Suzuki DF 2.5S (2012) Parts & Diagrams

OEM and aftermarket replacement parts for Suzuki DF 2.5S. Scroll down for exploded parts diagrams (21), specifications, and maintenance reference.

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Suzuki DF 2.5S (2012) Parts & Diagrams

🔎 Suzuki DF 2.5S Reference Library — Exploded parts diagrams (21 diagrams), specifications, common issues, and maintenance checklist.

The Suzuki DF 2.5S is a 4-Stroke OHV Single-Cylinder outboard motor. Designed for dinghies, inflatable boats, and small tenders where lightweight portability is essential.

Quick Reference Specifications

Specification Value
Engine Type 4-Stroke OHV Single-Cylinder
Horsepower 2 HP
Displacement 68 cc
Bore x Stroke 48.0 x 38.0 mm
Spark Plug (Type & Gap) NGK CR6HSA
Engine Oil Capacity 0.38 L
Recommended Engine Oil SAE 10W-30
Gear Case Oil Capacity 70 mL
Idle Speed (in gear) 1800-2000 RPM
Full Throttle RPM Range 4500-5500 RPM
Fuel Unleaded Gasoline, 87 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 2.5S:

  • 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 2.5S.

▶Fig. 1 - Cylinder Head (9 parts) Fig. 1 - Cylinder Head
Ref OEM Part # Part Name
1 11110-97J20 Cylinder Head
2 11141-97JL0 Cylinder Head Gasket
3 09206-08008 Cylinder Head Dowl Pin (NLA)
4 11118-97JL0 Cylinder Head Bolt
5 11119-97JL0 Cylinder Head Bolt
6 11171-97J10 Cylinder Head Cover
7 11189-97JL0 Cylinder Head Cover Gasket
8 01547-05107 BOLT
9 09482-00406 NGK CR6HSA Spark Plug
▶Fig. 10 - Clutch Lever (10 parts) Fig. 10 - Clutch Lever
Ref OEM Part # Part Name
1 21111-97J01 Clutch Lever
2 21112-97J00 Clutch Lever Knob
3 21221-97J00 Clutch Shaft Bushing
4 21222-97J00 Clutch Shaft Bushing
5 23211-97J10 Clutch Rod Arm
6 23213-97J00 Clutch Notch Spring
7 09160-08145 Washer (8x14x1.5)
8 09205-03012 Spring Pin (3x16)
9 09205-04002 Spring Pin (4x20)
10 09280-08005 O-Ring
▶Fig. 11- Shift Rod (3 parts) Fig. 11- Shift Rod
Ref OEM Part # Part Name
1 25111-97J10 Shift Rod (S)
2 09383-04002 E Ring
3 09280-06004 O-Ring
▶Fig. 12 - Drive Shaft (23 parts) Fig. 12 - Drive Shaft
Ref OEM Part # Part Name
1 57111-97J11 Drive Shaft (S)
2 57130-91J00 Drive Shaft Bushing
3 57311-97JM0 Pinion Gear
5 08332-1106A E Ring
6 57510-97JM0 Forward Gear
8 57611-97J10 Propeller Shaft Assembly
9 57621-97J10 Clutch Dog Shifter
10 59441-97J20 Return Spring
11 57631-97J10 Push Rod
45748 09181-10015 Shim (1.80)
45749 09181-10016 Shim (1.90) (NLA)
45750 09181-10017 Shim (2.00)
45751 09181-10018 Shim (2.10)
45752 09181-10019 Shim (2.20)
45839 09181-17002 Shim (0.30) (NLA)
45840 09181-17023 Shim (0.40)
45841 09181-17024 Shim (0.50) (NLA)
45842 09181-17025 Shim (0.60)(NLA)
45992 09181-12017 Washer (12x20x1.6)
45993 09181-12018 Washer (12x20x1.7) (NLA)
45994 09181-12019 Washer (12x20x1.8) (NLA)
45995 09181-12020 Washer (12x20x1.9) (NLA)
45996 09181-12021 Washer (12x20x2.0) (NLA)
▶Fig. 13 - Magneto (15 parts) Fig. 13 - Magneto
Ref OEM Part # Part Name
1 32102-97J10 Flywheel (NLA)
2 33410-97J21 Replaced by 33410-97J40
3 01550-06307 BOLT
4 08316-10107 Nut
5 08341-31039 Woodruff Key
6 33500-07H00 Spark Plug Cap
7 09180-06363 Spacer (6.2x12.6x6) (NLA)
8 37830-97J21 Emergency Switch Assembly
9 37823-97J00 Stop Switch Lanyard
10 37826-92E00 Nut
11 37835-91J00-YAY Stop Label
12 29404-93J11 Clamp (L:65)
13 19183-97J01 Throttle Cable Holder (NLA)
14 09408-00179 Clamp
15 09407-14407 Clamp (L:140)
▶Fig. 14 - Clamp Bracket (8 parts) Fig. 14 - Clamp Bracket
Ref OEM Part # Part Name
1 41111-97J31-0EP Clamp Bracket
2 41210-97J00 Clamp Handle
3 41213-94J01 Clamp Plate
4 41214-97J00 Clamp Screw Cap
5 59181-97J10 Tilt Lock Lever Spacer
6 09101-06009 Bolt (6x115)
7 29141-93J00 Nut (6mm)
8 09159-06079 Nut
▶Fig. 15 - Swivel Bracket (22 parts) Fig. 15 - Swivel Bracket
Ref OEM Part # Part Name
1 43111-97J31-0EP Swivel Bracket
2 43121-97J30-0EP Swivel Bracket Cover
3 43711-97J00 Steering Bushing
4 59111-97JL0 Swivel Shaft Bolt
5 09159-08018 Nut (8mm) (NLA)
6 09160-08082 Washer (8.5x16x1.2)
7 09160-08081 Washer (8.5x23x1.5)
8 45411-97J30 Thrust Block
9 54151-97JL0 Lower Thrust Mount
10 43751-97J01 Swivel Stopper Bracket
11 43752-97J00 Shaft Stopper (NLA)
12 59443-97J00 Spring Stopper
13 43415-97J10 Steering Adjuster Plate (NLA)
14 43430-97L00 Steering Adjuster Rubber
15 09119-06130 Bolt
16 09440-09042 Spring
17 41221-97JL0 Tilt Lock Lever
18 09116-06127 Bolt (6x12)
19 59181-97J10 Tilt Lock Lever Spacer
20 59444-97J10 Tilt Lock Spring
21 09116-06232 Bolt (6x30)
22 43110-97J31-0EP Swivel Bracket Assembly (Black)
▶Fig. 16 - Drive Shaft Housing (8 parts) Fig. 16 - Drive Shaft Housing
Ref OEM Part # Part Name
1 52111-97J30-0EP Drive Shaft Housing
2 52113-97J00 Drive Shaft Housing Gasket
3 29116-93J00 Bolt (6x20)
4 09205-03019 Spring Pin (3x10)
5 52112-97J10-0EP Reverse Thrust Stopper
6 29116-93J00 Bolt (6x20)
7 61155-97J01 Water Indicator Union
8 59178-97J00 Drain Plug Gasket
▶Fig. 17 - Gear Case (19 parts) Fig. 17 - Gear Case
Ref OEM Part # Part Name
1 55110-97J40-0EP Gear Case Housing
2 09262-17019 Bearing (17x35x8)
3 59311-97J20 Pinion Bushing
4 55321-87J01 Aluminum Anode
5 09103-06281 Bolt (6x14)
6 59178-97J00 Drain Plug Gasket
7 09248-08001 Drain Plug
8 09116-06099 Bolt (6x35)
9 59291-97J00 O-Ring
10 09282-10008 Oil Seal (10x21x4.5)
11 09116-06094 Bolt (6x15)
12 58110-97JA0-019 Propeller (3x7-1/2x6)
13 58120-97JA0 Proppeller Bushing
14 57635-91JL0 Propeller Stopper
15 58130-91JL0 Propeller Nut
16 09204-03003 Prop Nut Cotter Pin
17 56120-97J40-0EP Propeller Shaft Housing (NLA)
18 09282-12008 Oil Seal (12x24x4.5)
19 09262-12001 Bearing (12x28x8)
▶Fig. 18 - Lower Cover (7 parts) Fig. 18 - Lower Cover
Ref OEM Part # Part Name
1 61110-97J01-YR9 Lower Engine Cover
2 61135-97J00 Lower Cover Cushion (NLA)
3 29116-93J00 Bolt (6x20)
4 61151-91J01 Cushion
5 21131-97J20 Clutch Shift Mark
6 61211-97J00 Fuel Cock Mark
7 61212-97J00 Oil Level Mark (NLA)
▶Fig. 19 - Engine Cover (8 parts) Fig. 19 - Engine Cover
Ref OEM Part # Part Name
1 61411-97J10-YR9 Upper Engine Cover
2 61435-97J30 Rear Emblem Mark (2.5)
3 61443-97J20 Engine Cover Stripe - Starboard
4 61453-97J20 Engine Cover Stripe - Port
5 61611-97J01 Engine Cover Fastener
6 68111-99J00 S Emblem
7 61458-97J10 Engine Cover Label
8 09800-01017 Tool Set
▶Fig. 2 - Cylinder Block (29 parts) Fig. 2 - Cylinder Block
Ref OEM Part # Part Name
1 11200-97J00 Cylinder Block Assembly
2 59295-97J00 Crankshaft Oil Seal
3 09262-17023 Bearing (17x40x12)
4 11300-97J21 Crankshaft Case Assembly
5 09262-17023 Bearing (17x40x12)
6 11971-91J01 Oil Level Filler Lens
7 11351-97JL0 Crankcase Gasket
8 04221-05109 PIN
9 01550-06257 BOLT
10 59295-97J10 Driveshaft Oil Seal
11 59295-97J20 Crankshaft Oil Seal
12 11382-97J00 Oil Filler Cap
13 09280-15007 O-Ring
14 09168-10022 Drain Plug Gasket
15 09248-10008 Drain Plug
16 55321-95J00 Protection Anode
17 09126-05011 Protection Anode Screw
18 17670-91J02 Thermostat (50c)
19 17681-97J21 Thermostat Cover
20 17685-97J01 Thermostat Gasket
21 01550-06307 BOLT
22 01550-06207 BOLT
23 11173-97J00 Breather Plate (NLA)
24 02142-06127 SCREW 6X12
25 11179-97J00 Breather Plate Gasket
26 11174-97J00 Breather Hose (NLA)
27 11452-91J00 Reed Valve
28 02112-0612A SCREW
29 11431-97J11 Under Oil Seal Plate
▶Fig. 20 - Tiller Handle (18 parts) Fig. 20 - Tiller Handle
Ref OEM Part # Part Name
1 63111-97J21-0EP Tiller Handle
2 63210-97J00 Throttle Grip
3 59181-97J00 Tiller Handle Spacer
4 59315-97J00 Tiller Handle Bushing
5 63116-97J00 Tiller Handle Mount
6 09160-08152 Washer (8.5x28x1.5)
7 09116-08138 Bolt (8x40)
8 63244-97J00 Throttle Adjust Knob
9 09140-05005 Nut
10 57121-09G00 Upper Throttle Case
11 67821-97J00 Lower Throttle Case
12 63610-97J00 Throttle Cable Assembly
13 02112-05127 SCREW
14 23915-78A20 Cable Clamp (NLA)
15 59125-97J00 Throttle Screw (NLA)
16 33833-91J00 Tube (6x8x250)
17 09352-90134-600 Hose (9x13x600)
18 69714-97J01 Handle Grip Mark
▶Fig. 21 - Fuel Tank (9 parts) Fig. 21 - Fuel Tank
Ref OEM Part # Part Name
1 65110-97J11 Fuel Tank
2 65260-97J00 Fuel Tank Bracket (NLA)
3 65510-97J00 Fuel Tank Cap Assembly
4 09320-09059 Cushion
5 65281-97J10 Replaced by 65281-97J11
6 65284-97J11 Fuel Tank Grommet Rubber
7 66100-97JL0 Replaced by 66100-97JL1
45870 99011-97J07-03B Owners Manual DF 2.5 S/N 214221 & Older
45871 99011-97J08-03B Owners Manual DF 2.5 S/N 214222 & Newer
▶Fig. 3 - Crankshaft (29 parts) Fig. 3 - Crankshaft
Ref OEM Part # Part Name
1 12111-97J10-0B0 Piston
2 12140-97J00 Piston Ring Set
3 12151-97J00 Piston Pin
4 59382-97J00 Piston Pin Circlip
5 12160-97JL0-0A0 Connecting Rod Assembly
6 12163-92F00 Connecting Rod Bolt
7 12220-97JL1 Crankshaft Assembly
8 12242-97JL1 Spline
9 08211-17241 Thrust Washer
10 12710-97J00 Camshaft
11 12742-97J10 Oil Pump Shaft
12 12743-97J00 Shaft
13 12840-97J10 Rocker Arm
14 12842-22G10 Tappet Adjust Screw
15 12843-27A00 Tappet Adjust Nut
16 09261-04017 Pin (4x43)
17 12894-97JL0 Push Rod
18 12845-97J00 Cam Rocker Arm (NLA)
19 12847-22G00 Cam Rocker Arm Spring
20 09261-04005 Roller Pin (4x23.8)
21 08322-0104A Washer
22 12911-97JL0 Intake Valve
23 12915-97JL0 Exhaust Valve
24 12921-97JL0 Valve Spring
25 09289-04006 Valve Stem Oil Seal
26 12931-97J00 Valve Spring Retainer (NLA)
27 12932-05C00 Valve Cotter
28 12100-97J00-050 Piston & Ring Set (OS:0.50) (NLA)
29 12140-97J00-050 Piston Ring Set (OS:0.50) (NLA)
▶Fig. 4 - Intake Pipe/Silencer (8 parts) Fig. 4 - Intake Pipe/Silencer
Ref OEM Part # Part Name
1 13110-97J10 Intake Pipe
2 13119-97J00 Intake Pipe Gasket
3 13124-97J00 Carburetor Insulator
4 07120-06257 BOLT
5 07120-06357 Bolt (NLA)
6 13810-97J00 Silencer
7 13710-97J00 Flame Arrester (NLA)
8 09180-06348 Spacer
▶Fig. 5 - Carburetor (32 parts) Fig. 5 - Carburetor
Ref OEM Part # Part Name
1 13200-97J50 Carburetor Assembly
2 13236-97J30 Main Nozzle
4 13371-97J00 Needle Valve
5 13250-97J00 Carburetor Float
6 13254-97J00 Float Pin
7 13268-97J30 Spring
8 13251-97J00 Float Chamber Gasket
9 13245-97J00 Float Chamber
10 13249-97J00 Gasket
11 13247-97J00 Screw
12 13268-97J10 Spring
13 13616-97J00 Screw
14 13267-97J00 Screw (NLA)
16 13267-97J10 Screw
17 09493-27L01 Pilot Air Jet #135
18 09493-29004 Pilot Air Jet #145
19 13249-97J10 Gasket
20 13248-97J00 Plate (NLA)
21 13268-97J20 Spring
22 13534-97J10 Screw
23 13267-97J20 Screw (NLA)
24 13125-97J00 Carburetor Gasket
25 13413-97J10 Choke Rod
26 13436-91J00 Choke Rod Connector
27 13631-91J00 Choke Knob
28 09103-06522 Bolt
45672 09492-32011 Pilot Jet #32
45703 09492-34004 Pilot Jet #34
45717 09491-60014 Main Jet #60
45718 09491-62009 Main Jet #62
45719 09491-64003 Main Jet #64
45731 09492-36L01 Pilot Jet #36
▶Fig. 6 - Fuel Pump (13 parts) Fig. 6 - Fuel Pump
Ref OEM Part # Part Name
1 15100-97J00 Fuel Pump Assembly
2 15192-97J00 Replaced by 15192-97JL0
3 15191-97J20 Fuel Hose (Cock to Pump) (NLA)
4 18498-94J31 Hose Protector (12x15x390) (NLA)
5 18498-97J00 Hose Protector (12x15x260) (NLA)
6 59412-91J00 Fuel Hose Clip
7 09401-10412 Clip
8 01550-06257 BOLT
9 08310-00067 Nut
10 15115-97JL0 Fuel Pump Bracket
11 44421-13ER0 Hose (5x10x600)
12 09493-38001 Air Jet# 190 (NLA)
13 15821-97J00 Hose Protector (16x20.5x80) (NLA)
▶Fig. 7 - Water Pump (10 parts) Fig. 7 - Water Pump
Ref OEM Part # Part Name
1 17410-97JL1 Water Pump Case
2 09280-33005 O-Ring
3 09116-06232 Bolt (6x30)
4 17415-97J00 Water Pump Case Grommet
5 17461-97JM0 Water Pump Impeller
6 09202-02006 Pin
7 17471-97JL0 Water Pump Plate
8 17472-97JL0 Water Pump Plate Gasket
9 17561-97JM0 Water Tube (S)
10 17563-97J10 Water Tube Grommet
▶Fig. 8 - Recoil Starter (13 parts) Fig. 8 - Recoil Starter
Ref OEM Part # Part Name
1 18100-97JM0 Recoil Starter Assembly
2 18120-97J00 Reel (NLA)
3 18130-97J00 Ratchet Set
4 18142-04410 Spiral Spring
5 18210-97J00 Starter Grip
6 99000-81157-50M Rope (NLA)
7 18211-97J00 Starter Pulley (NLA)
8 01550-06207 BOLT
9 01550-06357 BOLT
10 69711-91J10 Label S.I.G.P.
11 61472-93E20 Recoil Starter Label (NLA)
12 61493-97J00 Clearance Label (NLA)
13 61494-97J00 Oil Label (NLA)
▶Fig. 9 - Oil Pump (4 parts) Fig. 9 - Oil Pump
Ref OEM Part # Part Name
1 16131-91J00 Oil Pump Inner Rotor
2 16132-91J00 Oil Pump Outer Rotor
3 16161-97J10 Oil Pump Rotor Plate
4 02142-0510B SCREW

100-Hour / Annual Service Checklist

Regular maintenance keeps your Suzuki DF 2.5S 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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