service repair manual

1. SERVICE MANUAL
TUNE-UP
SUZUKI
SUZUKI AMERICA CORPORATION
3251 E. Imperial Way
P.O. Box 1100
Brea, California 92621
SUZUKI DT2
1b determine model and year of manufacture of Suzuki outboard motors, refer
to numbers located on motor clamp bracket. The first six characters indicate the
model and second six characters are motor serial number. The first character of
serial number indicates year of manufacture. The years 1977, 1978 and 1979 are
identified by the letters "C," "D" and "F" respectively. Starting with 1980, the
first number in serial number corresponds with model year. For example, if first
number in serial number is 1, model year is 1981.
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
Hp/rpm ......................... , ... . ..... .2/4500
SIZES-CLEARANCES CONT.
Crankshaft Runout at Main
Suzuki OT2
Bore ....................... . ........... .41.0 mm Bearing Journal (Max.) ........ _.......... 0.03 mm·
(1.614 in.)
Stroke ......... . ......................... 37.8 mm
(1.488 in.)
Displacement ......... . ...................... 50 cc
(3.05 cu. in.)
Spark Plug:
NGK .................................... BR5HS
Electrode gap ...... . .................. 0.5-0.6 mm
(0.020-0.023 in.)
Magneto:
Breaker point gap ................ , .... 0.3-0.4 mm
(0.012-0.016 in.)
Carburetor:
Make .................................... Mikuni
Model ............ ... ...... . .... . ...... VM-11-10
Fuel:Oil Ratio ................. . ..... . _.... See Text
SIZES-CLEARANCES
Piston Ring End Gap ....... . .......... 0.10-0.25 mm
(0.004-0.010 in.)
Piston to Cylinder
Clearance .............. . ......... 0.053-0.060 mm
(0.0021-0.0024 in.)
Piston Pin Diameter ............... 11.996-12.000 mm
(0.4723-0.4724 in.)
(0.0012 in.)
Connecting Rod Small End
Side Shake (Max.) ........... . ...... , ..... 3.0 mm
(0.118 in.)
TIGHTENING TORQUES
Cylinder Head ............................ 8-12 N'm
(6-9 ft.-Ibs.)
Crankcase ....... . ............. . ... , ..... 8-12 N'm
(6-9 ft.-Ibs.)
Reed Plate ............................ 0.5-0.75 N'm
(4.5-6_6 in.-Ibs.)
Flywheel Nut ............... . .......... .40-~0 N'm
(30-37 ft.-lbs.)
Standard Screws:
5 mm ............. . ...... . ............. 2-4 N'm
(18-36 in.-Ibs.)
6 mm ....... . .... . .................... ·. .4-7 N'm
(36-62 in.-Ibs.)
8 mm ....... _. ........................ 10-16 N'm
(89-141 in.-Ibs.)
10 mm ....... .. .... . .................. 22-35 N'm
(195-310 in.-Ibs.)

2. SERVICE MANUAL Suzuki 013.5
SUZUKI DT3.5
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
TUNE·UP SIZES-CLEARANCES CONT.
Hp/rpm . ........... . ............ .. .... 3.5/4800-5300 Piston Pin Diameter ... . ............. 11.996-12.000 mm
Bore .. ...... ...... .. .. . ........ ..... .... .... 46 mm
(1.81 in.)
(0.4723-0.4724 in.)
Max. Crankshaft Runout at Main
Stroke .............•...... .. ......... ... .... 42 mm
(1.65 in.)
Bearing Journal ................. . . ........ 0.03 mm
Displacement ..... ....... . . ...... . ...... . . .. .. 69.8 cc
(4.3 cu. in.)
Spark Plug:
(0.0012 in.)
Max. Connecting Rod Small End
Side Shake .. . . ... . ............ . . . . . . . ..... .3.0 mm
NGK . . ........ ....... ..... ... ...... .. .... BP6HS
(0.12 in.)
Electrode Gap .... . .. ... . .. .. ... . ..... ... 0.6-0.7 mm
(0.024-0.028 in.)
TIGHTENING TORQUES
Ignition Type . ........ .. .. . .... . . ... .... Breaker Point
Power Head Mounting Screws and Nuts ... .. .. 15-20 N· m
(11-14 ft.-Ibs.)
Breaker Point Gap ........... . . .. . . .... .... 0.3-0.4 mm Crankcase ............ ... . ..... .. .. .. .. .... 8-12N·m
(0.012-0.016 in.) (6-8 ft.-Ibs.)
Ignition Timing@ 5000 rpm .. . ... . ...... .. .23.5° BTDC
Carburetor:
Flywheel Nut .......... ....... .... ...... .. 40-50 N· m
Make .. .. ..... ........ .. ...... ... .... .. . ... Mikuni
(29-36 ft.-Ibs.)
Standard Screws:
Model ................................... BV-18-15 5 mm ..... . .. .. .... ...... . .. ............. 2-4 N'm
Idle Speed (in gear) ........... . ......... .900-1000 rpm (1-3 ft.-Ibs.)
Fuel:Oil Ratio .. ...... ..... .. . ... . .. .. .. ........ 50:1 6mm ............... .... .................4-7N·m
(3-5 ft.-Ibs.)
SIZES-CLEARANCES 8 mm . .... ..... ...... ...... ...... ... ... 10-16 N'm
Piston Ring End Gap ......... .. .. .... .... 0.15-0.35 mm (7-11 ft.-Ibs.)
(0.006-0.014 in.) 10 mm ..... ... .......... .... .. .... ... .. 22-35 N'm
Piston to Cylinder Clearance ... . ........ 0.052-0.067 mm
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 BIA certified TC-W
engine oil or Suzuki "CCI" oil. When us-
ing 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 recommends 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 approximately 85 mL (2.9
ozs.) of SAE 90 hypoid outboard gear
oil. Reinstall vent and fill plugs securely
using a new gasket, if necessary. to en-
sure a water tight seal.
(0.0020-0.0026 in.)
FUEL SYSTEM
CARBURETOR. A Mikuni BV-18-15
carburetor is used. Refer to Fig. SZ2-1
for exploded view. Initial setting of pilot
air screw (15) from a lightly seated posi-
tion should be 3/.-11/. turns. Final car-
buretor adjustment should be made with
engine at normal operating temperature
and running in forward gear. Adjust
throttle stop screw (12) so engine idles
at approximately 900-1000 rpm. Adjust
pilot air screw so engine idles smooth
and will accelerate c1eanlv without
hesitation. If necessary. readjust throt-
tle stop screw to obtain 900-1000 rpm
idle speed.
Main fuel metering is controlled by
main jet (2). Standard main jet size for
normal operation is #90. Standard pilot
jet (14) size is #15.
(16-25 ft.-Ibs.)
To check float level. remove float bowl
(7) and invert carburetor body (1). Base
of float (6) should be 12-14 rnm (0.47-
0.55 in.) away from sealing ring surface
of carburetor body with sealing ring (3)
removed. Adjust float level by bending
float tang.
FUEL PUMP. A diaphragm fuel
pump (Fig. SZ2-2) is mounted on the
side of power head cylinder blOC
k and is
actuated by pressure and vacuum pulsa-
tions from the engine crankcase.
When servicing pump. defective or
questionable parts should be renewed.
Diaphragm should be renewed if air
leaks or cracks are found. or if
deterioration is evident.
REED VALVE. The reed valve is
located in a reed plate that is located
•

3. Suzuki DT4 OUTBOARD MOTOR
SUZUKI DT4
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
TUNE-UP
Hplrpm ...................... . ............... 4/5000
Bore .......... .. ............................ 50mm
(1.97 in.)
Stroke . . .................. . ................. 46 mm
(1.81 in.)
Displacement .......... .. .. . .. ........ .. . .... .. 90 cc
(5.5 cu. in.)
Spark Plug:
NGK ...... .. ...... . . ..... .... . ........... BP6HS
Electrode Gap .... . ......... . . . .......... 0.6-0.7 mm
(0.024-0.028 in.)
Ignition Type .. .. .. . . . ......... .. ......... .. . . .. CD!
Carburetor:
Make .................. .. ..... . ... ......... Mikuni
Model ................................... BV-18-15
Idle Speed (in gear) ... .. _. . _. . . .... ..... . .850-900 rpm
Fuel:Oil Ratio ..... .. . .See Text
SIZES-CLEARANCES
Piston Ring End Gap .. . ........... . ...... 0.15-0.35 mm
(0.006-0_014 in.)
Piston to Cylinder Clearance ............ 0_052-0_067 mm
(0.0020-0.0026 in_)
Piston Pin Diameter ..... __ .. _. _..... 11.995-12.000 mm
(0.4722-0.4724 in.)
SIZES-CLEARANCES CONT.
Max. Crankshaft Runout at Main
Bearing Journal .................. . _____ ... 0_05 mm
(0.002 in.)
Max. Connecting Rod Small End
Side Shake ...... .... . .......... . . .. ...... __ 4.0 mm
(0.16 in.)
TIGHTENING TORQUES
Power Head Mounting Screws ... .. . .. ....... 15-20 N· m
(11-14 ft.-Ibs_)
Crankcase ... .. . . .. . . _. __ ... __ .. ...... . __.. 8-12 N•m
(6-8 ft.-Ibs_)
Flywheel Nut . .. . .... .. .. ... _. _........ . .. .. .45 N'm
(32 ft.-lbs.)
Standard Screws:
5 mm ............ .. . . . , .. . .... ........... 2-4 N' m
(1-3 ft.-Ibs.)
6mm .............................. , ..... 4-7N·m
(3-5 ft.-Ibs.)
8mm .................................. 1O-16N·m
(7-11 ft.-Ibs.)
10mm ........... ... . ... ..... . ......... 22-35N·m
(16-25 ft.-Ibs.)
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. For normal service,
fuel:oil ratio should be 50: 1 on models
prior to 1986 and 100:1 on 1986 and
later models when using Suzuki Out-
board Motor Oil or a good quality NMMA
certified TC-W engine oil. When using
any other two-stroke oil, fuel:oil ratio
should be 20: 1 during break-in and 30:1
for normal service. Manufacturer
recommends regular or unleaded au-
tomotive gasoline having an 85 mini-
mum octane rating. Gasoline and oil
should be thoroughly mixed.
turns out from a lightly seated position.
Final atljustment should be made with
engine at normal operating temperature
and running in forward gear. Atljust
throttle stop screw (9) so engine idles at
approximately 850-900 rpm. Atljust pi-
lot air screw so engine idles smoothly
and will accelerate cleanly without hesi-
tation. If necessary, readjust throttle
stop screw to obtain 850-900 rpm idle
·speed.
Main fuel metering is controlled by
main jet (2). Standard main jet size for
normal operation is #97.5. Standard pi-
lot jet (10) size is #45.
To check float level. remove float
bowl (12) and invert carburetor body
(1). Base of float (3) should be 12-14 mm
(0.47-0.55 in.) away from gasket surface
of carburetor body with float bowl gas-
ket removed. Atljust float level by bend-
ing float tang.
The lower unit gears and bearings are
lubricated by approximately 190 mL
(6.4 ozs.) of SAE 90 hypoid outboard
gear oil. Reinstall vent and fill plugs se-
curely using a new gasket, if necessary,
to ensure a water tight seal.
FUEL SYSTEM
CARBURETOR. A Mikuni BV-18-15
carburetor is used. Refer to Fig. SZ3-1
for exploded view. Initial setting of pi-
lot air screw (6) should be 1 to 1-112
10
B 7 6 9 I 11
~~~
1 _
'--8-<
5--:'0"
Fig. SZ3·1- Exploded vi... 01 ""tunl 8'1-18-15
c.rbur.fOr.
1. Bods
2. Main jet
3. Float
4. Screw
.5. Plug
6. Pilot air screw
7. Choke le...("t
8. Choke k.nob
9. Idle ~xrelll
10. Pl/ot)et
11. <4skl't
12. Float bowl
FUEL PUMP. A diaphragm fuel
pump (Fig_ SZ3-2) is mounted on the
side of power head cylinder block and is
actuated by pressure and vacuum pulsa-
tions from the engine crankcase.
When servicing pump, defective or
questionable parts should be renewed.
Diaphragm should be renewed if air
leaks or cracks are found, or if
deterioration is evident.
SPEED CONTROL LINKAGE.
Engine speed is controlled by position of
throttle linkage. Ignition advance is
electronically controlled. A twist grip at
the steering handle is used to control
throttle settings.
•

4. Suzuki DTS, DT6 & DT8 OUTBOARD MOTOR
SUZUKI DT5, DT6 AN 0 DT8
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
TUNE·UP
Hp/rpm .............. . ............. . .... 5/4800-5500
Bore:
6/5200-5700
8/5200-5700
5Hp ... ..... . ............... . ...... . .. .. .. 43mm
(1.69 in.)
6&8Hp . . ............ ........ ... 0 • • • • • • • • • 50mm
(1.97 in.)
Stroke:
5Hp ............. .. . . . ................ . .. .39mm
(1.54 in.)
6&8Hp ..... 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42mm
(1.65 in.)
Number of Cylinders ........... .. .................. 2
Displacement:
5 HP ... ..... .. . .. .......... . ..... .. ...... . . 113 cc
(6.90 cu. in.)
6&8Hp . . .................................. 165cc
(10.07 cu. in.)
Spark Plug:
NGK ............. . .................. 0 . . . . BP6HS
Electrode Gap ............. ... ........... 0.8·0.9 mm
(0.031·0.035 in.)
Ignition Type .......... 0 0 0 • • • • • • • • • • • • • • • • • • • • • • CD!
Carburetor Make ............... .... .......... Mikuni
Idle Speed (in gear) .. ................... .. 600·650 rpm
Fuel:Oil Ratio ....... 0 • • • • • • o • • • • • 0 • • • • • • • See Text
LUBRICATION
SIZES-CLEARANCES
Piston Ring End Gap .......... 0 • • • • • • • 0.10-0.30 mm
(0.004-0,Oi2 in.)
Piston to Cylinder Clearance ......... 0.052·0.067 mm
(0.0020-0.0026 in.)
Piston Pin Diameter . .. . . . . . .11.996·12 .000 mm
(0.4723·0.4724 in.)
Max. Crankshaft Runout at
Main Bearing .Journal .....
Max. Connecting Rod Small
... ......... 0.0;; mm
(0.002 in.)
End Side Shake ......... . . . 0 0 " • • • • • • .4.0 mm
(0.160 in.)
TIGHTENING TORQUES
Power Head Mounting Screws .... . .. . .. 15-20 N'm
(11·15 ft.-lbs.)
Crankcase ........ . ..... .. . . ............. 8·12 N'm
(6·9 ft.·lbs.)
Flywheel Nut ............. . ............. 60·70 N'm
(44-52 ftAbs.)
Cylinder Head Screws ... .. . 0 • • • • • • • • • • • • • 20-26 N'm
Standard Screws:
5mm ...
6 mm ... . • . ...........
(15-19 ft.-lbs.)
.... 2-4 Nom
(1-3 ft. ·lbs.)
... 4-7 N'm
(3·5 ft.-Ibs.)
8 mm ..... 0 • 0 • • • • • • • • 0 • • • • • 0 0 0 • " • • • 10-16 N'm
(7-12 ft.-Ibs.)
10 mm ... 0 0 • • • • • • • • • • • • • • • • 0 • • • • • • • • • 22-35 N'm
(16-26 ft.-Ibs.)
The power head is lubricated by oil
mixed with the fuel. Recommended oil
is Suzuki Outboard Motor Oil or a good
quality NMMA certified TC-W two-
stroke engine oil. Fuel:oil ratio should
be 30: I during break-in of a new or
rebuilt engine. For normal service,
fuel:oil ratio should be 50: 1 on models
prior to 1986 and 100:1 for 1986 and
later models. Manufacturer recom-
mends regular or unleaded automotive
gasoline having an 85-95 octane rating.
Gasoline and oil should be thoroughly
mixed.
ni BV-18-14 is used on DT6 models and
Mikuni BV-24-18 is used on DT8 models.
Refer to Fig. SZ4-1 for exploded view.
Initial setting of pilot air screw (13)
should be :3/4 to 1-114 turns out from a
lightly seated position on Models DT5
and Drs, and 1-3/4 to 2-114 turns out on
Model DT6. Final carburetor adjustment
should be performed with engine at nor-
mal operating temperature and running
in forward gear. Adjust idle speed screw
( 11) so engine idles at approximately
600·650 rpm. Adjust pilot air screw (13)
The lower unit gears and bearings are
lubricated by approximately 240 mL
(8.1 oz.) of SAE 90 hypoid outboard gear
oil. Reinstall vent and fill plugs secure-
ly using a new gasket, if necessary, to
ensure a water tight seal.
FUEL SYSTEM
CARBURETOR. A Mikuni BV-IB-15
carburetor is used on DT5 models, Miku-

5. Suzuki DT9.9 & DT15 (1983-1987) & DT15C (1988) OUTBOARD MOTOR
SUZUKI DT9.9 & DT15 (1983-1987)
AND DT15C (1988)
CONDENSED SERVICE DATA
NOTE: Metric fasteners are used throughout outboard motor.
TUNE-UP
Hp/rpm ..... . .. . ........ .............. 9.9/450()'5300
1514700·5500
Bore ...... . .... ...... ..................... .. 59mm
(2.32 in.)
Stroke ................... .. ........ .. .... .. .52 mm
(2.05 in.)
Number of Cylinders ........ . ...................... 2
Displacement ..... . ... ........ ... . ............ 284 cc
(17.33 cu. in.)
Spark Plug:
NGK ......... .. ..................... . .. BR7HS-1O
Electrode Gap ........................... 0.9-1.0 mm
(0.035-0.039 in.)
Ignition Typ~ ... .. . . ............ ..... . ... . ..... .CD!
Carburetor Make .... . .. ................... . .. Mikuni
Idle Speed (in gear) ... ............... . .... 600·650 rpm
Fuel:Oil Ratio . ....... . . . . . .......... . ... See Text
SIZES-CLEARANCES
Piston Ring End Gap:
D1'9.9 and DTl5 (to 1987) ... . . ... .... 0.15-0.35 mm
(0.006·0.014 in.)
Wear Limit .. .. ... .. .. .... ............. 0.7 mm
(0.027 in.)
DT9.9 and DTl5 (1987) ... ... ...... .. 0.20-0.40 mm
(0.008·0.016 in.)
Wear Limit ............................ 0.8 mm
(0.031 in.)
DT15C ... .... ... . .. . ............... 0.10-0.25 mm
(0.004-0.010 in.)
Wear Limit ... . ... . ... ................. 0.8 mm
Piston-to-Cylinder
Clearance:
(0.031 in.)
DT9.9 and DT15 ... . . . ..... . ...... 0.052-0.067 mm
(0.0020-0.0026 in.)
DT15C .......... . ....... . ........ 0.042-0.062 mm
(0.0016-0.0024 in.)
Piston Pin Diameter ............... 13.995-14.000 mm
(0.5510-0.5512 in.)
Maximum Crankshaft Runout
at Main Bearing Journal .......... .
Maximum Connecting Rod
Small End Side Shake:
. ... 0.05 mm
(0.002 in.)
DT9.9 and DT15 . ..... ..... .. . ....... .. .4.0 mm
(0.157 in.)
SIZES-CLEARANCES CONT.
DTl5C ............................ . . .. 5.0 mm
(0.197 in.)
TIGHTENING TORQUES
Power Head Mounting Screws ..... . ....... 15-20 N'm
(11-15 ft.-Ihs.)
Crankcase:
6 mm ....... .. .. . .. ... ... . . ........... 8-12 N'm
8mm
Cylinder Head Screws:
(6-9 ft.-Ihs.)
.20-26 N'm
(15-19 ft.-Ihs.)
DT9.9 and DTl5 . . . . . . . . . . . . ...... 20-26 N'm
(15-19 ft.-Ihs.)
DTl5C . . .......... . ............. . ..... 21-25 N'm
(16-18 ft.-Ihs.)
Flywheel Nut . . . . . . . ...... . ........ 80-90 N'm
Standard Screws-
(Marked "4"):
5 mm ..... ... . ............... .
(59-66 ft.-Ihs.)
..... 2-4 N'm
(18-35 in.-Ihs.)
6 mm .... .... .. .. . . .. . . .. ... ....... . .. 4-7 N'm
(35-62 in.-Ihs.)
8 mm ............ ... . ............... 10-16 N'm
(7·12 ft.-Ihs.)
10 mm .......... . .. . .... . . . .... ..... 22-35 N'm
(1 6-26 ft.-Ihs.)
(Stainless Steel):
5 mm .... . ......... .. . . . . .. . .......... 2-4 N'm
(18-35 in.-Ihs.)
6 mm .... . ........ . .................. 6-10 N'm
(53-88 in.-Ihs.)
8 mm ........... . .. . . .. . . ........... 15-20 N'm
10 mm ......... ... ....... .
(Marked "700
) :
(11·15 ft.-Ihs.)
...... 34-41 N'm
(25-30 ft.·lhs.)
5 film ,.,' , . . ,., , . , .. , .. , •. , .... .3-6 N'm
(26-53 in.-Ihs.)
6mm .. .. ...... .. ... . .. . . . . . ... ",,8-12N'm
(71-106 in.-Ihs.)
8 mm . , , .. , .. ' . ' , .. , . . , . . , . . , . . ..... 18-28 N'm
(13-21 ft,-Ihs.)
10 mm .. . . . .. , , ..... ' .... , , . , .. ' , , . .40-60 N'm
(29-44 rUhs.)

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7. SERVICE MANUAL
LUBRICATION
The power head is lubricated by oil
mixed with the fuel. Recommended oil
is Suzuki Outboard Motor Oil or a good
quality NMMA certified TC-W two-
stroke engine oil. Recommended fuel is
no-lead or regular automotive gasoline
having an 85-95 octane rating. Fuel and
oil shouId be thoroughly mixed .
On all models except OTI5C, fuel:oil
ratio should be 30:1 during break-in of
a new or rebuilt engine. On DT9.9 and
OT15 models prior to 1986, fuel ratio af-
ter initial .5 hours of operation should
be 50: I when using a recommended oil.
On 1986 and later D1'9.9 and DT15
models, fuel ratio after initial 15 hours
of operation should be 100:1 when us-
ing a recommended oil.
Model DTl5C is equipped with auto-
matic oil iliection. When breaking-in a
new or rebuilt engine, mix a recom-
mended oil with the gasoline at a 50:1
ratio in combination with the oil iliec-
lion system to ensure sufficient lubri-
cation during break-in. Switch to
straight gasoline after completion of the
first tank of fuel.
Oil iIiection system on Model DTl5C
is equipped with a renewable oil filter
between oil tank and oil pump. Renew
filter after 50 hours of operation or af-
ter three months.
The lower unit gears and bearings are
lubricated by approximately 170 mL
(5.7 ozs.) of SAE 90 hypoid outboard
gear oil. Reinstall vent and fill plugs se-
curely using a new gasket, if necessary,
to ensure a water tight seal.
FUEL SYSTEM
CARBURETOR. A Mikuni B24-15
carburetor is used on D1'9.9 models and
Mikuni B24-18 carburetor is used on
DTl5 and DT15C models. Refer to Fig.
SZ6-1 for exploded view of carburetor.
Initial setling of pilot air screw (2) from
a lightly seated pOSition should be 1-114
to 1-3/4 turns on DT9.9 and OT15
models prior to 1987, 1-118 to 1-5/8
turns on Model DT9.9 after 1986, 7/8 to
1-3/8 turns on DTl5 models after 1986
and 1-li2 to 2 turns on Model OTI5C.
Final carburetor adjustment should be
made with engine running at normal
operating temperature in forward gear.
Adjust idle speed screw (4) so engine
idles at approximately 600-650 rpm. Ad-
just pilot air screw so engine idles
smoothly and will accelerate cleanly
without hesitation. As adjustments af-
fect each other, readjustment of idle
speed may be necessary.
Main fuel metering is controlled by
main jet (13). Standard main jet size for
normal operation is #110 on DT9.9
models, #122.5 on early DTl5 models
Suzuki OT9.9 & OT15 (1983-1987) & 0T15C (1988)
(prior to 1987) and #125 on late DTl5
and all OTI5C models. Standard pilotjet
(6) size is #52.5 on DT9.9 models, #57.5
on OTI5 models and #65 on DTl5C
models.
To check float level, remove float
bowl (10) and invert carburetor body
(I). Base of float (9-Fig. SZ6-2) should
Fig. SZ6-I-EJtploded .Ie.. of Wlltunl ry/H ""rbu-
retor .nd fu.' pump.
1. Uody
:.2. Pilo t air lICtc.....
:3. Spring
,1. Idle ~ ~~ :;.crcw
5. Spring
ti. Pilo tjt>t
7. Ga.!ikct
fl . Necdl<- '~l'c
1:1 , FIQAt
10. r'loat bowl
11 . Ga...kct
12. Sere,,·
13. Main jet
14. Choke l<:vcr
15. Choke kMb
16. Gwokct
17. Diaphrllgm
18. Check "'Idve a......, y,
19. Diaphragm
20. Gasket
21. CO'I..t
FIg. SZ6-2-Forproper _ /e••" _ of flost (9)
should be. d/s/.nee (0) of 23-25 mm (O.91~.98
In.) ....y from top of c.rburetor body ".nge.
be a distance (D) of 23-25 mm (0.91-0.98
in.) from top of carburetor body flange
on all models. Adjust float level by
bending float tang.
FUEL FILTER. A fuel filter assembly
mounted on engine port side is used to
filter the fuel prior to entering the fuel
pump assembly. Periodically unscrew
cup (5-Fig. SZ6-3) from base (1) and
withdraw filter element (4). Clean cup
(5) and filter element (4) in a suitable
solvent and blow dry with clean com-
pressed air. Inspect filter element (4).
If excessive blockage or damage is not-
ed, then the element must be renewed.
Reassembly is reverse order of disas-
sembly. Renew .'0" ring (3) and, if
needed, seal (2) during reassembly.
FUEL PUMP. The fuel pump is an in-
tegral part of the carburetor. The fuel
pump assembly can be overhauled with-
out carburetor removal, proceed as fol-
lows: Remove engine top cover and dis-
connect the fuel tank supply hose at the
outboard motor connector. Disconnect
the fuel supply hose at the fuel pump
inlet.
With reference to Fig. SZ6-1, disas-
semble the fuel pump assembly. Inspect
all components for damage and exces-
sive wear and renew if needed. Clean
components as needed with a suitable
cleaning solution. Blow dry with clean
compressed air. If compressed air is not
available, use only lint-free cloths to
Fig. SZ6-3-Exploded ./e.. of fUel filter -.rb/y.
1. &.'it!
2 Seal
3. "0" rillJC
4. Element
G. Cup