service repair manual

1. SERVICE MANUAL Suzuki DT8C & DT9.9C
SUZUKI DT8C, DT8C SAIL, DT9.9C and
DT9.9C SAIL
CONDENSED SERVICE DATA
NOTE: Metric faateners ara uaad throughout outboard motor_
TUNE-UP
Hplrpm ... . .................... .8/4700-5700
(6.0 kW)
9.9/5300-5700
(7.4 kW)
Bore. . . . ............................. 54.0 mm
(2.13 in.)
Stroke. . . . . . . . . . ................. .46.0 mm
(1.81 in.)
Number of Cylinders ............................. 2
Displacement ............................... 211 cc
(12.9 cu. in.)
Spark Plug .......................... NGK B6HS-1O
Electrode Gap .......................... 0.9-1.0 mm
(0.035-0.039 in.)
Ignition Type ................................. CDI
Ignition Timing ............. 110 ATDC at 600 rpm (1)
Maximum Timing Advance ..... 280
BTDC at 2000 rpm
Carburetor Make ....................... Mikuni B24
Compression Ratio. . . . . . . . . . . . . . . . . . . . .. . .... 7.2:1
Idle Speed (in gear)..600-650 rpm
Fuel:Oil Ratio ............................. See '!ext
(I)-On 1988 DT9.9C models, ignition timing is 12 degrees
ATDC at 600 rpm.
SIZES-CLEARANCES
Piston Ring End Gap ................... 0.15-0.30 mm
(0.006-0.012 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . .. . ... 0.8 mm
(0.030 in.)
Piston-to-Cylinder
Clearance .................. . .0.052-0.067 mm
(0.0020-0.0026 in.)
SIZES-CLEARANCES CONT_
Wear Limit ...................... " .... 0.147 mm
(0.0058 in.)
Piston Pin Diameter ............... 11.995-12.000 mm
(0.4722-0.4724 in.)
Wear Limit ........................... 11.980 mm
(0.4716 in.)
Cylinder Bore Diameter .. . . . . . . .54.000-54.015 mm
(2.1260-2.1266 in.)
Piston Diameter ................... 53.940-53.955 mm
(2.1236-2.1242 in.)
Allowable Crankshaft
Runout ....... .
Allowable Connecting Rod
Small End Side Shake ....... .
TIGHTENING TORQUES
........ 0'()5 mm
(0.002 in.)
. .. 4.0 mm
(0.157 in.)
Crankcase Screws. . . . . . . . . . . . . . . . .. 20-26 N-m
(15-19 ft.-Ibs.)
Cylinder Head Screws .................... 21-25 N-m
(15-18 ft.-Ibs.)
Flywheel Nut ........................... 80-90 N-m
(59-66 (tAbs.)
Standard Screws:
5 mm ............ 2-4 N-m
(18-35 in.-Ibs.)
6 mm. ........................... .4-7 N-m
(35-62 in.-Ibs.)
8 mm ........ . ..................... 10-16 N-m
(7-12 ft.-lbs.)
10 mm ....... . .................. 22-35 N'm
(16-26 ft.-bs.)
WBRICATION
The power head is lubricated by oil
mixed with the fuel. All models are
equipped with automatic oil injection.
The recommended oil is Suzuki Out-
board Motor Oil or a good quality NMMA
certified TC-W oil. Recommended fuel
is unleaded gasoline with a minimum
octane rating of 85.
Recommended lower unit lubricant is
Suzuki Outboard Motor Gear Oil or a
good quality SAE 90 hypoid gear oil.
Gearcase capacity is 175 mL (5.9 oz.).
Gearcase oil should be changed after in-
itial 10 hours of operation and after eve-
ry 100 hours of operation thereafter.
Reinstall drain and vent plugs securely,
using new gaskets if necessary to ensure
a watertight seal.
a lightly seated position is 1-1/2 to 2
turns out on Model DTl3C and 1-3/4 to 2-
114 turns out on Model DT9.9C. Final ad-
justment should be made with engine at
normal operating temperature and run-
ning in forward gear. Adjust idle speed
to 600-650 rpm in forward gear.
Main fuel metering is controlled by
fixed main jet (15). Standard main jet
size for normal operation is #105 on
Model DTl3C and #137.5 on Model
DT9.9C. Standard pilot jet (5) size for
normal operation is #85 on Model DTl3C
and #65 on Model DT9.9C,
On a new or rebuilt engine, the first
tank of fuel should be mixed with a rec-
ommended oil at a 50:1 ratio and used
in addition with the oil injection system
to ensure sufficient lubrication during
engine break-in. Gasoline and oil should
be thoroughly mixed in a separate con-
tainer. After first tank of fuel is deplet-
ed, switch to straight gasoline in fuel
tank.
FUEL SYSTEM
CARBURETOR. A Mikuni B24-15 car-
buretor is used on 8 hp models and a
Mikuni B24-18 carburetor is used on 9.9
hp models. Refer to Fig. SZ7-1 for ex-
ploded view of carburetor assembly. In-
itial adjustment of pilot screw (2) from
1b check float level, remove float bowl
(10) and invert carburetor. Measure float
level from carburetor body-to-float bowl
mating surface to top of float at a point
180 degrees from inlet valve as shown
in Fig. SZ7-2. Fioat level should be 23-

2. Suzuki DT9.9 & DT16 (Prior To 1983) OUTBOARD MOTOR
SUZUKI DT9.9 AN0 DT16
(PRIOR TO 1983)
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
TUNE·UP DT9.9
Horsepower ....................... . 9.9
Bore.............................. . 56mm
Stroke ............................ . 52mm
Displacement ...................... . 256 cc
Spark Plug:
NGK ............................ . B6HS
Electrode gap .................... . 0.6·0.7 mm
Magneto:
Breaker point gap ................. . Breakerless
Carburetor:
Make ........................... . Mikuni
Model ........................... . BV24·16
Fuel:OiI Ratio ...................... . 5.0:1
SIZES-CLEARANCES
Piston Ring End Gap ................ . 0.15-0.35 mm
Piston Pin Diameter ................. . 13.995-14.000 mm
Piston to Cylinder Wall
Clearance ........................ . 0.042-0.058 mm
Max. Crankshaft Runout at
Main Bearing Journal. ............. . 0.05 mm
Max. Connecting Rod Small End
Side Shake ....................... . 4.0mm
TIGHTENING TORQUES
Cylinder Head ...................... . 18-28 N'm
Crankcase:
6mm .......................... .. 8-12 N'm
8mm .......................... .. 18-28 N'm
Flywheel Nut ...................... . 8()..90 N'm
Standard Screws:
5mm .......................... . 2-4 N'm
6mm .......................... . 4·7 N'm
8mm ........................... . 10-16 N'm
10mm .......................... . 22·35 N'm
LUBRICATION
The power head is lubricated by oil
mixed with the fuel. Fuel:oil ratios
should be 30:1 during break-in of a new
or rebuilt engine and 50:1 for normal
service when using a NMMA certified
two-stroke engine oil or Suzuki "eCI"
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
normal service. Manufacturer recom·
mends regular or no-lead automotive
gasoline having an 85-95 octane rating.
Gasoline and oil should be thoroughly
mixed.
The lower unit gears and bearings are
lubricated by oil contained in the gear-
DT16
16
59mm
52mm
284 cc
B7HS
0.6-0.7 mm
Breakerless
Mikuni
BV24·19
50:1
0.15-0.35 mm
13.995-14.000 mm
0.042-0.058 mm
0.05 mm
4.0mm
18-28 N'm
8·12 N'm
18·28 N'm
80·90 N'm
2·4 N'm
4-7 N'm
10-16 N'm
22·35 N'm
case. SAE 90 hypoid outboard gear oil
is recommended. Oil capacity of gear-
case with integral exhaust outlet in the
lower housing is approximately 220 mL.
Oil capacity of gearcase with through·
the-propeller exhaust is approximately
200 mL. Reinstall vent and fill plugs se·
curely using a new gasket, if necessary,
to ensure a water tight seal.

3. SERVICE MANUAL Suzuki DT20 & DT25 (Prior To 1983)
SUZUKI DT20 and DT25
(PRIOR TO 1983)
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor_
TUNE-UP DT20
Hp ............................... . 19.8
Bore.............................. . 64mm
Stroke ............................ . 61.5 mm
Displacement ...................... . 396 cc
Spark Plug:
NGK ............................ . B7HS
Electrode Gap .................... . 0.6·0.7 mm
Magneto:
Breaker Point Gap ................ . Breakerless
Carburetor:
Make ........................... . Mikuni
Model ........................... . BV28-22
Fuel:Oil Ratio ...................... . 50:1
SIZES-CLEARANCES
Piston Ring End Gap ................ .
Piston Pin Diameter ................. .
0.15-0.35 mm
15.995·i6.000 mm
Piston to Cylinder Wall Clearance ..... . 0.060·0.090 mm
Max. Crankshaft Runout at Main
Bearing Joumal .................. . 0.05 mm
Max. Con. Rod Small End Side
Shake ........................... . 5.0mm
TIGHTENING TORQUES
Cylinder Head...................... . 18·28 N-m
Crankcase ......................... . 18·28 N'm
Exhaust Cover ..................... . 8·12 N'm
Flywheel Nut ...................... . 1()()"110 N-m
Standard Screws:
5mm .......................... . 2·4 N-m
6mm .......................... . 4·7 N-m
8mm .......................... . 10·16 N-m
10mm .......................... . 22·35 N-m
LUBRICATION regular or no·lead automotive gasoline
having an 85·95 octane rating. Gasoline
and oil should be thoroughly mixed.
The power head is lubricated by oil
mixed with the fuel. Fuel:oil ratios
should be 30:1 during break·in of a new
or rebuilt engine and 50:1 for normal
service when using a BIA certified two·
stroke engine oil 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 nor·
mal service. Manufacturer recommends
The lower unit gears and bearings are
lubricated by oil contained in the gear·
case. SAE 90 hypoid outboard gear oil
should be used. Gearcases with exhaust
outlet in gearcase require 380 mL of
gear oil while through·the·propeller ex·
haust models reqlire 300 mL of gear oil.
Reinstall vent and fill plugs securely us-
ing a new gasket, if necessary, to ensure
a water tight seal.
DT25
25
68mm
61.5 mm
447 cc
B7HS
0.6·0.7 mm
Breakerless
Mikuni
BV32-28
50:1
0.15-0.35 mm
15.995·16.000 mm
0.060-0.090 mm
0.05 mm
5.0mm
18·28 N'm
18·28 N-m
8·12 N'm
100·110 N'm
2·4 N-m
4-7 N-m
10-16 N-m
22·35 N-m
FUEL SYSTEM
CARBURETOR. A Mikuni car-
buretor is used on all models. Refer to
Fig. SZ8·1 for exploded view. Initial set-
ting of pilot air screw (5) from a lightly
seated position should be 11
12.2 turns on
DT20 models and 11/••13/. turns on DT25
models. Final carburetor adjustment
should be made with engine at normal
operating temperature and running in
forward gear. Adjust throttle stop
-

4. SERVICE MANUAL Suzuki DT20 (1986-1988) & DT25 (1985-1988)
SUZUKI DT20 (1986-1988) AND DT25 (1985-1988)
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
TUNE·UP
Hp/rpm .........................'.......20/4800-5500
25/4800·5500
Bore:
DT20 ......................................67mm
(2.64 in.)
DT25 ..................................... 71mm
(2.80 in.)
Stroke ...................................... 63 mm
(2.48 in.)
Number of Cylinders ............................... 2
Displacement:
DT20 ..................................... .444cc
(27.10 cu. in.)
DT25 ...................................... 499cc
(30.45 cu. in.)
Spark Plug:
NGK ..................................... BR7HS
Electrode Gap .......................... 0.8-0.9 mm
(0.031-0.035 in.)
Ignition Type .................................CD!
Carburetor Make ........................... Mikuni
Idle Speed (in gear) .................... 650·700 rpm
Fuel:Oil Ratio ........................... , .See Text
SIZES-CLEARANCES
Piston Ring End Gap ..... .
Piston-to-Cylinder Clearance:
............ 0.2·0.4 mm
(0.008-0.016 in.)
Prior to 1987 ...................... 0.067-0.082 mm
(0.0026-0.0032 in.)
After 1986 ........................ 0.087-0.102 mm
(0.0034-0.0040 in.)
Piston Pin Diameter ................. 17.995-18.000 mm
(0.7085·0.7087 in.)
Max. Crankshaft Runout at Main
Bearing Journal ................... , ... ".,0.05 mm
(0.002 in.)
Max. Connecting Rod Small End
Side Shake ................................. 5.0 mm
(0.20 in.)
TIGHTENING TORQUES
Power Head Mounting Screws ............... 15-20 N' m
(11-14 ft.-lbs.1
TIGHTENING TORQUES CONT.
Crankcase:
6mm ................................... 8-12N·m
(6-8 ft.·lbs.)
8mm .................................. 20-26 N'm
(14-19 ft.-Ibs.)
FlywheelNut ......... """, ........... 130-150N·m
(94-108 ftAbs.)
Cylinder Head Screws:
6mm ...................................8·12N·m
(6-8 ft.-lbs.)
8mm .................................. 20·26N·m
(14-19 ft.-Ibs.)
Gearcase Pinion Nut ....................... 18-22 N· m
(13-16 ft.-lbs.)
Propeller Shaft Nut ........................ 27-30 N· m
(19-21 ft.-Ibs.)
Standard Screws:
Unm.arked or Marked "4"
5mm ................................... 2-4N·m
(2-3 ft.-lbs.)
6mm ................................... 4-7N·m
(3·5 ft.-lbs.)
8mm ................................. 10-16N·m
(7·12 ft.-Ibs.)
10mm ................................ 22-35 N'm
(16·26 fUbs.)
Stainless Steel
5mm ................................... 2-4 N'm
(2-3 fUbs.)
6mm .................................. 6-10 N'm
(5-7 ft.-Ibs.)
8 mm ................................. 15-20N'm
(11-15 ft.-Ibs.)
10 mm ................................ 34-41 N'm
(25-30 ft.-lbs.)
Marked "7" or SAE Grade 5
5mm ................. , ................. 3-6N·m
(2-5 ftAbs.)
6mm .......... "" ....................8-12N·m
(6-9 in.·lbs.)
8mm ................................. 18·28N·m
(13·20 fUbs.)
10mm ............................... .40·60 N'm
(29-44 ft.-Ibs.)
LUBRICATION
The power head is lubricated by oil
mixed with the fuel. During break-in of
a new or rebuilt engine, fuel:oil ratio
should be 30:1 on 1985 D'I25 models and
25:1 on 1986 and later D'I25 and all
D'I20 models. Fuel:oil ratio for normal
service should be 50:1 on 1985 D'I25
models and 100:1 on 1986 and later
D'I25 and all D'I20 models. Recom-
mended oil is Suzuki Outboard Motor Oil
or a good quality NMMA certified Te-
W engine oil. Recommended fuel is
regular or unleaded gasoline having an
85 minimum octane rating. Manufactur-
er does not recommended using gasoline
containing alcohol additives. However,
unleaded gasoline containing ethanol
(grain alcohol) may be used providing
ethanol content does not exceed five
percent and minimum octane rating is
85.
NOTE: Manufacturer recommends NOT
using any gllllOline containing methanol
(wood alcohol).

5. Suzuki DT25C OUTBOARD MOTOR
SUZUKI DT25C
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
TUNE-UP
Hp/rpm . .. . ..................... 25/5000-5600 rpm
(18.6 kW)
Number of Cylinders ............................. 3
Bore ..................................... 62 mm
(2.44 in.)
Stroke .................................... 60 mm
(2.36 in.)
Displacement. .............................. 543 cc
(33.1 cu. in.)
Spark Plug .......................... NGK B7HS-1O
Electrode Gap .......................... 0.9-1.0 mm
(0.035-0.039 in.)
Ignition. . . . . . . . . . . ....................... CD!
Carburetor:
Make .................................... Mikuni
Model ................................... B26-20
Fuel:Oil Ratio ................... Automatic Metering
SIZES-CLEARANCES
Piston Ring End Gap .................. 0.15-0.35 mm
(0.006-0.014 in.)
Wear Limit ..............................0.8 mm
(0.030 in.)
Piston Pin Diameter ............... 15.995-16.000 mm
(0.6297-0.6299 in.)
Wear Limit ........................... 15.980 mm
(0.6291 in.)
Piston Pin Bore Diameter .......... 16.002-16.010 mm
(0.6300-0.6303 in.)
Wear Limit ........................... 16.030 mm
(0.6311 in.)
Standard Piston Diameter .......... 61.920-61.935 mm
(2.4378-2.4384 in.)
Standard Cylinder Bore
Diameter....................... 62.000-62.015 mm
(2.4409-2.4415 in.)
Piston-to-Cylinder
Clearance ........................ 0.072-0.087 mm
(0.0028-0.0034 in.)
Wear Limit. . . . . . . ...............0.167 mm
Max. Crankshaft Runout
at Main Journal ....... .
(0.0066 in.)
.............0.05 mm
(0.002 in.)
SIZES-CLEARANCES CONT_
Max. Connecting Rod Small
End Side Shake ...................... , ... 5.0 mm
TIGHTENING TORQUES
Cylinder Head:
(0.20 in.)
6 mm ................................. 8-12 N-m
(6-9 ftAbs.)
8 mm ................................ 21-25 N'm
(15-18 ft.-lbs.)
Crankcase:
6 mm ................................. 8-12 N'm
(6-9 ft.-Ibs.)
8 mm ................................ 20-26 N-m
(15-19 ft.-lbs.)
Flywheel Nut. . . . . . . . . . . . . . . . . . .130-150 N-m
(96-111 fUbs.)
Standard Screws-
Unmarked or Marked "4":
5 mm ................................. 2-4 N'm
(18-35 in.-lbs.)
6 mm ................................ A-7 N'm
(35-62 in.-lbs.)
8 mm ......... , .................... 10-16 N'm
(7-12 ft.-lbs.)
10 mm .............................. 22-35 N-m
(16-26 fL-lbs.)
Stainless Steel:
5 mm ................................. 2-4 N-m
(18-35 in.-lbs.)
6 mm ................................ 6-10 N-m
(53-88 in.-lbs.)
8 mm ............................... 15-20 N-m
(11-15 ft.-lbs.)
10 mm .............................. 34-41 N-m
(25-30 ft.-lbs.)
Marked "7":
5 mm ................................. 3-6 N-m
(27-53 in.-lbs.)
6 mm ................................ 8-12 N-m
(6-9 ft..-lbs.)
8 mm ............................... 18-28 N-m
(13-21 ft.-lbs.)
10 mm ........ , .................... AO-60 N-m
(29-44 ftAbs.)
LUBRICATION
The power head is lubricated by oil
mixed with the fueL Model DT25C is
equipped with automatic oil il'iection.
Recommended oil is Suzuki Outboard
Motor Oil or a good quality NMMA cer-
tified TC-W engine oiL Recommended
fuel is regular or unleaded gasoline hav-
ing an 85 minimum octane rating. Man-
ufacturer does not recommended using
gasoline containing alcohol additives.
However, unleaded gasoline containing
ethanol (grain alcohol) may be used
providing ethanol content does not ex-
ceed five percent and minimum octane
rating is 85.
NOTE: Manufacturer recommends NOT
using any gaaollne containing methanol
(wood alcohol).

6. SERVICE MANUAL
During break-in (first 10 hours of op-
eration) of a new or rebuilt engine, mix
a recommended oil with the fuel at a
50:1 ratio in combination with the oil in-
jection system to ensure adequate lubri-
cation during break-in process. Be cer-
tain oil and fuel is thoroughly mixed in
fuel tank. After initial 10 hours of op-
eration, switch to straight gasoline in
the fuel tank.
The lower unit gears and bearings are
lubricated with oil contained in the
gearcase. Recommended gearcase oil is
Suzuki Outboard Motor Gear Oil or a
suitable equivalent SAE 90 hypoid gear
oil. Gearcase capacity is approximate-
ly 230 mL (7.8 ozs.). Lower unit oil
should be changed after the first 10
hours of operation and after every 100
hours or seasonally thereafter. Reinstall
drain and vent plugs securely, using a
new gasket if necessary, to ensure wa-
ter tight seal.
FUEL SYSTEM
CARBURETOR. Three Mikuni B26-20
carburetors are used. Refer to l''ig. S"llO-
1 for exploded view. Initial setting of pi-
lot air screw (12) is 1-112 to 2 turns out
from a lightly seated position. Final ad-
justment should be made with engine at
normal operating temperature and run-
ning in forward gear. Adjust idle speed
1 Body
2. Gasket
3. HIgh speed nozzle
4, Chok(> rod
fi. Main Jet
6. Float
7, Float bowl
8, Drain screw
9. Float pin
10. Needle valve
11 Pilot jet
12, Pilot screw
13, Throttle control rods
with idle speed switch located on out-
side of lower cover so engine idles at ap-
proximately 650-700 rpm. Adjust pilot
air screw so engine idles smoothly and
will accelerate cleanly without hesita-
tion. Readjust idle speed to 650-700 rpm
if necessary.
Main fuel metering is controlled by
main jet (5). Standard main jet for nor-
mal operation is #125. Standard pilotjet
(11) for normal operation is #70.
To check float level, remove float
bowl (7) and invert carburetor body (1).
Measure float level from float bowl mat-
ing surface to bottom of float at 180 de-
grees from needle valve as shown in
Fig. SZIO-2. Float level shOUld be 16.5-
18.5 rom (0.65-0.73 in.). Bend tang on
float to adjust float level.
Fig. SZ1CJ-Z-MtJIlBure flollt level from float bowl
msllng surface to bottom of float 180 degrees
from naad/a valve ss shown. Bend tang on flost
to BdjuBt floet level.
Fig. SZ10·3-Exploded view of fuel filter ss-
semb/y.
1. Base
2. Seal
3. "0" ring
4 Filter
5. Bowl
Suzuki DT25C
FUEL FILTER. A fuel filter assembly
is used to filter the fuel prior to enter-
ing the fuel pump. Periodically unscrew
bowl (5-Fig. S"l10-3) and withdraw fil-
ter element (4). Clean bowl and filter el·
ement in a suitable solvent and blow
dry with clean compressed air. Inspect
filter element for excessive blockage or
other damage and renew if necessary.
Reassemble in reverse order of disas-
sembly. Renew' '0" ring (3) and seal (2)
upon reassembly.
FUEL PUMP. A diaphragm·type fuel
pump is used. Refer to Fig. SZIO-4 for
exploded view. Fuel pump is mounted
on the side of power head cylinder
block and is actuated by crankcase pul-
sations.
When servicing pump, scribe refer-
ence marks on pump body to aid align-
ment during reassembly. Defective or
questionable components should be reo
newed. Diaphragm should be renewed
if air leaks or cracks are noted, or if de-
terioration is evident.
REED VALVES. The reed valves are
located behind the intake manifold. The
intake manifold must be removed to ac·
cess reed block and valves assembly.
Renew reed valves (2-Fig. S"l10·5) if
petals are broken, cracked, warped,
rusted or bent, or if tiP of petal stands
open in excess of 0.2 mm (0.008 in.)
from seat area. Do not attempt to bend
or straighten a damaged reed petal.
Reed stop opening (0) should be 3.8 mm
(0.15 in.). When reassembling reed
valve assembly, apply Suzuki Thread
Lock 1342 or a suitable equivalent
thread locking compound to threads of
screws (4).
SPEED CONTROL LINKAGE. To ad-
just speed control linkage, loosen throt·
tie lever adjusting screws (i-Fig. S"lIO·
6) on top and bottom carburetors and
rotate throttle levers (2) counterclock-
6
3
Fig. SZ1D-4-ExpIoded view of fuel pump _
sembly.
L Cover
2. Diaphragm 6. Gasket
3. Ga<;ket. 7. Spring
4. Valve body 8. Spring seal
5 Plate 9. CheCK valve

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8. Suzuki DT25C
wise to full closed position. Hold levers
(2) closed and retighten screws (1). Ad-
just throttle link (4) so throttle arm (3)
is against stopper (5) and clearance (C)
is 0.5-1.5 mm (0.020-0.060 in.) with
throttle in fully closed position. Make
sure throttle plates are synchronized at
full closed and full open positions.
If throttle cables require adjustment,
loosen cable adjustment nuts and adjust
cables so core wires are tight with no
free movement in drum (6). Make sure
arm (3) contacts stopper (5) when throt-
tle is fully closed. Oil iJjection pump
control linkage should be checked
and/or adjusted after speed control link-
age adjustment. Refer to OIL INJEC-
TION section.
2
4~~---..l-J
Fig. SZIO-S-Cross-sectlonal view of reed bloclc
and valves as_mbly.
1. Reed block
2, Rk-ed petal
3. Reed stop
4. &ww
0, Reed stop opening
OIL INJECTION
CONTROL LINKAGE ADJUST-
MENT. Make sure speed control linkage
is properly adjusted. Initial length of
pump control rod (5-Fig. SZI0-7)
should be 77.5 mm (3.05 in.) as shown.
With throttle in fully closed position,
clearance (C) between lever stopper (6)
and boss (7) on pump housing should be
1 mm (0.040 in.) or less, but stopper (6)
should not contact boss (7). To adjust,
loosen nuts (4) and adjust length of rod
(5) as necessary. Make sure nuts (4) are
securely tightened after adjustment.
After adjusting pump control linkage,
recheck speed control linkage and read-
just if necessary. Refer to SPEED CON-
TROL LINKAGE section.
OIL FLOW SENSOR. Inline filter
contained in oil flow sensor should be
periodically removed and cleaned in a
suitable nonflammable solvent. Manu-
facturer recommends renewing filter if
excessive plugging or contamination is
noted.
To test oil flow sensor, remove sen-
sor and connect a suitable ohmmeter
between sensor red wire with blue trac-
er and black wire. Plug sensor inlet and
connect a vacuum source to sensor out-
let. With vacuum applied, ohmmeter
should show continuity. Remove vacu-
um source and sensor should show in-
finity.
BLEEDING PUMP. To bleed trapped
air from oil supply lines or pump, pro-
ceed as follows: Fill fuel tank with a
Fig. SZI0-6-Vlew of spMld
comrol linkage. Adjust Hnk-
age lIS described In teld.
1. Screw
2. Throttle lever
3. Throttle ann
4, Link rod
5. Stopper
6. Cable drum
OUTBOARD MOTOR
50: 1 mixture of recommended gasoline
and oil. Fill oil tank with a recom-
mended oil. Loosen bleed screw (B-Fig.
SZ10-7 or SZI0-8) two or three turns.
Start engine and allow to idle at 650-700
rpm until no air bubbles are noted at
bleed screw (B).
CHECKING OIL PUMP OUTPUT.
Start engine and allow to warm-up for
approximately five minutes. Stop en-
gine, disconnect oil pump control rod
from carburetor and remove oil tank.
Conneet oil gage 09900-20205 or a suita-
ble equivalent to oil pump supply hose.
Fill oil gage with a recommended oil un-
til oil is even with an upper reference
mark. Bleed system as previously de-
scribed. With oil pump control rod in
fully closed position, start engine and
allow to run at 1500 rpm for five
minutes. Oil consumption should be 1.0-
1.9 mL (0.035-0.065 oz.) in five minutes
at 1500 rpm. Move oil pump control rod
to fully open position, restart engine
and allow to run at 1500 rpm for two
minutes. Oil consumption should be 1.2-
1.7 mL (0.04-0.06 oz.) in two minutes at
1500 rpm. Renew oil pump assembly
(2-Fig. SZlO-8) if pump output is not
as specified. After reinstalling oil tank,
bleed air from oil iJjection system as
previously described.
NOTE: Results of 011 pump output test
msy vary according to weather conditions,
testing error or other conditions. The man-
ufacturer recommends repeating output
test procedure two or three times to ensure
the proper test results are obtained.
B
fig. SZI0-7-Vlewof011 Injection pump andeen·
trollinkage. Refer to text for controlllnkaga ad·
justment.
1. Throttle lever
2. Pump ass}'
3. Pump lever
4. Adjustment nuL<;
G. Control rod
!j, Stopper
7. !los>
B. Bleed SHeW