suzuki outboard engine dt-40 parts catalogue

8/17/2019 Suzuki Outboard Engine DT-40 Parts Catalogue

1/34


2/34

PREFACE

When i t b ec om es n e c z s s a r y t o r e p l a c e p a r t s on S U Z U K I

O U T BO A RD M O T O RS ,

always

u s e S U Z U K I GENUINE PARTS which have passed

a

st r ic t i n s p e c t i o n w h i c h g u a r a n t e e s

qua l i t y and pe r fo rmance .

T h i s parts

c a t a l o g u e c o v e r s t h e

l i s t

o f

a l l

s e r v i c e p a r t s f o r

S U Z U K I

DT40

QD.

I N S T R U C T I O N S FOR Q U O T I N G

T E

CATALOGUE

1.

DIENSIONS

Dimensions

o f

t h e

p a . r t s i n

t h i s

c a t al o g ue a r e i n d i c a t e d i n u n i t

millimeters.

2.

A BBRE V I A T I O E V S

A b b r ev i a ti o n s u s ed i a t h i s c a t a l o g u e are

as

fo l lows :

AR : As r e q u i r e d

ASSY

:

Assembly

E.No.

:

Engine number

F.No.

:

Frame number

NT

: Number

o f teeth

O K : O p t i o n a l

0s

:

O v e r s i z e

STD :

S t a n d a r d

d

ID

OD

L

LH

RH

-123456

123456-

:

Diameter

of

m a t e r i a l T : T h i c k n e s s

:

I n s i d e d i a m e t e r us : U n d e r s i z e

:

O u t s i d e d i a m e t e r :

Width

:

Length

:

L e f t h a n d s i d e

: R i g h t h a n d s i d e

:

From F.No.4001-301234

S,L,UL,LL

:

Transom typ e

: Up t o F .No.4001-301234

12 x 3 4 x

5 . 6

. * . * - . - .

F i g u r e s i n

the

d e s c r i p t i o n c ol um n

shw t h e

dimensions o f

parts.

T 7 T

3.

IN N ER

PARTS OF

ASSEMBLY

P a r t s n u mb er t h a t h a v e

a

p e r i o d

( . I mark i n

f r o n t o f

t h e

part d

on

a t e x t page are s e p a r a t e l y s e r v i c e d p a r t s

of

t h e assembly.

4. MODIFICATION NOTICE

A

p a r t s b u i l e t i n

w i l l

be

sent

t o you on

a l l

occas io ns when chan

p a r t s o c c u r , i n c l u d i n g i n t e r c h a n g e a b l e m o d i f i c a t i c n s b e t w ee n new p a

ones .

NOTE

5-

5-1.

5-2.

5-3.

T h e r e are s o m e d i f f e r e n t p a r t s f r o m t h o s e o f p r o d

mode l s among spa re pa r t s

for t h e

a d m i n i s t r a t i v e r

common use of them

w i t h

othe r mode l s .

I n r e s p e c t o f r u b b e r h o s e s an d v i n y l t u b e s , p l e a s

t o u s e them by c u t t i n g o f f a c c o r d i n g t o

t h e

l e n g t

m e n ti o n ed o n p a r t s c a t a l o g u e or what is a c t u a l l y

on t h e v e h i c l e .

Note

t h a t

t h e d r a w i ng s on t h e i l l u s t r a t i o n p a g e a

r e a d y

reference

o f s p a r e

parts

number , no t t o be

assembly manual .

When assembling, use

1 8 S U Z U K I

SERVICE

6

E N G I N E NUMBER

DT40 Q D ,

DT40R

QD

: 4001-300001-


3/34

FIG.

1

1

FIG.1 (B- 2) CYLINDER

Q T Y

E S C R I P T I O N

EF.NO. PART

NO.

6 7

-9.10

- 6 7

- 9 10

' 6 - 7

14

1

2

3

4

5

6

8

9

10

11

12

13

14

15-1

15-2

16

17

18

19

20

21

22

23

11161-94301-02M

COVER,

cyl inder head

11162-94300 GASKET, cylinder head cover

11141-94302

GASKET,

cylinder head

01107-08658 BOLT

08321-21088 LOCK WASER

08322-11088

WASI€R

01107-06258

BOLT

38321-21068 LOCK WASHER

08322-21068 WASI-ER

11291-94301

HOOK,

engine

01517-08208 BOLT

11111-94300-024

CYLINIER

*AD

11301-94304-02M CYLIN)ER/CRANKCASE ASSY

04211-09109 .PIN

01107-10558 .BOLT

01107-10658

.BOLT

01107-06258 .BOLT

08321-21108 .LOCK WASI-ER

08322-11108 .WASHER

17670-94300 THERMOSTAT

09343-02026

HOSE,

lubrication L:300)

09401-06403 C L I P

09404-06414 CLAMP, lubr icat ion hose

11400-94818 GASKET SET

1

1

1

1

10

10

10

4

4

4

1

2

1

2

6

2

8

8

1

1

2

1

1 OPT

B2


4/34

12 -

FBG.2

9--@

24

1

r l - 5

2

FIG.2

6-3)

CRANKSHAFF

Q T Y

DESCRIPTION

REF.NO. PAR T NO.

1-1

1-2

1-3

2-1

2-2

2-3

3-1

3-2

3-3

4-1

a-2

4-3

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

12110-94301

PISTON

12110-94301-025

PISTON

OS:C 25)

12110-94301-050

PISTON 0s:

05)

12140-94300

RING

SET

piston

12140-94300-025

RING

SET,

p i s % m

OS:O 25)

12140-94300-050

RING

5 3 3 ,

Piston (0S:O.

5)

12110-94352

PI TON

12110-94352-025

PISTON 0s

:0 25)

12110-94352-050

PISTON

OS:O5)

12140-94350 RING

SET,

piston

12140-94350-025

RING SET piston

05:0.25)

12140-94350-050

RING

SET,

Piston

OS:O5)

12151-97500

09381-18002

09263-18015

09169-18004

09283-30011

09283 30042

09282-17004

12200-94304

12161-94300

09263-25028

08211-25322

12211-94302

12221-94300

12232-94300

12321-94301

12231-94300

12240-94300

09262-30055

PIN, p is tm

CIRCLIP, Disto n p in

BEARING, p is to n p i n

WASt-ER, connecting rod

OIL SEAL, upper crank sha ft

OIL SEAL, lmer crankshaft

OIL SEAL, dr iv e sh af t upper

CRANKSHAfl ASSY

. OD connecting

.BEARING, crank

P i n

. AStER

.PIN, crank

.CRANKSHN, upper

.WEEL, middle lmer

.SEAL, labyrinth

.WEEL, m idd le upper

.CRANKSHAFT

, l a m

.BEARING, crankshaft

2

2

OPT

2

om

2

2 om

2

OM

2

om

2

O K

2 O K

2 OM

2 OM

2

om

2

4

2

4

1 30x55~1

1

1 17x28~

1

2

2

4

2

1

1

1

1

1

3 30x72~

B3


5/34

8343.3

3

FIG.3 6- 4)

INLET

CASE - EXHAUST

COVER

Q TY

. . REF.NO. PART NO. DESCRIPTION

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

01517-06308 BOLT

08321-31068 LOCK W A S l f R

08322-21068 WASHER

08310-11068 NUT

12480-94300-02M CASE, i n l e t

13125-95200 GASKET, carburetor

01411-08208 STUO BOLT

01421-0 6258

STUD

BOLT

13121-94301 GASKET, i n le t case

13122-94300

GASKET,

valve sheet

13150-94301 VALVE ASSY, reed

02122-06168 SCREW

08310-22088 NIT

08322-11088

WASNR

14151-94300 GASKET, exhaust cover

RATE, exhaust

14141-94300-02M

COVER,

exhaust

01517-06258 BOLT

CASE, s i lencer

14131-94300

13811-94300

02112-06458 SCREW

08322-21068

WASNR

8

2

2

2

1

1

1

2

1

1

1

1

2

2

2

1

1

14

1

2

2

I

c


6/34

FIG.4

1

3

2.2

1 r

.* _ ?

FIG.4 6- 5)

CAWRETOR

Q T Y

.

REF.NO. PA RT NO.

DESCRIPTION

1

2

3

4

5

6

7

8

9

10

1I

12

13

14

13

16

17

18

19

20

1

20-2

20

3

21

22

13200-94310

09492-80003

13271-93311

13269-95210

13235-95210

13250-93012

13251

95

210

13611-95211

0

916265002

13254-93010

13370-28110

09493-24007

13 12-94300

13613-94300

13268 96110

13267-95211

01411-08208

13410-94300

0949140007

09491 38007

094 91 42 003

094 91 3 8008

13631 93500

09305-04005

CARBURETOR ASSY

.JET, p i l o t

80)

.SPRIG, a i r screw

SCREW,

p i l o t a i r

.NOZZLE

.FLOAT

.GASKET,

float chamber

. B a T , f l o a t

PIN,

f l oa t

.VALVE ASSY,

needle

.JET, a i r

.BOLT

.BOLT

.SPRIN;,

stop screw

.SCREW,

t h r o t t l e

s t o p

.STUD BOLT

.ShAFT ASSY

.LOCK WASHER

.JET, main

200)

JET,

main

190)

JET, main 210)

JET, main

195)

KNOB,

starter

BUSHIN;,

starter

rod

1

1

1

1

1

1

1

4

4

1

1

1

1

1

1

1

1

1

1

1

OPT

1 OPT

1 OPT

1

1

DT40 QD Revised 1

Ju n . , 83

DT40 QD

E3 Revised

1 J u n . , 8 3

B5


7/34

1

2

4

5

5 01107-08258 BOLT

6

7

0832 -21088 LOCK

WASER

WASER

8322-11088

5

FIG.5 (B-

6

UPPER OIL SEAL HOUSING

Q ’ T Y

ESCRIPTION

E F N O

PART NO.

1 11411-9431JO HOUSING, upper oil seal 1

2

11413-94300 G A S K E T

1

3

02122-06208 SCEW 5

4 31911-94311-02M BRACKET, s t a r t i n g moto;. 1

6

4

4

T


8/34

FlG.6

@-

19

@- 78

12

I

12

-Q

-

13

I

6

FIG.6 6- 7) FUEL PUMP

Q TY

. REF.NO. PART NO. DE SC RIP TI ON

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

15100-94301

15170-94311

15181.-94301

15183-94301

15186-94300

15851-94300

01107-06408

08321-21068

15321-99700

09343-05137

09343-05137

094 01-09402

15410-93400

15415-93400

15412-93400

15413-93400

15416-93400

08322-21088

08310-22088

09343-05137

09404-06414

PUMP ASSY,

f u e l

.DIARiRAGM SET

.PLATE,

fu e l pump

.SCREW

.NJT

.SCREW

BOLT

LOCK

WASER

GASKET ,

fu e l pump

H O S E ,

f u e l (pump-ca rbu re tor )

H O S E ,

f u e l ( f i lt e r - pu m p )

CLIP, f u e l h o s e

FILTER ASSY, f u e l

.O RING

. S T H A I E R

.CUP

.PACKING

WASER

WT

H O SE, f u e l ( c o n n e c t o r - f i l t e r )

CLAMP, f u e l

hose

1

1

2

2

2

3

2

2

1

1

L:500-24

1 L:500-18

6

1

1

1

1

1

1

1

1 L:500-35

1

L:80

21

7

B7


9/34

FIG.7

.

7

FIG.7 (6- 8) WATER

FUMP

Q TY

REF.NO. PART NO. DES CRI PTI ON

1

S T Y E

1 L TY P E

1

4

1-1 17560-94 310 TUBE, wa te r

1-2 17560-94340 TUBE, wa ter

2 17411-95204 CASE, w a t e r pump

3 09162-08003 LOCK WASHER

4

6

7

8

9

10

. 11

1 2

09100-08139

BOLT

09420-04005 KEY

17461-95200

IMPELLER,

w er pump

17471-95203 PLATE, pump case h e r

55130-94302-02M

HOUSING

SET, d r i v e s h a f t BRG

09289-17004 .OIL SEAL, d r i v e s h a f t

09263-25025

.BEARING,

d r i v e s h a f t

17472-95300

GASKET

09206-11005

P IN

(11x20)

2


10/34

FIG. 8

25

8

FIG.8 (8- 9)

STARTER

Q’T Y

DESCRIPTION

REF.NO. PART NO.

1

1

M40R

1

1

1-1 18100-94315 STARTER

ASSY,

r ec o i l

1-2 18100-94320 STARTER

ASSY,

I E C O i l

2 18120-94300

. S E A = DRUM

3 18131-94302 .PAWL, d ri ve

4

5

6

7

. 8

.9

1Q

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

18 142-93000

.SPRING

18151-94300 .PLATE, dr iv e

18153-95200

.SPRING,

f r i c t i o n

18191-95202 .PLATE, guide

18192-95203 .RUBBER, gu ide p late

18195-95200 .CLIP

18335-94300

18162-94300

.WASI-ER

.WASER,

dr ive pla’ te

.BUSHIM;

18155-94300 .SFRING, r e tu r n

18124-94300

18332-94300 .BOLT

08310-11068

.KIT

18196-96301

.SPRING,

guide plate

18200-95202 .GRIP ASSY

18210-93001

.

GRIP

18281-96300 . EVER, stopper

18282-96300 .ARM stopper

.SPRIffi

8284-96300

18335-96300

. W A X R

18348-96300

. IN

18290-94300 .CABLE,

N S I

01517-08258 BOLT

01517-06258 8OLT

18411-94301 CUP, st ar te r

01517-08168 B a T

18711-94301-02M BRACE, n?c o i l

starter RH

01107-06208

BOLT

08322-21068

18721-94301-02M

BRACE,

rec oi l s ta r ter LH

01517-08258 BOLT

WAS+ER

1

1

1

1

1

1

1

1

1

1

1 M40R

1 M40R

1 M4OR

1 DT40R

1 DR40R

1

DT40R

1

2

1

3

1

2

2

1 Manual

3 Manual

DT40

QD


11/34

FIG.

9

6

9 - 4 1

'1 Q

1 2

8

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

Q T Y

EF.NO. PART NO.

DESCRIPTION

1

19121-94300 LEVER,

throttle control

19122-94300 LEVER, inter l i n k throt t le CONT 1

6

1 L:187

19135-94300 ROD

inter link-starter)

19131-95501 CONNECTOR

19136-94301

ROD

( inter link-starter) 1 L:55

4

9119-05010 BALL

PIVOT

6

08310-11058

NJT

, connector

1

9151-94300-02M

RETAINER,

s t a t o r

1

19161-94301

SPACER,

stator

1

9172-94311

STOPPER,

s tator

2

01104-05108 BOLT

2

8322-21058

WASER

2

09320-07006 CUSHION

1

09111-08043 BOLT , throttle lever 1

1

1

9184-94301 BRACKET ,

h r o t t l e

cable 1

19185-94300 SPRING,

throttle lever

1

9654-94300 ROD, CLUTCH

NSI level 1

19851-96301 LEVER,

NSI

1

19865-94300

S T A Y ,

N S I

cable

09160-10040 WASHER

09160-08054 WASHER

I

17

3

C2


12/34

FIG. 1 0

10

FIC.10 (C-

3) CLUTCH

19

25

Q T Y

EF.NO.

PART NO.

D E S C R I P T I O N

2

3

4

5

6 -1

6-2

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

21210-94301

09306-08003

W2r35-05010

23111-94301

09140-06004

25111-94310

25111-94350

09280-080 35

25211-95202

09280-11001

09205-03021

25311-94300

23311-94300

23131-94300

SHAFT,

c l u t c h

BUSHING, c l u t c h shaft c e n t e r

PIN, c l u t c h rod

ROD, c l u t c h

NUT

ROD, s h i f t (L:244)

ROD,

s h i f t

0

RING (ID:7.6,

d:1 . 8 )

GUIDE, s h i f t i n g

r o d

0

RING, s h i f t i n g rod gu ide

PIN, s h i f t rod

C AM , s h i f t

TURNBUCKLE, c l u t c h

rod

BOOTS,

c l u t c h rod

1

2

1

1

1

S T Y E

1

L

TYPE

2

1

1

1

1

1

21111-94303-02M LEVER, Clu tch

09260 10003

09440-07021

09306-10001

21120-94303

21212-94303

09205-04006

21241-94300

09204-01001.

25223-95200

09139-06003

09168-06002

25231-95501

25232-95501

09100-06020

09160-06015

BALL, c l u t c h n o t c h

SPRING,

c l u t c h n o t c h

BUSHING

,

c l u t c h l e v e r

s h a f t

PLATE, c l u t c h n o t c h

ARM, c l u t c h s h a f t c e n t e r

PIN,

c l u t c h s h a f t c e n t e r arm

ROD, c l u t c h arm

COTTER PIN, c l u t c h

a r m

r o d

D u g S EAL

SCREW, s h i f t

cam

s t o p

GASKET

HOLDER, magnet

MAGNET

BOLT

WASER

1

1

2

1

1

1

2

1

1

1

1

1

1

1


13/34

FIG.ll

11

12

13

3

/

11

FIG.11 (C-

4

STARTING MOTOR

Q T Y

REF.NO. PART

NO.

DESCRIPTION

1

2

3

5

6

7

8

9

10

11

12

13

1 4

15

16

17

31100-96310

31310-96300

31320-96300

31312-96300

31360-96300

31173-96300

31131-96300

31132-96300

31135-96300

31281-93340

01107-08258

08321-21088

08322-11088

31800-95502

31805-94350

01107-06208

08321-21068

MOTOR ASSY, starter

.ARMATURE

.PINION

.STOPPER

SET, pinion

. ASI-ER

.HOLDER ASSY

, brush

. B R USH (+>

.

BRUSH

(->

.

SPRING

. OLT

BOLT

LOCK WASHER

WASI-ER

RELAY, starter

BRACKET ,

starter

relay

BOLT

LOCK WASHER

1

1

1

1

1

1

1

1

2

2

2

2

2

1

1

1

1

1

c4

12


14/34

FIG.

1

2

11

FIG.12

(C-

5)

MAGNETO

Q T Y

REF.NO. PART NO. DE SC RIP TIO N

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

32101-94314

32120-95301

02112-05258

08321-21058

32140-95301

02112-05208

08321-21058

32150-95302

02112-05108

08321-21058

32102-94312

02122-05128

08341-31059

09160-18011

09164-18001

08310-22188

12

STATOR ASSY

.COIL,

l i g h t i n g (12V,8OW)

.scFEw

.LOCK WASNR

.COIL, i g n i t i o n p r im a r y

. S C R E W

.LOCK W A S R

.S€NSOR, i g n i t i o n t i m i n g

.SCAW

.LOCK WASHR

FLYWHEEL

SCFEW

K E Y

W A X R (18.5~35~4)

LOCK WASNR

NUT

1

1

2

2

1

2

2

2

4

4

1

3

1

1

1

1

DT40 QD

DT40 QD E3


15/34

FIG.

13

2

6

13

FIG.13

(C- 6)

IGNITION

Q’TY

EF.NO. PART NO. DESCRIPTION

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

32900-94310

01517-06168

08310-11068

08321-21068

36650-94302

09125-06020

36651-94300

36653-94301

33410-94310

33420-94310

01107-06208

08321-21068

33510-95510

09482-00198

09404-06401

C.D. I . UNn, i g n i t i m

BOLT

NJT

LOCK WASER

COVER, j u n c t i o n

box

SCREW

INSULATOR, Junc t ion box f r o n t

INSULATOR, j u n c t i o n box

C O I L

ASSY,

i g n i t i o n u p p e r

C O I L ASSY, i g n i t i o n lmer

BOLT

LOCK WASI-ER

CAP,

spark plug

SPARK PLUG.

(NGK RRHS)

CLAMP,

i g n i t i o n

coil

1

1

1

1

1

MANJAL

ST

4

MANUAL ST

1

irlANJALST

1

MANUAL ST

1

1

4

2

2

1

FIG.

14

14


16/34

l6

-0

1

FIG.^^ (c- 7) ELECTRICAL (1)

Q TY

REF.NO. PART

NO.

DESCRIPTION

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

32800-95720

02112-05258

G8310-11058

08321-21058

36740-95252

09481-20001

33810-96303

33811-96300

33885-94300

02152-06128

36612-94301

36632-95501

36613-94300

33812-94300

09404-06413

02152-06128

36899-94300

RECTIFIER ASSY

SCFEW

NUT

LOCK WASHER

CASE ASSY, fuse

.FUSE (20A)

CABLE

E S Y ,

starting motor

G R O M M , battery cable

CLAMP, battery cable

SCFEW

GRCMIYET

,

harness connector

CLAMP, connector grommet

GROMMZT, harness connector

CAP, battery cable

CLAMP, stop lead wire

SCEW

LEAD W I F E stop

1

ELECTRIC

1

2

4

1

1

1

TM-

15


17/34

F I G . 1 5 ( C -

8)

E L E C T R I C A L

2)

14

6

10 //

Q’TY

. ’

f ? E F N O

PART NO. DESCRIPTION

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

3772 1-95252

37725-94301

37726-94302

01107-06168

08321-21068

38600-94351

09100-05102

09162-05002

09404-06412

36630-94320

36631-94300

36630-94330

38423-95501

33816-96300

03242-06259

09404-06413

37800-93351

02152-06128

S W I T C H A S S Y , neutral

AC T U AT OR , n e u t r a l

s w i t c h

BR AC KET ,

neutral s w i t c h

BOL T

LOCK WASHER

SOLENOID ASSY, choke

BOLT

LOCK WASHER

C L AM P, chdte solenoid

W I R I N G H A R N E S S , remote

c o n t r o l

.CAP. remoto control harness

W I R I G HARNESS

remoto control

T E E ,

remoto control harness

C L AM P

SCREW

C L AM P,

N.S.I.

lead

S W l T C H A S S Y , s top

S C R W

1

1

1

2

2

1

2

2

1

1

1

1

1

1

1

- E L E C T R I C

1TMW

16


18/34

FIG.

14

22

I

FIG. 16 (D- 2)

C L A M P BRACKET

Q’TY

‘ ’ ‘

REF.NO. PART

NO. DESCRIPTION

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

41120-94313-024

BRACKET , ClaIIIp,

RHAH

41212-93000-02M

H A N D L E ,

clamp

09205-06007

41211-94301

41213-93002

09140-08003

09162-08003

09160-08014

09100-08199

09100-08159

09160-08015

09180-09013

09162-08003

09140-08003

09159-22002

09160-22017

41130-94300

45420-94301

09140-10015

09162-10002

09111-10015

09111-12006

09448-29003

41222-94301

41223-94301

41226-94301

41141-94300

41222-94350

41223-94350

PIN

SCREW

PLATE,

clamp

NUT

L O X WASHER

WASFER

8.5x23x1.5)

BOL T

BOL T

8x230)

WASHER

8.5x16x1.6)

SPAC ER

9.8~13.8~156)

LOCK W A X R

NUT

WT

W A S E R

22 .5~38~1)

SHAFT, bracket

PIN, t i l t l o c k

P U T .

Li’Y

W A S E R

BOi; L:57)

BOL T

L:27)

SPRING

ARM,

t i l t

l o c k

ARM,

tilt

stop

SPACER, t i l t s to p arm

ATTACHMENT, steering cable

ARM,

t i l t

lock

ARM, t i l t

stop

2

2

2

2

2

2

2

4

2

1

2

1

1

1

2

1

2

2

2

2

1

1

1

1

1

1

1

OK

OPT

7

I

T

OrnJ B

2

8

17


19/34

FIG.17 (0-

3) SWIVEL

BRACKET

Q ’TY

’ REF.NO. PART

NO.

DESCRIPTION

FIG.

17

1

2

3

4

5

6

7

8

9

10

12

13

14

15

16

17

18

. 1.9

20

21

22

23

24

43750-94304-02M

09100-08163

09160-08015

09440-11013

09343-12004

09443-12021

4

5231-94300

43411-94300

09306-26006

43111-94303-02M

22511-99000

09306-26005

09161-26001

43241-93102

45255-93000

45261-94301

45254-94300

45250-94301

45243-94301

45241-94300

09160-08015

09100-08162

43754-94301-02M

03142-05109

BRA XET , steering

BOLT

8x35)

WASI-ER

8.5x16x1.6)

SPRING

d: l .4phi )

BOOTS

L:60-21)

SPRING, reverse lock

ARM, reverse

l o c k

ADJUSTER,

steering

BUSHING, upper

BRACKl3, swivel

BUSHING, 1mer

WASHER

2 6 . 7 ~ 4 8 ~ 2 )

MARK, release lower

RUBBER, lever

LEVER, release

PIN, release arm

LINK, release arm

PIN,

release

lock

am

LINK, release lock

WASHER 8.5x16x1.6)

BOLT

8x30)

COVER , bracket

SCREW

GREASE NIPPLE

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

2

2

1 ELECTRIC

2 ELECTRIC

03

D

FIG.

08

18


20/34

14

.

REF.NO. PART

NO.

DESCRIPTION

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

11433-94302

11431-94303

52113-94300

52141-94311

09162-06001

09100-06058

54123-94300

54121-94300

09100-08163

09160-08015

54137-94300

54130-94300

09100-10148

09160-10040

09162-10002

09140-10015

GASKET 1

HOUSING,

lmer o i l

seal

1

GASKET,

housing 1

T U E , exhaust

LOCK WASHER

BOLT

6x15)

PLATE

MOUNT I NG, uppe r t h r u s t

BOLT

8x35)

WASER 8 . 5 ~ 1 6 ~ 1 . 6 )

CASE, u p p e r

mounting

MOUNTING, uppe r

BOLT

10x145)

WASER

(

1 0 . 5 ~ 1 8 ~ 1 . 6 )

LOCK WASHER

NUT

1

6

6

1

1

4

4

2

2

2

4

2

2

13

Q T Y

FIG.

1 9

19


21/34

14

@-- 19

18

FIG.19 0- 5) WIVESHAFT HOUSIK

Q T Y

DESCRIPTION

REF.NO. PAR T NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

PIN

9202-06015

09162-08003 LOCK WA WR

09160-08015 WASHER

09100-08160

BoL r

8x45)

09100-08161 BOLT 8x65)

52111-94312-02M HOUSING, driv es haft

54125-94300 M O W I N G , t h r u s t reverse

54151-94300

M O U N T I N G ,

lower

t h r u s t

54211-94303-02M

COVER, laver

mounting

09160-08015 WASHER 8 . 5 ~ 1 6 ~ 1 . 6 )

09162-08003

LOCK WASHER

09100-08095 BOLT 8x75)

54161-94300 MomI S , mer

54167-94300

M O U N T I N G ,

lower side

09205-10002 SPACER, h o u s in g

52131-94340-02M

CASE,

extens ion

09108-08110 STUD BOLT

NUT

9140-08003

09162-08003

LOCK WASHER

09206-11006

PIN

2

9

9

7

2

1

1

1

2

2

2

2

2

2

2

1 L T Y R

6 L

TYPE

6

6

2

i

20

FIG. Q

FIG.20 (0- 6) (TAR CASE


22/34

Q TY

REF.NO. PART NO. DESCRIPTION

55100-94302-Om C ASE

SFT,

gear 1

1

2

1

2

2

1

1

1

1

1

2

.BEARING, pin ion

9263-22029

09265-30004

.EEARNG

propel ler shaft

17631-93402 FILTER, wat er

55122-94300 SEAL, gear case

03142-04259 SCAN

55125-95202-OD TRIM TAB


55114-98502 COVER, gear case loder

09100-08090 BOLT (8x16)

03112-04109

TAPPING

SCEW

55320-93142 ZINC, protect ion 1

3

3

09100-08101 BOLT (8x40) 6

6

13 09248-10004 PLUG, dra in

14 09168-10022 GASKET, dra in p lug

15


57632-95304

STOPAR,

propel ler bushing 1

19-1 58100-94300-ClT PROPELLER (3 ~11 -1 /2~ 9 )

1 smo

19-2 58100-95210-01T PROPELLER (3 ~11-1 /2~10 )

1 S l O O O

0-1

09160-32006 WASER (32.6~45~1)

1 S l l O O

19-4 58100-95351-01T PROPELLER (3~1 1-3/ 8~14)

1

51400

19-5 58100-94311-01T PROPELLER ( 3 ~ 1 L 1 / 2 ~ 1 3 )

1

S1301 S

19-3 58100-95220-OlT PROPELLER (3 ~11-1 /4~11 )

19-6 58100-95391-01T PROPELLER (3~ 11-5 /8~12)

1

s1200

1

1

SPACER

7633-94300

57635-95300 WASER

09159 l8004

k T 1

55300-95500 ZINC ASSY, protect ion 1 om

17

Q6

T40

QD

F I G2

1

21


23/34

a

FIG.21

(D-

7) TRANSMISSION

Q T Y

REF.NO.

PART NO DESCRIPTION

1-1 57110-94313 SHAFT, d r i v e

1 S T Y E

1-2 57110-94350 SHAFr

d r i v e

1

L

TYPE

2 57130-94301 BUSHING (17x2 7~24)

1

3 09205-03019 PIN

1

4-1 08221-30425 SHIM (T:0.5)

0-1

4-2 09181-30004 SHIM (T:0.6) 0-1

4-3 09181-30005

SHIM

(T:0.7)

0-1

4-4 08221-30426 SHIM (T:0.8) 0-1

4-5 09181-30006 SHIM (T:0.9)

0-1

4-6 08211-30421

THRUST

WASER

(T

:1) 0-1

5 09160-26008 WASHER (26~42x3)

1

6 0-969-25014 BEARING, t h r u s t 1

7 09440-27009

SPRING

1

8 08211-22303 THRUST W A W R 1

109169-22002

i

WASER

10 57133-94301 COLLAR 1

11 57311-94310 PINION 1

12 09140-12021 NUT 1

0-1

3-1 08221-30425

13-2 09181-30004 SHIM (T:0.6) 0-1

13-3 09181-30005 SHIM (T:0.7)

0-1

SHIM (T:0.5)

13-4

13-5

13-6

14

15-1

15-2

16

.

17

18

19

08221-30426

09181-30006

082 11-30421

57510-94310

08211-20263

08211-20264

57631-95200

09209-08016

57521-94301

09202-05019

S H I M (T:0.8)

SHIM (T:0.9)

THRUST

WASKR (T :1)

GEAR,

forward

THRUST

WASt fR

(T

:2)

THRUST WASHER (T:2.2)

ROD, push

PIN,

p u s h

SHIFTER,

c l u t c h dog

PIN

0-1

0-1

0-1

1

0-1

0-1

1

1

1

1

I

13

~

DT40 QD

FIG. 21

22

FIG.21 (0- 8) TRANSMISSION


24/34

Q T Y

REF.NO. PART NO. DESCRIPTION

8 - 2

4

5

.

i,

20

21

22

23-1

23-2

23-3

23-4

23-5

23-6

24

25-1

25-2

25-3

25-4

25-5

25-6

26

27

28

29

30

.

3 1

32

09440-38003 SPRING, dog .

09440-07018

SPRING, r e t u r n

57610-94301

SHAFT,

propeller

09160-22018

THRUST

WASHER

(T : .8)

09160-22019 TIiUUST

WASHER

(T ~1.9)

09160-22020

THRUST

WASHER

(T

:2.0)

09160-22021 THRUSF WASHER (T:2.1)

091.60-22022

THRUST

WASHER (T t2.2)

09160-22023 THRUST

WASHER

(T ~2.3)

57521-94310 GEAR reverse

09181-35003 SHIW (T:0.5)

09181~35009 S H I M (T:0.6)

09181-35010

SHIM

(T:0.7)

09181-35011 SHIM (T:0.9)

09181-35001 SHIM (T:0.8)

09181-35002 SHIM (T:1.0)

09280-75001 0

RING

56120-94302-02M HOUSING, p r o p e l l e r shaft

08113-60070 .BEARING

.8EARII?G9263-22020

09289-22006 .OIL SEAL

09160-08015 WASHER (8.5X16XP. 6)

09100-08112 aOLT (8x30)

1

1

1

0-1

0-1

0-1

0-1

0-1

0-1

1

0-1

0-1

0-1

0-1

0-1

0-1

1

1

1

2

1

2

2

13

DT40 QD

FBG. 22

23


25/34

FIG.22 (E- 2) LOWER COVER

Q TY

. .

DESCRIPTION

EF.NO. PART NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

61110-94306-02M

COVER, lower

61113-94301

SEAL

09180-06112

SPACER

(6.8xlOx11.5)

09320-10018

CUSHION

09160-06047 W A X R (6.5~22~2)

09162-06001 LOCK WASER

09100-06089 BOLT (6x25)

61139-94300

BLOCK RH LH

01107-06108 BOLT

08322-21068 WASER

61631-98100 HOOK, lmer cover

09164-13005

WAVE WASER

09306-13002 BUSHING

67410-94301-02M

S W throttle

09306-10001 BUSHING

67417-94301-024

ARM, throttle

09205-04002

SPRING P I N

09119-05010 B A U , pivot

09250-30003 CAP, switch hole

39669-93502

CA?,

consent

13625-94300 CAP,

chcke

rod

guide

61633-96002-02M LEVER, hook

ROD

7413-94300

1

1

4

4

4

4

4

2 L:200

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

E2

FIG.

23

24

FIG.23 (E-

3) E N G I E

COVER


26/34

2

I

Q T Y

REF.NO. PART NO. DESC RIPT ION

1 61400-94870-02M COVER SET, engine

2 61431-94300-02M .HANDLE, tilt up 1

3 09160-06036 .WASHER (6.5x18x1.5) 3

5 . 09100-06019 .BOLT (6x16 ) 3

6 61422-94360 .EM8LEM, f r on t 1

7 61441-96300 .EMBLEM, side 2

8

61458-95201

.MARK,

safety warning

1

? 61457-93002 . ARK, warning 1

10 61443-94360 .DECAL RH 40 1

11 61453-94360 .DECAL LH 40

1

12 61435-94360 .EMBLEM, re ar I14Ott

1

13 21131-96003 .MARK,

clutch

s h i f t i n g 1

14 61112-94302 RUBBER, h e r cover

1

15

09800-81800 TOOL

ASSY 1

3

LOCK WASI-ER

09162-06001

FIG. 24

25


27/34

// 1-1 I

10

1

//

i6

FIG.24 (E- 4)

HANDLE

(MANUAL START)

Q'TY

ESCRIPTION

EF.NO. PART

NO.

1 63121-96301-02M

COVER, t i l l e r

h a n d l e 1

2 63114-94300

SPACER 1

3 09108-08036 STUD BOLT 2

4 09162-08003

LOCK WAStER

2

5 09140-08003 NUT 2.

7 63111-96301-02M WNOLE, t i l l e r

8

63115-96300 SPACER

1

9 6362 5-96300

GROMET 1

10-1 09404-06404

CLAMP 1

10-2 09404-06403

CLAMP 1

12 09125-06033 SCREW

1

13 63225-93200

BUSHING 1

14 63241-94300

ADJUSTER, g r i p 1

15 09160-06015

WASHER

6 . 5 ~ 1 3 ~ 1 )

1

16 09100-06019 BOLT 6x16) 1

17 09440-12027

SPRING 1

19 63227-93200

PIN,

handle

r o d

L:14)

1

20 63223-93200 STOPPER 1

21 09163-06001

LOCK WAStER 1

22 09126-06004 SCREW 6x20)

1

23 63210-93202

GRIP, h an d le 1

24,

6 63625-94300

GR OM M ELECTRIC

11 63610-94300

C A B E

, t h r o t t l e grip-lever) 2

1

3220-96300 ROO,

handle

8

1

OPT

3300-94300 BAR ASSY, extens ion

22

26

FIG.25 (E- 5) N E L

TANK


28/34

Q TY

- 1

ESCRIPTION

EF.NO. PART

NO.

1 6US.GAL

1 65000-95200 TANK SET, fuel (23L)

2

65510-98506 .CAP ASSY

1

3 65561-98502

.GASKET

1

4 65871-93010 .GASKET, fu el gauge

1

5 01107-06168 .BOLT 3

6 01107-06408 .BOLT 1

7 08322-21068 .WASl-ER 4

8 65850-95504 .GAUGE ASSY, fue l

1

10 65854-93001

.

GA S ( E T , s t ra i ne r 1

11 65853-93001 .S TRA INE R

1

12

02112-04108

.

FEW 2

13 65864-95200

.

FLOAT

1

14 65830-95500

.

FILTER, out le t 1

15 09168-12001

.

GASKET ( 12.5~20~1) 1

16 65700-95205

HOSE,

f u e l 1

17 65750-98505 .SOCKET 1

18 65750-93000 .SOCKET 1

19 65781-98500 .CLIP 4

20 65770-99702

.PUMP,

squeeze

1

9 65740-95500 .PLUG, tan k si de

1

M12,OD:13

1

om

1 65700-95271

H O S E ,

f u e l j o i n t

22 65720-98590 PLUG, fue l cmnec to r 1 Om,MlZ

€5

FIG.

26

27

FIG.26

(E-

6)

REMOTE

CONTROL


29/34

'0

I

16

i

Q TY

REF.NO. PART NO.

DESCRIPTION

1

2

3

4-1

4-2

4-3

4-4

4-5

4-6

5

6

7

8

9

.

10

11

12

13

14

15

16

67200-95550

67296-94300

37110-94301

37'141-93300

37141-93310

37141 93 320

37141-93330

37141 93340

37141-93350

67296-94310

36622-94300

36632-95501

36620 94 310

67275-94300

37820-95254

37823-95251

67288-94300

67271-94300

67288-94310

09140-06004

09125-06012

EMOTE

C ON T R OL BOX ASSY

.SCREW

. S W I T C H A S S Y , i g n i t i o n

. . KEY, spare (8511)

. . KEY,

spare (8512)

. . K E Y , spare (8513)

.

K E Y , spare (8611)

. . K E Y ,

spare (8612)

. . K E Y , spare (8613)

. S C E W

. C L AM P

. C L AM P

. W I R I N G

HARNESS, extension

.CABLE END

.SWTTCH,

emergency

. C A P

. A X R

.HOLDER, cable

. ASt-ER

.

LJT

. E W

1 Electr ic

4

1

1

1

1

1

1

4

1

1

1

2

1

1

2

1

3

3

3

. .

FIG.27

( E - 7 ) O P T : E L E C T R I C A L

(1)


30/34

FIG. 27

4

i

Q TY

REM

RE F.NO. P A RT NO. DE S C RIP T IO N

3

1 31101-94300

MOTOR SET,

starting 1

2 33800-94302

CABLE

&

S W ITCH S E T . startins

1

I

-

3-1 32 102-94302

ROTOR ASSY 1

3-2 32 102-943 2

ROTOR ASSY

1

4 32801-94300

R E C T I F I E R S E T 1

-

I

Y

. .

- 2

..

. ..

DT

40

QD El

FIG.28

E-8) O P T : E L E C T R I C A L

2

( M A NUA L S TA RTE R)


31/34

I

7

Q TY RE

R E F . N O . P A R T N O . D E S C R I P T I O N

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

3280 -9430

32800-95720

02 12-05258

08310-11058

0832 -2 058

36740-95252

09481-20001

36898-93300

37132-93700

36791-95200

39600-98300

39601-96712

02

2 04

08

08322-21048

39602-99711

36898-93300

R E C T I

F I

E R S E T

. R E C T I F I E R A S S Y

.SCREW

. N U T

.LOCK WASHER

.CA S E A S S Y ,

f u s e

. . F U S E (20A)

. L EA D W I R E, c o n s e n t

.

O NN EC TO R, w i r e

.HOLDER, f u s e

case

S OCK E T S E T

. S OC K E T A S S Y , l a m p

.SCREW

.WASHER

.PLUG

A SS Y, l a m p c o r d

. L EA D W I R E, c o n s e n t

1

1

.1

1

1

1

1

1

1

1

1

1

2

2

1

1

11

D T

40

QD El

FIG.29 (E-9) OPT: ELECTRICAL 3

Q TY


32/34

REM

EF.NO. PART

NO.

DESCRIPTION

1 32500-95721 REGULATOR A S S Y , v o l t a g e

2 01107-06208 BOLT 2

ELECTRIC

1

1

1

1

3 0832 1-2 1068 LOCK WASHER

4 08310-11068 NUT

5 3664 1-94 701 ADAPTER, 0.N. (L :160)

6 3664 2-94 702 ADAPTER, N.O. (L :300)

7 366 32- 9550 1 CLAMP,

c o n n e c to r g r o m t

8 366 39- 943 00 GROMMET,

h a rn e ss c o n n e c to r

9 36631-94300 CAP

8

DT

40

QD

E l

DT40

QD

El

FIG.

30 (E-10)

OPTIONAL: REMOTE CONTROL PARTS

FIG.30


33/34

8

7

Q T Y

R

EF.NO. PART NO. DESCRIPTION

1

67130-94302-G2M REMOTE CONTROL PARTS

2 67341-9430

1

STD

DT

4

3

1

1

.HOLDER

3

67440-93701 .GU IDE, c lu tc h c a b le

4 09 160-06015 .WASHER ( 6 . 5 ~ 1 3 ~ 1 )

5 09100-06058 .BOLT

6 67466-95200

.GUIDE, t h r o t t l e cab1.e

7 67414-9430C-02M . L E V E R , t h r o t t l e

.BALL PIVOT

09119-06047

DT 40 QD E l

DT40 q0 E l

- .

FIG.31

(E-11) OPT: METER

(DT4OR)

Q'TY


34/34

-FIG.31

REF.NO.

PART

NO. DESCRIPTION

REM

1

99 105-00160

TACHOMETER ASSY 1

2

99105-00165

SPEED METER ASSY ( k n o t ) 1

3 34850-94700

THERMO UNIT ( I n c l g r e a s e ) 1

4 34853-94301

SUPPORTER, h e a t s w i t c h 1

5

6

7

8

9

10

11

12

09404-08401

09160-08043

34854-95300

38500-95503

38501-95500

02112-05088

37820-95254

37823-95251

DT40 QD E l

CLAMP,

h e a t s w i t c h l e a d w i r e

1

WASHER, h e a t s w i t c h 1

FILLER, h e a t s w i t c h 1

BUZZER

ASSY, wa rn in g

1

BAND 1

SCREW 2

S W ITCH A S S Y , emergency

1

. AP

1

OT40

OD E l

El

suzuki outboard engine dt-40 parts catalogue

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