Suzuki DT2 User Manual

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 ............... . .......... ＮＴＰＭｾＰ＠ 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.)
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Suzuki DT2 Specifications

General

Engine Type	2-stroke
Starting System	Manual
Oil/Fuel Mix Ratio	50:1
Maximum Output	2 HP
Fuel Tank Capacity	1.2 L
Shaft Length	15 inches

Summary

CONDENSED SERVICE DATA

TUNE-UP

Engine tune-up specifications including H.P./RPM, bore, stroke, displacement, spark plug, magneto gaps.

SIZES-CLEARANCES

Specifications for piston ring end gap, piston-to-cylinder clearance, crankshaft runout, and rod side shake.

TIGHTENING TORQUES

Torque specifications for cylinder head, crankcase, reed plate, and flywheel nut.

LUBRICATION

Fuel and Oil Mixture

Recommended fuel:oil ratios for break-in and normal service for Suzuki outboard motors.

Lower Unit Lubrication

Lubrication of lower unit gears and bearings, including oil capacity details.

FUEL SYSTEM

Carburetor Adjustment

Details on the Mikuni carburetor, idle speed, and pilot air screw adjustment for optimal performance.

Float Level Adjustment

Procedure for checking and adjusting the float level in the carburetor for correct fuel delivery.

IGNITION SYSTEM

Breaker Points and Timing

Setting breaker point gap and checking/adjusting ignition timing.

COOLING SYSTEM

Water Pump Operation

Description of the rubber impeller type water pump responsible for engine cooling.

GEAR TYPE STARTER

Starter Assembly Maintenance

Steps for removing, disassembling, and setting tension on the gear type starter assembly.

LOWER UNIT

Propeller and Shear Pin

Information on propeller specifications, shear pin function, and optional propeller selection.

Gearcase Overhaul

Guidance on the removal, repair, and overhaul of the lower unit gearcase assembly.