Suzuki Dt225 Outboard Manuals Free Download

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Sep 09, 2014  Download 1986-2000 Suzuki Dt150 Dt175 Dt200 Dt225 2-stroke Outboard Repair Manual here: This Manual Covers The Following Machines: 1986 SUZUKI.

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PROPELLERS

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An outboard motor is designed to develop its rated power within a specified engine speed range. The maximum rated power delivered by the Suzuki models are shown in your service manual. If the standard propeller fails to meet the above requirement, use another pitch propeller to hold the engine speed within the range specified in your manual propeller selection chart.
Installing a propeller with pitch either too high or too low will cause incorrect maximum engine speed, which may result in severe damage to the motor.

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Disassembly of propeller shaft components

1. Slide propeller shaft away from reverse gear housing assembly

Account for reverse gear back-up shim thrust washer

2. Remove horizontal slider and forward gear thrust washer

3. Remove spring

4. Using special tool, push dog pin shifter.

5. Remove clutch dog shifter propeller shaft.

PROPELLER

• Inspect propeller for bent, chipped or broken blades and replace or repair if necessary.

• Inspect propeller bushing splines for wear or other damage and replace if necessary.

• Inspect propeller bushing for deterioration or slipping and replace if necessary.

PROPELLER SHAFT COMPONENTS

• Inspect horizontal slider and connector pin for excessive wear or other damage. Replace if necessary.

• Inspect clutch dog shifter for excessive wear, chip or other damage. Replace if necessary.

• Inspect dog pin for bent or other damage. Replace if necessary.

• Inspect propeller shaft / splines for wear, twist or other damage. Replace if necessary.

PROPELLER SHAFT BEARING HOUSING

• Inspect housing for cracks or other damage. Replace if necessary.

• Inspect propeller shaft bearings and reverse gear bearing for pitting, rough or other damage. Replace if necessary.

• Inspect oil seals and O-ring for cuts, nicks or tears.

Replacing propeller shaft oil seal

1. Remove retaining ring

2. Extract oil seals

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1 and washer 2.3 using oil seal remover.

Do not re-use oil seal once removed.

Always use a new oil seal.

3. Apply Water Resistant Grease to inner circumference of housing.

4. Using an oil seal installer, drive two oil seals (one at a time) into housing.

The lipped portion of seal should face towards propeller.

Apply Water Resistant Grease to seal lips.

5. Install washer and retaining ring.

PROPELLER INSTALLATION

1. Install spacer shaft, then slide on propeller

2. Fit spacer specified torque.

1 and propeller stopper 2 onto propeller3.4, washer 5 and nut 6, then tighten nut to

Propeller nut : 55 N.m (5.5 kg-m, 40.0 lb.-ft.)

3. Push cotter pin secure.

PROPELLER SELECTION FOR COUNTER

ROTATION

Suzuki Dt225 Outboard Manuals Free Download 7

For counter-rotation model, newly designed stainless steel propellers are available as follows.

Suzuki highly recommend to use the genuine Suzuki counterrotation propeller for the counter rotation model. In case of twin installation, always use on both engines, the same size normal rotation and counter-rotation propellers.

ENGINE CRANKED, BUT NOT START (OR STOPS SHORTLY AFTER STARTING)
UNSTABLE IDLING / TROLLING (OR ENGINE TENDS TO STALL)

• Incorrect by-pass air screw adjustment [NOTE3]
• IAC valve failure [NOTE3]
• IAC passage failure (clogged hose, etc.) [NOTE3]
• Spark plug failure
• Ignition coil failure
• ECM failure
• Wire continuity / connection failure
• Failure of high pressure fuel system components :
• Fuel injector (clog, stuck valve, etc.)
• Fuel pressure regulator (incorrect regulated pressure, etc.)
• Fuel pump (clogged suction filter, leakage in tank, etc.)
• Fuel filter (clog, etc.)
• Hose (clog, kink, leakage, etc.)

CHAPTER INDEX

GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE CONTROL SYSTEM
ENGINE ELECTRICAL
FUEL SYSTEM
POWER UNIT
MID UNIT
POWER TRIM AND TILT
LOWER UNIT
WIRE / HOSE ROUTING

GENERAL INFORMATION

Outboard

CONTENTS

WARNING / CAUTION / NOTE
GENERAL PRECAUTIONS
IDENTIFICATION NUMBER LOCATION
FUEL AND OIL
GASOLINE RECOMMENDATION
ENGINE OIL
ENGINE BREAK-IN
PROPELLERS
POWERHEAD DIRECTION OF ROTATION
SPECIFICATIONS
SERVICE DATA
TIGHTENING TORQUE
SPECIAL TOOLS
MATERIALS REQUIRED

Free

PERIODIC MAINTENANCE

CONTENTS

PERIODIC MAINTENANCE SCHEDULE
PERIODIC MAINTENANCE CHART
MAINTENANCE AND TUNE-UP PROCEDURES
ENGINE OIL / ENGINE OIL FILTER
GEAR OIL
LUBRICATION
SPARK PLUG
TAPPET CLEARANCE
IDLE SPEED
IGNITION TIMING
BREATHER AND FUEL LINE
LOW PRESSURE FUEL FILTER
HIGH PRESSURE FUEL FILTER
WATER PUMP / WATER PUMP IMPELLER
PROPELLER / NUT / COTTER PIN
ANODES AND BONDING WIRES
BATTERY
BOLT AND NUTS
FUEL MIXTURE CHECK (O2 FEEDBACK)
OIL PRESSURE
CYLINDER COMPRESSION

ENGINE CONTROL SYSTEM

CONTENTS

Suzuki Outboard Motor Manuals Online

ENGINE CONTROL SYSTEM STRUCTURE
SYSTEM STRUCTURE 1
SYSTEM STRUCTURE 2
WIRING DIAGRAM FOR ENGINE CONTROL
COMPONENTS FOR SYSTEM CONTROL
ENGINE CONTROL MODULE (ECM)
ECM CONNECTOR / TERMINALS LAYOUT
ECM INTERNAL STRUCTURE
SENSOR AND SWITCH
IGNITION SYSTEM
IGNITION CONTROL SYSTEM
ELECTRONIC FUEL INJECTION SYSTEM
FUEL INJECTION CONTROL SYSTEM
FUEL DELIVERY SYSTEM COMPONENTS
FUEL PUMP CONTROL SYSTEM
AIR INTAKE COMPONENTS
IDLE AIR CONTROL SYSTEM
CAUTION SYSTEM
OVER-REVOLUTION CAUTION SYSTEM
LOW OIL PRESSURE CAUTION SYSTEM
OVERHEAT CAUTION SYSTEM
LOW BATTERY VOLTAGE CAUTION SYSTEM
SELF-DIAGNOSTIC SYSTEM
PRIORITY / CODE / PATTERN FOR SELF-DIAGNOSTIC
SYSTEM OPERATION
CONDITION FOR SELF-DIAGNOSTIC SYSTEM OPERATION
FAIL-SAFE SYSTEM
PRE-PROGRAMMED VALUE FOR FAIL-SAFE SYSTEM
OPERATING HOUR INDICATION SYSTEM
OIL CHANGE REMINDER SYSTEM
START-IN-GEAR PROTECTION SYSTEM
O2 FEEDBACK SYSTEM INSPECTION
PRECAUTION ON SYSTEM INSPECTION
44-PIN TEST CORD
INSPECTION FOR ECM CIRCUIT VOLTAGE
INSPECTION FOR RESISTANCE
COMPONENT INSPECTIONS
TROUBLESHOOTING
REMOVAL / INSTALLATION
FLYWHEEL
CKP SENSOR / CMP SENSOR
OIL PRESSURE SWITCH

Suzuki Outboard Manuals Online

ELECTRICAL

CONTENTS

Suzuki Dt225 Outboard Manuals Free Downloads

BATTERY CHARGING SYSTEM OUTLINE
INSPECTION
REMOVAL / INSTALLATION
ELECTRIC STARTER SYSTEM
OUTLINE
TROUBLESHOOTING
INSPECTION
STARTER MOTOR
REMOVAL / INSTALLATION
DISASSEMBLY
INSPECTION & SERVICING
ASSEMBLY
PERFORMANCE TEST
MONITOR-TACHOMETER
INSPECTION
ERECTRIC PARTS HOLDER
REMOVAL / INSTALLATION