This workshop service repair manual covers Suzuki outboard motors and jet drives manufactured between 1992 and 1999, encompassing models from 75HP to 225HP. These 2-stroke gasoline-powered engines are known for their robust engineering and reliability. This manual provides detailed information to ensure optimal performance and longevity for your marine propulsion system, covering a wide range of models designed for various watercraft applications.
The purpose of this manual is to provide comprehensive guidance for the repair, maintenance, and troubleshooting of your Suzuki outboard motor or jet drive. It is intended for users ranging from first-time owners to professional technicians, offering detailed procedures for routine maintenance, tune-ups, lubrication, and system adjustments. Key areas covered include the power head, fuel and ignition systems, cooling system, gearcase, jet drives, and electrical components, supplemented by wiring diagrams and troubleshooting charts to address common issues effectively.
1992-1999 Suzuki 75HP-225HP TWO-Stroke Outboard & Jet Drives Workshop Service Manual
Models Covered:
Suzuki DT75 (1992-1999)
Suzuki DT85 (1992-1999)
Suzuki PU85 (1992-1999)
Suzuki DT90 (1992-1999)
Suzuki DT100 (1992-1999)
Suzuki DT115 (1992-1999)
Suzuki DT140 (1992-1999)
Suzuki PU140 (1992-1999)
Suzuki DT140 EFI (1992-1999)
Suzuki DT150 (1992-1999)
Suzuki DT150 EFI (1992-1999)
Suzuki DT175 (1992-1999)
Suzuki DT200 (1992-1999)
Suzuki DT200 EFI (1992-1999)
Suzuki DT225 (1992-1999)
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
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 /Specifications
CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's techniques /Specifications
CHAPTER THREE / TROUBLESHOOTING
Troubleshooting test equipment / Troubleshooting preparation / Starting difficulty / Fuel system component testing / Starting system / Ignition system / Warning systems / Oil injection system / Charging system / Power head / Cooling system / Gearcase / Trim system / Electronic fuel injection
CHAPTER FOUR / ROUTINE MAINTENANCE, LUBRICATION AND TUNE-UP
Routine maintenance / Power head / Fuel/oil mixture ratio / Oil injection systems / Gearcase lubricant level check / Gearcase lubricant change / Hydraulic trim system fluid inspection / Corrosion prevention / Propeller and propeller shaft service / Jet drive lubrication / Throttle and shift linkage lubrication / Steering and midsection lubrication / Battery maintenance / Electric starter maintenance / Cooling system maintenance / Flushing the cooling system / Fuel requirements / Fuel filter service / Fuel hoses and clamps / Preparation for storage / Submersion / Tune-up / Compression test / Spark plugs / Ignition timing / Carburetor adjustments / Removing carbon from the combustion chamber / On-boat test /Specifications
CHAPTER FIVE / SYNCHRONIZATION AND ADJUSTMENT
Shift cables and linkage / Throttle cable and linkage / Pilot screw / Idle speed / Choke solenoid / Throttle position sensor (TPS) / Oil pump linkage adjustment / Ignition timing /Specifications
CHAPTER SIX / FUEL SYSTEM
Carburetor / Intake manifold / Electronic fuel injection (EFI) system
CHAPTER SEVEN / ELECTRICAL AND IGNITION
Starting system / Charging system / Ignition system / Warning system / Battery requirements /Specifications
CHAPTER EIGHT / POWER HEAD
Flywheel removal and installation / Break-in procedure /Specifications
CHAPTER NINE / GEARCASE
Gearcase operation / Gearcase removal and installation / Water pump / Gearcase disassembly / Shim selection / Gear pattern inspection /Specifications
CHAPTER TEN / JET DRIVES
Jet drive removal and installation /Specifications
CHAPTER ELEVEN / MIDSECTION
Clamp brackets /Specifications
CHAPTER TWELVE / POWER TRIM SYSTEM
Fluid filling / Air bleeding /Specifications
CHAPTER THIRTEEN / OIL INJECTION SYSTEM
Oil flow switch removal, inspection and installation / Bleed air from the system /Specifications
CHAPTER FOURTEEN / REMOTE CONTROL
INDEX
WIRING DIAGRAMS
1992-1999 Suzuki 75HP-225HP TWO-Stroke Outboard & Jet Drives Workshop Service Manual
Models Covered:
Suzuki DT75 (1992-1999)
Suzuki DT85 (1992-1999)
Suzuki PU85 (1992-1999)
Suzuki DT90 (1992-1999)
Suzuki DT100 (1992-1999)
Suzuki DT115 (1992-1999)
Suzuki DT140 (1992-1999)
Suzuki PU140 (1992-1999)
Suzuki DT140 EFI (1992-1999)
Suzuki DT150 (1992-1999)
Suzuki DT150 EFI (1992-1999)
Suzuki DT175 (1992-1999)
Suzuki DT200 (1992-1999)
Suzuki DT200 EFI (1992-1999)
Suzuki DT225 (1992-1999)
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
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 /Specifications
CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's techniques /Specifications
CHAPTER THREE / TROUBLESHOOTING
Troubleshooting test equipment / Troubleshooting preparation / Starting difficulty / Fuel system component testing / Starting system / Ignition system / Warning systems / Oil injection system / Charging system / Power head / Cooling system / Gearcase / Trim system / Electronic fuel injection
CHAPTER FOUR / ROUTINE MAINTENANCE, LUBRICATION AND TUNE-UP
Routine maintenance / Power head / Fuel/oil mixture ratio / Oil injection systems / Gearcase lubricant level check / Gearcase lubricant change / Hydraulic trim system fluid inspection / Corrosion prevention / Propeller and propeller shaft service / Jet drive lubrication / Throttle and shift linkage lubrication / Steering and midsection lubrication / Battery maintenance / Electric starter maintenance / Cooling system maintenance / Flushing the cooling system / Fuel requirements / Fuel filter service / Fuel hoses and clamps / Preparation for storage / Submersion / Tune-up / Compression test / Spark plugs / Ignition timing / Carburetor adjustments / Removing carbon from the combustion chamber / On-boat test /Specifications
CHAPTER FIVE / SYNCHRONIZATION AND ADJUSTMENT
Shift cables and linkage / Throttle cable and linkage / Pilot screw / Idle speed / Choke solenoid / Throttle position sensor (TPS) / Oil pump linkage adjustment / Ignition timing /Specifications
CHAPTER SIX / FUEL SYSTEM
Carburetor / Intake manifold / Electronic fuel injection (EFI) system
CHAPTER SEVEN / ELECTRICAL AND IGNITION
Starting system / Charging system / Ignition system / Warning system / Battery requirements /Specifications
CHAPTER EIGHT / POWER HEAD
Flywheel removal and installation / Break-in procedure /Specifications
CHAPTER NINE / GEARCASE
Gearcase operation / Gearcase removal and installation / Water pump / Gearcase disassembly / Shim selection / Gear pattern inspection /Specifications
CHAPTER TEN / JET DRIVES
Jet drive removal and installation /Specifications
CHAPTER ELEVEN / MIDSECTION
Clamp brackets /Specifications
CHAPTER TWELVE / POWER TRIM SYSTEM
Fluid filling / Air bleeding /Specifications
CHAPTER THIRTEEN / OIL INJECTION SYSTEM
Oil flow switch removal, inspection and installation / Bleed air from the system /Specifications
CHAPTER FOURTEEN / REMOTE CONTROL
INDEX
WIRING DIAGRAMS
