Suzuki DT150/DT200 Outboard Service Manual 1986–2003

Official Suzuki DT150/DT200 outboard service manual covering 1986-2003 models. Includes detailed procedures, specifications, and troubleshooting for all systems, ensuring optimal performance and longevity of your V6 outboard.

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Document Details

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Document Number / Seller:
31305 / Jessica Anderson
File Size:
31.80 MB
File Type:
PDF
Language:
English
Pages:
616
Printable:
Yes
Category:
Outboard Motor
Last updated / verified
Jan 13, 2026

Models Covered & Key Technical Specifications

Suzuki DT150/DT200 Outboard Service Manual 1986–2003

Documents DT150/DT200 service procedures | Series: 1986–2003 Bundle.

  • Design Specifications: 2.7 liter 60° V6 architectures establish the core engine architecture.
  • Nominal Cooling Data: For optimal thermal management, 6.0 liters (12.7 US qt) ethylene glycol cooling logic provides the necessary parameters.
  • Technical Power Output: 1.4 kW starter motor output controls the heavy-duty electrical framework.
  • Standard Combustion Parameters: For precise ignition, 1.0–1.1 mm (0.039–0.043 in.) spark plug gap parameters are required.
  • Nominal Lubrication Standard: 3.7 liters (7.8 US pt) engine oil logic ensures the primary lubrication framework.
  • Design Feed Speed: Recommended operating range from 5000–8000 RPM dictates the engine performance framework.

Professional Workshop Service Manual & Technical Specifications

Suzuki DT150/DT200 Outboard Service Manual 1986–2003 (616 Pages) | Service Standards Electrical-Reference

Series-Validation: DT150, DT200, DT150SS, DT150 Super Six, V6 Outboard Models | System-Coverage: Power Unit, Fuel System, Ignition System / Electrical | Subsystem-Focus: Troubleshooting, Maintenance, Specifications

Outlining the operational framework across various systems and components, this manual details removal, disassembly, inspection, and reassembly procedures. It covers essential maintenance tasks, specifications, and troubleshooting guidance to ensure your Suzuki outboard motor operates efficiently and reliably.

MIDDLE Metric Parameters Calibration-Data
Engine Type Cycle 6
Bore mm (in) 84 (3.3)
Stroke mm (in) 81 (3.2)
Total Displacement cm³ (cu in) 2692 (164.3)
Standard Spark Plug NGK BHS-10

This manual documents torque specifications for various components to ensure proper vibration dampening and assembly integrity. It provides comprehensive coverage for engine disassembly, troubleshooting common issues, and detailed diagrams for each system.

Key procedures are outlined for the following systems and components: Electrical and Ignition System, Fuel System, Oil Injection System, Power Unit, Housing and Bracket, Power Trim and Tilt, Lower Unit, and Motor Setting/Optional Parts.

FAQ

What is the **required** fluid capacity for this outboard motor's lubrication system? keyboard_arrow_down

3.7 liters (7.8 US pt) of engine oil is required for the lubrication system, including the filter, to ensure optimal operation.

Calculate the **specified** spark plug gap for optimal ignition. keyboard_arrow_down

1.0–1.1 mm (0.039–0.043 in.) is the specified spark plug gap to ensure precise ignition timing.

What values are **essential** for correct cooling system operation? keyboard_arrow_down

6.0 liters (12.7 US qt) of ethylene glycol cooling fluid is essential to provide adequate thermal management for the engine.

Assess the **correct** engine oil type for proper lubrication. keyboard_arrow_down

SUZUKI CCI oil or BIA-certified oil is correct for lubrication, providing the best engine performance and minimizing combustion chamber deposits.

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Reviews (5)

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The troubleshooting guides are spot on. I was able to fix my motor without professional help!
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This manual has been a lifesaver for my outboard motor. The detailed instructions made repairs so much easier!
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Rated 5 out of 5 stars
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Had a question about the manual, emailed support, and got a helpful reply within minutes!
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I was impressed with the quick download process. The email link worked perfectly!