.
SIZES-CLEARANCES
Piston Riug End Gap ....................... 0.2·0.4 mm
(0.008-0.016 in.)
Piston Pin Diameter ................. 19.995·20.oo0mm
(0.7872·0.7874 in.)
Piston to Cylinder Wall Clearance:
DT50 (Prior to 1984) .................. 0.097·0.112 mm
(0.0038·0.0044 in.)
DT50(1984),DT60&DT65 ............ 0.112·0.127 mm
(0.0044-0.0050 in.)
Max. Cranksbaft Runout at Main
Bearing Journal ........................... 0.05mm
(0.002 in.)
Max. Connecting Rod Small End
Side Shake ................................. S.Omm
(0.20 in.)
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TIGHTENING TORQUES
Cylinder Head:
6mm ............... _.......... " _...... 8·12N-m
(6·9 ft.·lbs.)
10mm ............................... AO·60N-mt
(29-44 ftAbs.)
Crankcase .............................. .40·60 N -mt
(29-44 ft.·lbs.)
ExhaustCover ............................. 8·12N·m
.
(6-9 fUbs.)
FlywheelNut ........................... 200·210N·m
(145·152 ft.·lbs.)
GearcasePinionNut ....................... 31)..40 N'm
(22-29 ft.·lbs.)
Propeller Shaft Nut ........................ 50·60 N· m
(36-44 ft.·lbs.)
Standard Screws:
Unmarked or Marked "4"'
5mm ................................... 2·4N·m
(2·3 ft.·lbs.)
6mm ................................... 4·7N·m
(3·5 ft.·lbs.)
8mrn ................................. lO·16N-m
(7·12 ft.·lbs.)
10mm ................................ 22·35N"m
(16·26 ft.·lbs.)
Stainless Steel
5mm ................................... 2·4N·m
(2·3 ft.·lbs.)
6mm .................................. 6·ION-m
(6-7 ft.·lbs.)
gmm ................................. 15·20N-m
(11·15 ft. ·lbs.)
lOmm ................................ 34·41N·m
(25·30 ft. ·lbs.)
Marked "7" or SAE Grade 5
Omm ................................... 3·6N·m
(2·5 ft.·lbs.)
6mm .................................. g·12N·m
(6·9 ft.·lbs.)
8mm ................................. 18·28N·m
(13·20 ft.·lbs.)
10mm .................... '" ......... 40-60N·m
(29-44 ftAbs.)
tTorque values should be 46·54 N • m (34·39 ft. ·lbs.) on DT50
(1984) and DT60 models.
I
Suzuki OT50, OT60 & OT65 (Prior to 1985)
OUTBOARD MOTOR
LUBRICATION
The power head is lubricated by oil
mixed with the fuel. On models with·
t
out oil it\iection! fuel:oH ratios should
be 30:1 during break-in of a new or
A
rebuilt engine and 50:1 for normal servo
ice when using a NMMA certified TCWII two-stroke engine
on
or Suzuki
"CCI" oiL When using any other type
of two-stroke engine oil, fuel:oil ratios
should be 20:1 during break-in and 30:1
for nonnal 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"
oil or a NMMA certified TO-Wll twostrokE' 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 recommends regular or no-lead automotive
gasoline having an 85·95 octane rating.
Gasoline and oil should be thoroughly
mixed in fuel tank when u.'ied on models
without oil injection and when used
during break-in period on models
equipped with oil injection.
The lower unit gears and bearings are
lubricated by oil contained in the gear·
case. SAE 90 hypoid outboard gear oil
14·--4K
15
Fig. SZ14·1-ExpIoded view of Mlkuni cal'bur.
tors fyl1ical of ,,11 models.
1. Body
2. Throttle stop serew
3. Spri.'lg
4. PilotjM
5. ThroW", llhaft
connector
6, Choke shaft <:OClneetol'
7. r'-IPt air screw this Manual
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lL Spring
9. Main nouIe
10. Main jet
11, lnkt valve
12. Float pin
13.. FIQ8,t
14. Gasket
15. Fknit bow!
Fig. $%14-2-1«,.,., to htd tOt float
,pec#flc.Uoos,
LNセ@
lA>
should be used. Gearcase capacity is ap·
proximately 650 mL (22 oz.) of gear oil
and should be drained and refilled after
the first 10 hours of use and then after
every 50 hours of liSe. Reinstall vent and
fill plugs securely. using a new gasket if
needed, w ensure a watertight seal.
FUEL SYSTEM
CARBURETOR. Mikuni type B40-32
carburewrs are used on all models.
Refer w Fig. SZ14·1 for exploded view.
Initial setting of pilot air screw (7) from
a lightly seated position should be PI,
w 2'/. turns on DT50 models prior w 19l14
and DT65 models and 1'Is to 2'/, turns
on'i984 DT50 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
HbセfゥァN@
SZ14·11) in small incrementa
until engine idles at approximately
650· 700 rpm. Adjust pilot air screw so
engine idles smoothly and will accelerate
cleanly without hesitation. If neeessary,
readjust timing adjustment screw to obtain 650-700 rpm idle speed.
Main fuel metering is controlled by
main 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 models and number 167.5 on
DT65 models.
To cheek float level, remove float bowl
and invert carburetor. Distance (A - Fig.
SZ14·2) between main jet and bottom of
float should be 16.5-18.5 mm (0.65-0.75
in.) on DT50 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 level 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 adjustment at throttle shaft connector
(5-Fig. SZI4-1).
SPEED CONTROL LINKAGE. The
carburetor throttle valves must be oorrectly synchronized to open as the ignition is advanced to obtain optimum performance. To adjust the speed control
linkage, it is necessary to first check
(and adjust if required) the ignition maximum advance as outlined in the IGNI·
TION TIMING section. Disconneet car·
SZl4-l1) and
buretor link HcセfゥァN@
rotate speed control lever (L) toward
maximum speed position until it con·
tacta maximum speed stop. Set carburewr throttle plates completely open
then vary the length of carburetor link
(C) until ball joint connector will just at·
tach. Move speed control lever to full
retard position. Clearance (A) at car·
buretor throttle shaft actuating levers
should be 0.5·1.0 mm (0.020,0.040 in.).
REED VALVES. The inlet reed
valves (Fig. SZI4·3) are located on a
reed plate between inlet manifold and
crankease. The reed petals should seat
very lightly against the reed plate
throughout their entire length with the
least possible tension. 'rip of reed petal
must not stand open more than 0.2 mm
(0.008 in.)from contact surface. Reed
stop opening should be 7.6·8.0 mm
(O.3().O.31 in.) on DT50 models and
7.55·7.95 mm (0.30·0.31 in.) on DT60
and DT65 models.
Renew reeds if petals are broken,
cracked, warped, rusted or bent. Never
attempt w bend a reed petal or to
straighten a damaged reed. Never install a bent or damaged reed. Seating
surface of reed plate should be smooth
e' """"'1
1
6
Fig. SZ1.f..3- Exploftd yl.1M of Int.", nMn1iold
lHld rHd valv. ....mbly.
1. Manifold
4. Reed pet.als
2. Gasket
:'t Reed plate
5. Reed stop
6. Gaskill:
SERVICE MANUAL
Suzuki 0150, 0160 & 0165 (Prior to 1985)
Fig. SZ14.s- Use 011 pump .Ir biNd screw fA) to
bleed trapped air from 011 supply line or pump.
Flo. SZ1..... -lnlet manifold cap SCMW. should
be tightened In the HqU4»lc. shown above.
FUEL PUMP. A diaphragm type fuel
pump is mounted on the side of power
head cylinder block and is actuated by
pressure and vacuum pulsations from
the engine crankcases, Refer to Fig,
SZ14-5 for exploded view of fuel pump
assembly,
When servicing pump, scribe
reference marks aeross pump body to
aid in reassembly, Defective or questionable parts should be renewed, Diaphragm should be renewed if air leaks or
cracks are found, or if deterioration is
evident.
FUEL FILTER. A fuel filter (9
through 13- セQァL@
SZ14-5) 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 ·0" ring (11) if required.
OIL INJECTION
Models So Equipped
BLEEDING PUMP. To bleed
trapped air from oil supply line or pump.
firs! make sure outboard motor is in an
upright position and oil tank is full. Open
oil pump air bleed screw (A - Fig.
SZ14-S) three or four turns to allow oil
to seep out around screw threads, After
five seeouds or when no air bubbles are
noticed, close air bleed screw (A),
CHECKING
OIL PIJMP OUTLET.
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Start engine and allow to warm·up for
2,
3.
4.
5.
Ii.
1.
8.
9.
10.
11.
12.
13.
Fuel filter body
Packing
"0" ring
Filter
Bowl
1. 1Mt
O. OIIt:et
Dlaph""",,
Body
Dmphragrn
SPring
Body
Boセ@
rillgl>
lnsulator bhxk
approximately five minutes, then stop
engine. Disconnect oil pump control
cable (C - Fig, SZI4-7) at carburetor
throttle lever, Detech oil supply line at
oil 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 released position, start engine and ュ。ゥョセ@
taln 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 oil pump at maximum output
position, repeat previous procedure except use a suitable tool and hold oil pump
control cable (C) in fully extended position, Recommended oil consumption is
4,6-5.6 mL (O.16-l),19 oz,) in five minutes
at 1500 rpm,
If the obtained oil consumption
measurements are not within the recommended limite. 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 iguition coils are used on models with an
independent ignition system, Simultaneous ignition models may have
mechanical or electronic advance, Stator
plate is movable on simultaneous ignition models with mechanical advance
iセGMl@
セ」@
I[
L
'L.I
S,\ \
<"'\
\\
<;
\
,
ZLセ@
@I
Fig_ SZ14-1-11lsconn.ct 011 pump conftol c.ble
(e) at carburetor thrQttle lev., and ,eler to fe.t
for checking 011 pump output
while the stator plate is fIxed on models
with electronic advance. Refer to Fig,
SZ14-8 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
he 4· ATDC at 1000 rpm and 21 0 BTDC
on DT60 models and 25° BTDC on all
other models at 5000 rpm. On
simultaneous ignition models with
mechanical advance, ignition timing
should he 3° ATDC at 1000 rpm and 25°
BTDC at 5000 rpm, On simultaneous ignition models with electronic advance
(fixed stator plate), ignition timing
should be go BTDC at 1000 rpm and 25°
BTDC at 5000 rpm,
Iuitial setting of ignition timing on all
models with mechanical advance may be
accomplished as follows: Set throttle at
full advanL'C position, then align mark
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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 ill Fig, SZ14-4 tighten cap
screws,
Fig. SZ14-S-Exploftd vSew of diaphragm type
'"*1 pump and fuel flit., assemblies.
1. Cnwr
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