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1. Suzuki DT90 & DT100 OUTBOARD MOTOR
SUZUKI
DT90 AND DT100
CONDENSED SERVICE DATA
NOTE: Metric fasteners nre used throughout outboard motor.
TUNE-UP
IIp/rpm:
DT90 ... . .. . .... . . .. . . . ... .. . . ..... 90/5000-5600
DTlOO . . .. . . . .. . . . .... 100/5000-5600
Bore . ......... . . . . . . ............... 84 mm
Stroke
(:3.31 in.)
. . . ....... 64 mm
(2.52 in.)
.. .. . . ..... ... ... .4Number of Cylinders .
Displacement . .. .... 1419 cc
(86.6 cu. in.)
. .. ... .. . .......... NGK BRSIIS-IO
.O.!H.O mm
(0.035·0.0:39 in.)
.Suzuki Microlink
. ... .Mikuni
Spark Plug
Electrode Gap.
Ignition Type
Carburetor Make
SIZES-CLEARANCES
Piston Ring End Gap:
Standard ....
Wear Limit
Standard Piston Diameter
.0.20-0.40 mm
(0.008-0.016 in.)
... . . ............ .0.80 mm
(0.031 in.)
.83.865·8:3.880 mm
(3.3018-:3.:3024 in .)
Standard Cylinder Diameter . ..... .. 84.000-84.015 mm
(:3.:3071-3.3077 in.)
Piston·to-Cylinder Clearance:
Standard. . . . .. .. ... . ... 0.12-0.15 mm
Wear Limit ..
Piston Pin Diameter:
Standard
Wear Limit ..
Piston Pin Bore Diameter:
Standard .....
Wear Limit ...
(0.005-0.006 in.)
. .. 0.22 mm
(0.0087 in.)
. 19.9%-20.000 mm
(0.7872-0.7874 in.)
.. .. 19.980 mm
(0.7866 in.)
.. .20.002·20.010 mm
(0.787,5-0.7878 in.)
..... . .. 20.030 mm
(0.7886 in.)
Max. Allowable Crankshaft Runout at
Main Bearing .Journal ...... .
Max. Allowable Connecting Rod Small
End Side Shake
. .... 0.05 mm
(0.002 in.)
. ...... .5.0 mm
(0.20 in.)
TIGHTENING TORQUES
Cylinder Head Cover: . ... .. ...... ....... 8-12 N'm
Cylinder Head ...... . ... .
Cylinders ...... ... . . . . .. .. . . ..... .
(iI-106 in .-Ibs.)
.... 28-32 N'm
(21-24 ft.-Ibs.)
... 46-54 N'm
(34-40 ft.·lbs.)
Exhaust Cover .. .
Flywheel Nut
...... ... 8-12 N'm
(71-106 in.-Ibs.)
.250-260 N'm
(184-192 ft.-lbs.)
Gearcase Pinion Nut. . . . . . . . . .. . . . . . .. 80-100 N'm
Propeller Shaft Nut
(59-7:3 fUbs.)
. .50-62 N'm
Water Pump Housing ......... .. . . .
(37-45 ft.-Ibs.)
. 15-20 N'm
(11-14 ft.-Ibs.)
Standard Screws:
Unmarked or Marked " 4"
!'imm .... . ...... . ....... 2-4 N'm
(18·:35 in.-Ibs.)
6 mm ..... . ...... . .. . .. .. . .. . . . . ... .4-7N·m
(:35-62 in.-Ibs.)
.... .... 10·16 N'm
(88-141 in.-Ibs.)
8111111 ... . ... • ••.
10 mm .... . .. .... . . . .. ... .. .. . . . . .. 22-35 N'm
(16-25 ft.·lbs.)
Stainless Steel
5 mm .. ... .
6 nun . ..
8 mill ..... .. . . . . . . . . . . . .. . . . . .. .
.2-4 N'm
(18-35 in.-Ibs.)
.6-10 N'm
(5:3-88 in.-lbs.)
..... 15-20 N'm
(11-14 fUbs.)
.... :34-41 N'm
(25-30 ft.-lbs.)
10 mm ........ .
Marked "7":
5 mm
6 mm .
8 mill ....
10 mm .. ... . .
.. ...... 3-6 N'm
(26-5:3 in.-Ibs.)
..... 8-12 N'm
(71-106 in.-Ibs.)
... . .. ... 18-20 N'm
(13·14 fUbs.)
.... .40-60 N'm
(29-44 ft.-Ibs.)
LUBRICATION
The power head is lubricated by oil
mixed with the fu el. All models are
equipped with oil iljection. The recom-
mended oil is Suzuki Outboard Motor Oil
or a suitable equivalent NMMA certified
TC-WII engine oil. The recommended
fuel is unleaded gasoline with a mini-
mum pump oclane rating of 85.
ensure adequate engine lubrication. Af·
ter break-in period, switch to straight
gasoline in the fu el tank.
During break-in (first five hours of op-
eration), a 50; 1 fuel and oil mixture
should be used in the fuel tank in com-
bination with the oil iljection system to
The lower unit gears and bearings are
lubricated by oil contained in the gear-
case. The recommended oil is Suzuki
Outboard Motor Gear Oil or a good qual-

2. SERVICE MANUAL
ity SAE flO hypoid gear lubricalll. Gear-
case capacity is ~GO mL (l8.fl fl. oz.). The
gearca.-;e oil should be changed after the
first to hours of operation and every toO
hours thereafter.
FUEL SYSTEM
CARBURETOR. ~likuni BW:l6-24 car-
buretors are used on Model 011)0 and
Mikuni 3W40-:32 carburetor.; are used on
Model DTIOO. Two carburetor.; are used
on all models. l{efer to Fig. SZ18-1 for ex-
ploded view.
Standard main jet (12) size for normal
service is 111:32.;5 on D1WJ models and
#165 on DTlOO nlOdds. Standard pilotjN
(6) size for normal service is 1190 on m1l0
models and !i77.5 on m'lOO models.
Th check float le'e1, remo'e float bowl
and invert carburetol: Distance (D-Fig.
SZI8-2) between bottom of float: and
float bowl mating surface on carbure·
tor body should be 9.~-ll.ij mm (0.:37-
0.45 in.). Carefully bend rang on float
arm to adjust.
Initial selling of pilot air screw (3-
Fig. SZI8-1) from a lightly seated posi-
tion is I',. to I". turns. Final adjustment
should be pcrfonncd with engine at nor-
mal operating temperature, running in
forward gear. Adjust idle speed switch
(on lower engine cover) to obtain 600-
650 rpm in forward gear. Adjust pilot
screw (3) so engine idles smoothly and
will accelerate cleanly without hesi-
tation.
NOTE: II unabte to obtain 600·650 rpm in
lorward gear, adjust throttle stop screw on
top carburetor as necessary or check adjust·
ment 01 throttle valve sensor (2). ReIer to
IGNITION section.
FUEL PUMP, A diaphragm type fu el
pump is usee!. Fuel pump is mounted on
the power head and is actuated by
crankcase pulsations. I{efer to Fig. SZI8-
4 for an exploded view of pump as-
sembly.
Inspect diaphragms (2 and 4) for
cracking, detelioration or other damage.
Defective or questionable components
should be renewed. Match marks are
provided on cover (I) and body (:1) for
correct alignment during reassembly.
Tighten cover screws evenly in a cross-
ing pattern.
FUEL FILTER. A fuel fill er (Fig.
SZI8-4) is mounted on th.. power head.
Filter should be di!;&isembled to inspect
element (12) every 50 hours of opera-
tion. Clean clement in a suitable sol-
·enl. Renew element of excessive block-
age is noted.
REED VALVES. The inlet reed valves
are located on a V-shaped reed plate be-
tween int,lke manifold and cranke-ase.
Refer to Fig. SZI8·5. The reed petals
should seat very lightly against the reed
plate throughout their entire length
with the le,L<;t possihle tension. Renew
reeds if tip of reed petal stands open
more than 0.2 mm (O.OOS in .) from con-
tact surface. Reed stop opening should
be 10.5 mm (0.413 in.) as shown in Fig.
SZIS-7.
[{enew reeds if petals are broken,
eracked, warped, rllsted or bent. Never
attempt to bend a reed petal or straight-
en a damaged reed. Never install a bent
or damaged reed. Seating s1ll1-ac:e of
reed plate should be smooth and flat.
When installing reeds or reed stop, make
sure that petals are centered over the
inlet ports in reed plate, anti that reed
stops are centered over reed petals. Ap-
ply Suzuki Thread Lock 1:342 ora suita-
ble equivalent thread locking compound
to threads of reed stop screws during
reassembly. Install reed vain! assemblies
i.o intake manifold with alTow embossed
on inside of reed plate (on one end) fac-
ing toward outside of engine.
SPEED CONTROL LINKAGE. '11>
synchronize carburetor throttle valves.
loosen two screws (S-Fjg. SZI8-8) on
top earburetor throttle lever (L). Rotate
lever (L) clockwise until throttle v<llves
are eompletely closed, then retighten
screws (S). Be sure throttle valves open
and dose at exactly the same time. With
remote control in the neutral position,
loosen jam nuts (N-Fig. SZIS-9) and ad-
just lengt.h of rod (I) so a c:icarance of
Fig. SZIS-4-Exploded view
of fuel pump and fuel filter as-
sembly.
I C,I'l'r
:!. 1"}I j)phm~1Il
;j !-)dy
.1. U'iiJ ,h F1.Ijl.1I1
.j SI}l'"i lllol,
,; 11)111''' pbl~'
. , " 0" rinj(
K . ~hl1
~ I W".,ht'r
(I F,hl'r b..",-
11. Pt1ckin"
I:! FIJkr .-,I.·IIwnl
I:l . " 0" rloil.
If CIII'
Suzuki 0190 & 01100
Fig. SZI8-1-Exploded view of carburetors used
on all modelS.
Hood'
Thr;,n k· ';iln:
S('tl.$lI f"
:) Pilot ~·rt.".,
·1. Inll~t '.1' 1' 1: ".':11
I~in
(i . rUt" Jet
I. Jo'U;'l1
k 1I 1~~1 ~I )O!.~,1 "!lui...."
!I lif';."1
ill :1111 j"t 1I"ld';:r
II GiJ..s)WI
I i. ) l:dnJl'b
I:;. fin,-u bllwl
,.1. I.in'c rod
Fig. SZIS·2-Floal height (D) should be 9.5· I 1.5
mm (0.37-0.45 in.). Bend lang on float arm to
ad/usl.

3. Suzuki DT90 & 01100
I mm (OJH in.) is present between throt-
tle lever (.~) and stopper (5) on carbure-
tor. Refer 10 OIL IN.JECTION section for
iqjeLtion pump control linkage ad-
justment.
Fig. SZI8-6-Exploded view of intake manifold
and reed valve Bssemblles.
1 InUtkc rn:inlfold
2. CiiI.S).;.'-l
:3 Hced pau~
10.5mm (0.413 In.)
<1 H('l'd p(-l:,lb
:;. H('('d st(Jp
Fig. SZI8-7-Dls/Mce belween reed slap (5) and
reed plale (3) should be 10.5 mm (0.413 In.) ss
shown. CleafsnC6 between reed petal (4) Bnd reed
plele (3) musl not exceed 0.2 mm (0.008 In.).
R--~
Fig. SZ18-8-Refer to text to synchronize carbu-
retor thronle valves.
To ease engine stalting, ignition lim-
ing is electronically advanced to 5 de-
grees BTDC. The starting ignition ad-
vance duration is 15 seconds when
engine temperature is below 87°-1100 C
(:36°-44° F) and 5 seconds when enb'ine
is warmed to 97°-110° C (3(j0-44° F) or
above. After the initial timing advance
period. idle speed timing is controlled
by thp. idle speed adjustment switch.
The idle speed acljustment switch varies
timing from 7 degrees ATDC (slow) to
TDC (fast), changing idle speed approx-
imately 50 rpm per position.
Full throttle timing should be 2:3 de-
grees BTDC at 5000 rpm and is electron-
ically controlled by the Micro Link pro-
cessor. The processor uses information
from the gear counter coil and the throt-
tle valve sensor to determine the opti-
mum ignition timing for all operating
conditions. Hefer to IGNITION section
for throttle ,·alve sensor acljustment
procedure.
OIL INJECTION
BLEEDING PUMP. Air should be
purged from irjection system any time
an irljection system component has been
removed or renewed, or if outboard mo-
tor has been in storage.
While bleeding the system, a 50:1 fuel
and oil mixture must be used in the fuel
tank to ensure proper engine lubrication
during the bleeding procedure. Open
the air bleed screw (B-Fig. SZIH-Il) two
or three turns. Start engine and run at
MiO-700 rpm until air is no longer noted
at screw (n). Stop engine and tighten
screw (il) securely.
CHECKING OIL PUMP OUTPUT.
Start engine and warm-up for approxi-
mately five minutes. Stop engine. re-
move oil reservoir and disconnect oil
pump control rod (2-Fig. SZIS-Il) from
carbureto!: Connect Suzuki oil measur-
ing cylinder 08!J4HiH7!O to oil pump in-
let hose and fill with a recommended
engine oiL l3Ieed air from system as
previously outlined, then refill oil cyl-
inder to an upper reference mark. Ho-
tate oil pump control lever to the fully
closed (clockwise) position, start engine
and run at 1500 rpm for exactly five
1mm ro.cw in)';~;:~?
OUTBOARD MOTOR
minutes. After five minutes. slop engine
and note oil mea.,uring cylinder. Oil con-
sumption in five minutes at 1500 rpm
should be 2.5-4.5 mL (OJ)H5-0.152 fl. oz.).
Next. refill oil cylinder, rotate oil
pump control lever to the full-open
(counterclockwise) position, start en-
gine and run at 1500 rpm for exactly two
minutes. Stop engine and note oil cyl-
imler. Oil consumption in two minutes
at 1500 rpm should be (j.O-8.0 mL (0.203-
0.:304 fl. oz.). After reconnecting oil
pump control rod to carburetOl; be sure
carburetor throttle valves are properly
synchronized (SPEED CONTHOL LiNK-
AGE) and check acljustment of oil pump
control rod as outlined in PUMP CON-
TROL ROD ADJUSTMENT section.
NOTE: 011 pump output test results may
vary depending on testing error and ambient
temperature. To ensure accurate results, re-
peat test three times, or until results are
consistent.
Renew oil pump assembly (I) if out-
put is not as specified.
Be sure pump is properly engaged
with driven gear (:3) before tightening
fasteners.
OIL FLOW SENSOR. Oililow sensor
(9-Fig. SZIS-II) is connected in-line be-
tween oil reservoir and oil pump. The
oil flow sensor serves as an oil filter as
well a.g a sensor to detect insufficient oil
flow to pump. Should oil flow become
restricted, the sensor circuit closes, sig-
naling the microcomputer to decrea.,e
engine speed and activate the warning
lamp and buzzer.
The sensor filter should be periodical-
ly removed and cleaned in a SUitable sol-
vent. Henew filter if excessive blockage
is noted.
Tb test sensor. connect an ohmmeter
between sensor pinklblue wire and
black wire. No continuity should be
present. Next. plug sensor inlet and ap-
ply a vacuum to the outlet port. Zero
ohms should be noted with vacuum
applied.
PUMP CONTROL ROD ADJUST-
MENT. Make sure carburetor throttle
Fig. SZI8-9-VIew ofthrottle
linkage on all models.
I Link roo
1.. ThTOftl(' ann
3. Curhuret.or
4. Throttle I(''~'r
5. S(t)PrK'r
S . luu

4. SERVICE MANUAL
valves are properly synchronized as de-
scribed in SPEED CONTROL LINKAGE
section. With throttle in the fully closed
position, clearance (C-Fig. SZIS-12) be-
tween boss (4) and control lever (3)
should be less than 1.0 nlIn (0.0:,9 in.),
but lever (3) should not be touching boss
(4). Loosen nuts jam nuts (N) and vary
length of rod (2) to adjust.
IGNITION
All models are equipped with Suzuki
Micro Link ignition system. 1Ilicro Link
is comprised of a capacitor discharge ig-
nition system (CDl) and a microcom-
puter. The microcomputer processes in-
formation from various sensors and
switches including throttle valve open-
ing, engine rpm and shift lever position,
then determines the optimum ignition
timing. The ]llicro Link system also mon-
itors oil level, oil flow, water flow and
overspeed caution systems. If one or
more eaution systems indicate a mal-
function, the microcomputer activates
the appropriate warning buzzer and
lamp, and reduees engine speed to a
predetermined level.
TROUBLE-SHOOTING. Test ignition
system using Stevens 1I10dei CD-77 or a
suitable equivalent peak reading volt-
meter (PRV) and Suzuki Pocket Tester
09900-25002 or a suitable equivalent
ohmmeter. Refer to Figs. SZIS-14 and
SZIS-L3.
1b check ignition system peak voltage,
remove spark plugs, and refer to chart
in Fig. SZIS-16. Output is measured at
cranking speed only. Make sure battery
is fully charged and in good condition.
If peak voltage is less than specified in
chart, renew component being tested.
If testing ignition components using
Suzuki Pocket '!ester 09900-25002, or an
ohmmeter, refer to Figs. SZIS-14 and
SZIS-15 and proceed as follows:
COlDENSER ClIARGE COIL. Discon-
nect six-pin connector (Fig. SZIS-15)
leading from stator plate. Connect ohm-
meter between the black/red terminal
and the green terminal. Resistance
should be 180-270 ohms.
PULSER COILS. Disconnect the six-
pin connector leading from stator plate.
Connect tester between engine ground
and alternately to the red/green,
white/black, red/white and white/green
terminals. Resistance at each terminal
should be 160-230 ohms.
Air gap between pulser coils and the
flywheel should he 0.7!; mm (0.029 in.).
The manufacturer recommends using
Suzuki pulser eoil IDeating tool (part
09931-88710) to properly position puls-
er coils.
GEAR COUNTER COIL. Unplug con-
nectors leading from gear counter coil
(8-Fig. SZIS-15). Connect tester be-
tween the orange/green and the
black!green wire eonneetors. Resistance
should be 160-230 ohms.
Air gap between counter coil and the
flywheel ring gear teeth should be 0.5
mm (0.020 in.). Loosen counter coil
mounting screws and slide coils as
necessary to adjust.
Fig. SZI8-11-Exploded vIew
of all Injection pump and re-
lated components.
pnnp ~~'.
(';om rol rod
:1. DIi'('n "War
-1. G~k('l
R~'UlITl~ r
"0" ring
A ir/nil niixlnp; "~Il','
H Ch('(:k '1.Llv('
o. ()j[ fI()w s(:nsqr
L'I lllt'l'd Ii(;n' .....
Fig. SZI8·12-Refer to text
for all pump control rod ad-
Justment procedure.
Pump i;L'!iy
C.onlrol rod
:3 G<Jn l TI1 1 it.''(,'r
1. &$:.1
~ ,J(,m nuts
Suzuki OT90 & OT100
BATTERY CHARGE COILS. Unplug
the yellow and red wire connectors and
connect tester between the two connec-
tors. Resistance should be 0.4-0.6 ohm.
Note that checking resistance between
the yellow and red wires tests resistance
of both battery charge coils.
IGNITION COILS. Ignition coil primary
winding resistance should be 0.15-0.25
ohm. Connect tester between black and
carburetor
•

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