Description
This Clymer Suzuki 2-225 hp 1985 1986 1987 1988 1989 1990 1991 Outboard Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1985-1991 Suzuki 2 – 225 horsepower outboard boat engines including DT2, DT4, DT6, DT8, DT8 Sail, DT9.9, DT9.9 Sail, DT15, DT20, DT25, DT30, DT35, DT40, DT55, DT65, DT75, DT85, DT90, DT100, DT100 Super Four, DT115, DT140, DT150, DT150 Super Six, DT175, DT200, DT200 Exante, and DT225 motors.
Includes coverage for Jet drives. Provides general information for each model, covers tools and techniques, troubleshooting and testing, lubrication, maintenance and tune-up, timing, synchronization and adjustment, fuel system, electrical system, power head, gearcase, automatic rewind starter, power trim and tilt systems, oil injection system, Jet drives and complete wiring diagrams. Features 648 illustrated pages.
QUICK REFERENCE DATA
CHAPTER ONE, GENERAL INFORMATION
Manual organization, Notes, cautions and warnings, Torque specifications, Engine operation, Fasteners, Lubricants, Gasket sealant, Galvanic corrosion, Protection from galvanic corrosion, Propellers
CHAPTER TWO, TOOLS AND TECHNIQUES
Safety first, Basic hand tools, Test equipment, Service hints, Special tips, Mechanic’s techniques
CHAPTER THREE, TROUBLESHOOTING
Operating requirements, Starting system, Lighting system, Charging system, Ignition system, Breaker-point ignition component testing (1985-1989 DT 2), Transistorized ignition system (1990-on DT 2), Pointless electronic ignition (PEI) component testing, Integrated circuit (IC) and Micro Link ignition systems, Fuel system (carbureted models), Engine temperature and overheating, Engine
CHAPTER FOUR, LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication, Storage, Complete submersion, Anti-corrosion maintenance, Galvanic protection and bonding wires, Engine flushing, Tune-up
CHAPTER FIVE, TIMING, SYNCHRONIZATION AND ADJUSTMENT
Engine timing and synchronization, Timing adjustment, Throttle adjustment, Throttle valve sensor adjustment, DT 225 EFI
CHAPTER SIX, FUEL SYSTEM
Loss of high speed rpm (all DT 15), Off idle lean conditions (1988 DT 30 and 1989 DT 65), Fuel pump and filter, Carburetor removal/installation, Carburetor overhaul/adjustment, Throttle plunger carburetor (DT 2), Centerbowl carburetor (DT 4, DT 6; 1985-1987 DT 8), Integral fuel pump carburetor (1988-on DT 8; 1985-on DT 9.9, DT 15), Centerbowl single -throat carburetor (DT 20 through DT 85; DT115, DT140), Centerbowl dual-throat carburetor (V4 and V6), Carburetor cleaning and inspection, Reed valve assembly, Fuel tank, Fuel line, connector and primer bulb, Fuel injection system (DT 225 V6)
CHAPTER SEVEN, ELECTRICAL SYSTEMS
Electrical connectors, Battery, Lighting system (1985-1986 DT 9.9, DT 15, DT 40), Battery charging system, Electric starting systems, Starter motor, Magneto breaker point ignition (1985-1989 DT 2), Breakerless transistorized ignition (1990-on DT 2), PEI ignition, Integrated circuit (I.C.) ignition system, Micro Link ignition system (V4 and V6), Ignition coil (all models), CDI unit (all models)
CHAPTER EIGHT, POWER HEAD
Engine serial number, Fasteners and torque, Flywheel, Power head
CHAPTER NINE, GEARCASE
Propeller, Water pump, Gearcase, Propeller shaft clutch, Pinion gear depth and forward/reverse gear backlash, Pinion gear adjustment (1986-on DT 115, DT 140; V4 and V6), Propeller shaft end play (DT 8 through DT 65 only), Clutch pushrod dimension
CHAPTER TEN, AUTOMATIC REWIND STARTERS
Bendix starter, Overhead starter, Adjustment
CHAPTER ELEVEN, POWER TRIM AND TILT SYSTEM
Hydraulic pump, Troubleshooting, Pump oil pressure test, Component replacement
CHAPTER TWELVE, OIL INJECTION SYSTEM
System components, Operation, Low oil level warning light and buzzer, Oil flow sensor, Air/oil mixing valve, Oil pump service, Component replacement
CHAPTER THIRTEEN, JET DRIVES
Maintenance, Water pump, Jet drive, Bearing housing, Intake housing liner
INDEX
WIRING DIAGRAMS
