1992-1999 Suzuki 2-65hp Two Stroke Outboard Repair Manual by Clymer

Description

This 1992-1999 Clymer Suzuki 2-65hp Two Stroke Outboard Boat Engine Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1992-1999 Suzuki 2-65hp two-stroke outboards engines including DT2, DT2.2, DT4, DT5, DT6, DT8, DT9.9, DT15, DT25, DT30, DT40, DT55, DT65, PU40, and PU55 motors.

Provides coverage for Jet drive units. Includes general information on each model, tools and techniques, troubleshooting and testing, lubrication, maintenance and tune-up, synchronization and linkage adjustments, fuel system, electrical and ignition systems, power head, gearcase, Jet drives, rewind starter, power trim and tilt systems, midsection, oil injection system, remote control and complete wiring diagrams. Features 496 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
Troubleshooting test equipment, Troubleshooting preparation, Starting difficulty, Fuel system component testing, Starting system, Ignition system, Oil injection system, Charging system, Fuses and wire harnesses, Trim and tilt system, Power head, Cooling system, Gearcase

CHAPTER FOUR, LUBRICATION, MAINTENANCE AND TUNE-UP
Routine maintenance, Lubrication, Corrosion prevention, Tune-up

CHAPTER FIVE, SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
Carburetor synchronization, Static ignition timing adjustment, Carburetor adjustment

CHAPTER SIX, FUEL SYSTEM
Carburetor, Reed valves

CHAPTER SEVEN, ELECTRICAL AND IGNITION
Starting system components, Charging system, Ignition system, Warning system, Battery

CHAPTER EIGHT, POWER HEAD
Flywheel removal and installation, Power head, Power head assembly, Break-in procedure

CHAPTER NINE, GEARCASE
Gearcase operation, Propeller removal and installation, Gearcase, Water pump, Gearcase disassembly, Shim selection

CHAPTER TEN, JET DRIVES
Jet drive removal and installation

CHAPTER ELEVEN, REWIND STARTER
Rewind starter operation, Rewind starter repair

CHAPTER TWELVE, POWER TRIM/TILT AND MIDSECTION
Power trim and tilt system, Electric motor removal, Midsection

CHAPTER THIRTEEN, OIL INJECTION SYSTEM
Oil flow sensor removal, inspection and installation, Bleeding the system

CHAPTER FOURTEEN, REMOTE CONTROL

INDEX

WIRING DIAGRAMS