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Service Manual Application: Suzuki Workshop Service Manual DT 2 THRU 225 HP 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 DT Outboard Engines.

This workshop service repair manual gives step by step information on maintenance, repair and mechanic overhaul. This manual is detailed with hundreds of photos, pictures and illustrations to help guide you through repair procedures. It will help you understand, care for, and lower the repair and maintenance cost for your Suzuki Outboard Engine (motor) for a overall improved satisfaction with your ownership.

MODELS & YEARS COVERED:

DT2 (DT-2) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995 & 1996
DT2.2 (DT-2.2) 1997
DT4 (DT-4) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 & 1998
DT5Y (DT-5-Y) 1998, 1999, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1999, 2000, 2001 & 2002
DT6 ( DT-6) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 & 1997
DT8 (DT-8) 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 & 1997
DT9.9 ( DT-9.9) 1988 thru 1997
DT15 (DT-15) 1988-1989
DT20 (DT-20) 1988
DT25 (DT-25) 1990-1991
DT30 (DT-30) 1989-1997
DT35 (DT-35) 1988-1997
DT40 (DT-40) 1988-1998
DT55 (DT-55) 1988-1997
DT65 (DT-65) 1988-1997
DT75 (DT-75) 1988-1997
DT85 (DT-85) 1988-2000
DT90 (DT-90) 1989-1997
DT100 (DT-100) 1989-1996 & 1996-2001 EFI
DT140 (DT-140) 1988-1996 & 1996-2001 EFI
DT150 (150) 1988-1994 & 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 & 2003 EFI

DT175 (175) 1988-1992
DT200 (200) 1988-1992 & 1993-2000 EFI
DT225 (225) 1990-2003

SUPPLEMENT MANUAL- ADDITIONAL SERVICE DATA FOR 1999 & LATER MODELS (1999+ MODELS) INCLUDING CARBURETOR & IGNITION COIL SPECIFICATIONS.

1999+ DT4/DT5Y
1999+ DT5 DT6 & DT8
1999+ DT25C DT30C (DT25-C, DT30-C)
1999+ DT75 & DT85
1999+ DT100TC
1999+ DT115STC & DT140TC EFI (DT115-STC, DT140-TC)
1999+ DT150 / 175 / 200
1999+ DT225 M

Below is a SMALL sample of some of the chapters including some of the information contained in each chapter. There are many more chapters and data in this manual.

CHAPTERS

GENERAL INFORMATION

How To Use This Manual: can you do it, where to begin, avoiding trouble, maintenance or repair, directions and locations, professional help, purchasing parts, avoiding the most common mistakes.

Boating Saftey: regulations for your boat, documenting of vessels, registration of boats, numbering of vessels, sales and transfers, hull identification number, length of boats, capacity information, certificate of compliance, ventilation & systems, required saftey equipment, sound producing devices and much more.

Saftey In Service: dos & donts.

TOOLS & EQUIPMENT

Tools And Equipment: safety tools, work gloves, eye/ear protection, work clothes, chemicals, lubricants & penetrates, sealants, cleaners.

Tools: hand tools, socket sets, wrenches, pliers, screwdrivers, hammers, other common tools, special tools, electronic tools, gauges, measuring tools, micrometers & Calipers, dial indicators, telescoping gauges, depth gauges.

Fasteners/Measurements & Conversions: bolts, nuts & other threaded retainers, torque, standard and metric measurements.

Specifications Charts: conversion factors

MAINTENANCE

Engine Maintenance: serial number identification, 2-stroke oil, oil recommendations, filling, lower unit, draining & filling, fuel filter, relieving fuel system pressure, removal and installation, fuel/water separator, trim/tilt pivot points, inspection and lubrication, propeller.

Boat Maintenance: inside the boat, fiberglass hulls, trim tabs, adodes and lead wires, battery/cleaning/checking specific gravity/terminals/charging & safety/replacing battery cables.

Tune-UP: introduction, tune-up sequence, compression check, checking compression, low compression, spark plugs, spark plug heat range, spark plug service, removal and installation, spark plug gap, spark plug wires, timing and synchronization, DT2 (DT2.2) ignition timing, idle speed, DT4, DT6, DT9.9 and DT15, DT-15.

FUEL SYSTEM

Fuel and Combustion: fuel recommendations, octane rating, vapor pressure and additives, the bottom line with fuels, high altitude operation, alcohol blended fuels, abnormal combustion, factors affecting combustion.

Fuel System: carburetion, general information, carburetor circuits, basic functions, dual throat carburetors, removing fuel from the system, fuel pump.

Troubleshooting: fuel system, logical troubleshooting, common problems, fuel pump, fuel line, common broblems, combustion related piston failures.

Carburetor Service: DT2 & DT-2.2, removal, installation, disassembly, cleaning, inspection, assembly, DT4 & DT5Y, DT6 (DT-6) and 1988 DT8 (DT-8), DT20 (DT-20) to DT85, DT115 (DT-115), DT140 ( DT-140), V4 & V6 powerheads, DT4 THRU DT85, DT90 Thru DT200.

IGNITION & ELECTRICAL

Understanding and Troubleshooting Electrical Systems: basic electrical theory, how electricity works, water analogy, ohms, electrical components, power source, ground, protective devices, swithes & relays, load, wiring & harnesses, connectors, test equipment, jumper wired, test lights, open circuits, short circuits, wire and connector repair, electrical system precautions and much more.

Breaker Points Ignition (MAGNETO IGINITION): system testing, breaker points, point gap adjustment testing, condenser, ignition coil testing/removal/installation and much more.

Capacitor Discharge Ignition CDI System: description and operation, single cylinder ignition, Suzuki PEI ignition, System testing procedure, pulsar, charging gear counter coils, ignition coils, CDI unit and more.

OIL INJECTION

Oil Injection System: description and operation, oil pump, air/oil mixing valve, troubleshooting the oil injection system, bleeding the oil injection system, oil tank, oil pump, oil lines, oil pump discharge rate testing & adjustment, oil pump control rod adjustment.

Cooling System: water pump, thermostat, removal, installation, cleaning, inspection.

Oil Injection warning System: Low oil level, oil flow, troubleshooting the oil injection warning system, oil level sensor, oil flow sensor.

Overheat Warning System: overheat sensor, testing, removal, installation, light, buzzer.

POWER HEAD

Engine Mechanical: the two stroke cycle, flywheel removal, installation, inspection, powerhead, disassembly & assembly.
Powerhead Reconditioning: determine powerhead condition, primary compression test, secondary compression, buy or rebuild, powerheand overhaul tips, tools, cautions, cleaning, reaping damaged threads, power head preparation, cylinder block and head, general information, inspection, cylinder bores, pistons, piston pins, piston rings, connecting rods, the crankshaft, bearings.

Specifications Charts: Torque Specs, engine rebuilding specs & specifications.

LOWER UNIT

Lower Unit: general information, shifting principles, standard rotating unit, counter roatating unit, troubleshooting the lower unit, propeller removal & installation, lower unit, no reverse gear, lower unit with reverse gear.

Lower Unit Overhaul includes disassembly, cleaning, inspection, assembly, shimming procedure: DT4, DT5Y, DT6, DT8, DT9.9, DT15, DT20, DT25, DT30, DT35, DT40, DT55, DT65, DT75, DT85, DT115, DT140, V4 & V6, JET Drive

TRIM & TILT

Manual tilt, gas assist tilt, power tilt, power trim tilt and more.

Suzuki Workshop Service Manual, Owners Workshop Manual, Repair Guide, Repair Manual, 2hp, 2.2hp, 4hp, 5hp, 6hp, 8hp, 9.9hp, 15hp, 20hp, 25hp, 30hp, 35hp, 40hp, 55hp, 65hp, 75hp, 85hp, DT-90hp, 100hp, 140hp, 150hp, 175hp, 200 hp, 225hp, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 00, 01, 02, 03