🔎 Suzuki DF 25MSK8, DF 25MLK8, DF 25ESK8, DF 25ELK8, DF 25RLK8 Reference Library — Exploded parts diagrams (46 diagrams), specifications, common issues, and maintenance checklist.
The Suzuki DF 25MSK8, DF 25MLK8, DF 25ESK8, DF 25ELK8, DF 25RLK8 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 25MSK8, DF 25MLK8, DF 25ESK8, DF 25ELK8, DF 25RLK8:
-
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 25MSK8, DF 25MLK8, DF 25ESK8, DF 25ELK8, DF 25RLK8.
▶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 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 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 |
| 4 |
02162-05127 |
Screw (NLA) |
| 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 (16 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 |
68271-95J00 |
Emblem Front Mark (NLA) |
| 11 |
61435-89J61 |
Rear Emblem Mark (DF25) |
| 12 |
61458-99E31 |
Engine Cover Label |
| 13 |
69716-99E14 |
Fuel Limitation Label |
| 14 |
68110-94400 |
Weather Cover (NLA) |
| 15 |
09800-81822 |
Tool Set |
| 45658 |
61400-95Y12-0EP |
Engine Cover Set (NLA) |
| 45659 |
61400-95Y23-0EP |
Engine Cover Set |
| 45901 |
61443-95J01 |
Starboard Engine Cover Stripe |
| 45902 |
61453-95J01 |
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 |
12163-32C00 |
Connecting Rod Bolt (NLA) |
| 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 |
32801-95J00 |
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. 43 - Opt: Harness (2 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
36620-93J12 |
MAIN HARNESS EXT 6.5' |
| 2 |
36620-93J31 |
Replaced by 36620-93J32 |
▶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 |
32801-95J00 |
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 |
99011-95J02-03A |
Owners Manual DF 25 V-Twin - 2008 |
▶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 |
09355-70129-00B |
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 25MSK8, DF 25MLK8, DF 25ESK8, DF 25ELK8, DF 25RLK8 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.
