Suzuki DF 115BTGL4, DF 115BTGLW4, DF 115BTGX4, DF 115BTGXW4, DF 115BTGXZ4, DF 115BTGXZW4 (2023) Parts & Diagrams

OEM and aftermarket replacement parts for Suzuki DF 115BTGL4, DF 115BTGLW4, DF 115BTGX4, DF 115BTGXW4, DF 115BTGXZ4, DF 115BTGXZW4. Scroll down for exploded parts diagrams (45), specifications, and maintenance reference.

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Thermostat (60°C/140°F) – Fits Suzuki, Yamaha, Johnson/Evinrude, Mercury 4 - Stroke 70 - 300HP (Replaces 17670 - 90J00, 67F - 12411 - 01 - 00) - JLM Marine Boat Parts Limited
Thermostat (60°C/140°F) – Fits Suzuki, Yamaha, Johnson/Evinrude, Mercury 4-Stroke 70-300HP (Replaces 17670-90J00, 67F-12411-01-00)
$25.39
$25.39
files/Outboard_Thermostat_for_Suzuki_4_Stroke_4-6_Cyl_70-300_HP_Outboard_Motors__________17670-90J00_-_JLM_MARINE-8286867.jpgDefault Title
$25.39
Water Pump Impeller Kit - Fits Yamaha 70 - 300 HP Outboards (Replaces 67F - 12411 - 01 - 00, 67F - 12411 - 00 - 00) - JLM Marine Boat Parts Limited
Water Pump Impeller Kit - Fits Yamaha 70-300 HP Outboards (Replaces 67F-12411-01-00, 67F-12411-00-00)
$95.90
$95.90
files/Water_Pump_Impeller_Kit_for_Yamaha_70_to_300_HP_67F-12411-01_-_JLM_MARINE-8289395.jpgDefault Title
$95.90

Suzuki DF 115BTGL4, DF 115BTGLW4, DF 115BTGX4, DF 115BTGXW4, DF 115BTGXZ4, DF 115BTGXZW4 (2023) Parts & Diagrams

🔎 Suzuki DF 115BTGL4, DF 115BTGLW4, DF 115BTGX4, DF 115BTGXW4, DF 115BTGXZ4, DF 115BTGXZW4 Reference Library — Exploded parts diagrams (45 diagrams), specifications, common issues, and maintenance checklist.

The Suzuki DF 115BTGL4, DF 115BTGLW4, DF 115BTGX4, DF 115BTGXW4, DF 115BTGXZ4, DF 115BTGXZW4 is a 4-Stroke DOHC 16-Valve Inline 4-Cylinder outboard motor. Powers center-console boats, larger pontoons, and offshore-capable fishing craft.

Quick Reference Specifications

Specification Value
Engine Type 4-Stroke DOHC 16-Valve Inline 4-Cylinder
Horsepower 115 HP
Displacement 2,045 cc
Bore x Stroke 86.0 x 88.0 mm
Spark Plug (Type & Gap) NGK BKR6E
Engine Oil Capacity 5.7 L (with filter)
Recommended Engine Oil SAE 10W-40
Gear Case Oil Capacity 1,050 mL
Idle Speed (in gear) 650-750 RPM
Full Throttle RPM Range 5000-6000 RPM
Fuel Unleaded Gasoline, 91 Octane min.

Always verify specifications against your owner's manual for your specific serial number range.

Common Issues & Recommended Parts

Below are common maintenance scenarios for the Suzuki DF 115BTGL4, DF 115BTGLW4, DF 115BTGX4, DF 115BTGXW4, DF 115BTGXZ4, DF 115BTGXZW4:

  • Water Pump / Overheating: If the tell-tale stream is weak or absent, the water pump impeller likely needs replacement. Inspect annually or every 100 hours. → Recommended: Water Pump Impeller Kit
  • Engine Oil / Maintenance Light: 4-stroke engines require regular oil and filter changes. Use marine-grade oil rated for your engine. Change every 100 hours or annually. → Recommended: Oil Filter, Engine Oil
  • Fuel Injector Issues (EFI models): Rough idle or misfires may indicate clogged fuel injectors. Use fuel stabilizer and clean injectors periodically. → Recommended: Fuel Injector, Fuel Filter
  • Gear Case Oil Leak: Check lower unit seals if gear oil appears milky (water contamination). Replace seals and gaskets during lower unit service. → Recommended: Lower Unit Seal Kit, Drain Plug Gaskets
  • Anode Corrosion: Inspect sacrificial anodes regularly, especially in saltwater. Replace when 50% depleted to protect against galvanic corrosion. → Recommended: Zinc/Aluminum Anode Kit

Parts Diagrams & OEM Part Numbers

Expand the sections below to view detailed exploded parts diagrams and find the exact OEM replacement components for your Suzuki DF 115BTGL4, DF 115BTGLW4, DF 115BTGX4, DF 115BTGXW4, DF 115BTGXZ4, DF 115BTGXZW4.

▶Fig. 111 - Cylinder Head (29 parts) Fig. 111 - Cylinder Head
Ref OEM Part # Part Name
1 11100-99L00 HEAD ASSY,CYLIN
2 09103-06266 Bolt (6x40)
3 09206-08001 Knock Pin (8x11)
4 11115-85FA1-001 Valve Guide (OS:0.30)
5 11261-93J00 Protection Anode Cover
6 09280-22019 O-Ring
7 55321-87J01 Aluminum Anode
8 09128-06094 BOLT,ANODE PROT
9 01550-0820C BOLT
10 11117-89J00 Bolt
11 11141-99L00 GASKET,CYL HEAD
12 09116-08177 BOLT,CYL HEAD N
13 04211-13189 PIN
14 11170-99L00 COVER COMP,CYL
15 11173-99L00 PLATE,BREATHER
16 11179-90J00 Spark Plug Hole Gasket
17 11189-90J00 Cylinder Head Cover Gasket
18 11382-93J00 Oil Filler Cap
19 11174-99L00 HOSE COMP,BREAT
20 09280-26006 O-Ring
21 11194-99L00 GUARD, FUEL HOS
22 11199-99L00 GUIDE,FILTER
23 09401-20409 Clip
24 01547-0625C Bolt
25 01547-0655C 01547-0655C
26 02112-0612A SCREW
27 09482-00649 NGK LKR6E Spark Plug
28 09320-08517 CUSHION,CABLE H
29 09329-12006 CUSHION
▶Fig. 113 - Cylinder Block (15 parts) Fig. 113 - Cylinder Block
Ref OEM Part # Part Name
1 11291-99L00 HOOK,ENGINE
2 01550-1230C BOLT,ENGINE HOO
3 11301-99L00 BLOCK SET,CYLIN
4 11117-90J10 Crankcase Bolt
5 11216-90J10 Oil Gallery Plug Gasket
6 09248-18014 Plug (18x8)
7 09206-13019 Knock Pin
8 01550-0840C Bolt
9 11112-90J00 Oil Venturi Plug
10 09246-04009 Plug
11 11261-93J00 Protection Anode Cover
12 09280-22019 O-Ring
13 55321-87J01 Aluminum Anode
14 09103-06281 Bolt (6x14)
15 01550-0820C BOLT
▶Fig. 116 - Crankshaft (26 parts) Fig. 116 - Crankshaft
Ref OEM Part # Part Name
1 12111-99L00 PISTON
2 12140-92J10 Piston Ring Set
3 12151-99L00 PIN,PISTON
4 09381-21002 Piston Circlip
5 12160-92J10 Connecting Rod Assembly
6 12163-35F00 Connecting Rod Bolt
7 04221-04089 PIN 4X8
9 12220-99L00 CRANKSHAFT COMP
10 09202-05027 Pin (5x8.8)
13 09283-52006 Oil Seal (52x70x10)
14 12100-99L00-050 PISTON SET,OS(0
15 12140-92J10-050 Piston Ring Set (OS:0.50)
45870 12100-92841-0A0 Conn Rod Bearing Set (Green)
45871 12100-92840-025 Conn Rod Bearing Set (US:0.25)
45962 12340-85FB3-0A0 Crankshaft Bearing Set (Green)
45963 12340-85FB3-0B0 Crankshaft Bearing Set (Black)
45964 12340-85FB3-0C0 Crankshaft Bearing Set (NON)
45965 12340-85FB3-0D0 Crankshaft Bearing Set (Yellow)
45966 12340-85FB3-0E0 Crankshaft Bearing Set (Blue)
45967 12300-85854-0AA Crankshaft Bearing Set (Red/Green) (US:0.25)
45968 12300-85854-0BA Crankshaft Bearing Set (Red/Black) (US:0.25)
45969 12300-85854-0CA Crankshaft Bearing Set (Red) (US:0.25)
45970 12300-85854-0DA Crankshaft Bearing Set (Red/Yellow) (US:0.25)(NLA)
45971 12300-85854-0EA Crankshaft Bearing Set (Red/Blue) (US:0.25) (NLA)
45992 12300-85830 Crank Thrust Bearing Set
45993 12300-85830-012 Crank Thrust Bearing Set (OS:0.12)
▶Fig. 119 - Timing Chain (19 parts) Fig. 119 - Timing Chain
Ref OEM Part # Part Name
1 12732-90J01 GEAR,DRIVEN
2 12741-90J01 Camshaft Timing Sprocket
3 09103-12049 Bolt (12x25)
4 12733-90J00 Driven Gear Plug
5 04221-05109 PIN
6 09262-35068 Bearing (35x62x14)
7 09280-22022 O-Ring
8 08331-41269 Circlip
9 12761-90J00 Timing Chain
10 12771-90J00 Timing Chain Guide
11 12810-90J00 Timing Chain Tensioner
12 12813-73G00 Timing Chain Tensioner Pad
13 12812-90J00 Timing Chain Tensioner Spacer
14 12831-90J02 Tensioner Adjuster Assembly
15 01421-0616A BOLT,STUD
16 01550-0616A BOLT
17 01550-0620A BOLT
18 01550-0835A BOLT
19 08316-1006A Nut
▶Fig. 121 - Camshaft (44 parts) Fig. 121 - Camshaft
Ref OEM Part # Part Name
1 12711-99L00 CRANKSHAFT,INTA
2 12720-99L00 CAMSHAFT COMP,E
3 12891-69G00 Tappet
4-31 12892-69G10-293 Tappet Shim (2.925) (NLA)
4-32 12892-69G10-295 Tappet Shim (2.950) (NLA)
4-33 12892-69G10-298 Tappet Shim (2.975)
4-34 12892-69G10-300 Tappet Shim (3.00) (NLA)
5 12911-86FA2 Intake Valve
6 12915-86F51 Exhaust Valve
7 12921-90J01 Valve Spring
8 12931-90J00 Valve Spring Retainer
9 12932-85FA0 Valve Cotter
10 12933-86510 Valve Spring Seat
11 09289-06003 Valve Stem Seal
45748 12892-69G10-218 Tappet Shim (2.175)
45749 12892-69G10-220 Tappet Shim (2.200)
45750 12892-69G10-223 Tappet Shim (2.225) (NLA)
45751 12892-69G10-225 Tappet Shim (2.250)
45752 12892-69G10-228 Tappet Shim (2.275)
45753 12892-69G10-230 Tappet Shim (2.300)
45754 12892-69G10-233 Tappet Shim (2.325)
45755 12892-69G10-235 Tappet Shim (2.350)
45756 12892-69G10-238 Tappet Shim (2.375)
45757 12892-69G10-240 Tappet Shim (2.400)
45758 12892-69G10-243 Tappet Shim (2.425)
45759 12892-69G10-245 Tappet Shim (2.450)
45760 12892-69G10-248 Tappet Shim (2.475)
45761 12892-69G10-250 Tappet Shim (2.500)
45762 12892-69G10-253 Tappet Shim (2.525)
45763 12892-69G10-255 Tappet Shim (2.550)
45764 12892-69G10-258 Tappet Shim (2.575)
45765 12892-69G10-260 Tappet Shim (2.600)
45766 12892-69G10-263 Tappet Shim (2.625)
45767 12892-69G10-265 Tappet Shim (2.650)
45768 12892-69G10-268 Tappet Shim (2.675)
45769 12892-69G10-270 Tappet Shim (2.700)
45770 12892-69G10-273 Tappet Shim (2.725)
45771 12892-69G10-275 Tappet Shim (2.750)
45772 12892-69G10-278 Tappet Shim (2.775)
45773 12892-69G10-280 Tappet Shim (2.800)
45774 12892-69G10-283 Tappet Shim (2.825) (NLA)
45775 12892-69G10-285 Tappet Shim (2.850)
45776 12892-69G10-288 Tappet Shim (2.875) (NLA)
45777 12892-69G10-290 Tappet Shim (2.900)
▶Fig. 122 - Intake Manifold (9 parts) Fig. 122 - Intake Manifold
Ref OEM Part # Part Name
1 13110-99L10 MANIFOLD COMP,I
2 13119-99L00 GASKET,INTAKE M
3 13125-99L00 GASKET,THROTTLE
4 01421-0830C 01421-0830C
5 01550-0835C Bolt
6 08316-1008C Nut
7 18137-87L02 IAC Valve
8 18140-99L00 FILTER COMP,IAC
9 02112-34167 SCREW
▶Fig. 134 - Silencer (6 parts) Fig. 134 - Silencer
Ref OEM Part # Part Name
1 13710-99E00 Flame Arrester
2 13810-99L00 SILENCER COMP
3 13813-99L00 HOLDER,ARRESTER
4 09169-06090 Washer
5 09320-09059 Cushion
6 09116-06517 Bolt (6x25)
▶Fig. 136 - Ring Gear Cover (12 parts) Fig. 136 - Ring Gear Cover
Ref OEM Part # Part Name
1 11511-99L00 COVER,RING GEAR
2 11514-99L00 PLATE,RING GEAR
3 03542-06209 SCREW
4 11512-99L01 CUSHION,RING GE
5 11515-99L00 BRACE,RING GEAR
6 09103-06240 09103-06240
7 01421-0620C 01421-0620C
8 11519-99L00 WASHER,RING GEA
9 09169-06097 WASHER,RING GEA
10 08316-10067 Nut
11 61494-99L00 LABEL,OIL & CLE
12 69711-93E11 Label (S.I.G.P)
▶Fig. 143 - Fuel Vapor Separator (41 parts) Fig. 143 - Fuel Vapor Separator
Ref OEM Part # Part Name
1 15600-99L00 SEPARATOR ASSY,
2 13370-99L10 NEEDLE,VALVE AS
3 15200-92J20 Fuel Pump Assembly
4 15626-92J01 Seal
5 15628-99E00 Screw (L:15)
6 15629-99E10 Drain Screw
7 15641-88L00 Spacer
8 15642-88L00 Fuel Filter
9 15650-99E00 Float
10 15654-88L00 Pin
11 13684-99L00 HOSE,DRAIN
12 15760-88L00 Fuel Pressure Regulator
13 15644-88L00 O-Ring
14 15645-88L00 Regulator Holder
15 02112-0408A SCREW
16 15648-92J00 Ring
17 15643-88L10 Joint
18 15641-88L31 Bushing
19 15641-88L51 Bushing
20 15642-88L10 Fuel Filter
21 15612-88L00 Vapor Separator Cover
22 15613-88L00 O-Ring
23 15614-88L00 Screw
24 02142-0408B SCREW
25 15613-92J00 Gasket
26 15620-99L00 COVER ASSY
27 15610-92J00 VST Lower Case
28 09116-06517 Bolt (6x25)
29 09169-06090 Washer
30 15691-92J00 Cushion
31 15660-99L00 HOSE COMP,EVAP
32 36617-93J00 Harness Bracket
33 36617-93J10 Harness Bracket
34 09320-08517 CUSHION,CABLE H
35 09352-50003-065 HOSE,EVAPORATIO
36 09352-50003-120 HOSE,EVAPORATIO
37 09367-05004 JOINT,HOSE
38 09401-08412 Clip
39 09403-08329 09403-08329
40 01550-0612C BOLT
41 09403-11321 Clamp
▶Fig. 144 - Fuel Injector (14 parts) Fig. 144 - Fuel Injector
Ref OEM Part # Part Name
1 15681-99L00 HOSE,FUEL(SEP 2
2 15710-99L00 INJECTOR ASSY,F
3 15716-65DT0 Grommet Set
4 15423-99L00 GUARD,FUEL HOSE
5 15751-99L00 PIPE,DELIVERY
6 01550-0625C BOLT
7 09168-12013 Gasket
8 09320-08062 Cushion
9 09360-12008 Union Bolt
10 09363-08004 Union
11 09401-11425 Clip
12 01421-0820C 01421-0820C
13 01550-12167 BOLT
14 08316-1008C Nut
▶Fig. 146 - Fuel Pump (21 parts) Fig. 146 - Fuel Pump
Ref OEM Part # Part Name
1 15100-96J01 Fuel Pump Assembly
2 15190-99L00 HOSE COMP,FUEL
3 09251-07003 Cap
4 15195-96L00 Fuel Hose
5 15192-99L00 HOSE,FUEL(FILTE
6 15410-92J10 Fuel Filter Assembly
7 15411-92J10 Fuel Filter Cap
8 15412-92J00 Fuel Filter
9 15413-92J00 Fuel Filter Case
10 15415-92J00 Fuel Filter Seal
11 15421-99L00 BRACKET,FUEL FI
12 15195-96L10 HOSE,FUEL(PUMP
13 09280-33004 O-Ring
14 15193-99L00 HOSE,FUEL(2WAY
15 09403-12314 Clamp (NLA)
16 15831-96L00 Fuel Hose Union
17 09401-14409 Clip
18 09401-11006 CLIP,FUEL HOSE
19 08316-1008C Nut
20 09103-06211 Bolt (6x25)
21 01550-0616C BOLT
▶Fig. 160 - Water Pump (29 parts) Fig. 160 - Water Pump
Ref OEM Part # Part Name
1 17410-92J00 Water Pump Case
2 17461-90J01 Water Pump Impeller
3 17471-92J00 Water Pump Plate
4 17472-87E10 Water Pump Plate Gasket
6 17562-90J01 Water Tube Bushing
7 17563-87D01 Water Tube Bushing
8 17564-87D00 Water Pump Case Bushing
9 17631-90J00 Port Side Water Filter
10 17632-90J00 Starboard Side Water Filter
11 17635-90J00 Sub Water Tube Plug
12 09116-08131 Bolt (8x45)
13 09125-05046 Screw (5x12)
14 09161-16008 Washer (15.8x26x1)
15 09202-06031 Knock Pin (6x12)
16 09420-05009 Water Pump Key
17 09132-04034 Screw (4x18)
18 17413-92J01 Water Pump Case Sleeve
19 17416-92J11 Water Pump Case Seal
20 17612-90J01 Water Tube Spacer (X)
21 17400-92J23 Water Pump Repair Kit DF100/DF115/DF140
22 17500-90J11 KIT,WATER SUB T
23 17520-90J00 Water Sub Tube
24 17563-87D01 Water Tube Bushing
25 17635-87E00 Sub Water Filter
26 55332-87D01 Exhaust Seal Rubber
27 55333-87D02 Exhuast Seal Plate (NLA)
28 09125-06063 Screw (6x10)
45778 17561-90J03 Water Tube (L)
45779 17561-90J13 Water Tube (X)
▶Fig. 162 - Thermostat (43 parts) Fig. 162 - Thermostat
Ref OEM Part # Part Name
1 17700-99L00 FILTER ASSY,WAT
2 17720-99L00 CASE ASSY,FILTE
3 17721-99L00 CASE,FILTER UPP
4 17722-99L00 CASE,FILTER LOW
5 17723-99L00 CAP,FILTER CASE
6 09280-50008 O-Ring
7 17725-99L00 HOSE,WATER(THER
8 17726-99L00 HOSE,WATER(CASE
9 17727-99L00 HOSE,WATER(BYPA
10 17740-99L00 UNION COMP,WATE
11 09280-26006 O-Ring
12 09401-31407 Clip
13 17611-90J00 Water Pressure Valve Cover
14 17660-98L01 Water Pressure Valve
16 17681-99L00 COVER,THERMOSTA
17 17711-90J00 Water Hose 3 Way
18 09116-06121 Bolt (6x25)
19 09280-26006 O-Ring
20 09352-11154-050 HOSE,WATER(HLDR
21 17712-99L00 HOSE,WATER(3WAY
22 09352-50006-600 Hose (5x9x600)
23 17915-99L00 HOSE,FLUSH
24 17710-99L00 HOSE COMP,WATER
25 17581-99L01 PIPE,WATER OUTL
26 09280-26006 O-Ring
27 09401-15414 Clip
28 09401-08413 Clip
29 09401-14409 Clip
30 01550-0620C BOLT
31 01550-0620C BOLT
32 01550-0655C Bolt
33 09403-12420 CLAMP,WATER HOS
34 09403-16416 CLAMP
35 09408-00056 Clip
36 09408-00174 Clamp (NLA)
37 09408-00175 Clamp
38 01550-0612C BOLT
39 01550-0612C BOLT
40 01550-0625C BOLT
41 17730-99L00 FILTER ASSY
42 09280-40020 O RING(D:2.4,ID
45672 17670-90J01 Thermostat (60c)
45703 17670-90J11 Thermostat (71c)
▶Fig. 163 - Throttle Body (21 parts) Fig. 163 - Throttle Body
Ref OEM Part # Part Name
1 13300-99L10 BODY ASSY,THROT
2 13353-99E00 Adjuster Assembly
3 13315-99L01 BRACKET COMP,TH
4 01550-0820C BOLT
5 01550-0860C Bolt
6 13378-99L00 PLATE,THROTTLE
7 13421-90J02 GASKET,THROTTLE
8 19131-95502 Connector
9 09140-05005 Nut
10 13510-99L00 ROD COMP,THROTT
11 19140-99L00 LEVER COMP,THRO
12 09180-06230 Spacer (6.2x12.6x12.5)
13 09160-06046 Washer (6.5x20x1.5)
14 01550-0625C BOLT
15 19114-99L10 BUSH,THROTTLE L
16 19120-99L00 LEVER COMP,THRO
17 09180-06186 Spacer (6.2x12.6x21)
18 09160-06046 Washer (6.5x20x1.5)
19 01550-06357 BOLT
20 09160-06164 WASHER(6.5X18.0
21 09204-01006 Cotter Pin
▶Fig. 175 - Oil Pump (17 parts) Fig. 175 - Oil Pump
Ref OEM Part # Part Name
1 12632-92J12 Oil Pump Drive Gear
2 16113-92J11 Oil Pump Driven Gear
3 16400-99L00 PUMP ASSY,OIL
4 16440-99E01 VALVE ASSY,OIL
5 16520-90J00 Oil Pump Strainer
6 09168-16002 Gasket (16x22x2.0)
7 09181-12158 Washer (12x20x0.5)
8 09261-05006 Pin (5x18)
9 09280-22020 O-Ring
10 01547-0625A BOLT
11 01547-0635A BOLT
12 01550-0616A BOLT
13 08331-3112A Circlip
14 16510-61A32 Engine Oil Filter
15 16531-99L00 CASE,OIL FILTER
16 16539-99L01 GASKET,OIL FILT
17 01550-0825C Bolt
▶Fig. 180 - Oil Pan (20 parts) Fig. 180 - Oil Pan
Ref OEM Part # Part Name
1 11489-90J10 GASKET,OIL PAN
3 17913-93J00 Water Flush Plug
4 43112-94L01 Exhaust Pipe
5 61150-99E01 Water Indicator Tube Cover
6 09280-09016 O-Ring
7 61155-99E01 Water Indicator Tube
8 09116-08178 BOLT,OIL PAN(L4
9 09116-10129 Bolt (10x160)
10 09168-12012 Oil Drain Plug Gasket
11 09248-12009 Oil Drain Plug
12 17914-93J01 Water Flush Plug Gasket
13 16910-99L00 GAUGE COMP,OIL
14 16930-99L00 GUIDE,OIL LEVEL
15 09280-21015 O-Ring
16 01550-0616C BOLT
17 16934-99L00 CASE,OIL LEVEL
18 16941-99L00 GASKET,OIL LVL
19 01550-0625C BOLT
45689 11501-90J20-YAY Oil Pan
45690 11501-90J20-QTN PAN,OIL
▶Fig. 204 - Clutch Shaft (35 parts) Fig. 204 - Clutch Shaft
Ref OEM Part # Part Name
1 11118-95J00 Notch Spring Plug
2 19110-99L02 HOLDER COMP,CLU
3 21110-99L00 LEVER COMP,CLUT
4 21151-99L00 HOLDER,CLUTCH L
5 21155-99L00 HOLDER,SHIFT LE
6 21210-99L00 SHAFT COMP,CLUT
7 21230-99L00 ARM,CMP CLUTCH
8 22511-99011 Grease Nipple
10 23115-99L00 LINK,CLUTCH LEV
11 09160-06094 Washer (6.5x15x1.0)
12 09204-01006 Cotter Pin
13 09206-11019 PIN CLUTCH HOLD
14 09248-12011 Plug (12x9)
15 09260-10005 Ball
16 09306-06004 Bushing
17 09306-10022 Bushing
18 09306-12014 BUSH,CLUTCH HOL
19 09383-08005 E Ring
20 09440-07071 Spring
21 01550-0616C BOLT
22 01550-0825C Bolt
23 01550-0830C Bolt
24 01550-0855C Bolt
25 01550-0880C Bolt
26 08331-41359 Circlip
27 67340-99L00 HOLDER COMP,R/C
28 67345-99L00 PROTECTOR,R/CON
29 01550-0616C BOLT
30 67350-99L00 STOPPER COMP,R/
31 01550-0630C BOLT
32 67467-89J01 Cable Connector
33 09160-06055 Washer (7x12x1.0)
34 09385-06012 Clip
45901 23111-90J02 Clutch Rod (L)
45902 23111-90J12 Clutch Rod (X)
▶Fig. 210A - Shift Rod (12 parts) Fig. 210A - Shift Rod
Ref OEM Part # Part Name
1 25131-92J01 YOKE,SHIFTER
2 25141-92J01 Shift Rod Guide Housing
3 25222-90J01 Shift Guide Cover Seal
4 25232-90J00 Gear Case Magnet
5 25321-92J10 Horizontal Shift Slider
7 41226-97E00 Bushing
8 29116-93J00 Bolt (6x20)
9 09205-04014 Pin
10 09280-69001 O-Ring
11 09283-10011 Oil Seal (10x22x8)
45809 25111-92J00 Shift Rod (L)
45810 25111-92J10 Shift Rod (X)
▶Fig. 210B - Shift Rod (C/R) (12 parts) Fig. 210B - Shift Rod (C/R)
Ref OEM Part # Part Name
1 25131-92J01 YOKE,SHIFTER
2 25141-92J01 Shift Rod Guide Housing
3 25222-90J01 Shift Guide Cover Seal
4 25232-90J00 Gear Case Magnet
5 25321-92J20 Horizontal Shift Slider (C/R)
7 41226-97E00 Bushing
8 29116-93J00 Bolt (6x20)
9 09205-04014 Pin
10 09280-69001 O-Ring
11 09283-10011 Oil Seal (10x22x8)
45809 25111-92J00 Shift Rod (L)
45810 25111-92J10 Shift Rod (X)
▶Fig. 220A - Transmission (79 parts) Fig. 220A - Transmission
Ref OEM Part # Part Name
2 57133-90J02 Drive Shaft Collar
3 09164-31001 Wave Washer
4 09169-31001 Washer
5 09181-31001 Washer (31x46x2.0)
6 09265-25046 Bearing (25x52x19.25)
7 57300-99L10 GEAR SET
8 09140-14024 Nut
9 57500-87873 Drive Shaft Shim Set
11 57500-87861 Propeller Shaft Shim Set
13 09160-70002 Thrust Washer (5.25)
15 57500-92813 Gear Shim Set
17 09269-70001 Bearing (70x95x4.0)
18 57610-99L00 SHAFT COMP,PROP
19 57621-99L00 SHIFTER,CLUTCH
20 09202-07002 Pin (7x48)
21 57631-92J10 PIN,CONNECTOR
22 09440-09040 Detent Spring
23 06111-07004 STEEL BALL 7/32
24 06111-11004 BALL
25 09440-49004 Clutch Dog Spring
26 57616-90J00 Clutch Dog Spacer
28 56123-92J00 Oil Seal Protector Washer
29 09263-30051 Bearing (30x37x26)
30 09280-97001 O-Ring
31 09282-30007 Oil Seal (30x50x6)
32 08113-62090 B1 45X85X19 BEA
33 09387-52001 Set Ring (SUS)
34 09116-08122 Bolt (8x30)
35 56130-90J00 Drive Shaft Housing
36 09280-46004 O-Ring
37 09282-24004 Oil Seal (24x40x7)
38 09117-08110 Bolt (8x25)
39 56140-92J00 Forward Gear Bearing Housing
40 09206-09012 Knock Pin
41 09263-50001 Bearing (50x62x25)
45658 57110-92J60 Drive Shaft (L)
45659 57110-92J70 Drive Shaft (X)
45671 09181-45003 Shim (1.00)
45673 09181-70001 Shim (0.70)
45684 56120-92J01-YAY Propeller Shaft Bearing Housing
45702 09181-45004 Shim (1.10)
45704 09181-70002 Shim (0.80)
45715 56120-92J01-QTN HOUSING COMP,PR
45730 09181-45005 Shim (1.20)
45732 09181-70003 Shim (0.90)
45761 09181-45006 Shim (1.30)
45763 09181-70004 Shim (1.00)
45791 09181-45007 Shim (1.40)
45793 09181-70006 Shim (0.60)
45822 09181-45008 Shim (1.50)
45824 09181-70009 Shim (0.65)
45852 09181-45009 Shim (1.60)
45854 09181-70010 Shim (0.75)
45885 09181-70011 Shim (0.85)
45916 09181-70012 Shim (0.95)
45931 09181-40186 Shim (0.50)
45932 09181-41002 Shim (0.55)
45933 09181-41003 Shim (0.60)
45934 09181-41004 Shim (0.65)
45935 09181-41005 Shim (0.70)
45936 09181-41006 Shim (0.75)
45937 09181-40190 Shim (0.80)
45938 09181-41008 Shim (0.85)
45939 09181-41009 Shim (0.90)
45940 09181-41010 Shim (0.95)
45941 09181-40195 Shim (1.00)
45942 09181-41012 Shim (1.05)
45943 09181-41013 Shim (1.10)
45944 09181-41014 Shim (1.15)
45946 09181-70008 Shim (0.55)
45992 08211-30382 Thrust Washer (1.50)
45993 09160-30036 Thrust Washer (1.70)
45994 09160-30037 Thrust Washer (1.90)
45995 09160-30038 Thrust Washer (2.10)
45996 09160-30039 Thrust Washer (2.30)
45997 09160-30041 Thrust Washer (2.40)
45998 09160-30042 Thrust Washer (2.60)
45999 09160-30043 Thrust Washer (2.70)
46000 09160-30044 Thrust Washer (2.80)
▶Fig. 220B - Transmission (C/R) (91 parts)
Ref OEM Part # Part Name
2 56123-92J00 Oil Seal Protector Washer
3 09263-30051 Bearing (30x37x26)
4 09263-50001 Bearing (50x62x25)
5 09280-97001 O-Ring
6 09282-30007 Oil Seal (30x50x6)
7 09387-52001 Set Ring (SUS)
8 56130-90J00 Drive Shaft Housing
9 09280-46004 O-Ring
10 09282-24004 Oil Seal (24x40x7)
11 56140-92J30 Reverse Gear Housing
12 09206-09012 Knock Pin
13 09263-45004 Bearing (45x52x16)
14 09116-08122 Bolt (8x30)
15 09117-08110 Bolt (8x25)
17 57133-90J02 Drive Shaft Collar
18 09164-31001 Wave Washer
19 09169-31001 Washer
20 09181-31001 Washer (31x46x2.0)
21 09265-25046 Bearing (25x52x19.25)
22 57300-99L30 GEAR SET
23 09140-14024 Nut
24 57500-87873 Drive Shaft Shim Set
25-13 09181-41013 Shim (1.10)
25-14 09181-41014 Shim (1.15)
27 09160-60011 Washer (3.00)
28-13 09160-60018 SHIM,REVERSE GR
28-14 09160-60019 SHIM,REVERSE GR
28-15 09160-60020 SHIM,REVERSE GR
29 09160-70005 Washer (2.00)
30 57500-92813 Gear Shim Set
31 09269-60001 Bearing (60x85x3.0)
31-2 09181-70009 Shim (0.65)
31-4 09181-70010 Shim (0.75)
31-6 09181-70011 Shim (0.85)
31-9 09181-70004 Shim (1.00)
33 09269-70001 Bearing (70x95x4.0)
34 57610-99L10 SHAFT COMP,PROP
35 57621-99L00 SHIFTER,CLUTCH
36 57631-92J10 PIN,CONNECTOR
37 09440-09040 Detent Spring
38 06111-07004 STEEL BALL 7/32
39 06111-11004 BALL
40 09202-07002 Pin (7x48)
41 09440-49004 Clutch Dog Spring
42 57616-92J00 Clutch Dog Forward Spacer (NLA)
43 09160-30055 Washer (30x47x6)
44 09160-30056 Washer (32x47x3)
45 09269-30014 Thrust Bearing (30x47x2)
45658 56120-92J12-YAY Propeller Shaft Bearing Housing
45659 56120-92J12-QTN HOUSING,PROP SH
45673 57110-92J60 Drive Shaft (L)
45682 09181-40186 Shim (0.50)
45683 09160-35015 Washer (35x46x0.60)
45685 09160-60008 Washer (0.80) (NLA)
45688 09181-70006 Shim (0.60)
45704 57110-92J70 Drive Shaft (X)
45713 09181-41002 Shim (0.55)
45714 09160-35014 Washer (35x46x0.70)
45716 09160-60009 Washer (0.90)
45741 09181-41003 Shim (0.60)
45742 09160-35013 Washer (35x46x0.80)
45744 09160-60003 Washer (1.00)
45747 09181-70001 Shim (0.70)
45772 09181-41004 Shim (0.65)
45773 09160-35006 Washer (35x46x0.90)
45775 09160-60004 Washer (1.10)
45802 09181-41005 Shim (0.70)
45803 09160-35008 Washer (35x46x0.95)
45805 09160-60005 Washer (1.20)
45808 09181-70002 Shim (0.80)
45833 09181-41006 Shim (0.75)
45834 09160-35002 Washer (35x46x1.00)
45836 09160-60006 Washer (1.30)
45863 09181-40190 Shim (0.80)
45864 09160-35009 Washer (35x46x1.05)
45866 09160-60007 Washer (1.40)
45869 09181-70003 Shim (0.90)
45894 09181-41008 Shim (0.85)
45895 09160-35003 Washer (35x46x1.10)
45897 09160-60013 SHIM,REVERSE GR
45900 09181-70012 Shim (0.95)
45925 09181-41009 Shim (0.90)
45926 09160-35010 Washer (35x46x1.15)
45928 09160-60014 SHIM,REVERSE GR
45955 09181-41010 Shim (0.95)
45958 09160-60015 SHIM,REVERSE GR
45961 09181-70008 Shim (0.55)
45986 09181-40195 Shim (1.00)
45989 09160-60016 SHIM,REVERSE GR
46016 09181-41012 Shim (1.05)
46019 09160-60017 SHIM,REVERSE GR
▶Fig. 301 - Starting Motor (20 parts)
Ref OEM Part # Part Name
1 31100-92J00 Starter Motor Assembly
2 31150-92J00 Front Housing
3 31170-92J00 Rear Housing
4 31173-92J00 Brush Holder Assembly
5 31191-92J00 Shift Lever
6 31192-92J00 Screw Set
7 31220-92J00 Switch Assembly
8 31261-75F10 Through Bolt
9 31311-63J00 Armature
10 31340-92J00 Starting Motor Clutch Set
11 31312-92J00 Pinion Stopper Set
12 31320-92J00 Pinion Set
13 31341-92J00 Pinion Shaft
14 31343-63J00 Internal Gear
15 31344-63J00 Planetary Gear
16 31912-90J00 Starting Motor Band
17 31918-92J01 Lower Damper
18 01550-08207 BOLT
19 01550-10507 BOLT
20 04211-13149 PIN
▶Fig. 303 - Magneto (17 parts)
Ref OEM Part # Part Name
1 32102-99L00 FLYWHEEL COMP,M
2 32120-99L00 COIL COMP,BATT
3 32160-99L00 COIL COMP,IGN T
4 33220-64L10 Cam Position Sensor
5 36617-93J00 Harness Bracket
6 09103-06231 Bolt (6x35)
7 09103-16004 Bolt (16x50)
8 09160-16048 Washer (16.5x60x7.0)
9 01550-0616C BOLT
10 09106-05030 Bolt (5x10)
11 08341-31059 Woodruff Key 5mm
12 36617-93J10 Harness Bracket
13 09403-11321 Clamp
14 09403-13311 Clamp
15 09403-13413 CLAMP
16 09403-16313 CLAMP,STATOR LE
17 01550-0612C BOLT
▶Fig. 310 - Rectifier (25 parts)
Ref OEM Part # Part Name
1 33410-99L00 COIL ASSY,IGNIT
2 01550-0620C BOLT
3 11261-87E10 Protection Anode Cover
4 11265-87E10 Protection Cover Gasket
6 09103-06281 Bolt (6x14)
7 14151-90J00 Rectifier Gasket
8 36616-99L20 HOLDER,CONNECTO
9 36617-88L00 Harness Bracket (NLA)
10 32800-99L00 RECTIFIER & REG
11 32890-99L00 HOLDER,ELECTRIC
12 09160-06084 Washer (6.5x18x1.6)
13 09320-10075 Cushion
14 09320-09016 Cushion
15 09169-06062 Washer (6.3x17x1.6)
16 09329-01007 Cushion
17 29404-93J11 Clamp (L:65)
18 01550-06257 BOLT
19 01550-0620C BOLT
20 01550-0630C BOLT
21 01550-0612C BOLT
22 09116-06517 Bolt (6x25)
23 09169-06062 Washer (6.3x17x1.6)
24 09320-09016 Cushion
45778 55321-87J01 Aluminum Anode
45779 55321-87J11 Magnesium Anode
▶Fig. 315 - Sensor (23 parts)
Ref OEM Part # Part Name
1 13650-52G00 Inlet Air Temp Sensor
2 13655-87J01 Air Temp Sensor Grommet
3 18590-59S00 SENSOR ASSY,PRE
4 34830-87J20 Temp Sensor Assy
5 18640-98L01 SENSOR ASSY,KNO
6 34840-98J03 Trim Sensor Assembly
7 18213-98J30 Oxygen Sensor
8 34841-92J00 Trim Sensor Lever
10 34843-87L00 Trim Sensor Lower Cam
11 34846-87L00 Trim Sensor Washer
12 37820-99E02 Oil Pressure Switch
13 34845-92J00 Trim Sensor Bracket
14 09103-05028 BOLT,PRESSURE S
15 09103-06093 Replaced by 01550-06207
16 09125-05046 Screw (5x12)
17 09407-10404 Clamp (L:100)
18 36617-93J10 Harness Bracket
19 09407-14407 Clamp (L:140)
20 09407-18402 Clamp (L:165)
21 29103-93J00 Bolt (6x12)
22 09403-13413 CLAMP
23 09403-07340 Clamp
24 09403-11321 Clamp
▶Fig. 322 - Harness (35 parts)
Ref OEM Part # Part Name
1 33810-90J30 CABLE ASSY,STAR
2 08316-10087 Nut
3 36616-99L00 HOLDER,CABLE
4 36616-99L10 HOLDER,CONNECTO
5 01550-0616C BOLT
6 02142-0616C Screw
7 36610-99L30 HARNESS ASSY,WI
8 36618-43410 Oil Pressure Switch Cap (NLA)
9 09320-08510 Cushion (8.5x20x8)
10 01500-06167 BOLT
11 08310-00067 Nut
12 38860-76F01 Relay
13 38860-76F01 Relay
14 09481-15504 15 Amp Fuse
15 09481-30504 30 Amp Fuse
16 09481-60403 60 Amp Fuse
17 33634-96J00 Service Connector Cap
18 36721-98L00 Upper Cover O-Ring
19 36737-98L00 Fuse Puller
20 36738-98L00 Fuse Case Upper Cover
21 36617-88L00 Harness Bracket (NLA)
22 36617-93J10 Harness Bracket
23 36612-96J01 CAP,TERMINAL
24 08321-01067 Lock Washer
25 08310-00067 Nut
26 36617-93J00 Harness Bracket
27 36611-99L00 HARNESS ASSY,WI
28 01550-0612C BOLT
29 09403-11321 Clamp
30 09407-14403 Clamp (L:125)
31 09403-20308 Clip
32 09408-00213 09408-00213
33 09169-06053 Washer (6.3x16x1)
34 36617-99L00 BRACKET,R/CON C
35 01550-0612C BOLT
▶Fig. 326 - PTT Switch/Engine Control Unit (31 parts)
Ref OEM Part # Part Name
1 13580-98J04 Shift Position Sensor Assembly
2 13575-40F00 O-Ring
3 36617-87L20 Harness Clamp (NLA)
4 37721-93J00 Neutral Switch Assembly
5 37724-99L01 ARM,NEUTRAL SWI
6 37726-99L00 BRACKET,NEUTRL
7 37850-92J00 PTT Switch Assembly
8 37856-92J00 PTT Switch Tape
9 37857-92J01 PTT Switch Bushing
10 09160-05029 Washer (5.5x10x0.8)
11 09403-11321 Clamp
12 09407-10404 Clamp (L:100)
13 09407-14407 Clamp (L:140)
14 09448-10006 SPRING,NEUTRAL
15 01550-0612C BOLT
16 02122-04167 SCREW,NEUTRAL S
17 07130-05167 BOLT
18 08321-0105C 08321-0105C
19 38410-93J21 PTT Relay Assembly
20 38415-93J20 PTT Relay Holder
21 33925-92J00 ECU Cushion
22 33920-99LB0 UNIT,ENGINE CON
23 38890-99L00 ACTUATOR ASSY,S
24 38892-98J01 Shift Actuator Damper
25 38895-99L00 BRACKET,SHFT AC
26 01550-0616C BOLT
27 01550-0620C BOLT
28 01550-06357 BOLT
29 01550-0655C Bolt
30 38860-76F01 Relay
31 38915-90J00 Relay Holder
▶Fig. 335 - Clamp Bracket (22 parts)
Ref OEM Part # Part Name
3 41130-92J30 Clamp Bracket Shaft
4 55320-94900 Protection Anode Set
5 09116-06121 Bolt (6x25)
7 09159-12014 Nut (12x17)
8 09159-22006 Nut
9 09160-12128 Washer (12.5x35x3)
10 09160-12110 Washer (12.5x22x3.0)
11 41135-92J00 Clamp Bracket Shaft Washer
12 09106-10065 Bolt (10x20)
13 09160-10082 Washer (10.5x19x2.0)
14 09116-08137 Bolt (8x22)
15 29103-93J00 Bolt (6x12)
16 09403-13413 CLAMP
17 45421-90J00 Tilt Lock Pin
18 09159-14020 Nut (14mm)
19 55321-94910 Magnesium Anode
45658 41111-90J13-YAY Starboard Clamp Bracket
45659 41111-90J13-QTN BRACKET,CLAMP S
45689 41121-90J21-YAY Port Clamp Bracket
45690 41121-90J21-QTN BRACKET,CLAMP P
45809 09100-12091 Transom Bolt (12x115)
45810 09100-12090 Transom Bolt (12x150)
▶Fig. 336 - Swivel Bracket (38 parts)
Ref OEM Part # Part Name
2 36894-95201 Wire Lead (L:165)
3 36894-87D00 Wire Lead (L:195)
5 43211-93J11 Clamp Shaft Swivel Bushing
6 43711-97E11 Steering Bushing
8 09125-05050 Screw (5x8)
9 09125-06063 Screw (6x10)
10 09160-39001 Washer (39.5x64x1.0)
11 09169-28003 Washer (26.2x52x1)
12 09181-39001 Shim (39.5x64x0.3)
13 09250-10001 Plug
14 09282-39001 Oil Seal (38x51x5)
15 09380-38003 Circlip
16 29404-93J11 Clamp (L:65)
17 41220-95E13 Starboard Tilt Lock Lever
18 41221-95E40 Port Tilt Lock Lever
19 41224-95E01 Tilt Stopper Rod Bushing
20 41225-94400 Tilt Lock Arm Rubber
21 41228-90J00 Tilt Lock Spring
22 41230-95E00 Tilt Lock Lever Link
23 41233-95E10 Tilt Lock Spring Bracket
24 09125-06063 Screw (6x10)
25 09140-10032 Nut
26 09160-06082 Washer (6.5x13x1.0)
27 09204-01006 Cotter Pin
28 09440-19028 Spring
29 55127-87D00 Hose Union
30 09355-40805-00B Hose (4x8x2000)
31 09125-06063 Screw (6x10)
45658 22511-99011 Grease Nipple
45659 22511-99011 Grease Nipple
45748 43111-90J40-YAY Swivel Bracket (L)
45749 43111-90J40-QTN BRACKET,SWIVEL(
45750 43111-90J50-YAY Swivel Bracket (X)
45751 43111-90J50-QTN BRACKET,SWIVEL(
45839 43750-90J61-YAY Steering Bracket (L)
45840 43750-90J61-QTN BRACKET,STEERIN
45841 43750-90J71-YAY Steering Bracket (X)
45842 43750-90J71-QTN BRACKET COMP,ST
▶Fig. 337 - Trim Cylinder (28 parts)
Ref OEM Part # Part Name
1 48000-90J3B TRIM ASSY,POWER
2 38100-92J14 MOTOR ASSY,PTT
3 48400-90J03 PTT Manifold Assembly
4 48611-90J00 Metal Joint
5 48571-87L01 Reservoir Tank
6 48572-87J10 Plug
7 48557-90J00 O-Ring
8 48862-87J20 Reservoir Tank Bolt
9 48502-90J14 PUMP ASSY
10 48583-95E00 Drive Joint
11 48582-95E01 Filter
12 48585-95E00 O-Ring
13 48864-93J01 Manual Valve Set
14 48588-90J00 O-Ring Set
15 48862-92J20 Pump Bolt No. 1
16 48862-92J30 Pump Bolt No. 2
17 48862-90J21 Bolt
18 31281-92J10 Through Bolt
19 48121-90J00 Tilt Cylinder Lower Shaft
20 48321-90J00 Tilt Cylinder Upper Shaft
21 48326-95E00 Tilt Cylinder Lower Bushing
22 09116-10179 Bolt (10x35)
23 09380-22015 Circlip
24 55321-87J01 Aluminum Anode
25 09103-06281 Bolt (6x14)
26 36895-87D10 Wire Lead (L:310)
27 09125-05050 Screw (5x8)
28 55321-87J11 Magnesium Anode
▶Fig. 340 - PTT Motor (10 parts)
Ref OEM Part # Part Name
1 38100-92J14 MOTOR ASSY,PTT
2 31311-94900 Armature (NLA)
3 31173-94920 Brush Holder Assembly
4 31123-94910 O-Ring
5 31133-90J20 Brush Assembly
6 31133-94910 Brush
7 31136-90J20 Breaker Assembly
8 31135-94900 Spring
9 33799-97E00 Oil Seal
10 31111-94900 Yoke Screw
▶Fig. 401 - Engine Holder (31 parts)
Ref OEM Part # Part Name
2 09262-17019 Bearing (17x35x8)
3 09282-24003 Oil Seal (24x36x6)
4 09283-32044 Oil Seal (32x47x6)
5 09289-18001 Clutch Shaft Seal
6 08331-41359 Circlip
7 09262-35069 Bearing (35x62x16)
8 51211-90J30 GASKET,ENGINE H
9 09116-08160 Bolt (8x70)
10 09116-08178 BOLT,OIL PAN(L4
11 09206-08001 Knock Pin (8x11)
12 29117-93J10 Bolt (8x45) w/Washer
13 09160-08059 Washer (8.5x18x1.6)
14 04211-11129 11 X 12 DOWEL P
15 51122-90J00 Mount Case Cover
16 51123-90J01 Mount Case Cover Gasket
17 01550-0825A BOLT
18 54123-90J01 Upper Mount Plate
19 54112-90J21 Upper Mount Bolt
20 54130-90J40 Upper Mount
21 09159-12014 Nut (12x17)
22 54114-90J10 Washer
23 54125-90J11 Upper Thrust Mount
24 54148-99L00 COVER,UPPER MOU
25 09116-10181 Bolt (10x44)
26 09159-12014 Nut (12x17)
27 09160-12110 Washer (12.5x22x3.0)
28 09116-10181 Bolt (10x44)
29 09159-12014 Nut (12x17)
30 09160-12110 Washer (12.5x22x3.0)
45658 51110-99810-YAY HOLDER SET,ENGI
45659 51110-99810-Y5S HOLDER SET,ENGI
▶Fig. 405 - Drive Shaft Housing (23 parts)
Ref OEM Part # Part Name
2 09116-10181 Bolt (10x44)
3 09202-08006 Knock Pin (8x12)
4 09387-45001 Set Ring (SUS)
5 57130-92J01 Drive Shaft Bushing (X)
6 09125-06063 Screw (6x10)
7 36895-87D10 Wire Lead (L:310)
8 54121-87D01 Damper
9 54160-90J20 Lower Mount
10 54166-90J11 Lower Mount Bolt
11 09159-12014 Nut (12x17)
12 09160-12112 Washer (12x40x3.0)
13 54114-90J10 Washer
14 54151-90J00 Lower Thrust Mount
17 09116-10176 Bolt (10x44)
18 09160-12113 Washer (12.5x30x2.5)
45658 52111-90J02-YAY Drive Shaft Housing (L)
45659 52111-90J02-QTN HOUSING,DRV SHF
45660 52111-90J12-YAY Drive Shaft Housing (X)
45661 52111-90J12-QTN HOUSING,DRV SHF
45672 54211-90J01-YAY Lower Mount Bracket
45673 54221-90J02-YAY Lower Mount Cover
45703 54211-90J01-QTN BRACKET,LWR MOU
45704 54221-90J02-QTN COVER,LOWER MOU
▶Fig. 407A - Gear Case (47 parts)
Ref OEM Part # Part Name
2 09263-28016 Bearing (28.6x38x31.8)
3 55125-90J01 Trim Tab
4 09367-05003 Speedometer Hose Union
5 55321-90J01 Gear Case Anode
6 55332-87D12 Exhaust Seal Rubber
7 55333-87D10 Exhaust Seal Plate
8 09100-06131 Bolt (6x12)
9 09116-08137 Bolt (8x22)
10 09116-10150 Bolt (10x55)
11 09117-10039 Bolt (10x80)
12 09160-06085 Washer (6.5x15x1.0)
13 09168-10022 Drain Plug Gasket
14 09202-08006 Knock Pin (8x12)
15 09248-10008 Drain Plug
17 09362-09008 Nipple
18 09407-10404 Clamp (L:100)
20 58105-90J00 Propeller Bushing
22 58105-90J00 Propeller Bushing
23 57633-90J02 Propeller Nut Spacer
24 57635-92J10 STOPPER,PROPELL
25 09141-18005 Nut (18mm)
26 09160-18028 Washer (18.5x31x1.0)
27 09204-03003 Prop Nut Cotter Pin
28 55116-87E00 Gear Case Plug
29 57630-90J10 Propeller Hardware Kit DF70A/DF80A/DF90A/DF90 to DF140
30 25700-92J00 Gear Case Seal Kit DF140
45658 55110-90J16-YAY CASE,GEAR
45659 55110-90J16-QTN CASE COMP,GEAR
45673 09355-40805-600 Hose (4x8x600)
45676 990C0-00760-17P Aluminum Propeller 3x14x17
45678 990C0-00610-15P S/S Propeller 3x14x15
45704 09355-40805-600 Hose (4x8x600)
45707 990C0-00760-19P Aluminum Propeller 3x14x19
45709 990C0-00610-16P S/S Propeller 3x14x16
45735 990C0-00760-21P Aluminum Propeller 3x14x21
45737 990C0-00610-17P S/S Propeller 3x14x17
45766 990C0-00760-23P Aluminum Propeller 3x14x23
45768 990C0-00610-18P S/S Propeller 3x14x18
45796 990C0-00760-15P Aluminum Propeller 3x13-1/2x15
45798 990C0-00610-19P S/S Propeller 3x14x19
45829 990C0-00610-20P S/S Propeller 3x14x20
45859 990C0-00610-21P S/S Propeller 3x14x21
45890 990C0-00610-22P S/S Propeller 3x14x22
45921 990C0-00610-23P S/S Propeller 3x14x23
45951 990C0-00610-24P S/S Propeller 3x14x24
45982 990C0-00610-25P S/S Propeller 3x14x25
46012 990C0-00610-26P S/S Propeller 3x14x26
▶Fig. 407B - Gear Case (C/R) (40 parts)
Ref OEM Part # Part Name
2 09263-28016 Bearing (28.6x38x31.8)
4 09367-05003 Speedometer Hose Union
5 55321-90J01 Gear Case Anode
6 55332-87D12 Exhaust Seal Rubber
7 55333-87D10 Exhaust Seal Plate
8 09100-06131 Bolt (6x12)
9 09116-08137 Bolt (8x22)
10 09116-10150 Bolt (10x55)
11 09117-10039 Bolt (10x80)
12 09160-06085 Washer (6.5x15x1.0)
13 09168-10022 Drain Plug Gasket
14 09202-08006 Knock Pin (8x12)
15 09248-10008 Drain Plug
17 09362-09008 Nipple
18 09407-10404 Clamp (L:100)
20 58120-90J00 Propeller Bushing
21 57633-90J02 Propeller Nut Spacer
22 57635-92J10 STOPPER,PROPELL
23 09141-18005 Nut (18mm)
24 09160-18028 Washer (18.5x31x1.0)
25 09204-03003 Prop Nut Cotter Pin
26 55116-87E00 Gear Case Plug
27 57630-90J10 Propeller Hardware Kit DF70A/DF80A/DF90A/DF90 to DF140
28 25700-92J00 Gear Case Seal Kit DF140
45658 55110-92J01-YAY CASE,GEAR
45659 55110-92J01-QTN CASE COMP,GEAR
45673 09355-40805-600 Hose (4x8x600)
45676 990C0-0061L-15P S/S Propeller 3x14x15 CCR
45704 09355-40805-600 Hose (4x8x600)
45707 990C0-0061L-16P S/S Propeller 3x14x16 CCR
45717 55125-92J00-YAY Trim Tab
45718 55125-92J00-QTN TAB,TRIM
45735 990C0-0061L-17P S/S Propeller 3x14x17 CCR
45766 990C0-0061L-18P S/S Propeller 3x14x18 CCR
45796 990C0-0061L-19P S/S Propeller 3x14x19 CCR
45827 990C0-0061L-20P S/S Propeller 3x14x20 CCR
45857 990C0-0061L-21P S/S Propeller 3x14x21 CCR
45888 990C0-0061L-22P S/S Propeller 3x14x22 CCR
45919 990C0-0061L-23P S/S Propeller 3x14x23 CCR
45949 990C0-0061L-24P S/S Propeller 3x14x24 CCR
▶Fig. 410 - Side Cover (41 parts)
Ref OEM Part # Part Name
3 61827-99L00 STAND,SIDE COVE
4 09136-06149 Screw (6x55)
5 61814-99L00 SILENCER,SIDE C
6 61824-99L00 SILENCER,SIDE C
7 61134-99L00 SEAL,ENGINE HOL
8 09409-05302-5PK Pin
9 09139-06249 SCREW
10 17913-93J00 Water Flush Plug
11 17914-93J01 Water Flush Plug Gasket
13 09116-08174 Bolt (8x38)
14 09169-08050 Front Panel Washer
15 09320-11023 CUSHION,FRONT P
16 61632-93J00 Engine Cover Hook Shaft
17 61633-96J02 Starboard Rear Hook Lever
18 61634-96J02 Port Rear Hook Lever
19 61641-93J10 Engine Cover Hook
21 61673-96J03 Hook Lever Latch
22 09116-06127 Bolt (6x12)
23 09160-13014 Washer (13.2x25x1.0)
24 09164-14008 Wave Washer
25 09202-04022 Hook Lever Pin
26 09306-13007 Bushing
27 09103-05026 Bolt (5x10)
28 61124-99L00 GROMMET,R/CON C
29 09407-25402 Clamp (L:248)
30 17917-87L00 Water Flush Connector
31 09329-14004 CUSHION,SIDE CV
32 09329-14003 Side Cover Cushion
33 61648-99L00 SPRING,HOOK LEV
34 09306-13011 BUSH,HOOK LVR F
35 61458-90J01 Engine Cover Label
36 67361-90J10 Rigging Hose Adapter
37 09208-06011 PIN,HOSE ADAPTE
45658 61811-99L00-YAY COVER,SIDE STBD
45659 61811-99L00-QTN COVER COMP,SIDE
45677 61645-90J01-YAY Front Hook Lever
45689 61820-99L00-YAY COVER COMP,SIDE
45690 61820-99L00-QTN COVER COMP,SIDE
45708 61645-90J01-QTN LEVER,HOOK FRON
45992 61830-99L00-YAY PANEL COMP,FRON
45993 61830-99L00-QTN PANEL COMP,FRON
▶Fig. 420 - Engine Cover (30 parts)
Ref OEM Part # Part Name
2 41225-94401 RUBBER,TILT LOC
3 61112-99L00 SEAL,ENGINE COV
4 61610-93J01 FASTENER COMP
5 61621-93J01 Fastener Bracket
6 61682-99L00 STAND,ENGINE CO
7 09329-10024 Cushion
8 01547-0616C BOLT,HARNESS B
9 01547-0620C Bolt
10 01550-0612C BOLT
11 61437-99L00 SEAL,AIR INTAKE
14 61441-92J10 Suzuki Mark
15 68111-93J00 Emblem Mark 'S'
17 09800-81841 Tool Set
18 99011-99L40-03B MANUAL,OWNER'S
19 61446-99L00 DECAL(MPC)
20 61112-92J10 Side Cover Rubber
21 61432-92J10 Tilt Up Louver
22 03542-06169 SCREW
24 09800-81841 Tool Set
25 99011-90JA1-03B MANUAL,OWNERS
45658 61401-99811-YAY Engine Cover Set
45659 61401-99821-QTN COVER SET,ENGIN
45670 61453-99L00 STRIPE,ENG CVR
45673 61435-99L20 MARK,EMBLEM REA
45680 61435-99L20 MARK,EMBLEM REA
45701 61453-99L10 STRIPE,ENG CVR
45704 61435-99L30 MARK,EMBLEM REA
45711 61435-99L30 MARK,EMBLEM REA
45992 61443-99L00 STRIPE,ENG COVE
45993 61443-99L10 STRIPE,ENG CVR
▶Fig. 442 - Drag Link (16 parts)
Ref OEM Part # Part Name
1 41161-94400 Steering Cable Seal
2 67701-90J01 Drag Link Assembly
3 67721-99E00 Drag Link Spacer
4 67725-99E00 Drag Link Bolt
5 67726-99E00 Lock Nut
6 67728-99E00 Washer
7 67467-89J01 Cable Connector
8 09385-06012 Clip
9 09160-06055 Washer (7x12x1.0)
10 67600-90J00 Tie Rod Kit (NLA)
11 67631-90J00 Tie Rod Bracket
12 67725-99E10 Replaced by 67725-99E20
13 67726-99E00 Lock Nut
14 09100-12081 Bolt (12x25)
15 09160-12066 Washer (12.5x22x2.5)
16 09180-09022 Tie Rod Spacer (NLA)
▶Fig. 460 - Meter (6 parts)
Ref OEM Part # Part Name
2 09471-12108 Bulb (12v 1.7w)
4 09471-12077 Bulb (12v, 1.7w)
45658 34800-93J02 Black Trim Gauge
45659 34800-93J13 White Trim Gauge
45717 34200-93J02 Black Tachometer w/Monitor Function
45718 34200-93J14 Tachometer w/Monitor - White
▶Fig. 475 - Squeeze Pump (1 parts)
Ref OEM Part # Part Name
1 65770-90J04 Squeeze Pump
▶Fig. 501 - Opt: Meter (30 parts)
Ref OEM Part # Part Name
2 09471-12028 Bulb (12v, 3.4w)
3 34191-92E00 Water Pressure Tubing
4 09407-14407 Clamp (L:140)
5 36615-96300 Resin Terminal
7 09471-12103 Bulb (12v, 3.4w)
9 34310-92E00 Fuel Gauge Lead (NLA)
10 34360-92E00 Adapter Harness (NLA)
11 09471-12103 Bulb (12v, 3.4w)
13 09471-12103 Bulb (12v, 3.4w)
15 34191-92E00 Water Pressure Tubing
16 09407-14407 Clamp (L:140)
17 09471-12103 Bulb (12v, 3.4w)
19 09471-12077 Bulb (12v, 1.7w)
20 34190-87D00 Speedometer Sensor
21 34190-95500 Speedometer Sensor (NLA)
22 03112-0630B Screw
45658 34100-93J00 Black Speedometer 0-80 MPH
45659 34100-93J13 White Speedometer 0-80 MPH
45660 34100-93J22 Black Speedometer 0-50 MPH
45661 34100-93J33 White Speedometer 0-50 MPH
45671 34650-93J20 Black Water Pressure Gauge*
45675 34200-93J43 Black Tachometer w/Troll Mode Scale
45702 34650-93J33 White Water Pressure Gauge
45706 34200-93J54 White Tachometer w/Troll Mode Scale
45809 34600-93J02 Black Voltmeter
45810 34600-93J13 White Voltmeter
45870 34300-93J02 Black Fuel Gauge
45871 34300-93J13 White Fuel Gauge
45992 34500-93J02 Black Hour Meter
45993 34500-93J13 White Hour Meter
▶Fig. 507 - Opt: Water Pressure Gauge Sub Kit (8 parts)
Ref OEM Part # Part Name
1 34660-90J04 Water Pressure Gauge Install Kit
2 09352-50006-600 Hose (5x9x600)
3 09352-50006-600 Hose (5x9x600)
4 09367-06006 3 Way
5 09401-08413 Clip
6 18498-99EA0 Protector (L:80) (NLA)
7 09407-25402 Clamp (L:248)
8 17917-87L00 Water Flush Connector
▶Fig. 508 - Opt: Remote Control (66 parts)
Ref OEM Part # Part Name
2 36628-92E01 Wire Harness Grommet
3 37110-93J12 Ignition Switch Assembly
5 37143-99E01 Key Cap
6 37149-93J00 Cylinder Body Cap
7 37721-93J91 Neutral Switch Assembly
8 37820-93J11 Emergency Stop Switch Assembly
9 37823-92E02 Stop Switch Lanyard
10 37826-92J10 Nut
11 37850-96L00 PTT Switch Assembly
12 38500-93J90 Warning Buzzer
13 67212-95600 Washer (NLA)
14 67296-92E11 Screw (3x15)
15 67220-95630 Plate Assembly
16 67223-99E10 Brake Adjustment Knob
17 67229-95600 Roller (NLA)
18 67232-95600 Bushing
19 67238-87D00 Drive Gear
20 67241-99E11 Free Throttle Lever
21 67243-95600 Bushing (NLA)
22 67244-95600 Wave Washer (NLA)
23 67245-95600 Free Throttle Drum (NLA)
24 67251-96L00 Handle Lever
25 67252-95600 Bushing
26 67253-95600 Washer (NLA)
27 67255-96L00 Neutral Lock Arm
28 67256-95600 Neutral Lock Holder
29 67257-96L00 Lever Cap
30 77811-54GB0-0PG Chrome S Emblem
31 67258-99E00 Neutral Arm Bracket
32 67259-87D00 Neutral Arm Spring (NLA)
33 67261-96L00 Grip
34 67296-96L10 Screw
35 67264-95600 Washer (NLA)
36 67267-96L00 Wire Cover
37 67273-95600 Spacer
38 67275-95600 Cable End
39 67292-94300 E Ring
40 67294-95600 Spacer
41 67296-90J20 Screw
42 67296-96L00 Screw
43 67296-95630 Screw
44 67296-95610 Screw
45 67297-95600 Washer
46 09100-08232 Bolt (8x30)
47 67269-96L10 Screw (5x12)
48 09140-06020 Nut (6mm)
49 67288-94320 Washer (6.5x24x2)
50 67224-96L00 Brake Arm
51 67238-96L00 Shift Gear
52 67284-94L10 Handle Lever Mark
53 67140-95601 Twin Remote Attachment Kit
54 09180-06105 Spacer (6.1x10x14) (NLA)
55 67296-95640 Screw (L:165)
56 67288-94320 Washer (6.5x24x2)
45748 37141-99E00 (931) Ignition Key
45749 37141-99E10 (932) Ignition Key
45750 37141-99E20 (933) Ignition Key
45751 37141-99E30 (934) Ignition Key
45752 37141-99E40 (935) Ignition Key
45753 37141-99E50 (936) Ignition Key
45754 37141-99E60 (937) Ignition Key
45755 37141-99E70 (938) Ignition Key
45756 37141-99E80 (939) Ignition Key
45757 37141-99E90 (940) Ignition Key
45758 37141-99EA0 (941) Ignition Key
45759 37141-99EB0 (942) Ignition Key
▶Fig. 517 - Opt: Concealed Remocon (1) (29 parts)
Ref OEM Part # Part Name
1 67200-93J34 Flush Mount Control Box
2 67298-92E50 Spring
3 67296-94310 Screw
4 67295-92E10 Screw (3x12)
5 37850-92E27 PTT Switch Assembly
6 67288-92E60 Washer
7 67296-92E52 Screw
8 67255-92E50 Neutral Lock Arm
9 67251-92E50 Handle Lever
10 67261-92E50 Grip
11 67256-92E50 Neutral Lock Holder
12 67257-92E00 Lever Cap
13 67242-92E50 Free Accel Shaft
14 67288-92E20 Washer
15 67296-88D10 Screw (5x16)
16 67288-92E70 Washer (NLA)
17 67296-88D20 Screw (6x35) (NLA)
18 67295-92E50 Screw (6x30) (NLA)
19 67287-92E50 Nut (NLA)
20 09160-06104 Washer (6.5x24x2)
21 67296-88D30 Screw (5x30) (NLA)
22 67254-92E50 Lock Arm Cover
23 36890-93J00 Wire Harness
24 67275-95600 Cable End
25 67273-95600 Spacer
26 67283-92E50 Lever Decal (NLA)
27 67284-92E50 Clutch Decal (NLA)
28 67274-92E50 Base
29 67211-92E50 Flush Mount Cover
▶Fig. 518 - Opt: Concealed Remocon (2) (43 parts)
Ref OEM Part # Part Name
1 67200-93J34 Flush Mount Control Box
2 67222-92E50 Dual Plate
3 67292-94300 E Ring
4 67288-92E10 Washer (NLA)
5 67291-92E00 Snap Ring (NLA)
6 67223-92E50 Brake Adjust (NLA)
7 67221-92E50 Holder Assembly (NLA)
8 67224-92E50 Brake Shoe Assembly (NLA)
9 67225-92E50 Brake Disk (NLA)
10 09140-06020 Nut (6mm)
11 67294-92E00 Spacer (NLA)
12 37721-95500 Neutral Switch Assembly
13 67296-92E11 Screw (3x15)
14 67226-92E10 Bolt (NLA)
15 67296-92E20 Screw (5x25) (NLA)
16 67240-92E50 Throttle Arm Assembly (NLA)
17 67228-92E00 Washer (NLA)
18 67286-92E00 Bolt (6x18) (NLA)
19 67230-92E00 Shift Arm Assembly (NLA)
20 09125-05042 Screw (5x10)
21 67234-92E00 Gear Case (NLA)
22 67245-92E00 Free Throttle Drum (NLA)
23 67227-92E00 Stopper (NLA)
24 67296-88D10 Screw (5x16)
25 67225-92E00 Spring (NLA)
26 09125-04004 Screw (4x6)
27 67233-92E00 Spring (NLA)
28 67235-92E00 Shift Lock Plate (NLA)
29 67239-92E10 Shift Pin Plate
30 67236-92E00 Roller (NLA)
31 67237-92E01 Spring (NLA)
32 67238-92E50 Drive Gear (NLA)
33 67239-92E00 Pin
34 67246-92E50 Drive Shaft (NLA)
35 67252-92E00 Bushing (NLA)
36 67291-92E10 Snap Ring (NLA)
37 67253-92E10 Washer
38 67252-92E10 Bushing (NLA)
39 67253-95600 Washer (NLA)
40 67231-92E00 Shift Gear
41 67232-95600 Bushing
42 67241-92E50 Free Accel Rod (NLA)
43 67232-92E50 Bushing (NLA)

100-Hour / Annual Service Checklist

Regular maintenance keeps your Suzuki DF 115BTGL4, DF 115BTGLW4, DF 115BTGX4, DF 115BTGXW4, DF 115BTGXZ4, DF 115BTGXZW4 running reliably season after season. Most of these tasks can be performed with basic tools and the factory service manual.

  1. Replace water pump impeller and inspect wear plate
  2. Change engine oil and oil filter (check drain plug washer)
  3. Replace spark plugs and check ignition timing
  4. Drain and refill lower unit gear oil; inspect for water contamination
  5. Inspect fuel lines, primer bulb, and fuel filter for deterioration
  6. Check and replace sacrificial anodes (zinc or aluminum)
  7. Inspect propeller for damage; check shaft seal and cotter pin
  8. Check valve clearance (refer to service manual for specifications)
  9. Lubricate all grease points (steering, tilt tube, shift linkage)
  10. Inspect control cables and throttle/shift linkage for smooth operation
  • Pro Tip: Always flush the engine with fresh water after saltwater use — even a quick 10-minute flush significantly extends component life.
  • Pro Tip: Use fuel stabilizer in the tank before winter storage, and fog the cylinders to prevent internal corrosion during extended periods of non-use.

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