Suzuki DF 25ES, DF 25EL, DF 25RL (2011) Parts & Diagrams

🔎 Suzuki DF 25ES, DF 25EL, DF 25RL Reference Library — Exploded parts diagrams (45 diagrams), specifications, common issues, and maintenance checklist.

The Suzuki DF 25ES, DF 25EL, DF 25RL is a 4-Stroke SOHC 4-Valve Inline 3-Cylinder outboard motor. Commonly used on jon boats, pontoons, and mid-size utility craft.

Quick Reference Specifications

Specification	Value
Engine Type	4-Stroke SOHC 4-Valve Inline 3-Cylinder
Horsepower	25 HP
Displacement	489 cc
Bore x Stroke	60.4 x 57.0 mm
Spark Plug (Type & Gap)	NGK CPR6EA-9
Engine Oil Capacity	1.5 L
Recommended Engine Oil	SAE 10W-40
Gear Case Oil Capacity	330 mL
Idle Speed (in gear)	800-900 RPM
Full Throttle RPM Range	5000-6000 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 25ES, DF 25EL, DF 25RL:

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 25ES, DF 25EL, DF 25RL.

▶Fig. 1 - Cylinder Head (18 parts)

Ref	OEM Part #	Part Name
1	11110-95J00	Stbd Cylinder Head (NLA)
2	11120-95J00	Port Cylinder Head (NLA)
3	11115-93J10-001	Valve Guide (OS:0.5)
4	11119-95J02	Cylinder Head Bolt
5	11141-95J00	Cylinder Head Gasket
6	11261-99E00	Protection Anode Cover
7	55321-95J00	Protection Anode
8	09126-05011	Protection Anode Screw
9	09280-10013	O-Ring
10	01550-06207	BOLT
11	04211-13189	PIN
12	09493-20012	Air Jet #100
13	11452-95J00	Reed Valve (NLA)
14	02112-0612A	SCREW
15	11171-95J00	Cylinder Head Cover
16	11189-95J00	Cylinder Head Cover Gasket
17	01550-06127	BOLT
18	09482-00427	NGK BKR6E Spark Plug

▶Fig. 10 - Thermostat (14 parts)

Ref	OEM Part #	Part Name
1	17610-95J00-0EP	Water Pressure Valve Cover
2	17616-95J00	Water Pressure Valve Cover O-Ring
3	17660-99E01	Water Pressure Valve
4	17670-94J02	Thermostat (60c)
5	17681-95J00	Thermostat Cover (NLA)
6	17685-95J11	Thermostat Gasket
7	17689-95J00	Oil Gallery Plate
8	17693-95J00	Oil Gallery Gasket
9	17913-93J00	Water Flush Plug
10	17914-93J01	Water Flush Plug Gasket
11	01550-06207	BOLT
12	01550-06207	BOLT
13	01550-06257	BOLT
14	17917-87L00	Water Flush Connector

▶Fig. 11 - Throttle Control Non-Remote Control (8 parts)

Ref	OEM Part #	Part Name
1	19141-95J00	Throttle Cam (NLA)
2	19184-95J00	Throttle Cable Bracket
3	09160-06047	Washer (6.2x20x2)
4	09180-06186	Spacer (6.2x12.6x21)
5	01550-06167	BOLT
6	01550-06357	BOLT
7	18642-95J00	NSI Cable Bracket (NLA)
8	01550-06167	BOLT

▶Fig. 12 - Throttle Control Remote Control (14 parts)

Ref	OEM Part #	Part Name
1	19141-95J00	Throttle Cam (NLA)
2	19184-95J00	Throttle Cable Bracket
3	09160-06047	Washer (6.2x20x2)
4	09180-06186	Spacer (6.2x12.6x21)
5	01550-06167	BOLT
6	01550-06357	BOLT
7	19120-95J00	Throttle Control Lever
8	19122-95J00	Throttle Interlink Lever
9	19185-95J00	Throttle Lever Spring
10	19761-95J00	Throttle Cable Stay
11	63610-95J12	Throttle Cable Assembly
12	01550-06127	BOLT
13	09160-06047	Washer (6.2x20x2)
14	01550-06167	BOLT

▶Fig. 13 - Oil Pump (10 parts)

Ref	OEM Part #	Part Name
1	16131-95J00	Oil Pump Inner Rotor
2	16132-95J00	Oil Pump Outer Rotor
3	16152-95J00	Oil Relief Valve Spring
4	16153-95J00	Relief Valve Spring Retainer (NLA)
5	16161-95J00	Oil Pump Plate
6	16520-95J00	Oil Strainer
7	16522-95J01	Oil Strainer Pipe
8	09168-16002	Gasket (16x22x2.0)
10	01550-0616A	BOLT
11	16151-95J00	Oil Pump Relief Valve

▶Fig. 14 - Oil Pan (35 parts)

Ref	OEM Part #	Part Name
1	11261-93J00	Protection Anode Cover
3	29103-93J30	Bolt (8x25)
4	09103-06281	Bolt (6x14)
5	09280-22019	O-Ring
6	11489-95J01	Oil Pan Gasket
7	11501-95J02-0EP	Oil Pan (NLA)
8	43112-94L01	Exhaust Pipe
9	09116-08126	Bolt (8x65)
10	09116-10137	Bolt (10x70)
11	09168-12011	Water Plug Gasket
12	09168-12012	Oil Drain Plug Gasket
13	09168-12017	Gasket (12x17x1)
14	09248-12007	Oil Drain Plug
15	09248-12007	Oil Drain Plug
16	09248-12009	Oil Drain Plug
17	09282-15L01	Oil Seal *
18	04211-13149	PIN
19	08313-20087	Nut
20	11540-95J00	Exhaust Pipe
21	11543-95J00	Exhaust Hose (NLA)
22	09103-06196	Bolt (6x30) (NLA)
23	09280-15003	O-Ring
24	09407-14407	Clamp (L:140)
25	11381-95J00	Oil Level Gauge (NLA)
26	09280-16013	Oil Level Gauge O-Ring
27	54112-95J01	Upper Mount Bolt (NLA)
28	54120-95J00	Upper Thrust Mount (NLA)
29	54130-95J00	Upper Mount
30	54148-95J00-0EP	Stbd Upper Mount Cover (NLA)
31	54149-95J00-0EP	Port Upper Mount Cover (NLA)
32	09116-08131	Bolt (8x45)
33	09159-10050	Nut
34	09160-10140	Washer (10.5x18x3)
45689	55321-87J01	Aluminum Anode
45690	55321-87J11	Magnesium Anode

▶Fig. 15 - Clutch Shaft Non-Remote Control (18 parts)

Ref	OEM Part #	Part Name
1	21126-95J01	Clutch Shaft Holder
2	21211-95J01	Clutch Shaft
4	23131-95J00	Clutch Rod Boot (NLA)
5	23213-89J01	Notch Plate Spring No. 1
6	23214-89J10	Notch Plate Spring No. 2 (NLA)
7	09160-05029	Washer (5.5x10x0.8)
8	09204-01002	Cotter Pin
9	09383-04002	E Ring
10	01550-06127	BOLT
11	01550-06127	BOLT
12	21111-95J00	Front Shift Lever
13	23115-95J00	Clutch Lever Link (NLA)
14	09111-06069	Bolt (6x28.8)
15	09160-06082	Washer (6.5x13x1.0)
16	09160-08082	Washer (8.5x16x1.2)
17	09164-08017	Wave Washer
45717	23111-95J00	Clutch Rod (S)
45718	23111-95J10	Clutch Rod (L) (NLA)

▶Fig. 16 - Clutch Shaft Remote Control (17 parts)

Ref	OEM Part #	Part Name
1	21126-95J01	Clutch Shaft Holder
2	21211-95J01	Clutch Shaft
4	23131-95J00	Clutch Rod Boot (NLA)
5	23213-89J01	Notch Plate Spring No. 1
6	23214-89J10	Notch Plate Spring No. 2 (NLA)
7	09160-05029	Washer (5.5x10x0.8)
8	09204-01002	Cotter Pin
9	09383-04002	E Ring
10	01550-06127	BOLT
11	01550-06127	BOLT
12	21241-95J00	Clutch Lever Link
13	23210-95J00	Clutch Lever
14	09160-06084	Washer (6.5x18x1.6)
15	09180-06230	Spacer (6.2x12.6x12.5)
16	01550-06257	BOLT
45717	23111-95J00	Clutch Rod (S)
45718	23111-95J10	Clutch Rod (L) (NLA)

▶Fig. 17 - Clutch Rod (12 parts)

Ref	OEM Part #	Part Name
1	23311-95J00	Clutch Rod Connector
2	25111-95J20	Shift Rod
3	25211-95J10	Shift Rod Guide
4	25215-95J01	Shift Rod Guide Stopper (NLA)
5	25232-96302	Gear Case Magnet
6	25311-95J00	Shift Cam
7	29141-93J00	Nut (6mm)
8	25231-96301	Magnet Spacer (NLA)
9	09205-02004	Spring Pin (2.5x12)
10	09280-08005	O-Ring
11	09280-15007	O-Ring
12	29116-93J00	Bolt (6x20)

▶Fig. 18 - Drive Shaft (52 parts)

Ref	OEM Part #	Part Name
1	55332-95J01	Exhaust Seal Rubber
2	56120-96332-0EP	Propeller Shaft Bearing Housing
3	09263-20047	Bearing (20x26x20)
4	09289-20009	Oil Seal
5	08113-60060	B1 30X55X13 BEA
6	56130-95J02-0EP	Drive Shaft Housing
7	09282-17006	Oil Seal
8	56132-95J00	Drive Shaft Housing Gasket
9	09116-06094	Bolt (6x15)
10	09116-06121	Bolt (6x25)
11	09280-75002	O-Ring
13	57133-95J00	Drive Shaft Collar
14	09166-17005	Washer (17.1x26x3.0)
15	09265-17002	Bearing (17x40x17.25)
16	57311-91L00	Pinion Gear
17	09159-08046	Nut
19	57510-94L00	Forward Gear
20	57521-94L00	Reverse Gear
23	09181-16008	Shim (2.0)
25	57610-96311	Propeller Shaft Assembly
26	57621-89J10	Clutch Dog Shifter
27	09202-05021	Clutch Dog Shifter Pin
28	09209-08016	Push Pin
29	09440-07074	Spring
30	09440-35004	Spring
31	57631-95J00	Push Rod
45675	09160-15030	Washer (1.7)
45678	09160-20068	Washer (1.6)
45679	08221-30404	Shim (0.2)
45681	09181-25190	Shim (0.80)
45706	09160-15031	Washer (1.8) (NLA)
45709	09160-20069	Washer (1.8)
45710	09181-30158	Shim (0.50)
45712	09181-25248	Shim (0.90)
45734	09160-15032	Washer (1.9) (NLA)
45737	09160-20070	Washer (2.0)
45738	09181-30162	Shim (0.8)
45740	09181-25251	Shim (1.00)
45765	08211-15203	Washer (2.0)
45768	09160-20071	Washer (2.2)
45769	09181-30167	Shim (1.00)
45771	09160-25032	Thrust Washer (1.10)
45795	09160-15033	Washer (2.1) (NLA)
45798	09160-20072	Washer (2.4)
45801	09160-25033	Thrust Washer (1.20)
45826	08211-15204	Washer (2.2)
45829	09160-20073	Washer (2.6)
45832	09160-25034	Thrust Washer (1.30) (NLA)
45862	09160-25035	Thrust Washer (1.40)
45893	09181-25268	Shim (1.50)
45992	57110-95J00	Drive Shaft (S) (NLA)
45993	57110-95J10	Drive Shaft (L)

▶Fig. 19 - Starting Motor (30 parts)

Ref	OEM Part #	Part Name
1	31100-95J01	Starter Motor Assembly
2	31131-94J00	Plus Brush Set
3	31135-90J00	Spring
4	31151-94J01	Gear Case
5	31152-90J00	Center Plate (NLA)
6	31153-90J00	Planet Gear Bracket (NLA)
7	31171-96J00	Dust Cover Kit
8	31173-94J01	Brush Holder
9	31191-96J00	Shift Lever (NLA)
10	31220-94J00	Magnet Switch
11	31310-90J00	Armature
12	31320-94J00	Pinion Assembly (NLA)
13	31341-94J00	Pinion Shaft (NLA)
14	31343-90J00	Internal Gear (NLA)
15	31344-90J00	Planetary Gear (NLA)
16	31360-93J01	Washer Set
17	31913-93J00	Terminal
18	31914-93J00	Terminal Cap
19	31912-95J00	Starting Motor Band (NLA)
20	31918-95J00	Starter Damper (NLA)
21	08316-10087	Nut
22	01550-08207	BOLT
23	01550-08257	BOLT
24	31911-95J00	Starting Motor Bracket (NLA)
25	01550-08307	BOLT
26	04211-11129	11 X 12 DOWEL P
27	04221-06129	PIN 6X12
28	36645-94J00	Wire Lead (NLA)
29	38860-76F01	Relay
30	38915-90J00	Relay Holder

▶Fig. 2 - Cylinder Block (20 parts)

Ref	OEM Part #	Part Name
1	11218-95J00	Cylinder Block Cover (NLA)
2	11219-95J01	Cylinder Block Cover Gasket
3	01547-06207	BOLT 6 X 20
4	04221-06129	PIN 6X12
5	11300-95850	Cylinder Block Set
7	09246-04009	Plug
8	09262-25145	Camshaft Bearing (25x42x9) (NLA)
9	09262-35067	Crankshaft Lower Bearing (35x72x17)
10	08110-62080	BEARING,UPPER
11	09283-34014	Oil Seal (34x46x8)
12	09283-38025	Oil Seal (38x56x7)
13	11112-53A00	Oil Venturi Plug
14	09493-20012	Air Jet #100
15	11351-95J01	Crankcase Gasket
16	09116-10143	Bolt (10x40) (NLA)
17	09116-08128	Bolt (8x40)
18	04221-08149	PIN
19	16510-87J02	Engine Oil Filter
20	11291-95J00	Engine Hook (NLA)
21	01550-06167	BOLT

▶Fig. 20 - Magneto (9 parts)

Ref	OEM Part #	Part Name
3	01550-06257	BOLT
4A	09106-05030	Bolt (5x10)
5	09103-16001	Flywheel Bolt (16x40)
6	09160-16046	Washer (16.5x36x4.5) (NLA)
7	09420-04008	Key
45658	32102-95J00	Flywheel (NLA)
45659	32102-95J10	Flywheel (NLA)
45689	32120-95J00	Stator & Pulser Coil
45690	32120-95J10	Stator & Pulser Coil (NLA)

▶Fig. 21 - Rectifier/Ignition Coil (12 parts)

Ref	OEM Part #	Part Name
1	32800-95J01	Rectifier & Regulator Assembly
2	01550-06257	BOLT
3	32900-95J00	CDI Unit
5	32890-95J01	Electric Parts Holder (NLA)
6	09160-06054	Washer (6.5x22.1.6)
7	09320-12090	Cushion
8	09321-06036	Cushion
9	01550-06127	BOLT
10	33410-95J00	Ignition Coil Assembly
11	01550-06167	BOLT
12	09403-09316	Clamp (NLA)
13	33510-93E00	Spark Plug Cap

▶Fig. 22 - Sensor/Switch (17 parts)

Ref	OEM Part #	Part Name
1	34830-87J20	Temp Sensor Assy
2	37820-80002	Oil Pressure Switch Assembly
3	36360-89J00	Warning Indicator (NLA)
4	36367-89J00-019	Warning Label (NLA)
5	37830-95J03	Emergency Switch Assembly
6	37835-91J00-YAY	Stop Label
7	09160-12067	Washer (12.5x23x1.0)
8	09403-12308	Clamp (NLA)
9	09407-10404	Clamp (L:100)
10	09408-00012	Clamp
11	37721-95J02	Neutral Switch Assembly
12	37725-95600	Switch Actuator
13	37161-89E13	Start Switch Assembly
14	09159-14014	Nut (10mm)
15	37163-95J00	Starting Switch Plug (NLA)
16	01550-08127	BOLT 8 X 12
17	09408-00024	Clamp

▶Fig. 23 - Harness (14 parts)

Ref	OEM Part #	Part Name
1	33810-95J00	Starter Motor Cable Assembly
3	09403-14315	Clamp (NLA)
5	09408-00184	Clamp
6	09403-13413	CLAMP
8	36616-95J00	Connector Holder (NLA)
9	02142-06167	6 X 16 CROSS SC
45689	36610-95J01	Wiring Harness Assembly
45690	36610-95J10	Wiring Harness Assembly (NLA)
45691	36610-95J20	Wiring Harness Assembly (NLA)
45748	29404-93J11	Clamp (L:65)
45749	29404-93J11	Clamp (L:65)
45839	01550-06127	BOLT
45840	01550-06127	BOLT
45841	01550-06127	BOLT

▶Fig. 24 - Clamp Bracket (24 parts)

Ref	OEM Part #	Part Name
1	41111-95J01-0EP	Stbd Clamp Bracket
2	41121-95J00-0EP	Port Clamp Bracket
3	41130-95J01	Clamp Bracket Shaft
4	41211-95J00	Clamp Screw
5	41212-91J00	Clamp Handle
6	41213-94J01	Clamp Plate
7	09205-06007	Spring Pin (6x25)
8	09159-22006	Nut
9	41135-93J00	Clamp Bracket Shaft Washer
10	09100-06165	Bolt (6x180) (NLA)
11	29141-93J00	Nut (6mm)
12	09160-06082	Washer (6.5x13x1.0)
13	09180-06342	Spacer (NLA)
14	55321-87J01	Aluminum Anode
15	09103-06281	Bolt (6x14)
16	41151-94500	Clamp Bracket Shaft Cap
17	41153-95J00	Transom Bolt Cap (NLA)
18	09100-10309	Transom Bolt (10x110) (NLA)
19	09159-10050	Nut
20	09160-10139	Washer (10.5x35x3) (NLA)
21	09160-10140	Washer (10.5x18x3)
22	45420-95J01	Tilt Lock Pin
23	45425-95J00	Tilt Lock Pin Stopper (NLA)
24	09441-17004	Tilt Lock Pin Spring

▶Fig. 25 - Swivel Bracket (48 parts)

Ref	OEM Part #	Part Name
1	22511-99011	Grease Nipple
3	43211-87J00	Swivel Bracket Bushing
4	43711-89J10	Steering Bushing
6	09181-39001	Shim (39.5x64x0.3)
7	09282-39001	Oil Seal (38x51x5)
8	09160-39001	Washer (39.5x64x1.0)
8A	43721-95J00	Steering Upper Plate (NLA)
9	09380-38003	Circlip
10	09420-05003	Key (NLA)
11	55321-87J01	Aluminum Anode
12	09103-06281	Bolt (6x14)
13	41225-94502	Release Arm Pin
14	45211-95J00	Reverse Lock Spring
15	45231-95J00	Reverse Lock Arm
16	45241-95J00	Reverse Lock Arm Link
17	45250-95J00	Release Link
18	45261-95J00	Release Lever
19	09160-06082	Washer (6.5x13x1.0)
20	09200-06069	Reverse Lock Arm Pin
21	09200-06070	Reverse Lock Arm Link Pin
22	09204-01002	Cotter Pin
23	09306-22006	Bushing
24	41223-95J00	Tilt Stop Arm (NLA)
25	09106-10078	Bolt (10x28.5)
26	43412-93901	COVER,STEERING
27	43417-95J00	Steering Adjuster (NLA)
28	09100-08227	Bolt (8x27) (NLA)
29	09160-08082	Washer (8.5x16x1.2)
30	29440-93J00	Steering Adjuster Spring
31	43411-95J00	Steering Adjuster Lever (NLA)
32	43415-95J00	Steering Adjuster Plate
33	43512-95J00	Steering Adjuster Shaft (NLA)
34	43514-95J00	Steering Adjuster Washer
35	43514-95J10	Steering Adjuster Friction Plate (NLA)
36	43516-89J00	Steering Adjuster Washer
37	09116-08137	Bolt (8x22)
38	09159-08131	Steering Adjuster Nut (NLA)
40	45710-95J01	Shallow Water Drive Arm
41	45722-95J00	Shallow Water Drive Arm Spring
42	09106-10078	Bolt (10x28.5)
43	43755-95J01	Steering Bracket Attachment
44	09100-10270	Bolt (10x25)
45	09162-10005	Lock Washer
46	21131-94J00-YAY	Clutch Shift Mark
45689	43111-95J00-0EP	Swivel Bracket (S) (NLA)
45690	43111-95J10-0EP	Swivel Bracket (L)
45778	43750-95J00-0EP	Steering Bracket (S) (NLA)
45779	43750-95J10-0EP	Steering Bracket (L)

▶Fig. 26 - Drive Shaft Housing (21 parts)

Ref	OEM Part #	Part Name
2	09116-10143	Bolt (10x40) (NLA)
3	09202-06023	Knock Pin (6x10)
4	57130-96300	Drive Shaft Bushing (NLA)
5	09125-06063	Screw (6x10)
6	55321-87J01	Aluminum Anode
7	09103-06281	Bolt (6x14)
8	36894-87D00	Wire Lead (L:195)
9	54151-95J00	Lower Thrust Mount (NLA)
10	54160-95J00	Lower Mount (NLA)
11	54166-95J02	Mount Bolt
12	54167-96J00	Lower Side Mount
13	54170-95J00	Lower Side Cushion (NLA)
14	54211-95J00-0EP	Lower Mount Bracket (NLA)
15	54221-95J00-0EP	Lower Mount Cover (NLA)
16	54240-95J00	Lower Thrust Reverse Mount (NLA)
17	29116-93J10	Bolt (8x35)
18	09125-06063	Screw (6x10)
19	09159-12014	Nut (12x17)
20	09160-12110	Washer (12.5x22x3.0)
45658	52111-95J00-0EP	Drive Shaft Housing (S)
45659	52111-95J10-0EP	Drive Shaft Housing (L) (NLA)

▶Fig. 27 - Gear Case (27 parts)

Ref	OEM Part #	Part Name
1	55100-95J00-0EP	Gear Case Housing
2	55114-96310	Gear Case Under Cover
3	09263-20046	Bearing (20.6x27x25.4)
4	09265-25015	Bearing (25x52x16.25)
5	09116-08122	Bolt (8x30)
6	17566-87D12	GROMMET
7	09202-06023	Knock Pin (6x10)
8	55125-96310	Trim Tab Anode
9	09116-08137	Bolt (8x22)
10	09248-10008	Drain Plug
11	09168-10022	Drain Plug Gasket
13	58120-96401	Type P Propeller Bushing
14	57632-95J00	Propeller Stopper Bushing
15	57633-96300	Propeller Nut Spacer
16	09141-14008	Nut 14mm
17	09160-14028	Propeller Nut Washer
18	09204-03003	Prop Nut Cotter Pin
19	57630-96300	Propeller Hardware Kit DT20/30/25c/30c DF25/DF30
20	25700-95J00	Gear Case Seal Kit - DF25 V-Twin
45992	58100-96472-019	P1001 Propeller 3x10-1/4x10
45993	58100-91L50-019	P1101 Propeller 3x10-1/4x11
45994	58100-96482-YAY	P1201 Propeller 3x10-1/4x12
45995	58100-96492-019	P1311 Propeller 3x10-1/4x13
45996	58100-95D01-019	P1401 Propeller 3x10-1/4x14
45997	58100-96372-019	P911 Propeller 3x10-1/4x9
45998	58100-96472-019	P1001 Propeller 3x10-1/4x10
46000	58100-96462-019	P1501 Propeller 3x10-1/4x15

▶Fig. 28 - Side Cover (36 parts)

Ref	OEM Part #	Part Name
1	61810-95J01-0EP	Stbd Side Cover
3	61851-95J01	Side Cover Protector (NLA)
4	09160-05024	Washer (5.5x16x1.5)
6	09320-05016	Cushion (NLA)
7	09139-06249	SCREW
8	09136-06149	Screw (6x55)
10	61831-95J00-0EP	Front Panel (NLA)
11	09116-08137	Bolt (8x22)
12	09202-08006	Knock Pin (8x12)
13	61412-95J00	Instrument Panel Hook (NLA)
14	02142-05127	SCREW
15	09308-12012	Grommet (NLA)
16	61157-89J00	Water Indicator Hose
17	09401-08413	Clip
18	09320-13024	Cushion (NLA)
19	61632-93J00	Engine Cover Hook Shaft
20	61633-95J01	Rear Hook Lever
21	61641-95J00	Engine Cover Hook
22	61673-95J00	Hook Lever Latch
23	09103-06092	Bolt (6x15)
24	09160-06160	Washer (6.5x24x4)
25	09160-13008	Washer (13.5x31.5x0.5)
26	09164-14008	Wave Washer
27	09202-04022	Hook Lever Pin
28	09306-13007	Bushing
29	03542-06209	SCREW
30-2	61124-95J10	Cable Grommet (NLA)
31	61134-95J00	Side Cover Seal
32	61135-95J00	Side Cover Cushion
33	18498-90J01	Hose Protector
34	54144-95J00	Upper Mount Stbd Seal (NLA)
35	54145-95J00	Upper Mount Port Seal (NLA)
45687	61124-95J00	Cable Grommet (NLA)
45689	61821-95J20-0EP	Port Side Cover
45690	61821-95J11-0EP	Port Side Cover (NLA)
45746	61124-95J20	Cable Grommet (NLA)

▶Fig. 29 - Engine Cover (15 parts)

Ref	OEM Part #	Part Name
2	61112-95J00	Engine Cover Seal
3	61433-95J00	Air Intake Inner Cover (NLA)
5	61610-95J00	Rear Fastener
6	09140-06020	Nut (6mm)
7	09160-06094	Washer (6.5x15x1.0)
8	61465-95J00	Engine Cover Emblem (NLA)
10	68111-18G20	Emblem Mark 'S'
11	61435-95J41	Rear Emblem Mark (DF25)
12	61458-99E31	Engine Cover Label
13	68110-94400	Weather Cover (NLA)
14	09800-81822	Tool Set
45658	61400-95Y52-0EP	Engine Cover Set
45659	61400-95Y63-0EP	Engine Cover Set
45901	61443-95J21	Starboard Engine Cover Stripe
45902	61453-95J21	Port Engine Cover Stripe

▶Fig. 3 - Crankshaft (16 parts)

Ref	OEM Part #	Part Name
1	12111-95J00-0B0	Piston
2	12140-75F30	Piston Ring Set
3	12151-54A50	Piston Pin
4	09381-17005	Piston Pin Circlip (NLA)
6	12163-69J00	Connecting Rod Bolt
7	04221-03059	PIN
8	12220-95J00-0B0	Crankshaft
9	12730-95J10	Idle Gear Assembly
10	12735-95J10	Idle Gear Shaft
11	09160-08122	Washer (8.5x18x3.2)
12	09160-12067	Washer (12.5x23x1.0)
13	08316-1008A	Nut
14	12100-95J00-050	Piston & Ring Set (0.50) (NLA)
15	12140-75F30-050	Piston Ring Set (0.50) (NLA)
45778	12160-95J01-0A0	Connecting Rod Assembly
45779	12160-95J01-0B0	Connecting Rod Assembly

▶Fig. 30 - Tiller Handle (27 parts)

Ref	OEM Part #	Part Name
1	63111-95J00-0EP	Tiller Handle (NLA)
2	63114-95L00	Handle Cover Spacer
3	63115-89J00	Tiller Handle Bushing
4	63115-96310	Handle Cover Inside Spacer
5	63118-94300	Tiller Handle Shim (0.3)
6	63121-95J00-0EP	Tiller Handle Cover
7	63122-95J00	Tiller Handle Protector (NLA)
8	63131-95J00-0EP	Tiller Handle Bracket
9	63210-93E30	Handle Grip
10	63220-96320	Handle Rod
11	63223-89J00	Handle Rod Stopper (NLA)
12	63225-93200	Handle Rod Bushing
13	63227-93200	Handle Rod Pin
14	63240-97E10	Handle Grip Adjuster
15	63610-95J01	Throttle Cable Assembly
16	09100-10220	Bolt (10x35)
17	09116-08137	Bolt (8x22)
18	09125-05042	Screw (5x10)
19	09126-06015	Screw (6x23)
20	09160-10098	Washer (10x18x1.0)
21	09163-06001	Lock Washer (6.4x12x0.5)
22	09164-32005	Wave Washer
23	09440-12027	Spring
24	33833-91J00	Tube (6x8x250)
25	37830-95J03	Emergency Switch Assembly
26	09160-12067	Washer (12.5x23x1.0)
27	37835-91J00-YAY	Stop Label

▶Fig. 31 - Fuel Tank (14 parts)

Ref	OEM Part #	Part Name
1	65720-986L0	Fuel Connector
2	09103-06237	Bolt (6x12.5)
3	65000-95D01	6 Gallon Suzuki Fuel Tank (NLA)
4	65520-95D00	Fuel Tank Cap Assembly (NLA)
5	65561-95D00	Fuel Tank Cap Gasket
6	65740-95D01	Fuel Tank Connector (13mm)
7	65831-95D00	Fuel Outlet Filter
8	65890-95D00	Outlet Assembly
9	65892-95D00	Fuel Outlet O-Ring
10	65700-87J28	Fuel Hose
11	65750-87J11	Fuel Hose Connector
12	65750-95501	Fuel Hose Connector (13mm)
13	65770-95505	Squeeze Pump (NLA)
14	65781-98500	Hose Clip

▶Fig. 32 - Remocon Cable Remote Control (7 parts)

Ref	OEM Part #	Part Name
1	67467-89J01	Cable Connector
2	09160-06055	Washer (7x12x1.0)
3	09385-06012	Clip
4	67340-95J00	Remocon Cable Holder (NLA)
5	67350-95J01	Remocon Cable Holder
6	09116-06094	Bolt (6x15)
7	09308-08013	Grommet

▶Fig. 33 - Drag Link Remote Control (6 parts)

Ref	OEM Part #	Part Name
1	41161-94400	Steering Cable Seal
2	67701-95J00	Drag Link Assembly (NLA)
3	67721-89J00	Drag Link Spacer
4	67725-96J00	Drag Link Bolt
5	67726-99E00	Lock Nut
6	67728-99E00	Washer

▶Fig. 34 - Remote Control Box (63 parts)

Ref	OEM Part #	Part Name
1	67200-94J21	67200-94J30
2	37859-90J00	Spacer
3	36628-92E00	Wire Harness Grommet
4	37110-94J02	Igntion Switch Assembly
6	37143-99E01	Key Cap
7	37721-93J91	Neutral Switch Assembly
8	37820-93J05	Emergency Stop Switch Assembly
9	37823-92E02	Stop Switch Lanyard
10	09160-06104	Washer (6.5x24x2)
11	38500-93J00	Warning Buzzer*
12	67212-95600	Washer (NLA)
13	67213-92E00	Buzzer Bracket (NLA)
14	09125-05042	Screw (5x10)
15	67296-92E11	Screw (3x15)
16	67220-95630	Plate Assembly
17	67223-99E10	Brake Adjustment Knob
18	67229-95600	Roller (NLA)
19	67232-95600	Bushing
20	67238-87D00	Drive Gear
21	67241-99E10	Free Throttle Lever (NLA)
22	67243-95600	Bushing (NLA)
23	67244-95600	Wave Washer (NLA)
24	67245-95600	Free Throttle Drum (NLA)
25	67251-99E10	Handle Lever
26	67252-95600	Bushing
27	67253-95600	Washer (NLA)
28	67255-99E00	Neutral Lock Arm
29	67256-95600	Neutral Lock Holder
30	67257-99E00	Lever Cap
31	67258-99E00	Neutral Arm Bracket
32	67259-87D00	Neutral Arm Spring (NLA)
33	67261-99E00	Grip
34	67296-94310	Screw
35	67264-95600	Washer (NLA)
36	67267-95610	Wire Cover (Black)
37	67273-95600	Spacer
38	67275-95600	Cable End
39	67288-92E00	Washer
40	67292-94300	E Ring
41	67294-95600	Spacer
42	67296-90J10	Rear Cover Screw
43	67296-94300	Screw (4x10)
44	67296-95600	Screw
45	67296-95610	Screw
46	67297-95600	Washer
47	68165-16B01-13L	Suzuki Emblem
48	09100-08232	Bolt (8x30)
49	09126-05003	Screw (5x12)
50	09140-06020	Nut (6mm)
51	36620-94J01	21 ft. Main Wiring Harness (NON PT or PTT)
52	09481-10501	10 Amp Fuse
45778	37141-99E00	(931) Ignition Key
45779	37141-99E10	(932) Ignition Key
45780	37141-99E20	(933) Ignition Key
45781	37141-99E30	(934) Ignition Key
45782	37141-99E40	(935) Ignition Key
45783	37141-99E50	(936) Ignition Key
45784	37141-99E60	(937) Ignition Key
45785	37141-99E70	(938) Ignition Key
45786	37141-99E80	(939) Ignition Key
45787	37141-99E90	(940) Ignition Key
45788	37141-99EA0	(941) Ignition Key
45789	37141-99EB0	(942) Ignition Key

▶Fig. 35 - Opt: Meter (23 parts)

Ref	OEM Part #	Part Name
1	34190-95500	Speedometer Sensor (NLA)
2	03112-06303	Screw (NLA)
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)
13	09471-12103	Bulb (12v, 3.4w)
15	09471-12103	Bulb (12v, 3.4w)
17	36615-96300	Resin Terminal
18	09471-12028	Bulb (12v, 3.4w)
19	34190-87D00	Speedometer Sensor
45671	34500-93J02	Black Hour Meter
45673	34200-93J22	Black Tachometer
45702	34500-93J13	White Hour Meter
45704	34200-93J34	White Tachometer
45717	34100-93J22	Black Speedometer 0-50 MPH
45718	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. 36 - Opt: Switch (27 parts)

Ref	OEM Part #	Part Name
1	37100-96J01	Ignition Switch Panel Assembly
2	37139-99E00	Ignition Switch Panel
3	38500-93J90	Warning Buzzer
4	09407-14403	Clamp (L:125)
5	37803-93J06	Emergency Stop Switch Panel Assembly
6	37825-99E00	Emergency 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	37820-93J05	Emergency Stop Switch Assembly
14	37139-99E20	Ignition Switch Panel
15	03121-0516A	SCREW
16	38500-93J90	Warning Buzzer
17	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. 37 - Opt: Top Mount Single (1) (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. 38 - Opt: Top Mount Single (2) (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. 39 - 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. 4 - Camshaft (17 parts)

Ref	OEM Part #	Part Name
2	12894-95J00	Push Rod
3	12961-95J00	Rocker Arm
4	12962-88C00	Pivot (NLA)
5	12966-95J00	Push Rod Guide (NLA)
6	09108-06125	Stud Bolt (NLA)
7	09140-06021	Nut
8	01547-0612A	BOLT
9	12891-95J00	Tappet
10	12911-95J00	Intake Valve (NLA)
11	12915-95J00	Exhaust Valve
12	12921-95J00	Valve Spring (NLA)
13	12931-78G00	Valve Spring Retainer
14	12932-24400	Valve Cotter
15	12933-51E00	Valve Spring Seat
16	09289-05006	Valve Stem Seal
45658	12710-95J00	Camshaft (NLA)
45659	12710-95J10	Camshaft (NLA)

▶Fig. 40 - Opt: Concealed Remocon (2) (42 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	67246-92E50	Drive Shaft (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	67226-92E50	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	67232-92E50	Bushing (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)

▶Fig. 41 - Opt: Remocon Attachment (10 parts)

Ref	OEM Part #	Part Name
1	67700-95J01	Drag Link Assembly
2	67100-95J01	Remocon Attachment Set
3	43755-95J01	Steering Bracket Attachment
4	09100-10270	Bolt (10x25)
5	09162-10005	Lock Washer
6	67701-95J00	Drag Link Assembly (NLA)
7	67721-89J00	Drag Link Spacer
8	67725-96J00	Drag Link Bolt
9	67726-99E00	Lock Nut
10	67728-99E00	Washer

▶Fig. 42 - Opt: Electrical (14 parts)

Ref	OEM Part #	Part Name
1	32000-95J01	Battery Charging Kit
2	32801-95J01	Rectifier/Regulator Set (NLA)
3	32800-95J01	Rectifier & Regulator Assembly
4	36615-96300	Resin Terminal
5	29404-93J11	Clamp (L:65)
6	01550-06257	BOLT
6A	09408-00024	Clamp
7	39600-95J00	Receptacle Set (NLA)
8	36740-95J00	Fuse Case Assembly (NLA)
9	37801-98300	Lead (NLA)
10	39601-95D00	Lighting Receptacle Assembly
11	36634-93910	Connector Cap
12	39602-93900	Lamp Cord Plug Assembly
13	36990-87D00	Terminal & Sleeve Set

▶Fig. 44 - Opt: Starting Motor (31 parts)

Ref	OEM Part #	Part Name
1	31000-95J00	Electric Starter Kit (NLA)
2	11511-95J01	Magneto Cover
3	31101-95J00	Starter Motor Set (NLA)
4	31100-95J01	Starter Motor Assembly
5	31911-95J00	Starting Motor Bracket (NLA)
6	31912-95J00	Starting Motor Band (NLA)
7	31918-95J00	Starter Damper (NLA)
8	36645-94J00	Wire Lead (NLA)
9	38860-76F01	Relay
10	38915-90J00	Relay Holder
11	01550-08207	BOLT
12	01550-08257	BOLT
13	01550-08307	BOLT
14	04211-11129	11 X 12 DOWEL P
15	04221-06129	PIN 6X12
16	08316-10087	Nut
17	32102-95J00	Flywheel (NLA)
18	32120-95J00	Stator & Pulser Coil
19	32801-95J01	Rectifier/Regulator Set (NLA)
20	32800-95J01	Rectifier & Regulator Assembly
21	36615-96300	Resin Terminal
22	29404-93J11	Clamp (L:65)
23	01550-06257	BOLT
24	09408-00024	Clamp
25	09407-10404	Clamp (L:100)
26	33800-95J00	Starting Cable Set (NLA)
27	33810-95J00	Starter Motor Cable Assembly
28	36610-95J01	Wiring Harness Assembly
29	37161-89E13	Start Switch Assembly
30	09159-14014	Nut (10mm)
31	61465-95J00	Engine Cover Emblem (NLA)

▶Fig. 45 - Opt: Remocon Parts Set (28 parts)

Ref	OEM Part #	Part Name
1	67130-95J04	PARTS ASSY, REM
2	21241-95J00	Clutch Lever Link
3	23210-95J00	Clutch Lever
4	09160-05029	Washer (5.5x10x0.8)
5	09160-06084	Washer (6.5x18x1.6)
6	09180-06230	Spacer (6.2x12.6x12.5)
7	09204-01002	Cotter Pin
8	01550-06257	BOLT
9	19120-95J00	Throttle Control Lever
10	19122-95J00	Throttle Interlink Lever
11	19185-95J00	Throttle Lever Spring
12	19761-95J00	Throttle Cable Stay
13	63610-95J12	Throttle Cable Assembly
14	09160-06047	Washer (6.2x20x2)
15	01550-06127	BOLT
16	01550-06167	BOLT
17	67467-89J01	Cable Connector
18	09160-06055	Washer (7x12x1.0)
19	09385-06012	Clip
20	67340-95J00	Remocon Cable Holder (NLA)
21	67350-95J01	Remocon Cable Holder
22	09116-06094	Bolt (6x15)
23	09308-08013	Grommet
24	36610-95J20	Wiring Harness Assembly (NLA)
25	36616-95J00	Connector Holder (NLA)
26	37163-95J00	Starting Switch Plug (NLA)
27	02142-06167	6 X 16 CROSS SC
28	61124-95J20	Cable Grommet (NLA)

▶Fig. 46 - Opt: Gasket Set (11 parts)

Ref	OEM Part #	Part Name
1	11410-95811	Engine Gasket Set
2	11141-95J00	Cylinder Head Gasket
3	11189-95J00	Cylinder Head Cover Gasket
4	11219-95J01	Cylinder Block Cover Gasket
5	11351-95J01	Crankcase Gasket
6	13119-95J00	Port Intake Manifold Gasket
7	13122-95J00	Stbd Intake Manifold Gasket
8	13125-95J00	Carburetor Gasket
9	11489-95J01	Oil Pan Gasket
10	56132-95J00	Drive Shaft Housing Gasket
11	99011-95J06-03A	Owners Manual DF 25 V-Twin - 2011

▶Fig. 5 - Intake Manifold (6 parts)

Ref	OEM Part #	Part Name
1	13110-95J01	Intake Manifold
2	13119-95J00	Port Intake Manifold Gasket
3	13122-95J00	Stbd Intake Manifold Gasket
4	01550-08407	BOLT 8 X 40
5	11184-95J00	Breather Hose (NLA)
6	09401-14409	Clip

▶Fig. 6 - Carburetor (49 parts)

Ref	OEM Part #	Part Name
2	13236-95J00	Main Nozzle
5	13239-94J00	Rubber Cap
6	13250-94J00	Carburetor Float
7	13370-94J00	Needle Valve
8	13247-94J00	Screw
9	13375-26E00	Valve Clip
10	13254-94J00	Float Pin
11	13802-94J00	Screw
12	13534-94J00	Stop Screw
13	13268-94J00	Spring
14	13251-94J00	Float Chamber Gasket
16	13279-94J00	Drain Screw
17	13523-94J00	O-Ring
18	13345-94J00	U-Ring
20	13247-94J00	Screw
21	13361-94J00	Cable Holder
22	13362-94J00	Cable Guide
23	13363-94J00	Cable Sealing Cap
24	13364-94J00	Starter Valve
25	13365-94J00	Spring
26	13295-14G00	O-Ring
27	13684-94J00	Pipe (NLA)
28	09401-05402-XC0	Clip
29	13428-95J00	Heater Guard
30	13367-94J00	Screw
31	13368-95J01	STARTER ASSY
32	13494-94J00	Clip
33	13495-94J00	Rubber Cap
34	13493-95J00	Plunger
35	13441-94J00	Spring
36	09103-06228	Bolt (6x105)
37	13125-95J00	Carburetor Gasket
38	13124-95J00	Carburetor Insulator
39	13880-95J00	Outlet Tube (NLA)
40	13882-95J00	Outlet Tube Plate (NLA)
41	09180-06353	Spacer
43	01550-06167	BOLT
44	13640-95J01	Starter Knob
45	09159-14014	Nut (10mm)
45658	13200-95J01	CARBURETOR ASSY
45659	13200-95J10	Carburetor Assembly
45672	13240-95J00	Float Chamber Assembly (NLA)
45676	13346-95J00	Cover
45703	13240-95J10	Float Chamber Assembly (NLA)
45707	13346-95J10	Cover (NLA)
45717	09491-27020	Main Jet #135
45718	09491-26021	Main Jet #130
45748	09492-48016	Pilot Jet #48
45749	09492-45040	Pilot Jet #45

▶Fig. 7 - Magneto Cover/Recoil Starter/Silencer (22 parts)

Ref	OEM Part #	Part Name
1	11511-95J01	Magneto Cover
2	01550-08257	BOLT
3	18100-95J00	Recoil Starter Assembly
4	18120-96320	Reel (NLA)
5	18130-89J00	Ratchet Set
6	18142-89J00	Spiral Spring
7	18191-95J00	Rope Guide (NLA)
8	18210-93002	Grip Assembly
9	18280-95J00	NSI Set (NLA)
10	18290-95J00	Wire (NLA)
11	18293-89J00	Spring (NLA)
12	18151-96310	Friction Plate (NLA)
13	01570-06167	BOLT
14	99000-81159-50M	Starter Rope 6mm Diameter (NLA)
15	18193-95J00	Recoil Starter Seal (NLA)
16	01550-08257	BOLT
17	13710-95J00	Flame Arrester
18	13811-95J00	Upper Cover Silencer
19	03542-05169	SCREW
20	03542-05359	SCREW
21	61472-93E33	LABEL,RECOIL,ST
22	69711-93E11	Label (S.I.G.P)

▶Fig. 8 - Fuel Pump (20 parts)

Ref	OEM Part #	Part Name
1	15100-95J04	Fuel Pump Assembly
2	15131-99E00	Fuel Pump Rod
3	15192-95J11	HOSE,FUEL PUMP
4	15410-87J30	Fuel Filter
5	15419-87J00	Fuel Filter Cap
6	09401-11423	Clip
7	15421-95J00	Fuel Filter Bracket (NLA)
8	15422-96J01	Fuel Filter Clamp
9	18498-99E11	Hose Protector (L:610)
10	18498-96J21	Hose Protector (13.5x16.5x370)
11	09280-26005	O-Ring
12	09343-70503-00B	Fuel Hose (7x12x2000)
13	15193-95J11	HOSE,FUEL PUMP
14	09401-11423	Clip
15	09401-10412	Clip
16	09401-12412	CLIP
17	09408-00069	Clamp (NLA)
18	09408-00105	Clamp
19	01550-06127	BOLT
20	01550-06257	BOLT

▶Fig. 9 - Water Pump (20 parts)

Ref	OEM Part #	Part Name
1	17410-95J00	Water Pump Case
2	17413-95J00	Water Pump Case Sleeve
3	17416-95J00	Water Pump Case Seal
4	17461-96312	Water Pump Impeller
5	17471-95J01	Water Pump Plate
6	17472-96304	Water Pump Plate Gasket
8	17565-91L00	Water Tube Grommet
9	17566-96303	Water Tube Grommet
10	17631-95J00	Port Side Water Filter
11	17632-95J00	Starboard Side Water Filter
12	09108-06146	Stud Bolt (6x52)
13	09116-06094	Bolt (6x15)
14	29141-93J00	Nut (6mm)
15	09160-06082	Washer (6.5x13x1.0)
16	09420-04006	Impeller Key
17	03142-04259	SCREW
18	17400-95J03	Water Pump Repair Kit DF25 V-Twin
19	09320-08062	Cushion
45839	17560-95J00	Water Tube (S) (NLA)
45840	17560-95J10	Water Tube (L) (NLA)

100-Hour / Annual Service Checklist

Regular maintenance keeps your Suzuki DF 25ES, DF 25EL, DF 25RL 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.

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