🔎 Suzuki DF 140TLK2,DF 140TXK2,DF 140TXZK2 Reference Library — Exploded parts diagrams (63 diagrams), specifications, common issues, and maintenance checklist.
The Suzuki DF 140TLK2,DF 140TXK2,DF 140TXZK2 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 |
140 HP |
| Displacement |
2,044 cc |
| Bore x Stroke |
86.0 x 88.0 mm |
| Spark Plug (Type & Gap) |
NGK BKR6E |
| Engine Oil Capacity |
5.5 L |
| Recommended Engine Oil |
SAE 10W-40 |
| Gear Case Oil Capacity |
800 mL |
| Idle Speed (in gear) |
650-750 RPM |
| Full Throttle RPM Range |
5600-6200 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 140TLK2,DF 140TXK2,DF 140TXZK2:
-
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 140TLK2,DF 140TXK2,DF 140TXZK2.
▶Fig. 1 - Cylinder Head (28 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11100-90J11 |
Cylinder Head |
| 2 |
11115-85FA1-001 |
Valve Guide (OS:0.30) |
| 4 |
09206-08001 |
Knock Pin (8x11) |
| 5 |
11261-93J00 |
Protection Anode Cover |
| 6 |
09280-22019 |
O-Ring |
| 7 |
55321-87J01 |
Aluminum Anode |
| 9 |
01550-08207 |
BOLT |
| 10 |
11117-89J00 |
Bolt |
| 11 |
11141-92J01 |
Cylinder Head Gasket |
| 12 |
09116-08125 |
Bolt (8x50) |
| 13 |
04211-13189 |
PIN |
| 14 |
11170-90J01 |
Cylinder Head Cover |
| 15 |
11173-90J00 |
Breather Plate |
| 16 |
11179-90J00 |
Spark Plug Hole Gasket |
| 17 |
11189-90J00 |
Cylinder Head Cover Gasket |
| 18 |
11382-99E00 |
Oil Filler Cap |
| 19 |
18498-90J20 |
Breather Hose Protector * |
| 20 |
09280-26006 |
O-Ring |
| 21 |
09355-13207-00B |
Breather Hose |
| 22 |
09401-20409 |
Clip |
| 23 |
01547-06257 |
BOLT 6X25 |
| 24 |
01547-06557 |
BOLT 6 X 55 |
| 25 |
02112-0612A |
SCREW |
| 26 |
09482-00427 |
NGK BKR6E Spark Plug |
| 45717 |
11128-90J00 |
Camshaft Housing Bolt |
| 45718 |
09103-06266 |
Bolt (6x40) |
| 45870 |
09128-06021 |
Bolt (6x14) |
| 45871 |
09103-06281 |
Bolt (6x14) |
▶Fig. 10 - Fuel Injector (32 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
15440-90J00 |
H/P Fuel Filter |
| 2 |
15680-90J01 |
Fuel Hose |
| 3 |
15710-65D00 |
Fuel Injector |
| 4 |
15716-65DT0 |
Grommet Set |
| 5 |
15735-58B00 |
Delivery Pipe Insulator |
| 6 |
15751-90J03 |
Delivery Pipe |
| 7 |
15770-90J02 |
Fuel Cooler |
| 8 |
15773-90J10 |
UNION,FUEL HOSE |
| 9 |
15775-90J00 |
Fuel Cooler Bracket (NLA) |
| 10 |
15830-99E00 |
3 Way Union |
| 11 |
09160-06084 |
Washer (6.5x18x1.6) |
| 12 |
09168-12013 |
Gasket |
| 13 |
09169-06062 |
Washer (6.3x17x1.6) |
| 14 |
09320-08501 |
Cushion |
| 15 |
09320-08062 |
Cushion |
| 20 |
09360-12008 |
Union Bolt |
| 21 |
09363-08004 |
Union |
| 22 |
09401-11425 |
Clip |
| 23 |
01421-08357 |
BOLT,STUD |
| 25 |
01550-06167 |
BOLT |
| 26 |
01550-12167 |
BOLT |
| 27 |
08316-10087 |
Nut |
| 45673 |
09356-75137-600 |
Fuel Hose (L:600) |
| 45674 |
09356-75137-600 |
Fuel Hose (L:600) |
| 45675 |
09356-75137-600 |
Fuel Hose (L:600) |
| 45676 |
09356-75137-600 |
Fuel Hose (L:600) |
| 45681 |
01500-06257 |
BOLT |
| 45704 |
09343-75002-600 |
Hose (7.5x13.5x600) |
| 45705 |
09343-75002-600 |
Hose (7.5x13.5x600) |
| 45706 |
09343-75002-600 |
Hose (7.5x13.5x600) |
| 45707 |
09343-75002-600 |
Hose (7.5x13.5x600) |
| 45712 |
09116-06202 |
Bolt w/Washer (6x25) |
▶Fig. 11 - Fuel Pump DF 140T (S/N 682148 & Older) DF 140Z (S/N 680233 & Older) (16 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
15100-90J11 |
Fuel Pump Assembly |
| 2 |
15191-90J10 |
Fuel Hose |
| 3 |
15192-90J11 |
Fuel Hose |
| 4 |
15410-87J10 |
Fuel Filter |
| 5 |
15420-90J10 |
Fuel Filter Bracket |
| 6 |
18498-99E11 |
Hose Protector (L:610) |
| 7 |
18498-99E11 |
Hose Protector (L:610) |
| 8 |
18498-99E11 |
Hose Protector (L:610) |
| 9 |
18498-99E11 |
Hose Protector (L:610) |
| 10 |
09280-26005 |
O-Ring |
| 11 |
09320-05016 |
Cushion (NLA) |
| 12 |
44421-12FR0 |
Hose (6.5x11.5x600) |
| 13 |
09401-11415 |
Clip |
| 14 |
09403-11314 |
Clamp |
| 15 |
01550-06167 |
BOLT |
| 16 |
01550-06257 |
BOLT |
▶Fig. 12 - Fuel Pump DF 140T (S/N 682149 & Newer) DF 140Z (S/N 680234 & Newer) (22 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
15100-90J11 |
Fuel Pump Assembly |
| 2 |
15191-90J10 |
Fuel Hose |
| 2A |
15190-90J30 |
Fuel Hose |
| 3 |
15192-90J11 |
Fuel Hose |
| 4 |
15410-87J30 |
Fuel Filter |
| 5 |
15419-87J00 |
Fuel Filter Cap |
| 6 |
09401-11423 |
Clip |
| 7 |
15422-96J01 |
Fuel Filter Clamp |
| 8 |
15420-90J30 |
Fuel Filter Bracket (NLA) |
| 9 |
09320-05016 |
Cushion (NLA) |
| 10 |
18498-99E11 |
Hose Protector (L:610) |
| 11 |
18498-99E11 |
Hose Protector (L:610) |
| 13 |
18498-99E11 |
Hose Protector (L:610) |
| 14 |
09280-26005 |
O-Ring |
| 16.2 |
09401-11423 |
Clip |
| 17 |
01550-06167 |
BOLT |
| 18 |
01550-06257 |
BOLT |
| 45672 |
09355-70129-600 |
Fuel Hose (7x12x600) |
| 45673 |
09401-11423 |
Clip |
| 45703 |
09343-70503-600 |
Fuel Hose (7x12x600) |
| 45992 |
18498-99E11 |
Hose Protector (L:610) |
| 45993 |
18498-99E11 |
Hose Protector (L:610) |
▶Fig. 13 - Water Pump DF 140T (S/N 682148 & Older) DF 140Z (S/N 680233 & Older) (22 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
17400-90812 |
Water Pump Case Set |
| 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 |
17635-87E00 |
Sub Water Filter |
| 11A |
17635-90J00 |
Sub Water Tube Plug |
| 12 |
09117-08110 |
Bolt (8x25) |
| 13 |
09125-05046 |
Screw (5x12) |
| 14 |
09161-16008 |
Washer (15.8x26x1) |
| 15 |
09202-06031 |
Knock Pin (6x12) |
| 16 |
09420-05009 |
Water Pump Key |
| 18 |
17612-90J01 |
Water Tube Spacer (X) |
| 19 |
17400-90J20 |
Water Repair Pump Kit DF90/DF115/DF140 |
| 45674 |
03112-04309 |
SCREW 4X30 |
| 45705 |
09132-04034 |
Screw (4x18) |
| 45778 |
17561-90J03 |
Water Tube (L) |
| 45779 |
17561-90J13 |
Water Tube (X) |
▶Fig. 14 - Water Pump DF 140T (S/N 682149 & Newer) DF 140Z (S/N 680234 & Newer) (26 parts)
| Ref |
OEM Part # |
Part Name |
| 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 |
17416-92J00 |
Water Pump Case No. 1 Seal |
| 20 |
17417-92J00 |
Water Pump Case No. 2 Seal |
| 21 |
17416-92J11 |
Water Pump Case Seal |
| 22 |
17612-90J01 |
Water Tube Spacer (X) |
| 45658 |
17410-92J00 |
Water Pump Case |
| 45659 |
17410-92J00 |
Water Pump Case |
| 45680 |
17400-92J00 |
Water Pump Repair Kit DF90/DF100/DF115/DF140 |
| 45711 |
17400-92J23 |
Water Pump Repair Kit DF100/DF115/DF140 |
| 45778 |
17561-90J03 |
Water Tube (L) |
| 45779 |
17561-90J13 |
Water Tube (X) |
▶Fig. 15 - Thermostat (29 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11196-90J00 |
Water Return Hose |
| 2 |
17611-90J00 |
Water Pressure Valve Cover |
| 3 |
17660-90J00 |
Water Pressure Valve |
| 5 |
17681-90J02 |
Thermostat Cover |
| 6 |
17711-90J00 |
Water Hose 3 Way |
| 7 |
09116-06121 |
Bolt (6x25) |
| 8 |
09280-26006 |
O-Ring |
| 10 |
09352-50006-600 |
Hose (5x9x600) |
| 12 |
09352-50006-600 |
Hose (5x9x600) |
| 13 |
09352-50006-600 |
Hose (5x9x600) |
| 14 |
09352-50006-600 |
Hose (5x9x600) |
| 15 |
09352-50006-600 |
Hose (5x9x600) |
| 16 |
09352-50006-600 |
Hose (5x9x600) |
| 17 |
09352-50006-600 |
Hose (5x9x600) |
| 18 |
09352-50006-600 |
Hose (5x9x600) |
| 19 |
09352-50006-600 |
Hose (5x9x600) |
| 20 |
09352-50006-600 |
Hose (5x9x600) |
| 21 |
09367-06002 |
3 Way |
| 22 |
09401-08413 |
Clip |
| 23 |
09401-14409 |
Clip |
| 24 |
09401-31407 |
Clip |
| 24A |
09401-31201 |
Clip |
| 25 |
09408-00024 |
Clamp |
| 26 |
09408-00069 |
Clamp (NLA) |
| 27 |
01550-06257 |
BOLT |
| 45748 |
17670-90J01 |
Thermostat (60c) |
| 45749 |
17670-90J11 |
Thermostat (71c) |
| 45962 |
09352-50006-600 |
Hose (5x9x600) |
| 45963 |
09352-50006-600 |
Hose (5x9x600) |
▶Fig. 16 - Throttle Body (18 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
13300-90J00 |
Throttle Body Assembly |
| 2 |
13421-90J01 |
Throttle Body Gasket |
| 4 |
13510-90J00 |
Throttle Rod |
| 5 |
09205-02006 |
Spring Pin (2x12) |
| 6 |
19115-90J00 |
Throttle Lever Holder |
| 7 |
19121-90J00 |
Throttle Lever No. 1 |
| 8 |
19130-90J10 |
Throttle Rod No. 2 |
| 9 |
19131-95502 |
Connector |
| 10 |
19148-90J00 |
Throttle Lever (NLA) |
| 11 |
67473-89J00 |
Connector Pin |
| 12 |
09119-05010 |
Pivot Ball |
| 13 |
09140-05005 |
Nut |
| 14 |
09160-06046 |
Washer (6.5x20x1.5) |
| 15 |
09180-06186 |
Spacer (6.2x12.6x21) |
| 16 |
01550-06167 |
BOLT |
| 17 |
01550-06357 |
BOLT |
| 45717 |
01550-08607 |
BOLT |
| 45718 |
01550-08557 |
BOLT |
▶Fig. 17 - Oil Pump (17 parts)
| Ref |
OEM Part # |
Part Name |
| 3 |
16400-90J00 |
Oil Pump Assembly |
| 4 |
16440-99E01 |
VALVE ASSY,OIL |
| 5 |
16451-90J00 |
Oil Pump O-Ring |
| 6 |
16520-90J00 |
Oil Pump Strainer |
| 7 |
09168-16002 |
Gasket (16x22x2.0) |
| 8 |
09181-12158 |
Washer (12x20x0.5) |
| 9 |
09261-05006 |
Pin (5x18) |
| 11 |
01547-06257 |
BOLT 6X25 |
| 12 |
01547-06357 |
BOLT 6X35 |
| 13 |
01550-0616A |
BOLT |
| 14 |
08331-3112A |
Circlip |
| 45658 |
12630-92811 |
Oil Pump Gear Set |
| 45659 |
12632-92J12 |
Oil Pump Drive Gear |
| 45689 |
16113-90J00 |
Oil Pump Driven Gear (NLA) |
| 45690 |
16113-92J11 |
Oil Pump Driven Gear |
| 45931 |
09280-22020 |
O-Ring |
| 45932 |
09280-22020 |
O-Ring |
▶Fig. 18 - Oil Filter (7 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11241-54E00 |
Oil Filter Stand |
| 2 |
16510-82703 |
Engine Oil Filter |
| 3 |
16600-92J11 |
COOLER ASSY,OIL |
| 4 |
16621-73G01 |
GASKET,OIL COOL |
| 5 |
09280-56005 |
O-Ring |
| 6 |
09280-60007 |
O-Ring |
| 7 |
09280-70005 |
O-Ring |
▶Fig. 19 - Oil Pan (17 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11489-90J00 |
Oil Pan Gasket |
| 2 |
11501-90J04-0EP |
Oil Pan |
| 3 |
17913-99E12 |
Water Plug |
| 4 |
43112-94L01 |
Exhaust Pipe |
| 5 |
61150-99E01 |
Water Indicator Tube Cover |
| 6 |
09280-09005 |
O-Ring |
| 7 |
61155-99E01 |
Water Indicator Tube |
| 8 |
09116-08128 |
Bolt (8x40) |
| 9 |
09116-10129 |
Bolt (10x160) |
| 10 |
09168-12012 |
Oil Drain Plug Gasket |
| 12 |
09280-13005 |
O-Ring |
| 13 |
16910-90J10 |
Oil Level Gauge |
| 14 |
16930-90J01 |
Oil Level Gauge Guide |
| 15 |
09280-09008 |
O-Ring |
| 16 |
01550-06127 |
BOLT |
| 45962 |
09248-12007 |
Oil Drain Plug |
| 45963 |
09248-12009 |
Oil Drain Plug |
▶Fig. 2 - Cylinder Block (13 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11291-90J10 |
Engine Hook |
| 2 |
01550-1230C |
BOLT,ENGINE HOO |
| 4 |
11117-90J01 |
Crankcase Bolt (NLA) |
| 5 |
11216-77E00 |
Oil Gallery Plug Gasket |
| 6 |
09248-18011 |
Oil Gallery Plug |
| 7 |
11330-90J00 |
Crankcase Cover |
| 8 |
11332-90J00 |
Crankcase O-Ring |
| 9 |
09206-13019 |
Knock Pin |
| 10 |
01550-06207 |
BOLT |
| 11 |
01550-08407 |
BOLT 8 X 40 |
| 12 |
11112-90J00 |
Oil Venturi Plug |
| 13 |
09246-04009 |
Plug |
| 45717 |
11300-92J00 |
Cylinder Block Assembly |
▶Fig. 20 - Clutch Shaft DF 140T (S/N 375471 & Older) DF 140Z (S/N 371346 & Older) (18 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
21110-90J02 |
Clutch Lever |
| 2 |
21151-90J01 |
Clutch Lever Holder |
| 3 |
21210-90J01 |
Clutch Shaft |
| 4 |
21221-90J00 |
Clutch Shaft Holder Bushing |
| 5 |
21230-90J00 |
Clutch Shaft Arm |
| 6 |
21311-90J00 |
Clutch Shaft Holder |
| 7 |
22511-99011 |
Grease Nipple |
| 9 |
23115-90J00 |
Clutch Lever Link |
| 10 |
09117-08071 |
Bolt (8x35) |
| 11 |
09160-06094 |
Washer (6.5x15x1.0) |
| 12 |
09204-01006 |
Cotter Pin |
| 13 |
09306-06004 |
Bushing |
| 14 |
09306-10001 |
Bushing |
| 15 |
09306-16004 |
Clutch Shaft Bushing |
| 16 |
09383-08004 |
E Ring |
| 17 |
01550-06307 |
BOLT |
| 45870 |
23111-90J02 |
Clutch Rod (L) |
| 45871 |
23111-90J12 |
Clutch Rod (X) |
▶Fig. 21 - Clutch Shaft DF 140T (S/N 375472 to 682148) DF 140Z (S/N 375472 to 680233) (15 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
21110-90J02 |
Clutch Lever |
| 2 |
21151-90J01 |
Clutch Lever Holder |
| 3 |
21210-90J10 |
Clutch Shaft |
| 4 |
21230-90J00 |
Clutch Shaft Arm |
| 5 |
22511-99011 |
Grease Nipple |
| 7 |
23115-90J10 |
Clutch Lever Link |
| 8 |
09160-06094 |
Washer (6.5x15x1.0) |
| 9 |
09204-01006 |
Cotter Pin |
| 10 |
09248-12005 |
Plug |
| 11 |
09306-06004 |
Bushing |
| 12 |
09306-10001 |
Bushing |
| 13 |
09383-08004 |
E Ring |
| 14 |
01550-06307 |
BOLT |
| 45809 |
23111-90J02 |
Clutch Rod (L) |
| 45810 |
23111-90J12 |
Clutch Rod (X) |
▶Fig. 22 - Clutch Shaft DF 140T (S/N 682149 & Newer) DF 140Z (S/N 680234 & Newer) (22 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
21110-92J00 |
Clutch Lever |
| 2 |
21151-92J00 |
Clutch Lever Holder |
| 3 |
21210-92J00 |
Clutch Shaft |
| 4 |
21230-92J02 |
ARM COMP,CLUTCH |
| 5 |
22511-99011 |
Grease Nipple |
| 7 |
23115-92J00 |
Clutch Lever Link |
| 8 |
09160-06094 |
Washer (6.5x15x1.0) |
| 9 |
09204-01006 |
Cotter Pin |
| 10 |
09248-12005 |
Plug |
| 11 |
09306-06004 |
Bushing |
| 12 |
09306-10001 |
Bushing |
| 13 |
09383-08004 |
E Ring |
| 14 |
01550-06307 |
BOLT |
| 15 |
11118-95J00 |
Notch Spring Plug |
| 16 |
21131-93J00 |
Clutch Lever Bushing |
| 17 |
09205-10006 |
Pin (10.2x10) |
| 18 |
09260-10005 |
Ball |
| 19 |
09403-13413 |
CLAMP |
| 20 |
09440-07071 |
Spring |
| 21 |
01550-06167 |
BOLT |
| 45809 |
23111-90J02 |
Clutch Rod (L) |
| 45810 |
23111-90J12 |
Clutch Rod (X) |
▶Fig. 23 - Clutch Rod (S/N 682148 & Older) (15 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
25131-90J01 |
Shifter Yoke |
| 2 |
25141-90J03 |
Shift Rod Housing |
| 3 |
25222-90J01 |
Shift Guide Cover Seal |
| 4 |
25232-90J00 |
Gear Case Magnet |
| 5 |
25321-90J00 |
Horizontal Shift Slider |
| 7 |
09117-06031 |
Bolt (6x20) |
| 8 |
09160-30037 |
Thrust Washer (1.90) |
| 9 |
09205-04014 |
Pin |
| 10 |
09260-10005 |
Ball |
| 11 |
09280-69001 |
O-Ring |
| 12 |
09283-10011 |
Oil Seal (10x22x8) |
| 13 |
09440-07033 |
Cam Notch Spring |
| 14 |
08331-4138A |
Circlip |
| 45809 |
25350-90J01 |
Shift Assist Rod (L) |
| 45810 |
25350-90J11 |
Shift Assist Rod (X) |
▶Fig. 24 - Clutch Rod (S/N 682149 & Newer) (11 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
25131-92J01 |
YOKE,SHIFTER |
| 2 |
25141-92J01 |
Shift Rod Guide Housing |
| 3 |
25222-92J01 |
Shift Guide Cover Seal |
| 4 |
25232-90J00 |
Gear Case Magnet |
| 5 |
25321-92J10 |
Horizontal Shift Slider |
| 7 |
29116-93J00 |
Bolt (6x20) |
| 8 |
09205-04014 |
Pin |
| 9 |
09280-69001 |
O-Ring |
| 10 |
09283-10011 |
Oil Seal (10x22x8) |
| 45809 |
25111-92J00 |
Shift Rod (L) |
| 45810 |
25111-92J10 |
Shift Rod (X) |
▶Fig. 25 - Clutch Rod C/R (S/N 680233 & Older) (14 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
25131-90J01 |
Shifter Yoke |
| 2 |
25141-90J03 |
Shift Rod Housing |
| 3 |
25222-90J01 |
Shift Guide Cover Seal |
| 4 |
25232-90J00 |
Gear Case Magnet |
| 5 |
25321-92J00 |
Horizontal Shift Slider |
| 6 |
25350-90J11 |
Shift Assist Rod (X) |
| 7 |
09117-06031 |
Bolt (6x20) |
| 8 |
09160-30037 |
Thrust Washer (1.90) |
| 9 |
09205-04014 |
Pin |
| 10 |
09260-10005 |
Ball |
| 11 |
09280-69001 |
O-Ring |
| 12 |
09283-10011 |
Oil Seal (10x22x8) |
| 13 |
09440-07033 |
Cam Notch Spring |
| 14 |
08331-4138A |
Circlip |
▶Fig. 26 - Clutch Rod C/R (S/N 680234 & Newer) (10 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
25131-92J01 |
YOKE,SHIFTER |
| 2 |
25141-92J01 |
Shift Rod Guide Housing |
| 3 |
25222-92J01 |
Shift Guide Cover Seal |
| 4 |
25232-90J00 |
Gear Case Magnet |
| 5 |
25321-92J20 |
Horizontal Shift Slider (C/R) |
| 6 |
25111-92J10 |
Shift Rod (X) |
| 7 |
29116-93J00 |
Bolt (6x20) |
| 8 |
09205-04014 |
Pin |
| 9 |
09280-69001 |
O-Ring |
| 10 |
09283-10011 |
Oil Seal (10x22x8) |
▶Fig. 27 - Starting Motor (25 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
31100-90J01 |
Starter Motor Assembly |
| 2 |
31131-90J01 |
Brush Set (+) |
| 3 |
31135-90J00 |
Spring |
| 4 |
31151-90J00 |
Gear Case |
| 5 |
31152-90J00 |
Center Plate (NLA) |
| 6 |
31153-90J00 |
Planet Gear Bracket (NLA) |
| 7 |
31171-90J00 |
Dust Cover Kit |
| 8 |
31173-90J02 |
Brush Holder |
| 9 |
31191-90J00 |
Shift Lever (NLA) |
| 10 |
31220-90J00 |
Magnet Switch |
| 11 |
31310-90J00 |
Armature |
| 12 |
31320-90J00 |
Pinion Assembly |
| 13 |
31341-90J00 |
Pinion Shaft (NLA) |
| 14 |
31343-90J00 |
Internal Gear (NLA) |
| 15 |
31344-90J00 |
Planetary Gear (NLA) |
| 16 |
31360-90J00 |
Washer Set (NLA) |
| 17 |
31912-90J00 |
Starting Motor Band |
| 19 |
38910-92E00 |
Relay |
| 20 |
38860-76F01 |
Relay |
| 21 |
38915-90J00 |
Relay Holder |
| 22 |
01550-08207 |
BOLT |
| 23 |
01550-10507 |
BOLT |
| 24 |
04211-13149 |
PIN |
| 45675 |
31918-90J00 |
Lower Damper |
| 45706 |
31918-90J11 |
DAMPER,LWR |
▶Fig. 28 - Magneto (16 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
32102-92J10 |
Flywheel |
| 4 |
33220-76G02 |
Cam Position Sensor |
| 5 |
33833-91J00 |
Tube (6x8x250) |
| 6 |
09103-06231 |
Bolt (6x35) |
| 7 |
09103-16004 |
Bolt (16x50) |
| 8 |
09160-16048 |
Washer (16.5x60x7.0) |
| 9 |
01547-06167 |
BOLT 6X16 |
| 10 |
02162-05167 |
BOLT |
| 10A |
09106-05030 |
Bolt (5x10) |
| 11 |
08341-31059 |
Woodruff Key 5mm |
| 12 |
32118-90J00 |
Mag Bolt Label (NLA) |
| 45689 |
32120-90J00 |
Battery Charge Coil |
| 45690 |
32120-90J10 |
Battery Charge Coil |
| 45691 |
32120-90J20 |
Battery Charge Coil |
| 45717 |
32160-87J00 |
CKP/CMP/Ignition Timimg Coil |
| 45718 |
32160-87L01 |
CKP/Ignition Timimg Coil |
▶Fig. 29 - Rectifier (23 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
11265-87E10 |
Protection Cover Gasket |
| 5 |
14151-90J00 |
Rectifier Gasket |
| 7 |
32890-90J01 |
Electric Parts Holder |
| 8 |
32891-90J00 |
Electric Parts Holder Cover |
| 9 |
09160-06054 |
Washer (6.5x22.1.6) |
| 10 |
09320-10075 |
Cushion |
| 11 |
09320-12090 |
Cushion |
| 12 |
09329-01007 |
Cushion |
| 13 |
29404-93J11 |
Clamp (L:65) |
| 14 |
01550-06167 |
BOLT |
| 15 |
01550-06207 |
BOLT |
| 16 |
01550-06307 |
BOLT |
| 17 |
02162-06127 |
BOLT |
| 45658 |
11261-87E10-0EP |
Protection Anode Cover |
| 45659 |
11261-87E10 |
Protection Anode Cover |
| 45717 |
55321-87J01 |
Aluminum Anode |
| 45718 |
55321-87J11 |
Magnesium Anode |
| 45748 |
09128-06021 |
Bolt (6x14) |
| 45749 |
09103-06281 |
Bolt (6x14) |
| 45809 |
32800-90J00 |
Rectifier & Regulator |
| 45810 |
32800-90J10 |
Rectifier & Regulator |
| 45811 |
32800-90J20 |
Rectifier & Regulator |
| 45812 |
32800-90J30 |
Rectifier & Regulator |
▶Fig. 3 - Ring Gear Cover (6 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11510-90J00 |
Ring Gear Cover |
| 2 |
11512-99E01 |
Ring Gear Cover Cushion |
| 3 |
09125-06111 |
Screw (6x18) |
| 4 |
61472-93E33 |
LABEL,RECOIL,ST |
| 5 |
69711-93E11 |
Label (S.I.G.P) |
| 7 |
61494-90J00 |
Oil Label |
▶Fig. 30 - Ignition Coil (10 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
33410-90J00 |
Ignition Coil Assembly |
| 2 |
33710-90J00 |
High Tension Cord |
| 3 |
33740-90J00 |
High Tension Cord |
| 4 |
33420-90J00 |
Ignition Coil Assembly |
| 5 |
33720-90J00 |
High Tension Cord |
| 6 |
33730-90J00 |
High Tension Cord |
| 7 |
09408-00035 |
Clamp (NLA) |
| 9 |
08322-01067 |
Washer (6.5x13x1.0) |
| 45870 |
01550-06207 |
BOLT |
| 45871 |
01550-06257 |
BOLT |
▶Fig. 31 - Sensor (19 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
13650-52G00 |
Inlet Air Temp Sensor |
| 2 |
13655-87J01 |
Air Temp Sensor Grommet |
| 4 |
34200-99E01 |
Tachometer (NLA) |
| 5 |
36615-96300 |
Resin Terminal |
| 6 |
09471-12179 |
Bulb (Red) |
| 7 |
34830-87JA0 |
Temp Sensor Assy |
| 8 |
34830-87JA0 |
Temp Sensor Assy |
| 9 |
34830-87J20 |
Temp Sensor Assy |
| 10 |
37820-99E02 |
Oil Pressure Switch |
| 11 |
09280-09005 |
O-Ring |
| 12 |
02162-05207 |
SCREW |
| 14 |
34804-99E00 |
Trim Sender Set - 2 Wire |
| 15 |
01550-06167 |
BOLT |
| 16 |
09125-06063 |
Screw (6x10) |
| 17 |
29404-93J11 |
Clamp (L:65) |
| 45670 |
09407-14403 |
Clamp (L:125) |
| 45701 |
09407-14407 |
Clamp (L:140) |
| 45717 |
18590-68H00 |
MAP Sensor |
| 45718 |
18590-68H00 |
MAP Sensor |
▶Fig. 32 - Harness (27 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
33810-90J30 |
CABLE ASSY,STAR |
| 2 |
33831-90J00 |
PTT Relay Plate |
| 3 |
08316-10087 |
Nut |
| 4 |
33832-90J00 |
Trim Relay Ground Cable (NLA) |
| 5 |
33634-99E00 |
Service Connector Cap |
| 6A |
09481-30501 |
30 Amp Fuse |
| 6B |
33634-96J00 |
Service Connector Cap |
| 8 |
36630-92E00 |
Instrument Wire Assembly |
| 9 |
36682-92E00 |
Wire Harness |
| 10 |
02142-06167 |
6 X 16 CROSS SC |
| 11 |
36865-90J00 |
Main Fuse Terminal |
| 12 |
09481-60401 |
60 Amp Fuse |
| 13 |
01570-06107 |
BOLT |
| 14 |
08310-00067 |
Nut |
| 15 |
09251-09008 |
Cap |
| 16 |
36617-90J00 |
Joint Connector Bracket |
| 18 |
09481-15501 |
15 Amp Fuse |
| 19 |
09407-14407 |
Clamp (L:140) |
| 45674 |
36625-93J10 |
ECM Battery Lead |
| 45705 |
36625-93J10 |
ECM Battery Lead |
| 45809 |
36610-90J00 |
Wiring Harness Assembly |
| 45810 |
36610-90J20 |
Wiring Harness Assembly |
| 45811 |
36610-90J30 |
Wiring Harness Assembly |
| 45812 |
36610-90J61 |
Wiring Harness Assembly |
| 45813 |
36610-90J92 |
Wiring Harness Assembly |
| 45839 |
36616-90J00 |
Remocon Connector Holder (NLA) |
| 45840 |
36616-90J10 |
Remocon Connector Holder |
▶Fig. 33 - PTT Switch Engine Control Unit (2002 & 2003) (13 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
37725-95600 |
Switch Actuator |
| 3 |
37726-90J00 |
Switch Bracket |
| 4 |
37850-99E05 |
PTT Switch Assembly |
| 5 |
01550-06167 |
BOLT |
| 6 |
38410-94552 |
PTT Relay Assembly |
| 7 |
09251-09008 |
Cap |
| 8 |
33920-92J54 |
Engine Control Unit |
| 9 |
33925-87J00 |
ECU Cushion |
| 11 |
38910-92E00 |
Relay |
| 12 |
38860-76F01 |
Relay |
| 13 |
38915-90J00 |
Relay Holder |
| 45658 |
37721-99E02 |
Neutral Switch Assembly |
| 45659 |
37721-99E12 |
Neutral Switch Assembly |
▶Fig. 34 - PTT Switch Engine Control Unit (2004 & Newer) (21 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
37721-99E12 |
Neutral Switch Assembly |
| 2 |
37725-95600 |
Switch Actuator |
| 3 |
37726-90J00 |
Switch Bracket |
| 4 |
37850-99E05 |
PTT Switch Assembly |
| 5 |
01550-06167 |
BOLT |
| 6 |
38410-93J12 |
PTT Relay Assembly |
| 7 |
38415-93J00 |
PTT Relay Holder |
| 8 |
09251-09008 |
Cap |
| 9 |
33920-92J54 |
Engine Control Unit |
| 10 |
33925-87J00 |
ECU Cushion |
| 11 |
29404-93J11 |
Clamp (L:65) |
| 12 |
38860-76F01 |
Relay |
| 13 |
38915-90J00 |
Relay Holder |
| 14 |
37722-93J14 |
Tilt Limit Switch Assembly |
| 15 |
09403-09316 |
Clamp (NLA) |
| 17 |
01550-06127 |
BOLT |
| 18 |
37721-93J00 |
Neutral Switch Assembly |
| 19 |
37726-90J10 |
Switch Bracket |
| 20 |
09137-04004 |
Screw (4x16) |
| 45673 |
09407-14407 |
Clamp (L:140) |
| 45704 |
09407-14407 |
Clamp (L:140) |
▶Fig. 35 - Clamp Bracket (30 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
41111-92J03-0EP |
Starboard Clamp Bracket |
| 2 |
41121-92J04-0EP |
Port Clamp Bracket |
| 4 |
41135-92J00 |
Clamp Bracket Shaft Washer |
| 5 |
41153-94500 |
Transom Bolt Cap |
| 6 |
55320-94900 |
Protection Anode Set |
| 7 |
09116-06121 |
Bolt (6x25) |
| 9 |
09125-06063 |
Screw (6x10) |
| 11 |
09159-22006 |
Nut |
| 12 |
09160-12044 |
Washer (12.5x35x3.2) |
| 14 |
09162-12005 |
Lock Washer |
| 15 |
09106-10065 |
Bolt (10x20) |
| 16 |
09160-10082 |
Washer (10.5x19x2.0) |
| 17 |
45421-87D03 |
Tilt Lock Pin |
| 18 |
09159-14020 |
Nut (14mm) |
| 19 |
29404-93J11 |
Clamp (L:65) |
| 20 |
48140-93J01 |
Tilt Limit Switch Cam |
| 21 |
48144-93J00 |
Tilt Limit Switch Holder |
| 23 |
48145-93J00 |
Tilt Limit Switch Cover |
| 45670 |
09160-12066 |
Washer (12.5x22x2.5) |
| 45679 |
01550-06207 |
BOLT |
| 45701 |
09160-12110 |
Washer (12.5x22x3.0) |
| 45710 |
09103-06278 |
Bolt (6x25) |
| 45717 |
41130-95541 |
Clamp Bracket Shaft |
| 45718 |
41130-95543 |
Clamp Bracket Shaft |
| 45719 |
41130-92J03 |
Clamp Bracket Shaft |
| 45870 |
09100-12090 |
Transom Bolt (12x150) |
| 45871 |
09100-12045 |
Bolt (12x115) (NLA) |
| 45872 |
09100-12091 |
Transom Bolt (12x115) |
| 45931 |
09140-12028 |
Nut |
| 45932 |
09159-12014 |
Nut (12x17) |
▶Fig. 36 - Swivel Bracket (36 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
36894-95201 |
Wire Lead (L:165) |
| 3 |
36894-87D00 |
Wire Lead (L:195) |
| 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 |
| 45658 |
22511-99011 |
Grease Nipple |
| 45659 |
22511-99011 |
Grease Nipple |
| 45748 |
43111-92J20-0EP |
Swivel Bracket (L) (NLA) |
| 45749 |
43111-92J40-0EP |
Swivel Bracket (L) (NLA) |
| 45750 |
43111-92J30-0EP |
Swivel Bracket (X) |
| 45751 |
43110-92820-0EP |
Swivel Bracket & Trim Ram Set |
| 45778 |
43211-87D00 |
Clamp Shaft Swivel Bushing |
| 45779 |
43211-93J11 |
Clamp Shaft Swivel Bushing |
| 45839 |
43750-90J00-0EP |
Steering Bracket (L) |
| 45840 |
43750-90J61-0EP |
Steering Bracket (L) |
| 45841 |
43750-90J11-0EP |
Steering Bracket (X) |
| 45842 |
43750-90J71-0EP |
Steering Bracket (X) |
▶Fig. 37 - Trim Cylinder (28 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
48503-92J04 |
Manifold Sub Assembly |
| 3 |
48601-94900 |
Piston & Ram Assembly |
| 4 |
48627-95E00 |
O-Ring Set |
| 6 |
48633-94900 |
O-Ring Set (Pack of 2) |
| 8 |
48570-95E01 |
Reservoir Assembly |
| 9 |
48572-95E00 |
Cap |
| 10 |
48588-94900 |
O-Ring (Pack of 6) |
| 11 |
48650-94900 |
Free Piston |
| 12 |
48405-87D00 |
Tilt O-Ring Set |
| 13 |
48615-97E00 |
Piston Ring Set |
| 14 |
48861-92J01 |
Reservoir Bolt |
| 15 |
48121-92J00 |
Tilt Cylinder Lower Shaft |
| 16 |
48311-94501 |
Trim Cylinder Ram Pad |
| 17 |
48321-87D03 |
Tilt Cylinder Upper Shaft |
| 18 |
48326-95E00 |
Tilt Cylinder Lower Bushing |
| 19 |
09116-10179 |
Bolt (10x35) |
| 20 |
09140-08023-XC0 |
Nut (8mm) |
| 21 |
29162-93J10 |
Lock Washer |
| 22 |
09306-17001 |
Bushing |
| 23 |
09380-17009 |
Circlip |
| 24 |
36894-87D00 |
Wire Lead (L:195) |
| 25 |
09125-06063 |
Screw (6x10) |
| 45689 |
48401-92J00 |
Piston Assembly |
| 45690 |
48401-92J02 |
Piston Assembly |
| 45778 |
48630-92J00 |
Trim Cylinder Head |
| 45779 |
48630-96J04 |
Trim Cylinder Head |
| 45839 |
48641-92J00 |
PTT Manifold (NLA) |
| 45840 |
48641-96J04 |
MANIFOLD,PTT |
▶Fig. 38 - PTT Motor (21 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
31111-94900 |
Yoke Screw |
| 3 |
31123-87D60 |
O-Ring |
| 4 |
31133-90J20 |
Brush Assembly |
| 4A |
31133-94910 |
Brush |
| 5 |
31135-94900 |
Spring |
| 6 |
31136-90J20 |
Breaker Assembly |
| 7 |
31173-94920 |
Brush Holder Assembly |
| 8 |
31311-94900 |
Armature (NLA) |
| 9 |
33799-97E00 |
Oil Seal |
| 10 |
31281-92J10 |
Through Bolt |
| 11 |
48502-92J05 |
PTT Pump Assembly |
| 12 |
48582-95E01 |
Filter |
| 13 |
48583-95E00 |
Drive Joint |
| 14 |
48585-95E00 |
O-Ring |
| 15 |
48588-94900 |
O-Ring (Pack of 6) |
| 16 |
48862-92J20 |
Pump Bolt No. 1 |
| 17 |
48862-92J30 |
Pump Bolt No. 2 |
| 18 |
48864-92J02 |
Manual Valve Set |
| 19 |
29404-93J11 |
Clamp (L:65) |
| 45658 |
38100-92J03 |
PTT Motor Assembly |
| 45659 |
38100-92J14 |
MOTOR ASSY,PTT |
▶Fig. 39 - Engine Holder DF 140T (S/N 682148 & Older) DF 140Z (S/N 680233 & Older) (33 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
09160-18031 |
Exhaust Plug Gasket |
| 4 |
51115-90J00 |
Water Return Union |
| 5 |
51211-90J10 |
Engine Holder Gasket |
| 6 |
09116-08160 |
Bolt (8x70) |
| 7 |
09116-08128 |
Bolt (8x40) |
| 8 |
09206-08001 |
Knock Pin (8x11) |
| 9 |
09280-26006 |
O-Ring |
| 10 |
09282-24003 |
Oil Seal (24x36x6) |
| 11 |
09283-32044 |
Oil Seal (32x47x6) |
| 12 |
01550-06257 |
BOLT |
| 13 |
01550-0890B |
BOLT |
| 14 |
09160-08039 |
Washer (8.5x19x2.3) |
| 15 |
09164-08020 |
Wave Washer |
| 16 |
04211-11129 |
11 X 12 DOWEL P |
| 17 |
09262-17019 |
Bearing (17x35x8) |
| 18 |
09289-18001 |
Clutch Shaft Seal |
| 19 |
54112-90J10 |
Upper Mount Bolt |
| 20 |
54130-90J31 |
Upper Mount |
| 21 |
09140-12029 |
Nut |
| 22 |
54113-90J00 |
Upper Mount Bolt Washer |
| 23 |
09160-12110 |
Washer (12.5x22x3.0) |
| 24 |
54125-90J01 |
Upper Thrust Rev Mount |
| 25 |
54148-90J11-0EP |
Upper Mount Cover |
| 27 |
09159-12014 |
Nut (12x17) |
| 28 |
09160-10082 |
Washer (10.5x19x2.0) |
| 29 |
09164-13007-XC0 |
Washer (12.5x22x2.5) |
| 30 |
08331-41359 |
Circlip |
| 45658 |
51110-90832-0EP |
Engine Holder Set (NLA) |
| 45659 |
51110-90822-0EP |
Engine Holder Set |
| 45683 |
09100-10157-XC0 |
Bolt (10x45) |
| 45714 |
09116-10176 |
Bolt (10x44) |
| 45717 |
09248-18006 |
Exhaust Plug |
| 45718 |
09248-18010 |
Exhaust Plug |
▶Fig. 4 - Crankshaft (24 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
12111-92J00 |
Piston |
| 2 |
12140-92J10 |
Piston Ring Set |
| 3 |
12151-86FA0 |
Piston Pin |
| 4 |
09381-21002 |
Piston Circlip |
| 5 |
12160-92J00 |
Connecting Rod Assembly |
| 6 |
09159-08121 |
Nut |
| 8 |
12220-99L00 |
CRANKSHAFT COMP |
| 11 |
09283-52004 |
Oil Seal (52x70x10) |
| 12 |
12100-92J01-050 |
Piston & Ring Set (OS:0.50) |
| 13 |
12140-92J10-050 |
Piston Ring Set (OS:0.50) |
| 45839 |
12100-92841-0A0 |
Conn Rod Bearing Set (Green) |
| 45840 |
12100-92840-025 |
Conn Rod Bearing Set (US:0.25) |
| 45901 |
12340-85FB3-0A0 |
Crankshaft Bearing Set (Green) |
| 45902 |
12340-85FB3-0B0 |
Crankshaft Bearing Set (Black) |
| 45903 |
12340-85FB3-0C0 |
Crankshaft Bearing Set (NON) |
| 45904 |
12340-85FB3-0D0 |
Crankshaft Bearing Set (Yellow) |
| 45905 |
12340-85FB3-0E0 |
Crankshaft Bearing Set (Blue) |
| 45906 |
12300-85854-0AA |
Crankshaft Bearing Set (Red/Green) (US:0.25) |
| 45907 |
12300-85854-0BA |
Crankshaft Bearing Set (Red/Black) (US:0.25) |
| 45908 |
12300-85854-0CA |
Crankshaft Bearing Set (Red) (US:0.25) |
| 45909 |
12300-85854-0DA |
Crankshaft Bearing Set (Red/Yellow) (US:0.25)(NLA) |
| 45910 |
12300-85854-0EA |
Crankshaft Bearing Set (Red/Blue) (US:0.25) (NLA) |
| 45931 |
12300-85830 |
Crank Thrust Bearing Set |
| 45932 |
12300-85830-012 |
Crank Thrust Bearing Set (OS:0.12) |
▶Fig. 40 - Engine Holder DF 140T (S/N 682149 & Newer) DF 140Z (S/N 680234 & Newer) (32 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
51110-90843-0EP |
Engine Holder Set |
| 2 |
09160-18031 |
Exhaust Plug Gasket |
| 3 |
09248-18010 |
Exhaust Plug |
| 4 |
51115-90J00 |
Water Return Union |
| 5 |
51211-90J22 |
Engine Holder Gasket |
| 6 |
09116-08160 |
Bolt (8x70) |
| 7 |
09116-08128 |
Bolt (8x40) |
| 8 |
09206-08001 |
Knock Pin (8x11) |
| 9 |
09280-26006 |
O-Ring |
| 10 |
09282-24003 |
Oil Seal (24x36x6) |
| 11 |
09283-32044 |
Oil Seal (32x47x6) |
| 12 |
01550-06257 |
BOLT |
| 13 |
29117-93J10 |
Bolt (8x45) w/Washer |
| 14 |
09160-08059 |
Washer (8.5x18x1.6) |
| 15 |
04211-11129 |
11 X 12 DOWEL P |
| 16 |
09262-17019 |
Bearing (17x35x8) |
| 17 |
09289-18001 |
Clutch Shaft Seal |
| 18 |
51122-90J00 |
Mount Case Cover |
| 19 |
51123-90J01 |
Mount Case Cover Gasket |
| 20 |
01550-0825A |
BOLT |
| 21 |
54123-90J01 |
Upper Mount Plate |
| 22 |
54112-90J21 |
Upper Mount Bolt |
| 23 |
54130-90J40 |
Upper Mount |
| 24 |
09159-12014 |
Nut (12x17) |
| 25 |
54114-90J10 |
Washer |
| 26 |
54125-90J11 |
Upper Thrust Mount |
| 27 |
54148-90J11-0EP |
Upper Mount Cover |
| 28 |
09116-10176 |
Bolt (10x44) |
| 29 |
09159-12014 |
Nut (12x17) |
| 30 |
09160-12110 |
Washer (12.5x22x3.0) |
| 31 |
08331-41359 |
Circlip |
| 32 |
54123-90J01 |
Upper Mount Plate |
▶Fig. 41 - Driveshaft Housing (20 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
09116-10176 |
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) |
| 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 |
| 15 |
54211-90J01-0EP |
Lower Mount Bracket |
| 16 |
54221-90J02-0EP |
Lower Mount Cover |
| 17 |
09116-10176 |
Bolt (10x44) |
| 18 |
09160-12113 |
Washer (12.5x30x2.5) |
| 45658 |
52111-90J02-0EP |
Drive Shaft Housing (L) |
| 45659 |
52111-90J12-0EP |
Drive Shaft Housing (X) |
| 45839 |
36895-87D01 |
Wire Lead (L:210) |
| 45840 |
36895-87D10 |
Wire Lead (L:310) |
▶Fig. 42 - Gear Case (39 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
55110-90J16-0EP |
Gear Case Housing |
| 2 |
09263-28016 |
Bearing (28.6x38x31.8) |
| 3 |
55125-90J01 |
Trim Tab |
| 4 |
55127-87D00 |
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 |
09407-14407 |
Clamp (L:140) |
| 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 |
| 45673 |
09355-40805-00B |
Hose (4x8x2000) |
| 45676 |
990C0-00760-15P |
Aluminum Propeller 3x13-1/2x15 |
| 45704 |
09355-40805-00B |
Hose (4x8x2000) |
| 45707 |
990C0-00760-17P |
Aluminum Propeller 3x14x17 |
| 45735 |
990C0-00760-19P |
Aluminum Propeller 3x14x19 |
| 45766 |
990C0-00760-21P |
Aluminum Propeller 3x14x21 |
| 45796 |
990C0-00760-23P |
Aluminum Propeller 3x14x23 |
| 45827 |
990C0-00610-16P |
S/S Propeller 3x14x16 |
| 45857 |
990C0-00610-18P |
S/S Propeller 3x14x18 |
| 45888 |
990C0-00610-20P |
S/S Propeller 3x14x20 |
| 45919 |
990C0-00610-22P |
S/S Propeller 3x14x22 |
| 45949 |
990C0-00610-24P |
S/S Propeller 3x14x24 |
| 45980 |
990C0-00610-26P |
S/S Propeller 3x14x26 |
▶Fig. 43 - Gear Case (C/R) (31 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
55110-92J00-0EP |
Gear Case Housing (C/R) |
| 2 |
09263-28016 |
Bearing (28.6x38x31.8) |
| 3 |
55125-92J00 |
Trim Tab |
| 4 |
55127-87D00 |
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 |
| 16 |
09355-40805-00B |
Hose (4x8x2000) |
| 17 |
09362-09008 |
Nipple |
| 18 |
09407-14407 |
Clamp (L:140) |
| 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 |
| 45676 |
990C0-0061L-18P |
S/S Propeller 3x14x18 CCR |
| 45707 |
990C0-0061L-20P |
S/S Propeller 3x14x20 CCR |
| 45735 |
990C0-0061L-22P |
S/S Propeller 3x14x22 CCR |
| 45766 |
990C0-0061L-24P |
S/S Propeller 3x14x24 CCR |
▶Fig. 44 - Transmission (87 parts)
| 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) |
| 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) |
| 20 |
09202-07002 |
Pin (7x48) |
| 21A |
09440-09040 |
Detent Spring |
| 21B |
06111-07004 |
STEEL BALL 7/32 |
| 21C |
06111-11004 |
BALL |
| 23 |
57616-90J00 |
Clutch Dog Spacer |
| 24 |
56120-92J01-0EP |
Propeller Shaft Bearing Housing |
| 25 |
56123-92J00 |
Oil Seal Protector Washer |
| 26 |
09263-30051 |
Bearing (30x37x26) |
| 27 |
09280-97001 |
O-Ring |
| 28 |
09282-30007 |
Oil Seal (30x50x6) |
| 29 |
08113-62090 |
B1 45X85X19 BEA |
| 30 |
09387-52001 |
Set Ring (SUS) |
| 31 |
09117-08047 |
Bolt (8x30) |
| 32 |
56130-90J00 |
Drive Shaft Housing |
| 33 |
09280-46004 |
O-Ring |
| 34 |
09282-24004 |
Oil Seal (24x40x7) |
| 35 |
09117-08110 |
Bolt (8x25) |
| 36 |
56140-92J00 |
Forward Gear Bearing Housing |
| 38 |
09263-50001 |
Bearing (50x62x25) |
| 13516 |
09206-09012 |
Knock Pin |
| 13547 |
09206-09012 |
Knock Pin |
| 45658 |
57110-90J20 |
Drive Shaft (L) |
| 45659 |
57110-92J60 |
Drive Shaft (L) |
| 45660 |
57110-90J30 |
Drive Shaft (X) |
| 45661 |
57110-92J70 |
Drive Shaft (X) |
| 45671 |
09181-45003 |
Shim (1.00) |
| 45673 |
09181-70001 |
Shim (0.70) |
| 45675 |
57610-92J00 |
Propeller Shaft Assembly |
| 45676 |
57621-92J00 |
Clutch Dog Shifter |
| 45678 |
57631-87E00 |
Connector Pin |
| 45679 |
09440-50002 |
Clutch Dog Spring |
| 45702 |
09181-45004 |
Shim (1.10) |
| 45704 |
09181-70002 |
Shim (0.80) |
| 45706 |
57610-92J20 |
Propeller Shaft Assembly |
| 45707 |
57621-92J20 |
Clutch Dog Shifter |
| 45709 |
57631-92J10 |
PIN,CONNECTOR |
| 45710 |
09440-49004 |
Clutch Dog Spring |
| 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) |
| 45839 |
57300-92801 |
Pinion & Gear Set |
| 45840 |
57300-92820 |
Pinion & Gear Set |
| 45841 |
57300-92862 |
Pinion & Gear Set |
| 45852 |
09181-45009 |
Shim (1.60) |
| 45854 |
09181-70010 |
Shim (0.75) |
| 45870 |
09140-14021 |
Nut |
| 45871 |
09140-14024 |
Nut |
| 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) |
| 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. 45 - Transmission (C/R) (85 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 |
| 13 |
09263-45004 |
Bearing (45x52x16) |
| 14 |
09117-08047 |
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) |
| 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) |
| 29-2 |
09160-70005 |
Washer (2.00) |
| 30-2 |
09181-70009 |
Shim (0.65) |
| 31 |
09269-60001 |
Bearing (60x85x3.0) |
| 32 |
09269-70001 |
Bearing (70x95x4.0) |
| 35A |
09440-09040 |
Detent Spring |
| 35B |
06111-07004 |
STEEL BALL 7/32 |
| 35C |
06111-11004 |
BALL |
| 36 |
09202-07002 |
Pin (7x48) |
| 12055 |
57610-92J11 |
Propeller Shaft Assembly (NLA) |
| 12086 |
57610-92J31 |
Propeller Shaft Assembly (C/R) |
| 12420 |
57621-92J00 |
Clutch Dog Shifter |
| 12451 |
57621-92J20 |
Clutch Dog Shifter |
| 12785 |
57631-87E00 |
Connector Pin |
| 12816 |
57631-92J10 |
PIN,CONNECTOR |
| 45658 |
56120-92J11-0EP |
Propeller Shaft Bearing Housing (NLA) |
| 45659 |
56120-92J12-0EP |
Propeller Shaft Bearing Housing |
| 45673 |
57110-90J30 |
Drive Shaft (X) |
| 45679 |
57300-92810 |
Pinion & Gear Set |
| 45680 |
09140-14024 |
Nut |
| 45682 |
09181-40186 |
Shim (0.50) |
| 45683 |
09160-35015 |
Washer (35x46x0.60) |
| 45685 |
09160-60008 |
Washer (0.80) (NLA) |
| 45686 |
09160-70004 |
Washer (3.70) (NLA) |
| 45687 |
09181-70006 |
Shim (0.60) |
| 45704 |
57110-92J70 |
Drive Shaft (X) |
| 45710 |
57300-92830 |
Pinion & Gear Set |
| 45711 |
09140-14021 |
Nut |
| 45713 |
09181-41002 |
Shim (0.55) |
| 45714 |
09160-35014 |
Washer (35x46x0.70) |
| 45716 |
09160-60009 |
Washer (0.90) |
| 45738 |
57300-92850 |
Pinion & Gear Set |
| 45739 |
09140-14024 |
Nut |
| 45741 |
09181-41003 |
Shim (0.60) |
| 45742 |
09160-35013 |
Washer (35x46x0.80) |
| 45744 |
09160-60003 |
Washer (1.00) |
| 45746 |
09181-70001 |
Shim (0.70) |
| 45772 |
09181-41004 |
Shim (0.65) |
| 45773 |
09160-35006 |
Washer (35x46x0.90) |
| 45775 |
09160-60004 |
Washer (1.10) |
| 45777 |
09181-70010 |
Shim (0.75) |
| 45802 |
09181-41005 |
Shim (0.70) |
| 45803 |
09160-35008 |
Washer (35x46x0.95) |
| 45805 |
09160-60005 |
Washer (1.20) |
| 45807 |
09181-70002 |
Shim (0.80) |
| 45833 |
09181-41006 |
Shim (0.75) |
| 45834 |
09160-35002 |
Washer (35x46x1.00) |
| 45836 |
09160-60006 |
Washer (1.30) |
| 45838 |
09181-70011 |
Shim (0.85) |
| 45863 |
09181-40190 |
Shim (0.80) |
| 45864 |
09160-35009 |
Washer (35x46x1.05) |
| 45866 |
09160-60007 |
Washer (1.40) |
| 45868 |
09181-70003 |
Shim (0.90) |
| 45894 |
09181-41008 |
Shim (0.85) |
| 45895 |
09160-35003 |
Washer (35x46x1.10) |
| 45899 |
09181-70012 |
Shim (0.95) |
| 45925 |
09181-41009 |
Shim (0.90) |
| 45926 |
09160-35010 |
Washer (35x46x1.15) |
| 45930 |
09181-70004 |
Shim (1.00) |
| 45955 |
09181-41010 |
Shim (0.95) |
| 45986 |
09181-40195 |
Shim (1.00) |
| 45992 |
09206-09012 |
Knock Pin |
| 45993 |
09206-09012 |
Knock Pin |
| 46016 |
09181-41012 |
Shim (1.05) |
▶Fig. 46 - Side Cover (45 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
61112-90J00 |
Side Cover Rubber Seal |
| 3 |
61810-90J10-0EP |
Starboard Side Cover |
| 4 |
61817-89J01 |
Side Cover Plug |
| 5 |
61820-90J11-0EP |
Port Side Cover |
| 6 |
61827-90J00 |
Side Cover Holder (NLA) |
| 8 |
09116-08174 |
Bolt (8x38) |
| 9 |
09139-06249 |
SCREW |
| 10 |
09136-06149 |
Screw (6x55) |
| 11 |
09169-08039 |
Washer (8.5x30x1.5) (NLA) |
| 12 |
09320-11023 |
CUSHION,FRONT P |
| 13 |
09321-08026 |
CUSHION |
| 15 |
09403-20308 |
Clip |
| 20 |
61641-87D00 |
Engine Cover Hook |
| 21 |
61645-90J01-0EP |
Front Hook Lever |
| 22 |
09116-06127 |
Bolt (6x12) |
| 23 |
09160-13014 |
Washer (13.2x25x1.0) |
| 24 |
09164-14008 |
Wave Washer |
| 25 |
09306-13008 |
Bushing |
| 28 |
67300-90802 |
Remocon Holder Set |
| 29 |
67343-90J01 |
Remocon Cable Stopper |
| 30 |
09407-25402 |
Clamp (L:248) |
| 31 |
01550-06167 |
BOLT |
| 32 |
01550-06257 |
BOLT |
| 33 |
67341-90J32 |
Remocon Cable Holder |
| 34 |
67343-90J20 |
Remocon Cable Stopper |
| 35 |
67344-90J00 |
Remocon Cable Grommet |
| 36 |
01550-06167 |
BOLT |
| 37 |
01580-08257 |
BOLT |
| 45673 |
61633-90J02-0EP |
Rear Hook Lever |
| 45674 |
61633-90J02-0EP |
Rear Hook Lever |
| 45675 |
61637-90J00 |
Engine Cover Rear Starboard Hook |
| 45676 |
61638-90J00 |
Engine Cover Rear Port Hook |
| 45683 |
09307-13006 |
Bushing |
| 45684 |
61124-90J01 |
Remote Control Grommet |
| 45689 |
61134-90J02 |
Side Cover Seal |
| 45690 |
61134-90J11 |
Side Cover Seal |
| 45704 |
61633-90J02-0EP |
Rear Hook Lever |
| 45705 |
61633-90J02-0EP |
Rear Hook Lever |
| 45706 |
61637-90J10 |
Engine Cover Rear Starboard Hook |
| 45707 |
61638-90J10 |
Engine Cover Rear Port Hook |
| 45714 |
09307-13006 |
Bushing |
| 45715 |
61124-90J31 |
Remote Control Grommet |
| 45839 |
61831-90J03-0EP |
Front Panel |
| 45840 |
61831-90J03-0EP |
Front Panel |
| 45841 |
61831-90J11-0EP |
Front Panel |
▶Fig. 47 - Engine Cover (2002) (31 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
61400-92802-0EP |
Engine Cover Set |
| 2 |
61621-87D02 |
Front Fastener Bracket |
| 3 |
61644-90J00 |
Rear Fastener Bracket |
| 4 |
09229-04028-XC0 |
Rivet |
| 5 |
09229-04046 |
Rivet |
| 6 |
61431-92J02-0EP |
Tilt Up Handle |
| 7 |
61432-92J00 |
Tilt Up Louver |
| 8 |
61433-92J00 |
Air Intake Inner Cover |
| 9 |
61438-92J00 |
Air Intake Inner Cushion (NLA) |
| 10 |
61439-90J01 |
Tilt Up Handle Seal |
| 11 |
61439-92J01 |
Tilt Up Handle Seal |
| 12 |
61610-93J01 |
FASTENER COMP |
| 13 |
61680-90J01 |
Starboard Rear Fastener |
| 14 |
61690-90J01 |
Port Rear Fastener |
| 15 |
09329-10024 |
Cushion |
| 16 |
09329-10025 |
Cushion |
| 17 |
09250-12015 |
CAP(OD:12.3) |
| 18 |
01550-06127 |
BOLT |
| 19 |
01550-06167 |
BOLT |
| 20 |
01550-06957 |
BOLT |
| 21 |
01550-06207 |
BOLT |
| 22 |
03541-0616A |
SCREW |
| 24 |
68111-90J01 |
Emblem Mark |
| 25 |
68681-19C00-Y2D |
Emblem Side Mark |
| 26 |
61435-92J00 |
Rear Emblem Mark (140) (NLA) |
| 27 |
61458-99E31 |
Engine Cover Label |
| 28 |
69716-99E14 |
Fuel Limitation Label |
| 29 |
61469-87D00-HY6 |
Counter Rotation Mark |
| 30 |
09800-81841 |
Tool Set |
| 45680 |
61443-90J00 |
Starboard Engine Cover Stripe |
| 45711 |
61453-90J00 |
Port Engine Cover Stripe |
▶Fig. 48 - Engine Cover (2003-2009) (34 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
61410-92846-0EP |
61410-92847-0EP |
| 2 |
61621-87D02 |
Front Fastener Bracket |
| 3 |
61644-90J00 |
Rear Fastener Bracket |
| 5 |
09229-04046 |
Rivet |
| 7 |
61432-92J00 |
Tilt Up Louver |
| 8 |
61433-92J00 |
Air Intake Inner Cover |
| 9 |
61438-92J00 |
Air Intake Inner Cushion (NLA) |
| 10 |
61439-90J01 |
Tilt Up Handle Seal |
| 11 |
61439-92J01 |
Tilt Up Handle Seal |
| 12 |
61610-93J01 |
FASTENER COMP |
| 13 |
61680-90J01 |
Starboard Rear Fastener |
| 14 |
61690-90J01 |
Port Rear Fastener |
| 15 |
09329-10024 |
Cushion |
| 16 |
09329-10025 |
Cushion |
| 17 |
09250-12015 |
CAP(OD:12.3) |
| 18 |
01550-06127 |
BOLT |
| 19 |
01550-06167 |
BOLT |
| 20 |
01550-06957 |
BOLT |
| 21 |
01550-06207 |
BOLT |
| 22 |
03542-06169 |
SCREW |
| 23 |
61435-92J11 |
Rear Emblem Mark |
| 25 |
61446-87J01 |
EFI Decal |
| 26 |
68111-90J01 |
Emblem Mark |
| 27 |
61458-99E31 |
Engine Cover Label |
| 28 |
69716-99E14 |
Fuel Limitation Label |
| 29 |
61469-87D00-HY6 |
Counter Rotation Mark |
| 30 |
09800-81841 |
Tool Set |
| 31 |
61580-92J00 |
Air Intake Inner Plate (NLA) |
| 45681 |
61443-90J11 |
Starboard Engine Cover Stripe |
| 45712 |
61453-90J11 |
Port Engine Cover Stripe |
| 45748 |
09229-04028-XC0 |
Rivet |
| 45749 |
09229-04025 |
Rivet |
| 45809 |
61431-92J02-0EP |
Tilt Up Handle |
| 45810 |
61431-92J02-0EP |
Tilt Up Handle |
▶Fig. 48a - Engine Cover (2010 & Newer) (31 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
61410-92876-0EP |
61410-92878-0EP |
| 2 |
61621-87D02 |
Front Fastener Bracket |
| 3 |
61644-90J00 |
Rear Fastener Bracket |
| 4 |
09229-04025 |
Rivet |
| 5 |
09229-04046 |
Rivet |
| 6 |
61431-92J02-0EP |
Tilt Up Handle |
| 7 |
61432-92J00 |
Tilt Up Louver |
| 8 |
61433-92J00 |
Air Intake Inner Cover |
| 9 |
61438-92J00 |
Air Intake Inner Cushion (NLA) |
| 10 |
61439-90J01 |
Tilt Up Handle Seal |
| 11 |
61439-92J01 |
Tilt Up Handle Seal |
| 12 |
61610-93J01 |
FASTENER COMP |
| 13 |
61680-90J01 |
Starboard Rear Fastener |
| 14 |
61690-90J01 |
Port Rear Fastener |
| 15 |
09329-10024 |
Cushion |
| 16 |
09329-10025 |
Cushion |
| 17 |
09250-12015 |
CAP(OD:12.3) |
| 18 |
01550-06127 |
BOLT |
| 19 |
01550-06167 |
BOLT |
| 20 |
01550-06957 |
BOLT |
| 21 |
01550-06207 |
BOLT |
| 22 |
03542-06169 |
SCREW |
| 23 |
61422-92J12 |
Front Emblem Mark (140) |
| 24 |
61435-92J22 |
Rear Emblem Mark (140) |
| 26 |
61446-87L13 |
DECAL,EFI |
| 27 |
68111-18G20 |
Emblem Mark 'S' |
| 28 |
61458-99E31 |
Engine Cover Label |
| 29 |
09800-81841 |
Tool Set |
| 30 |
61580-92J00 |
Air Intake Inner Plate (NLA) |
| 45682 |
61443-90J42 |
Starboard Engine Cover Stripe |
| 45713 |
61453-90J42 |
Port Engine Cover Stripe |
▶Fig. 49 - Fuel Hose (23 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
65700-87J28 |
Fuel Hose |
| 2 |
65750-87J11 |
Fuel Hose Connector |
| 3 |
65750-95501 |
Fuel Hose Connector (13mm) |
| 4 |
65770-95505 |
Squeeze Pump (NLA) |
| 5 |
65781-98500 |
Hose Clip |
| 6 |
65720-986L0 |
Fuel Connector |
| 7 |
09103-06237 |
Bolt (6x12.5) |
| 8 |
09160-06085 |
Washer (6.5x15x1.0) |
| 9 |
65721-90J00 |
Fuel Connector |
| 10 |
09103-06092 |
Bolt (6x15) |
| 11 |
09140-06020 |
Nut (6mm) |
| 12 |
09160-06085 |
Washer (6.5x15x1.0) |
| 13 |
09180-06334 |
Spacer (NLA) |
| 14 |
65700-90J07 |
Fuel Hose |
| 15 |
65750-95501 |
Fuel Hose Connector (13mm) |
| 16 |
65770-95505 |
Squeeze Pump (NLA) |
| 17 |
65781-98500 |
Hose Clip |
| 18 |
09401-11415 |
Clip |
| 19 |
09251-07003 |
Cap |
| 20 |
09401-11423 |
Clip |
| 21 |
09251-07003 |
Cap |
| 22 |
09367-08001 |
Hose Joint |
| 23 |
65770-95505 |
Squeeze Pump (NLA) |
▶Fig. 5 - Timing Chain (20 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
12732-90J01 |
GEAR,DRIVEN |
| 2 |
12733-90J00 |
Driven Gear Plug |
| 3 |
12741-90J01 |
Camshaft Timing Sprocket |
| 4 |
09103-12049 |
Bolt (12x25) |
| 5 |
09262-35068 |
Bearing (35x62x14) |
| 6 |
09262-35069 |
Bearing (35x62x16) |
| 7 |
09280-22022 |
O-Ring |
| 8 |
04221-05109 |
PIN |
| 9 |
08331-41269 |
Circlip |
| 10 |
12761-90J00 |
Timing Chain |
| 11 |
12771-90J00 |
Timing Chain Guide |
| 12 |
12810-90J00 |
Timing Chain Tensioner |
| 13 |
12813-73G00 |
Timing Chain Tensioner Pad |
| 14 |
12812-90J00 |
Timing Chain Tensioner Spacer |
| 15 |
12831-90J02 |
Tensioner Adjuster Assembly |
| 16 |
01421-0616A |
BOLT,STUD |
| 17 |
01550-0616A |
BOLT |
| 18 |
01550-0620A |
BOLT |
| 19 |
01550-0835A |
BOLT |
| 20 |
08316-1006A |
Nut |
▶Fig. 50 - 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. 51 - Opt: Meter (2002-2004) (31 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
34190-87D00 |
Speedometer Sensor |
| 2 |
34800-90J02 |
Trim Meter Assembly (NLA) |
| 3 |
09471-12180 |
Bulb (NLA) |
| 6 |
09471-12179 |
Bulb (Red) |
| 7 |
34191-92E00 |
Water Pressure Tubing |
| 8 |
09407-14407 |
Clamp (L:140) |
| 9 |
36615-96300 |
Resin Terminal |
| 10 |
34190-95500 |
Speedometer Sensor (NLA) |
| 11 |
03112-06303 |
Screw (NLA) |
| 12 |
34600-92E00 |
Volt Meter (NLA) |
| 13 |
09471-12180 |
Bulb (NLA) |
| 14 |
34300-92E01 |
Fuel Gauge Set (NLA) |
| 15 |
34320-92E01 |
Fuel Gauge (NLA) |
| 16 |
34310-92E00 |
Fuel Gauge Lead (NLA) |
| 17 |
34360-92E00 |
Adapter Harness (NLA) |
| 18 |
09471-12180 |
Bulb (NLA) |
| 19 |
34500-92E00 |
Hour Meter (NLA) |
| 20 |
09471-12180 |
Bulb (NLA) |
| 21 |
34650-92E00 |
Water Pressure Gauge (NLA) |
| 22 |
34191-92E00 |
Water Pressure Tubing |
| 23 |
09407-14407 |
Clamp (L:140) |
| 24 |
34652-92E00 |
Union (NLA) |
| 25 |
36658-95600 |
Cable Grommet (NLA) |
| 26 |
09471-12180 |
Bulb (NLA) |
| 27 |
09320-08028 |
Grommet |
| 45748 |
34102-92E00 |
Speedometer Set (80mph) (NLA) |
| 45749 |
34102-92E10 |
Speedometer Set (50mph) (NLA) |
| 45750 |
34102-92E20 |
Speedometer Set (45knt) |
| 45778 |
34100-92E00 |
Speedometer (80mph) (NLA) |
| 45779 |
34100-92E10 |
Speedometer (50mph) (NLA) |
| 45780 |
34100-92E20 |
Speedometer (45kt) (NLA) |
▶Fig. 52 - Opt: Meter (2005 & Newer) (31 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
09471-12103 |
Bulb (12v, 3.4w) |
| 4 |
09471-12028 |
Bulb (12v, 3.4w) |
| 5 |
34191-92E00 |
Water Pressure Tubing |
| 6 |
09407-14407 |
Clamp (L:140) |
| 7 |
36615-96300 |
Resin Terminal |
| 9 |
09471-12103 |
Bulb (12v, 3.4w) |
| 11 |
34310-92E00 |
Fuel Gauge Lead (NLA) |
| 12 |
34360-92E00 |
Adapter Harness (NLA) |
| 13 |
09471-12103 |
Bulb (12v, 3.4w) |
| 15 |
09471-12103 |
Bulb (12v, 3.4w) |
| 17 |
34191-92E00 |
Water Pressure Tubing |
| 18 |
09407-14407 |
Clamp (L:140) |
| 19 |
09471-12103 |
Bulb (12v, 3.4w) |
| 21 |
36615-96300 |
Resin Terminal |
| 22 |
09471-12077 |
Bulb (12v, 1.7w) |
| 45658 |
34800-93J02 |
Black Trim Gauge |
| 45659 |
34800-93J13 |
White Trim Gauge |
| 45671 |
34500-93J02 |
Black Hour Meter |
| 45673 |
34650-93J20 |
Black Water Pressure Gauge* |
| 45677 |
34200-93J02 |
Black Tachometer w/Monitor Function |
| 45702 |
34500-93J13 |
White Hour Meter |
| 45704 |
34650-93J33 |
White Water Pressure Gauge |
| 45708 |
34200-93J14 |
Tachometer w/Monitor - White |
| 45717 |
34100-93J00 |
Black Speedometer 0-80 MPH |
| 45718 |
34100-93J13 |
White Speedometer 0-80 MPH |
| 45719 |
34100-93J22 |
Black Speedometer 0-50 MPH |
| 45720 |
34100-93J33 |
White Speedometer 0-50 MPH |
| 45870 |
34600-93J02 |
Black Voltmeter |
| 45871 |
34600-93J13 |
White Voltmeter |
| 45931 |
34300-93J02 |
Black Fuel Gauge |
| 45932 |
34300-93J13 |
White Fuel Gauge |
▶Fig. 54 - Opt: Harness (23 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
36631-94300 |
Cap |
| 4 |
36990-87D00 |
Terminal & Sleeve Set |
| 5 |
36620-92E00 |
21' Main Wire Harness (NLA) |
| 6 |
34660-90J04 |
Water Pressure Gauge Install Kit |
| 7 |
09352-50006-600 |
Hose (5x9x600) |
| 8 |
09352-50006-600 |
Hose (5x9x600) |
| 9 |
09367-06006 |
3 Way |
| 10 |
09401-08413 |
Clip |
| 11 |
18498-99EA0 |
Protector (L:80) (NLA) |
| 12 |
09407-25402 |
Clamp (L:248) |
| 13 |
17917-87L00 |
Water Flush Connector |
| 16 |
38500-93J00 |
Warning Buzzer* |
| 45658 |
36620-87D20 |
Wiring Harness Extension (NLA) |
| 45659 |
36620-95302 |
Wiring Harness Extension (NLA) |
| 45671 |
36620-93J12 |
MAIN HARNESS EXT 6.5' |
| 45672 |
36620-93J22 |
HARNESSADAPTER |
| 45674 |
36620-93J04 |
21' Main Wiring Harness |
| 45702 |
36620-93J42 |
HARNESS EXT 10' |
| 45703 |
36620-93J31 |
Replaced by 36620-93J32 |
| 45705 |
36620-93J54 |
16' Main Wiring Harness |
| 45717 |
36660-94400 |
Meter Extension Harness (NLA) |
| 45718 |
36660-94480 |
Trim Wire Harness (6 ft) (NLA) |
| 45733 |
36620-93J64 |
26' Main Wiring Harness |
▶Fig. 56 - Opt: Switch (2002-2004) (16 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
37100-92E00 |
Ignition Switch Panel Assembly (NLA) |
| 2 |
37139-92E01 |
Single Ingition Switch Panel |
| 3 |
37803-92E00 |
Emergency Stop Switch Assembly (NLA) |
| 4 |
37825-92E00 |
Emergency Switch Panel |
| 5 |
37805-92E00 |
PTT Switch Set (NLA) |
| 6 |
37855-92E00 |
PTT Switch Panel (NLA) |
| 7 |
37210-92E00 |
Lighting Switch Set (NLA) |
| 8 |
37212-92E00 |
Lighting Switch Panel (NLA) |
| 9 |
37100-92E01 |
Ignition Switch Panel Assembly (NLA) |
| 10 |
37139-92E01 |
Single Ingition Switch Panel |
| 12 |
37110-99E02 |
Ignition Switch Assembly |
| 13 |
37820-92E05 |
Emergency Stop Switch Assembly |
| 14 |
37139-99E20 |
Ignition Switch Panel |
| 15 |
03121-0516A |
SCREW |
| 16 |
37805-99E00 |
PTT Switch Assembly |
| 17 |
37855-99E00 |
PTT Switch Panel |
▶Fig. 57 - Opt: Switch C/R (2002-2004) (50 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
37100-92E00 |
Ignition Switch Panel Assembly (NLA) |
| 2 |
37139-92E01 |
Single Ingition Switch Panel |
| 3 |
37803-92E00 |
Emergency Stop Switch Assembly (NLA) |
| 4 |
37825-92E00 |
Emergency Switch Panel |
| 5 |
37805-92E00 |
PTT Switch Set (NLA) |
| 6 |
37855-92E00 |
PTT Switch Panel (NLA) |
| 7 |
37210-92E00 |
Lighting Switch Set (NLA) |
| 8 |
37212-92E00 |
Lighting Switch Panel (NLA) |
| 9 |
37100-92E14 |
Dual Ignition Switch Assembly (NLA) |
| 10 |
37110-99E02 |
Ignition Switch Assembly |
| 12 |
37820-92E95 |
Emergency Stop Switch Assembly (NLA) |
| 13 |
37139-92E10 |
Dual Ignition Switch Panel Only (NLA) |
| 14 |
03121-0516A |
SCREW |
| 15 |
37100-92E14 |
Dual Ignition Switch Assembly (NLA) |
| 16 |
37110-99E02 |
Ignition Switch Assembly |
| 18 |
37143-99E01 |
Key Cap |
| 19 |
37820-92E95 |
Emergency Stop Switch Assembly (NLA) |
| 20 |
37139-92E11 |
Dual Ignition Switch Panel Only (NLA) |
| 21 |
03121-0516A |
SCREW |
| 23 |
37139-92E01 |
Single Ingition Switch Panel |
| 25 |
37110-99E02 |
Ignition Switch Assembly |
| 26 |
37820-92E05 |
Emergency Stop Switch Assembly |
| 27 |
37139-99E20 |
Ignition Switch Panel |
| 28 |
03121-0516A |
SCREW |
| 29 |
37805-99E00 |
PTT Switch Assembly |
| 30 |
37855-99E00 |
PTT Switch Panel |
| 45674 |
37141-99E00 |
(931) Ignition Key |
| 45679 |
37100-92E01 |
Ignition Switch Panel Assembly (NLA) |
| 45705 |
37141-99E10 |
(932) Ignition Key |
| 45710 |
37100-99E00 |
Single Ignition Switch Assembly |
| 45733 |
37141-99E20 |
(933) Ignition Key |
| 45764 |
37141-99E30 |
(934) Ignition Key |
| 45794 |
37141-99E40 |
(935) Ignition Key |
| 45825 |
37141-99E50 |
(936) Ignition Key |
| 45855 |
37141-99E60 |
(937) Ignition Key |
| 45886 |
37141-99E70 |
(938) Ignition Key |
| 45917 |
37141-99E80 |
(939) Ignition Key |
| 45947 |
37141-99E90 |
(940) Ignition Key |
| 45962 |
37141-92E00 |
(11) Ignition Key |
| 45963 |
37141-92E10 |
(12) Ignition Key |
| 45964 |
37141-92E20 |
(13) Ignition Key |
| 45965 |
37141-92E30 |
(14) Ignition Key |
| 45966 |
37141-92E40 |
(15) Ignition Key |
| 45967 |
37141-92E50 |
(16) Ignition Key |
| 45968 |
37141-92E60 |
(17) Ignition Key |
| 45969 |
37141-92E70 |
(18) Ignition Key |
| 45970 |
37141-92E80 |
(19) Ignition Key |
| 45971 |
37141-92E90 |
(20) Ignition Key |
| 45978 |
37141-99EA0 |
(941) Ignition Key |
| 46008 |
37141-99EB0 |
(942) Ignition Key |
▶Fig. 58 - Opt: Switch (2005 & Newer) (35 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
37100-96J01 |
Ignition Switch Panel Assembly |
| 2 |
37139-99E00 |
Ignition Switch Panel |
| 2A |
38500-93J90 |
Warning Buzzer |
| 2B |
09407-14403 |
Clamp (L:125) |
| 3 |
37803-93J06 |
Emergency Stop Switch Panel Assembly |
| 4 |
37825-99E00 |
Emergency Switch Panel |
| 5 |
37805-93J00 |
PTT Switch Assembly |
| 6 |
37855-99E00 |
PTT Switch Panel |
| 7 |
37210-93J00 |
Lighting Switch Set (NLA) |
| 8 |
37212-93J00 |
Lighting Switch Panel (NLA) |
| 10 |
37110-93J02 |
Ignition Switch Assembly |
| 12 |
37143-99E01 |
Key Cap |
| 13 |
37820-93J95 |
Emergency Stop Switch Assembly |
| 14 |
37139-99E10 |
Ignition Switch Panel |
| 15 |
03121-0516A |
SCREW |
| 15A |
38500-93J90 |
Warning Buzzer |
| 15B |
09407-14403 |
Clamp (L:125) |
| 17 |
37110-93J02 |
Ignition Switch Assembly |
| 18 |
37820-93J05 |
Emergency Stop Switch Assembly |
| 19 |
37139-99E20 |
Ignition Switch Panel |
| 20 |
03121-0516A |
SCREW |
| 21 |
38500-93J90 |
Warning Buzzer |
| 22 |
09407-14403 |
Clamp (L:125) |
| 45962 |
37141-99E00 |
(931) Ignition Key |
| 45963 |
37141-99E10 |
(932) Ignition Key |
| 45964 |
37141-99E20 |
(933) Ignition Key |
| 45965 |
37141-99E30 |
(934) Ignition Key |
| 45966 |
37141-99E40 |
(935) Ignition Key |
| 45967 |
37141-99E50 |
(936) Ignition Key |
| 45968 |
37141-99E60 |
(937) Ignition Key |
| 45969 |
37141-99E70 |
(938) Ignition Key |
| 45970 |
37141-99E80 |
(939) Ignition Key |
| 45971 |
37141-99E90 |
(940) Ignition Key |
| 45972 |
37141-99EA0 |
(941) Ignition Key |
| 45973 |
37141-99EB0 |
(942) Ignition Key |
▶Fig. 6 - Camshaft (44 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
12711-92J00 |
Intake Camshaft |
| 2 |
12720-92J00 |
Exhaust Camshaft |
| 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 |
| 7 |
12921-90J00 |
Replaced by 12921-90J01 |
| 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) |
| 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) |
| 45809 |
12915-86F51 |
Exhaust Valve |
| 45810 |
12915-86FA1 |
Exhaust Valve |
▶Fig. 60 - Opt: Top Mount Dual (1)(2005 & Newer) (32 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
67200-88L12 |
Duel Binnacle Top Mount Control |
| 2 |
67261-93J00 |
Grip No 1 |
| 3 |
67263-93J00 |
Grip No 2 |
| 4 |
37850-93J10 |
PTT Switch Assembly |
| 5 |
67295-92E10 |
Screw (3x12) |
| 6 |
67296-88D10 |
Screw (5x16) |
| 7 |
67288-92E20 |
Washer |
| 8 |
67296-92E70 |
Screw |
| 9 |
67288-92E40 |
Washer |
| 10 |
67257-92E00 |
Lever Cap |
| 11 |
67251-93J00 |
Handle Lever |
| 12 |
67296-92E60 |
Screw |
| 13 |
67288-92E30 |
Washer |
| 14 |
67253-92E00 |
Washer |
| 15 |
36890-93J10 |
Wire Harness |
| 16 |
37220-92E00 |
Mode Changing Switch Assembly |
| 17 |
67282-93J00 |
Decal |
| 18 |
67296-92E30 |
Screw |
| 19 |
09160-05024 |
Washer (5.5x16x1.5) |
| 20 |
67287-92E00 |
Nut |
| 21 |
67275-95600 |
Cable End |
| 22 |
67273-95600 |
Spacer |
| 23 |
67273-92E10 |
Grommet (NLA) |
| 24 |
67295-92E00 |
Screw |
| 25 |
67271-92E00 |
Cover |
| 26 |
67211-93J10 |
Top Binnacle Cover |
| 27 |
67296-92E70 |
Screw |
| 28 |
67500-93J10 |
Dual Binnacle Box Spacer |
| 29 |
09125-05135 |
Screw (5x65) |
| 30 |
09160-05029 |
Washer (5.5x10x0.8) |
| 31 |
09140-05005 |
Nut |
| 32 |
67140-95600 |
Replaced by 67140-95601 |
▶Fig. 61 - Opt: Top Mount Dual (2)(2005 & Newer) (53 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
67200-88L12 |
Duel Binnacle Top Mount Control |
| 2 |
67222-92E00 |
Dual Plate |
| 3 |
67223-92E00 |
Brake Adjust (NLA) |
| 4 |
67288-92E00 |
Washer |
| 5 |
67292-94300 |
E Ring |
| 6 |
67288-92E10 |
Washer (NLA) |
| 7 |
67291-92E00 |
Snap Ring (NLA) |
| 8 |
67221-92E00 |
Shift Assembly (NLA) |
| 9 |
67224-92E00 |
Brake Arm Assembly (NLA) |
| 10 |
67294-92E00 |
Spacer (NLA) |
| 11 |
37721-92E11 |
Neutral Switch Assembly |
| 12 |
67296-92E11 |
Screw (3x15) |
| 13 |
67296-88D10 |
Screw (5x16) |
| 14 |
67296-92E20 |
Screw (5x25) (NLA) |
| 15 |
67226-92E00 |
Bolt (NLA) |
| 16 |
67226-92E10 |
Bolt (NLA) |
| 17 |
67240-92E00 |
Throttle Arm Assembly (NLA) |
| 18 |
67228-92E00 |
Washer (NLA) |
| 19 |
67286-92E00 |
Bolt (6x18) (NLA) |
| 20 |
67230-92E00 |
Shift Arm Assembly (NLA) |
| 21 |
09125-05042 |
Screw (5x10) |
| 22 |
67234-92E00 |
Gear Case (NLA) |
| 23 |
67245-92E00 |
Free Throttle Drum (NLA) |
| 24 |
67227-92E00 |
Stopper (NLA) |
| 25 |
09126-06006 |
Screw (6x20) |
| 26 |
67225-92E00 |
Spring (NLA) |
| 27 |
09125-04004 |
Screw (4x6) |
| 28 |
67296-95610 |
Screw |
| 29 |
67233-92E00 |
Spring (NLA) |
| 30 |
67235-92E00 |
Shift Lock Plate (NLA) |
| 31 |
67232-95620 |
Bushing (NLA) |
| 32 |
67269-92E00 |
Bracket (NLA) |
| 33 |
67296-88D10 |
Screw (5x16) |
| 34 |
09140-06020 |
Nut (6mm) |
| 35 |
67236-92E00 |
Roller (NLA) |
| 36 |
67237-92E01 |
Spring (NLA) |
| 37 |
67238-92E00 |
Drive Gear (NLA) |
| 38 |
67239-92E00 |
Pin |
| 39 |
67246-92E00 |
Drive Shaft |
| 40 |
67252-92E00 |
Bushing (NLA) |
| 41 |
67291-92E10 |
Snap Ring (NLA) |
| 42 |
67253-92E10 |
Washer |
| 43 |
67252-92E10 |
Bushing (NLA) |
| 44 |
67274-92E00 |
Flange |
| 45 |
67253-95600 |
Washer (NLA) |
| 46 |
67231-92E00 |
Shift Gear |
| 47 |
67232-95600 |
Bushing |
| 48 |
67241-92E00 |
Free Accel Rod (NLA) |
| 49 |
67243-92E00 |
Grommet (NLA) |
| 50 |
67239-92E10 |
Shift Pin Plate |
| 51 |
67272-92E10 |
Flange Seal (NLA) |
| 52 |
67287-92E10 |
Nut (NLA) |
| 53 |
67296-92E80 |
Screw (NLA) |
▶Fig. 62 - Opt: Top Mount Single (1) (2005 & Newer) (32 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
67200-88L02 |
Single Binnacle Control Box |
| 2 |
67261-93J00 |
Grip No 1 |
| 3 |
67263-93J00 |
Grip No 2 |
| 4 |
37850-93J10 |
PTT Switch Assembly |
| 5 |
67295-92E10 |
Screw (3x12) |
| 6 |
67296-88D10 |
Screw (5x16) |
| 7 |
67288-92E20 |
Washer |
| 8 |
67295-92E00 |
Screw |
| 9 |
67296-92E70 |
Screw |
| 10 |
67288-92E40 |
Washer |
| 11 |
67257-92E00 |
Lever Cap |
| 12 |
67251-93J00 |
Handle Lever |
| 13 |
67296-92E60 |
Screw |
| 14 |
67288-92E30 |
Washer |
| 15 |
67253-92E00 |
Washer |
| 16 |
36890-93J00 |
Wire Harness |
| 17 |
67281-93J00 |
Decal |
| 18 |
67296-92E30 |
Screw |
| 19 |
09160-05024 |
Washer (5.5x16x1.5) |
| 20 |
67287-92E00 |
Nut |
| 21 |
67275-95600 |
Cable End |
| 22 |
67273-95600 |
Spacer |
| 23 |
67273-92E00 |
Grommet |
| 24 |
67274-92E00 |
Flange |
| 25 |
67296-95610 |
Screw |
| 26 |
67271-92E00 |
Cover |
| 27 |
67211-93J00 |
Top Binnacle Cover |
| 28 |
67296-92E70 |
Screw |
| 29 |
67500-93J00 |
Single Binnacle Box Spacer |
| 30 |
09125-05135 |
Screw (5x65) |
| 31 |
09160-05029 |
Washer (5.5x10x0.8) |
| 32 |
09140-05005 |
Nut |
▶Fig. 63 - Opt: Top Mount Single (2) (2005 & Newer) (48 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
67200-88L02 |
Single Binnacle Control Box |
| 2 |
67222-92E00 |
Dual Plate |
| 3 |
67223-92E00 |
Brake Adjust (NLA) |
| 4 |
67288-92E00 |
Washer |
| 5 |
67292-94300 |
E Ring |
| 6 |
67288-92E10 |
Washer (NLA) |
| 7 |
67291-92E00 |
Snap Ring (NLA) |
| 8 |
67221-92E00 |
Shift Assembly (NLA) |
| 9 |
67224-92E00 |
Brake Arm Assembly (NLA) |
| 10 |
67294-92E00 |
Spacer (NLA) |
| 11 |
37721-95500 |
Neutral Switch Assembly |
| 12 |
67296-92E11 |
Screw (3x15) |
| 13 |
67296-88D10 |
Screw (5x16) |
| 14 |
67296-92E20 |
Screw (5x25) (NLA) |
| 15 |
67226-92E00 |
Bolt (NLA) |
| 16 |
67226-92E10 |
Bolt (NLA) |
| 17 |
67240-92E00 |
Throttle Arm Assembly (NLA) |
| 18 |
67228-92E00 |
Washer (NLA) |
| 19 |
67286-92E00 |
Bolt (6x18) (NLA) |
| 20 |
67230-92E00 |
Shift Arm Assembly (NLA) |
| 21 |
09125-05042 |
Screw (5x10) |
| 22 |
67234-92E00 |
Gear Case (NLA) |
| 23 |
67245-92E00 |
Free Throttle Drum (NLA) |
| 24 |
67227-92E00 |
Stopper (NLA) |
| 25 |
09126-06006 |
Screw (6x20) |
| 26 |
67225-92E00 |
Spring (NLA) |
| 27 |
09125-04004 |
Screw (4x6) |
| 28 |
67233-92E00 |
Spring (NLA) |
| 29 |
67235-92E00 |
Shift Lock Plate (NLA) |
| 30 |
67232-95620 |
Bushing (NLA) |
| 31 |
67269-92E00 |
Bracket (NLA) |
| 32 |
67296-88D10 |
Screw (5x16) |
| 33 |
09140-06020 |
Nut (6mm) |
| 34 |
67236-92E00 |
Roller (NLA) |
| 35 |
67237-92E01 |
Spring (NLA) |
| 36 |
67238-92E00 |
Drive Gear (NLA) |
| 37 |
67239-92E00 |
Pin |
| 38 |
67246-92E00 |
Drive Shaft |
| 39 |
67252-92E00 |
Bushing (NLA) |
| 40 |
67291-92E10 |
Snap Ring (NLA) |
| 41 |
67253-92E10 |
Washer |
| 42 |
67252-92E10 |
Bushing (NLA) |
| 43 |
67253-95600 |
Washer (NLA) |
| 44 |
67231-92E00 |
Shift Gear |
| 45 |
67232-95600 |
Bushing |
| 46 |
67241-92E00 |
Free Accel Rod (NLA) |
| 47 |
67243-92E00 |
Grommet (NLA) |
| 48 |
67239-92E10 |
Shift Pin Plate |
▶Fig. 64 - Opt: Gasket Set (12 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
11141-92J01 |
Cylinder Head Gasket |
| 3 |
11189-90J00 |
Cylinder Head Cover Gasket |
| 4 |
11265-87E10 |
Protection Cover Gasket |
| 5 |
11489-90J00 |
Oil Pan Gasket |
| 6 |
13119-90J00 |
Intake Manifold Gasket |
| 7 |
13421-90J01 |
Throttle Body Gasket |
| 8 |
14151-90J00 |
Rectifier Gasket |
| 9 |
17472-87E10 |
Water Pump Plate Gasket |
| 45658 |
11400-92856 |
GASKET SET |
| 45659 |
11400-92862 |
Engine Gasket Set |
| 45931 |
51211-90J10 |
Engine Holder Gasket |
| 45932 |
51211-90J22 |
Engine Holder Gasket |
▶Fig. 65 - Optional (13 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
67282-95610 |
Port Decal (Black) (NLA) |
| 2 |
68165-16B01-13L |
Suzuki Emblem |
| 3 |
67140-95600 |
Replaced by 67140-95601 |
| 45748 |
99011-92J00-03A |
O/M DF140 2002 |
| 45749 |
99011-90J02-03A |
O/M DF90/115/140 2003 |
| 45750 |
99011-90J03-03A |
O/M DF90/115/140 2004 |
| 45751 |
99011-90J04-03A |
O/M DF90/115/140 2005 |
| 45752 |
99011-90J05-03A |
O/M DF90/115/140 2006 |
| 45753 |
99011-90J06-03A |
O/M DF90/115/140 2007 (NLA) |
| 45754 |
99011-90J07-03A |
O/M DF90/115/140 2008 |
| 45755 |
99011-90J08-03A |
O/M DF90/100/115/140 2009 |
| 45756 |
99011-90J09-03A |
O/M DF90/100/115/140 2010 |
| 45757 |
99011-90J11-03A |
O/M DF90/100/115/140 2011 |
▶Fig. 7 - Intake Manifold (15 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
13110-90J02 |
Intake Manifold |
| 2 |
13119-90J00 |
Intake Manifold Gasket |
| 3 |
13140-90J00 |
Water Jacket Cover |
| 4 |
13145-90J00 |
Water Jacket Cover O-Ring |
| 5 |
18134-77E00 |
IAC Valve Gasket |
| 6 |
18137-77E00 |
IAC Valve |
| 7 |
18141-90J00 |
IAC Hose |
| 8 |
09329-12004 |
Cushion |
| 9 |
01421-08357 |
BOLT,STUD |
| 10 |
01421-08507 |
STUD BOLT |
| 11 |
01550-06207 |
BOLT |
| 12 |
01550-08407 |
BOLT 8 X 40 |
| 13 |
01550-08757 |
BOLT |
| 14 |
04211-11129 |
11 X 12 DOWEL P |
| 15 |
08316-10087 |
Nut |
▶Fig. 8 - Silencer (10 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
13710-99E00 |
Flame Arrester |
| 2 |
13810-90J01 |
Silencer Assembly |
| 3 |
13813-90J01 |
HOLDER,FLAME AR |
| 4 |
13840-90J00 |
Silencer Duct |
| 5 |
13851-90J01 |
Silencer Grommet |
| 6 |
09160-06084 |
Washer (6.5x18x1.6) |
| 7 |
09169-06075 |
Washer |
| 8 |
09320-09059 |
Cushion |
| 45901 |
01550-06307 |
BOLT |
| 45902 |
09116-06215 |
Bolt (6x30) w/Washer |
▶Fig. 9 - Fuel Vapor Separator (28 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
15600-90J01 |
Fuel Vapor Separator Assembly |
| 2 |
13370-99E00 |
Needle Valve Assembly |
| 3 |
13373-39110 |
Needle Valve Plate |
| 4 |
15200-90J00 |
Fuel Pump Assembly |
| 5 |
15626-90J00 |
Seal |
| 6 |
15628-99E00 |
Screw (L:15) |
| 7 |
15629-99E10 |
Drain Screw |
| 8 |
15641-90J00 |
Fuel Pump Spacer |
| 8A |
15642-90J00 |
Fuel Pump Filter |
| 9 |
15650-99E00 |
Float |
| 10 |
15654-99E00 |
Float Pin |
| 11 |
15683-87J00 |
Drain Hose (L:120) |
| 12 |
15760-87J00 |
Fuel Pressure Regulator |
| 13 |
02112-0408A |
SCREW |
| 14 |
02112-0510A |
SCREW |
| 15 |
15647-93J00 |
Fuel Pump Bushing |
| 16 |
13671-13F00 |
Clip |
| 17 |
18498-90J01 |
Hose Protector |
| 18 |
09160-06084 |
Washer (6.5x18x1.6) |
| 19 |
09169-06075 |
Washer |
| 20 |
09320-09059 |
Cushion |
| 21 |
44420-44AR0 |
Hose (5x8.2x600) |
| 22 |
09401-08412 |
Clip |
| 23 |
09403-13413 |
CLAMP |
| 24 |
09408-00124 |
Clamp |
| 25 |
01550-06127 |
BOLT |
| 45683 |
01550-06257 |
BOLT |
| 45714 |
09116-06202 |
Bolt w/Washer (6x25) |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Suzuki DF 140TLK2,DF 140TXK2,DF 140TXZK2 running reliably season after season. Most of these tasks can be performed with basic tools and the factory service manual.
- Replace water pump impeller and inspect wear plate
- Change engine oil and oil filter (check drain plug washer)
- Replace spark plugs and check ignition timing
- Drain and refill lower unit gear oil; inspect for water contamination
- Inspect fuel lines, primer bulb, and fuel filter for deterioration
- Check and replace sacrificial anodes (zinc or aluminum)
- Inspect propeller for damage; check shaft seal and cotter pin
- Check valve clearance (refer to service manual for specifications)
- Lubricate all grease points (steering, tilt tube, shift linkage)
- 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.
