Re: dt65 over heating
I think everyone has heard from their grandfather that removing the thermostat from his 58 Ford made it run cooler since the thermostat controls the amount of water that is directed into the radiator. Your outboard does not have a radiator, the thermostat, when closed, keeps cooling water away from a narrow cooling strip that travels down across the area of the plugs, causing it to heat up quickly. When the motor warms, it opens allowing water through. If the thermostat is completely removed, there might be so much flow allocated to that narrow strip around the plugs that you may be losing flow around the cylinders. It's just a theory but I'm pretty sure Suzuki designed the cooling system to work with a thermostat. Most of the other suggestions are pretty easy to check, let me know what you find.