🔎 Suzuki DF 40ATL Reference Library — Exploded parts diagrams (43 diagrams), specifications, common issues, and maintenance checklist.
The Suzuki DF 40ATL is a 4-Stroke DOHC 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 DOHC Inline 3-Cylinder |
| Horsepower |
40 HP |
| Displacement |
941 cc |
| Bore x Stroke |
72.5 x 76.0 mm |
| Spark Plug (Type & Gap) |
NGK DCPR6E |
| Engine Oil Capacity |
2.7 L |
| Recommended Engine Oil |
SAE 10W-40 |
| Gear Case Oil Capacity |
610 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 40ATL:
-
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 40ATL.
▶Fig. 111 - Cylinder Head (31 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11100-88L20 |
HEAD ASSY,CYLIN |
| 2 |
11115-73G01-001 |
Valve Guide |
| 3 |
09103-06266 |
Bolt (6x40) |
| 4 |
09206-08001 |
Knock Pin (8x11) |
| 5 |
11261-93J00 |
Protection Anode Cover |
| 6 |
09280-22019 |
O-Ring |
| 8 |
09103-06281 |
Bolt (6x14) |
| 9 |
01550-08207 |
BOLT |
| 10 |
11119-87J00 |
Cylinder Head Bolt |
| 11 |
11141-88L00 |
Cylinder Head Gasket |
| 12 |
01550-08457 |
BOLT |
| 13 |
04211-13189 |
PIN |
| 14 |
11382-99E00 |
Oil Filler Cap |
| 15 |
09280-26006 |
O-Ring |
| 16 |
11170-88L10 |
Cylinder Head Cover |
| 17 |
11189-88L00 |
Cylinder Head Cover Gasket |
| 18 |
01547-06257 |
BOLT 6X25 |
| 19 |
01547-06457 |
BOLT 6X45 |
| 20 |
11173-88L00 |
Breather Plate (NLA) |
| 21 |
02142-0612A |
SCREW |
| 22 |
11174-88L00 |
Breather Hose |
| 23 |
09401-15414 |
Clip |
| 24 |
09403-17312 |
CLAMP,BREATHER |
| 25 |
01550-06127 |
BOLT |
| 26 |
11194-88L10 |
Fuel Hose Guard |
| 27 |
01550-06167 |
BOLT |
| 28 |
09482-00446 |
NGK DCPR6E Spark Plug |
| 29 |
11115-73G01-001 |
Valve Guide |
| 30 |
11382-93J00 |
Oil Filler Cap |
| 45839 |
55321-87J01 |
Aluminum Anode |
| 45840 |
55321-87J11 |
Magnesium Anode |
▶Fig. 113 - Cylinder Block (9 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11291-88L00 |
Engine Hook |
| 2 |
01550-08207 |
BOLT |
| 3 |
11301-88L10 |
Cylinder Block Set |
| 4 |
11117-89J20 |
Crankcase Bolt |
| 5 |
09206-13019 |
Knock Pin |
| 6 |
01550-08407 |
BOLT 8 X 40 |
| 7 |
11112-88L00 |
Oil Venturi Plug (NLA) |
| 8 |
55321-87J01 |
Aluminum Anode |
| 9 |
09103-06281 |
Bolt (6x14) |
▶Fig. 116 - Crankshaft (22 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
12111-88L00 |
Piston |
| 2 |
12140-88L00 |
Replaced by 12140-88L01 |
| 3 |
12151-54A50 |
Piston Pin |
| 4 |
09381-18002 |
Piston Pin Circlip |
| 5 |
12160-88L01 |
Connecting Rod Assembly |
| 6 |
12163-69J00 |
Connecting Rod Bolt |
| 7 |
04221-04089 |
PIN 4X8 |
| 9 |
12220-88L00 |
Crankshaft |
| 11 |
09283-37005 |
Oil Seal (36.5x49x6) |
| 12 |
12281-87J00 |
Oil Seal (39.3x44x7) |
| 13 |
12100-88L01-050 |
Piston & Ring Set (OS:0.50) |
| 14 |
12140-88L00-050 |
Piston Ring Set (OS:0.50) (NLA) |
| 45870 |
12100-51810-0A0 |
Connrod Bearing Set (Green) |
| 45871 |
12100-51810-0B0 |
Connrod Bearing Set (Black) |
| 45872 |
12100-51810-0C0 |
Connrod Bearing Set (Non) |
| 45873 |
12100-51810-0D0 |
Connrod Bearing Set (Yellow) |
| 45874 |
12100-51810-0E0 |
Connrod Bearing Set (Blue) |
| 45931 |
12340-75FA0-0A0 |
Crankshaft Bearing Set (Green) |
| 45932 |
12340-75FA0-0B0 |
Crankshaft Bearing Set (Black) |
| 45933 |
12340-75F00-0C0 |
Crankshaft Bearing Set (Non) |
| 45934 |
12340-75F00-0D0 |
Crankshaft Bearing Set (Yellow) |
| 45935 |
12340-75F00-0E0 |
Discontinued |
▶Fig. 119 - Timing Chain (12 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
12761-88L00 |
Timing Chain |
| 2 |
12771-87J00 |
Timing Chain Guide |
| 3 |
12776-85FA0 |
Timing Chain Guide Bolt |
| 4 |
12811-88L00 |
Timing Chain Tensioner |
| 5 |
09100-08260 |
Bolt (8x30) |
| 6 |
09160-08123 |
Washer (8.5x20x1.2) |
| 7 |
12812-73G10 |
Timing Chain Tensioner Spacer |
| 8 |
12813-73G00 |
Timing Chain Tensioner Pad |
| 9 |
12831-90J02 |
Tensioner Adjuster Assembly |
| 10 |
01550-0620A |
BOLT |
| 11 |
12821-88L00 |
Timing Chain Tensioner Link (NLA) |
| 12 |
01550-0612A |
BOLT |
▶Fig. 121 - Camshaft (56 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
12710-88L00 |
Intake Camshaft |
| 2 |
12720-88L00 |
Exhaust Camshaft |
| 3 |
12741-88L00 |
Camshaft Timing Sprocket |
| 4 |
09103-10189 |
Bolt (10x23) |
| 5 |
09160-10093 |
Washer (10.5x24x2.3) |
| 6 |
04221-05109 |
PIN |
| 7 |
12891-73G01 |
Tappet |
| 8-32 |
12892-73G01-280 |
Tappet Shim (2.80) (NLA) |
| 8-33 |
12892-73G01-282 |
Tappet Shim (2.82) (NLA) |
| 8-34 |
12892-73G01-284 |
Tappet Shim (2.84) (NLA) |
| 8-35 |
12892-73G01-286 |
Tappet Shim (2.86) (NLA) |
| 8-36 |
12892-73G01-288 |
Tappet Shim (2.88) (NLA) |
| 8-37 |
12892-73G01-290 |
Tappet Shim (2.90) (NLA) |
| 8-38 |
12892-73G01-292 |
Tappet Shim (2.92) |
| 8-39 |
12892-73G01-294 |
Tappet Shim (2.94) (NLA) |
| 8-40 |
12892-73G01-296 |
Tappet Shim (2.96) (NLA) |
| 8-41 |
12892-73G01-298 |
Tappet Shim (2.98) |
| 8-42 |
12892-73G01-300 |
Tappet Shim (3.00) (NLA) |
| 9 |
12911-88L00 |
Intake Valve |
| 10 |
12915-73G20 |
Exhaust Valve |
| 11 |
12921-87J10 |
Valve Spring |
| 12 |
12931-78G00 |
Valve Spring Retainer |
| 13 |
12932-24400 |
Valve Cotter |
| 14 |
12933-51E00 |
Valve Spring Seat |
| 15 |
09289-05006 |
Valve Stem Seal |
| 45870 |
12892-65H00-218 |
Tappet Shim (2.18) |
| 45871 |
12892-73G01-220 |
Tappet Shim (2.20) |
| 45872 |
12892-65H00-222 |
Tappet Shim (2.22) (NLA) |
| 45873 |
12892-73G01-224 |
Tappet Shim (2.24) |
| 45874 |
12892-73G01-226 |
Tappet Shim (2.26) |
| 45875 |
12892-73G01-226 |
Tappet Shim (2.26) |
| 45876 |
12892-73G01-230 |
Tappet Shim (2.30) |
| 45877 |
12892-65H00-232 |
Tappet Shim (2.32) |
| 45878 |
12892-73G01-234 |
Tappet Shim (2.34) |
| 45879 |
12892-65H00-236 |
Tappet Shim (2.36) |
| 45880 |
12892-65H00-238 |
Tappet Shim (2.38) |
| 45881 |
12892-73G01-240 |
Tappet Shim (2.40) |
| 45882 |
12892-65H00-242 |
Tappet Shim (2.42) |
| 45883 |
12892-65H00-244 |
Tappet Shim (2.44) |
| 45884 |
12892-65H00-246 |
Tappet Shim (2.46) |
| 45885 |
12892-65H00-248 |
Tappet Shim (2.48) |
| 45886 |
12892-65H00-250 |
Tappet Shim (2.50) |
| 45887 |
12892-65H00-252 |
Tappet Shim (2.52) |
| 45888 |
12892-65H00-254 |
Tappet Shim (2.54) |
| 45889 |
12892-73G01-256 |
Tappet Shim (2.56) |
| 45890 |
12892-65H00-258 |
Tappet Shim (2.58) |
| 45891 |
12892-65H00-260 |
Tappet Shim (2.60) |
| 45892 |
12892-73G01-262 |
Tappet Shim (2.62) |
| 45893 |
12892-73G01-264 |
Tappet Shim (2.64) |
| 45894 |
12892-65H00-266 |
Tappet Shim (2.66) |
| 45895 |
12892-65H00-266 |
Tappet Shim (2.66) |
| 45896 |
12892-65H00-270 |
Tappet Shim (2.70) |
| 45897 |
12892-65H00-272 |
Tappet Shim (2.72) |
| 45898 |
12892-65H00-274 |
Tappet Shim (2.74) (NLA) |
| 45899 |
12892-73G01-276 |
Tappet Shim (2.76) |
| 45900 |
12892-73G01-278 |
Tappet Shim (2.78) |
▶Fig. 124 - Intake Manifold/Silencer/Exhaust Cover (15 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
13110-88L00 |
Intake Manifold |
| 2 |
13119-88L00 |
Intake Manifold Gasket |
| 3 |
13125-88L00 |
Throttle Body Gasket |
| 4 |
01421-08607 |
STUD BOLT |
| 5 |
01550-08307 |
BOLT |
| 6 |
01550-08407 |
BOLT 8 X 40 |
| 7 |
08316-10087 |
Nut |
| 8 |
18137-88L01 |
Replaced by 18137-88L02 |
| 9 |
02112-34167 |
SCREW |
| 10 |
13810-88L00 |
Silencer |
| 11 |
13820-88L01 |
HOLDER,SILENCER |
| 12 |
01550-06127 |
BOLT |
| 13 |
14141-88L10 |
COVER,EXHAUST |
| 14 |
14151-88L00 |
Exhaust Cover Gasket |
| 15 |
01550-06207 |
BOLT |
▶Fig. 136 - Ring Gear Cover (12 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11510-88L00 |
Ring Gear Cover |
| 2 |
01550-06307 |
BOLT |
| 3 |
09320-09501 |
Cushion |
| 4 |
03542-06209 |
SCREW |
| 5 |
11514-88L00 |
Ring Gear Cover Plate |
| 6 |
11411-88L00 |
Upper Oil Seal Housing (NLA) |
| 7 |
11413-88L00 |
Upper Oil Seal Gasket |
| 8 |
01550-06257 |
BOLT |
| 9 |
04221-04089 |
PIN 4X8 |
| 10 |
61472-88L01 |
LABEL,MAG COVER |
| 11 |
69711-93E11 |
Label (S.I.G.P) |
| 12 |
61494-88L02 |
LABEL,OIL & CLE |
▶Fig. 143 - Fuel Vapor Separator (35 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
15600-88L14 |
Fuel Vapor Separator Assembly |
| 2 |
13370-88L10 |
Needle Valve Assembly |
| 3 |
15200-88L00 |
Fuel Pump Assembly |
| 4 |
15626-88L01 |
Seal |
| 5 |
15628-99E00 |
Screw (L:15) |
| 6 |
15629-99E10 |
Drain Screw |
| 7 |
15641-88L00 |
Spacer |
| 8 |
15642-88L00 |
Fuel Filter |
| 9 |
15650-99E00 |
Float |
| 10 |
15654-88L00 |
Pin |
| 11 |
15683-87J00 |
Drain Hose (L:120) |
| 12 |
15760-88L00 |
Fuel Pressure Regulator |
| 13 |
15644-88L00 |
O-Ring |
| 14 |
15645-88L00 |
Regulator Holder |
| 15 |
02112-0408A |
SCREW |
| 16 |
02142-0408B |
SCREW |
| 17 |
15643-88L10 |
Joint |
| 18 |
15641-88L31 |
Bushing |
| 19 |
15641-88L51 |
Bushing |
| 20 |
15642-88L10 |
Fuel Filter |
| 21 |
15612-88L00 |
Vapor Separator Cover |
| 22 |
15613-88L00 |
O-Ring |
| 23 |
15613-92J00 |
Gasket |
| 24 |
15614-88L00 |
Screw |
| 25 |
01550-06307 |
BOLT |
| 26 |
09169-06075 |
Washer |
| 27 |
09160-06084 |
Washer (6.5x18x1.6) |
| 28 |
09320-09059 |
Cushion |
| 29 |
09352-50005-00B |
Hose (5x8.2x2000) |
| 30 |
09401-08412 |
Clip |
| 31 |
18498-88L10 |
Evap Hose Protector (L:730) |
| 32 |
09320-08517 |
CUSHION,CABLE H |
| 33 |
09408-00043 |
Clamp |
| 34 |
09408-00121 |
Clamp (NLA) |
| 35 |
09408-00145 |
Clip |
▶Fig. 144 - Fuel Injector (9 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
15710-85K00 |
Fuel Injector |
| 2 |
15716-65DT0 |
Grommet Set |
| 3 |
09320-08062 |
Cushion |
| 4 |
15750-88L10 |
Delivery Pipe (NLA) |
| 5 |
07120-06357 |
Bolt (NLA) |
| 6 |
09180-06198 |
Spacer (6.2x12x16) |
| 7 |
15681-88L10 |
Fuel Hose |
| 8 |
09401-11425 |
Clip |
| 9 |
09408-00174 |
Clamp (NLA) |
▶Fig. 146 - Fuel Pump (19 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
15100-90J11 |
Fuel Pump Assembly |
| 2 |
01550-06257 |
BOLT |
| 3 |
09280-26005 |
O-Ring |
| 4 |
15410-88L00 |
Fuel Filter |
| 5 |
15419-87J00 |
Fuel Filter Cap |
| 6 |
09401-11423 |
Clip |
| 7 |
15422-96J01 |
Fuel Filter Clamp |
| 8 |
15421-88L00 |
Fuel Filter Bracket |
| 9 |
01550-06167 |
BOLT |
| 10 |
15191-88L10 |
Fuel Hose |
| 11 |
15192-88L20 |
Fuel Hose |
| 12 |
09343-70503-080 |
Fuel Hose (7x12x80) |
| 13 |
18498-99E11 |
Hose Protector (L:610) |
| 14 |
18498-96J21 |
Hose Protector (13.5x16.5x370) |
| 15 |
15197-88L00 |
Fuel Hose Clamp Bracket |
| 16 |
01550-06127 |
BOLT |
| 17 |
09403-11320 |
Clamp |
| 18 |
09401-11423 |
Clip |
| 19 |
09408-00145 |
Clip |
▶Fig. 160 - Water Pump (22 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
17410-88L00 |
Water Pump Case |
| 2 |
17413-95J00 |
Water Pump Case Sleeve |
| 3 |
17416-95J00 |
Water Pump Case Seal |
| 4 |
17564-88L01 |
Water Pump Case Bushing |
| 5 |
29141-93J00 |
Nut (6mm) |
| 6 |
29162-93J00 |
Lock Washer |
| 7 |
09108-06143 |
Stud Bolt (L:45) |
| 8 |
09108-06144 |
Stud Bolt (L:31) |
| 9 |
17461-96312 |
Water Pump Impeller |
| 10 |
17471-95J01 |
Water Pump Plate |
| 11 |
17472-96304 |
Water Pump Plate Gasket |
| 12 |
17560-88L10 |
Water Tube (L) |
| 13 |
17562-87L01 |
Water Tube Grommet |
| 14 |
17562-87L01 |
Water Tube Grommet |
| 15 |
09116-06236 |
Bolt (6x16) |
| 16 |
17631-96320 |
Water Filter |
| 17 |
03142-04309 |
SCREW 4 X 30 |
| 19 |
09125-05046 |
Screw (5x12) |
| 20 |
09420-04006 |
Impeller Key |
| 21 |
17400-88L01 |
Water Pump Repair Kit DF40A/DF50A/DF60A |
| 45675 |
17635-87E00 |
Sub Water Filter |
| 45706 |
17635-87E10 |
Gear Case Plate |
▶Fig. 162 - Thermostat (16 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
17611-90J00 |
Water Pressure Valve Cover |
| 2 |
17660-99E01 |
Water Pressure Valve |
| 3 |
09116-06121 |
Bolt (6x25) |
| 4 |
09280-26006 |
O-Ring |
| 5 |
17670-93955 |
Thermostat (60c) |
| 6 |
17681-88L00 |
Thermostat Cover |
| 7 |
01550-06207 |
BOLT |
| 8 |
11196-88L00 |
Water Return Hose |
| 9 |
09401-25406 |
Clip |
| 10 |
18498-94J20 |
Hose Protector (L:320) (NLA) |
| 11 |
17712-88L01 |
HOSE,WATER(SEPA |
| 12 |
09352-50006-600 |
Hose (5x9x600) |
| 13 |
09359-50901-980 |
Hose |
| 14 |
09401-08413 |
Clip |
| 15 |
09401-10412 |
Clip |
| 16 |
09408-00175 |
Clamp |
▶Fig. 163 - Throttle Body (11 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
13300-88L01 |
Throttle Body Assembly |
| 2 |
13315-88L00 |
Throttle Body Bracket (NLA) |
| 3 |
01550-06457 |
BOLT |
| 4 |
01550-06167 |
BOLT |
| 5 |
01550-08207 |
BOLT |
| 6 |
13510-88L00 |
Throttle Rod |
| 7 |
19120-88L01 |
Throttle Lever |
| 8 |
19131-95502 |
Connector |
| 9 |
09140-05005 |
Nut |
| 10 |
09160-06047 |
Washer (6.2x20x2) |
| 11 |
01550-06407 |
BOLT |
▶Fig. 175 - Oil Pump (9 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11433-88L00 |
Under Oil Seal Gasket |
| 2 |
16400-88L00 |
Oil Pump Assembly |
| 3 |
01547-0640A |
BOLT |
| 4 |
04211-09109 |
DOWEL PIN |
| 5 |
16520-88L00 |
Oil Pump Strainer |
| 6 |
09280-12008 |
O-Ring |
| 7 |
01570-0616A |
BOLT |
| 8 |
16519-87L00 |
Engine Holder Seal |
| 9 |
16510-87J02 |
Engine Oil Filter |
▶Fig. 180 - Oil Pan (19 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11489-88L01 |
Oil Pan Gasket |
| 3 |
09116-08128 |
Bolt (8x40) |
| 4 |
09168-12012 |
Oil Drain Plug Gasket |
| 5 |
09248-12009 |
Oil Drain Plug |
| 7 |
11552-88L00 |
Water Jacket Cover Gasket |
| 8 |
09116-06121 |
Bolt (6x25) |
| 9 |
17913-93J00 |
Water Flush Plug |
| 10 |
17914-93J01 |
Water Flush Plug Gasket |
| 11 |
11543-88L01 |
SILENCER,EXHAUS |
| 12 |
43112-94L01 |
Exhaust Pipe |
| 13 |
09116-10124 |
Bolt (10x150) |
| 14 |
16910-88L00 |
Oil Level Gauge |
| 15 |
16930-88L00 |
Oil Level Gauge Guide |
| 16 |
09280-09008 |
O-Ring |
| 17 |
01550-06127 |
BOLT |
| 45689 |
11501-88L01-0EP |
Oil Pan |
| 45690 |
11501-88L01-Y5S |
Oil Pan (NLA) |
| 45809 |
11551-88L00-0EP |
Water Jacket Oil Pan Cover |
| 45810 |
11551-88L00-Y5S |
Water Jacket Oil Pan Cover |
▶Fig. 204 - Clutch Shaft (23 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
21126-88L00 |
Clutch Shaft Holder |
| 2 |
21151-88L00 |
Clutch Lever Holder |
| 3 |
01550-06167 |
BOLT |
| 4 |
01550-06307 |
BOLT |
| 5 |
21210-88L01 |
Clutch Shaft |
| 6 |
23111-88L11 |
Clutch Rod (L/X) |
| 7 |
29141-93J00 |
Nut (6mm) |
| 8 |
23115-88L00 |
Clutch Lever Link |
| 9 |
23210-88L00 |
Clutch Control Lever |
| 10 |
09160-06055 |
Washer (7x12x1.0) |
| 11 |
09385-06012 |
Clip |
| 12 |
23213-89J01 |
Notch Plate Spring No. 1 |
| 13 |
23214-89J00 |
Notch Plate Spring No. 2 (NLA) |
| 14 |
01550-08127 |
BOLT 8 X 12 |
| 15 |
23311-95J00 |
Clutch Rod Connector |
| 16 |
67341-88L01 |
Remocon Cable Holder |
| 17 |
01550-06167 |
BOLT |
| 18 |
67343-88L01 |
Remocon Cable Stopper |
| 19 |
09352-70104-600 |
Hose (7x10.2x600) |
| 20 |
01570-06167 |
BOLT |
| 21 |
67467-89J01 |
Cable Connector |
| 22 |
09160-06055 |
Washer (7x12x1.0) |
| 23 |
09385-06012 |
Clip |
▶Fig. 206 - Clutch Rod (15 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
25111-88L10 |
Shift Rod (L) |
| 2 |
25211-87J00 |
Shift Rod Guide |
| 3 |
09280-08005 |
O-Ring |
| 4 |
09280-11005 |
Shift Rod O-Ring |
| 5 |
25212-94401 |
Shift Rod Lower Guide |
| 6 |
09205-02013 |
Spring Pin (2.5x16) |
| 7 |
09205-03021 |
Spring Pin (3.5x12) |
| 8 |
09205-02004 |
Spring Pin (2.5x12) |
| 9 |
25223-96J00 |
Seal, Shift Rod Dust |
| 10 |
25232-96302 |
Gear Case Magnet |
| 11 |
25311-88L00 |
Shift Cam |
| 12 |
08331-3115A |
Circlip |
| 13 |
21121-93300 |
Clutch Notch Plate |
| 14 |
09260-10005 |
Ball |
| 15 |
09440-07078 |
Spring |
▶Fig. 220 - Transmission (57 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
57110-88L12 |
Drive Shaft Assembly (L) |
| 2 |
57133-88L01 |
Drive Shaft Collar |
| 3 |
57133-94400 |
Drive Shaft Spring Collar |
| 4 |
09205-03019 |
Spring Pin (3x10) |
| 5 |
09265-20015 |
Bearing (20x42x15) |
| 6 |
57300-88810 |
Pinion & Gear Set |
| 7 |
09140-12034 |
Pinion Nut |
| 12 |
08211-20263 |
Thrust Washer (2.00) |
| 13 |
57610-94403 |
Propeller Shaft Assembly |
| 14 |
57621-87J03 |
Clutch Dog Shifter |
| 15 |
09202-05022 |
Clutch Dog Shifter Pin |
| 16 |
57634-88L00 |
Push Pin |
| 17 |
09440-08043 |
Return Spring |
| 18 |
09440-40002 |
Clutch Dog Spring |
| 19 |
57631-95303 |
Push Rod |
| 21 |
09263-22020 |
Bearing (22.225x28.575.19.05) |
| 22 |
09289-22007 |
Oil Seal (21.2x35x5) |
| 23 |
09262-35070 |
Bearing (35x62x14) |
| 24 |
09280-75001 |
O-Ring |
| 25 |
09116-08122 |
Bolt (8x30) |
| 27 |
09282-17005 |
Oil Seal (16x32x6) |
| 28 |
08331-41329 |
Circlip |
| 29 |
55122-88L00 |
Gear Case Seal Ring |
| 30 |
09202-06025 |
Pin (6x17) |
| 31 |
09202-06027 |
Pin (6x23) |
| 45677 |
56120-94321-0EP |
Propeller Shaft Bearing Housing |
| 45683 |
56130-87J12-0EP |
Drive Shaft Bearing Housing |
| 45708 |
56120-94321-Y5S |
Propeller Shaft Bearing Housing |
| 45714 |
56130-87J12-Y5S |
HOUSING,DRIVE S |
| 45870 |
09181-35101 |
Shim (0.50) |
| 45871 |
09181-33001 |
Washer (1.50) |
| 45872 |
09181-33002 |
Washer (0.60) |
| 45873 |
09181-33003 |
Washer (0.65) |
| 45874 |
09181-33004 |
Washer (0.70) (NLA) |
| 45875 |
09181-33005 |
Washer (0.75) |
| 45876 |
09181-33006 |
Washer (0.80) |
| 45877 |
09181-33007 |
Washer (0.85) |
| 45878 |
09181-33008 |
Washer (0.90) |
| 45879 |
09181-33009 |
Washer (0.95) |
| 45880 |
09181-35110 |
Shim (1.00) |
| 45901 |
09181-30186 |
Shim (0.50) |
| 45902 |
09181-30187 |
Shim (0.60) |
| 45903 |
09181-30188 |
Shim (0.70) |
| 45904 |
09181-30190 |
Shim (0.80) |
| 45905 |
09181-30192 |
Shim (0.90) |
| 45931 |
08221-35455 |
Shim (0.50) |
| 45932 |
09181-35131 |
Shim (0.60) |
| 45933 |
09181-35132 |
Shim (0.70) |
| 45934 |
08221-35456 |
Shim (0.80) |
| 45935 |
09181-35136 |
Shim (0.90) |
| 45936 |
08211-35451 |
Shim (1.00) |
| 45962 |
09160-22018 |
Washer (1.80) |
| 45963 |
09160-22019 |
Washer (1.90) |
| 45964 |
09160-22020 |
Washer (2.00) |
| 45965 |
09160-22021 |
Washer (2.10) |
| 45966 |
09160-22022 |
Washer (2.20) |
| 45967 |
09160-22023 |
Washer (2.30) |
▶Fig. 301 - Starting Motor (21 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
31100-94J22 |
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 |
31170-94J00 |
Starter Motor Cover Assembly |
| 18 |
31912-88L00 |
Starter Motor Band |
| 19 |
31918-87L00 |
Lower Damper |
| 20 |
01550-06167 |
BOLT |
| 21 |
01550-08307 |
BOLT |
▶Fig. 303 - Magneto (12 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
32102-88L01 |
Flywheel |
| 2 |
09103-14024 |
Flywheel Bolt (14x50) |
| 3 |
09160-14065 |
Washer (14.5x36x4.5) |
| 4 |
09420-04008 |
Key |
| 5 |
32120-88L00 |
Battery Charging Coil |
| 6 |
32160-88L01 |
CKP/Ignition Timimg Coil |
| 7 |
09106-05030 |
Bolt (5x10) |
| 8 |
33220-64L10 |
Cam Position Sensor |
| 9 |
01547-06167 |
BOLT 6X16 |
| 10 |
09403-13413 |
CLAMP |
| 11 |
01550-06127 |
BOLT |
| 12 |
02112-06307 |
SCREW, 6X30 CRO |
▶Fig. 310 - Rectifier/Ignition Coil (8 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
32800-88L01 |
Rectifier/Regulator Assembly |
| 2 |
01550-06257 |
BOLT |
| 3 |
32890-88L01 |
Electric Parts Holder |
| 4 |
09116-06202 |
Bolt w/Washer (6x25) |
| 5 |
09169-06062 |
Washer (6.3x17x1.6) |
| 6 |
09320-09016 |
Cushion |
| 7 |
33410-87L00 |
Ignition Coil Assembly |
| 8 |
01547-06207 |
BOLT 6 X 20 |
▶Fig. 315 - Sensor (12 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
34830-87J20 |
Temp Sensor Assy |
| 2 |
34840-98J03 |
Trim Sensor Assembly |
| 3 |
09136-05041 |
Screw (5x20) |
| 4 |
09160-05029 |
Washer (5.5x10x0.8) |
| 5 |
01550-06207 |
BOLT |
| 6 |
37820-99E02 |
Oil Pressure Switch |
| 7 |
09403-07340 |
Clamp |
| 8 |
36656-88L00 |
PTT Cable Grommet |
| 9 |
09407-14407 |
Clamp (L:140) |
| 10 |
34841-88L01 |
Trim Sensor Lever |
| 11 |
34845-88L02 |
Trim Sender Bracket |
| 12 |
29404-93J11 |
Clamp (L:65) |
▶Fig. 322 - Harness (25 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
33810-88L10 |
Starter Motor Cable Assembly |
| 2 |
08316-10087 |
Nut |
| 3 |
36610-88LG1 |
Wiring Harness Assembly |
| 4 |
33634-96J00 |
Service Connector Cap |
| 5 |
36668-87L00 |
Service Connector Cap |
| 6 |
09320-08510 |
Cushion (8.5x20x8) |
| 7 |
36737-96J00 |
Fuse Puller (NLA) |
| 8 |
36721-96J00 |
Upper Cover O-Ring |
| 9 |
36738-88L00 |
Fuse Case Upper Cover |
| 10 |
38860-76F01 |
Relay |
| 11 |
38860-76F01 |
Relay |
| 12 |
09481-15501 |
15 Amp Fuse |
| 13 |
09481-30501 |
30 Amp Fuse |
| 14 |
09481-30401 |
30 Amp Fuse |
| 15 |
36612-96J01 |
CAP,TERMINAL |
| 16 |
36618-43410 |
Oil Pressure Switch Cap (NLA) |
| 17 |
08310-00067 |
Nut |
| 18 |
08321-01067 |
Lock Washer |
| 19 |
09407-14403 |
Clamp (L:125) |
| 20 |
09407-14407 |
Clamp (L:140) |
| 21 |
36617-88L00 |
Harness Bracket (NLA) |
| 22 |
36617-88L10 |
Harness Bracket |
| 23 |
36617-93J10 |
Harness Bracket |
| 24 |
01550-06127 |
BOLT |
| 25 |
09407-18402 |
Clamp (L:165) |
▶Fig. 326 - PTT Switch/Engine Control Unit (13 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
37721-93J00 |
Neutral Switch Assembly |
| 2 |
09137-04004 |
Screw (4x16) |
| 3 |
37725-88L00 |
Neutral Switch Bracket |
| 4 |
09407-10404 |
Clamp (L:100) |
| 5 |
09408-00184 |
Clamp |
| 6 |
38410-93J12 |
PTT Relay Assembly |
| 7 |
38415-93J00 |
PTT Relay Holder |
| 8 |
01550-06127 |
BOLT |
| 9 |
33930-88L20 |
Engine Control Unit |
| 10 |
33925-88L10 |
ECU Cushion |
| 11 |
37850-92J00 |
PTT Switch Assembly |
| 12 |
37856-92J00 |
PTT Switch Tape |
| 13 |
37857-92J01 |
PTT Switch Bushing |
▶Fig. 335 - Clamp Bracket (18 parts)
| Ref |
OEM Part # |
Part Name |
| 3 |
41130-87J11 |
Clamp Bracket Shaft |
| 4 |
45421-89J00 |
Tilt Lock Pin |
| 5 |
09160-12066 |
Washer (12.5x22x2.5) |
| 6 |
55321-87J01 |
Aluminum Anode |
| 7 |
09103-06281 |
Bolt (6x14) |
| 9 |
09159-12014 |
Nut (12x17) |
| 10 |
09159-22006 |
Nut |
| 11 |
09160-12044 |
Washer (12.5x35x3.2) |
| 12 |
09160-12126 |
Washer (12.5x22x3) |
| 13 |
09159-10050 |
Nut |
| 14 |
09160-10082 |
Washer (10.5x19x2.0) |
| 15 |
41135-93J00 |
Clamp Bracket Shaft Washer |
| 45658 |
41111-88L20-0EP |
Starboard Clamp Bracket |
| 45659 |
41111-88L20-Y5S |
Starboard Clamp Bracket |
| 45689 |
41121-88L10-0EP |
Port Clamp Bracket |
| 45690 |
41121-88L10-Y5S |
Port Clamp Bracket |
| 45870 |
09100-12093 |
Transom Bolt (12x100) |
| 45871 |
09100-12091 |
Transom Bolt (12x115) |
▶Fig. 336 - Swivel Bracket (27 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
43211-87J00 |
Swivel Bracket Bushing |
| 3 |
43711-89J10 |
Steering Bushing |
| 5 |
22511-99011 |
Grease Nipple |
| 6 |
36894-95201 |
Wire Lead (L:165) |
| 7 |
36895-87D01 |
Wire Lead (L:210) |
| 8 |
36895-87D01 |
Wire Lead (L:210) |
| 9 |
09125-06063 |
Screw (6x10) |
| 10 |
09125-05050 |
Screw (5x8) |
| 11 |
43755-88L00 |
Steering Bracket Attachment |
| 12 |
09108-10161 |
Stud Bolt (10x20) |
| 13 |
09159-10050 |
Nut |
| 14 |
09160-10141 |
Washer (10.5x19x2) |
| 15 |
09160-39003 |
Washer (39.5x58x0.3) |
| 16 |
09282-39001 |
Oil Seal (38x51x5) |
| 17 |
09160-39002 |
Washer (39.5x58x1) |
| 18 |
09380-38003 |
Circlip |
| 19 |
41226-97E00 |
Bushing |
| 20 |
41270-89J11 |
LEVER,TILT LOCK |
| 21 |
41280-89J04 |
Port Tilt Lock Lever |
| 22 |
45731-96312 |
Spring Bracket |
| 23 |
09116-06236 |
Bolt (6x16) |
| 24 |
41230-97E10 |
Tilt Lock Spring |
| 25 |
09205-03012 |
Spring Pin (3x16) |
| 45658 |
43111-88L21-0EP |
Swivel Bracket (L) |
| 45659 |
43111-88L21-Y5S |
Swivel Bracket (L) |
| 45748 |
43750-88L22-0EP |
Steering Bracket (L) |
| 45749 |
43750-88L21-Y5S |
Steering Bracket (L) |
▶Fig. 337 - Trim Cylinder (28 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
48000-88L30 |
TRIM ASSY,POWER |
| 2 |
29404-93J11 |
Clamp (L:65) |
| 3 |
38100-88L12 |
PTT Motor Assembly |
| 4 |
48320-87J10 |
Up Pressure Valve |
| 5 |
48330-87J10 |
Down Pressure Valve |
| 6 |
48510-97E00 |
Gear Pump Assembly |
| 7 |
48541-87J10 |
Bolt (NLA) |
| 8 |
48541-87J20 |
Bolt (NLA) |
| 9 |
48551-88L00 |
Manual Valve |
| 10 |
48553-88L00 |
Washer Seal |
| 11 |
48557-87J10 |
O-Ring Set |
| 12 |
48571-88L01 |
Reservoir Tank |
| 13 |
48572-87L00 |
Plug |
| 14 |
48582-97E01 |
Filter |
| 15 |
48583-87J10 |
Drive Joint |
| 16 |
48611-88L00 |
Metal Joint (NLA) |
| 17 |
48681-87J11 |
Circlip |
| 18 |
48862-87J20 |
Reservoir Tank Bolt |
| 19 |
47225-87J00 |
Tilt Cylinder Lower Collar (NLA) |
| 20 |
48121-89J10 |
Tilt Cylinder Lower Shaft |
| 21 |
48321-89J11 |
Tilt Cylinder Upper Shaft |
| 22 |
48325-89J00 |
Tilt Cylinder Upper Bushing |
| 23 |
48326-87J00 |
Tilt Cylinder Lower Bushing |
| 24 |
09380-12002 |
Snap Ring |
| 25 |
09116-10179 |
Bolt (10x35) |
| 26 |
55321-87J01 |
Aluminum Anode |
| 27 |
09103-06281 |
Bolt (6x14) |
| 28 |
09160-10139 |
Washer (10.5x35x3) (NLA) |
▶Fig. 340 - PTT Motor (9 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
38100-88L12 |
PTT Motor Assembly |
| 2 |
31311-87J10 |
Armature (NLA) |
| 3 |
31173-88L12 |
Brush Holder Assembly |
| 4 |
31123-97E10 |
O-Ring |
| 5 |
31133-94910 |
Brush |
| 6 |
31135-94900 |
Spring |
| 7 |
31136-87J11 |
Breaker |
| 8 |
33799-97E00 |
Oil Seal |
| 9 |
31111-87J10 |
Screw (NLA) |
▶Fig. 401 - Engine Holder (25 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
51211-88L00 |
Engine Holder Gasket |
| 3 |
09116-08159 |
Bolt (8x55) |
| 4 |
01550-0845A |
BOLT |
| 5 |
01550-0885A |
BOLT |
| 6 |
09202-08006 |
Knock Pin (8x12) |
| 7 |
09202-08006 |
Knock Pin (8x12) |
| 8 |
51122-88L00 |
Mount Case Cover |
| 9 |
51123-88L00 |
Mount Case Cover Gasket |
| 10 |
01550-0825A |
BOLT |
| 11 |
09202-08006 |
Knock Pin (8x12) |
| 12 |
54137-88L00 |
Upper Mount Cover |
| 13 |
09116-10176 |
Bolt (10x44) |
| 14 |
51170-88L00 |
Water Indicator Bracket |
| 15 |
29116-93J00 |
Bolt (6x20) |
| 16 |
09282-17011 |
Oil Seal (16.5x28x6) |
| 17 |
54124-88L20 |
Upper Thrust Bracket |
| 18 |
54130-88L00 |
Upper Mount |
| 19 |
54166-95J02 |
Mount Bolt |
| 20 |
54114-90J10 |
Washer |
| 21 |
09159-12014 |
Nut (12x17) |
| 22 |
54114-90J10 |
Washer |
| 23 |
54121-88L00 |
Upper Thrust Front Mount |
| 24 |
54123-88L00 |
Upper Thrust Rear Mount |
| 45658 |
51110-88L10-0EP |
Engine Holder |
| 45659 |
51110-88L10-Y5S |
Engine Holder |
▶Fig. 405 - Drive Shaft Housing (18 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
09116-10176 |
Bolt (10x44) |
| 3 |
09202-08006 |
Knock Pin (8x12) |
| 6 |
09116-10176 |
Bolt (10x44) |
| 8 |
54151-88L00 |
Lower Thrust Mount |
| 9 |
54160-88L10 |
Lower Mount |
| 10 |
54167-87L01 |
Lower Side Mount |
| 11 |
54180-88L01 |
DAMPER,FORWARD |
| 12 |
54166-95J02 |
Mount Bolt |
| 13 |
09159-12014 |
Nut (12x17) |
| 14 |
54114-90J10 |
Washer |
| 45658 |
52111-88L10-0EP |
Drive Shaft Housing (L) |
| 45659 |
52111-88L10-Y5S |
Drive Shaft Housing (L) (NLA) |
| 45748 |
54221-88L20-0EP |
Lower Mount Stbd Cover |
| 45749 |
54221-88L20-Y5S |
Lower Mount Stbd Cover |
| 45778 |
54231-88L10-0EP |
Lower Mount Port Cover |
| 45779 |
54231-88L10-Y5S |
Lower Mount Port Cover |
| 45839 |
54211-87J30-0EP |
Lower Mount Bracket |
| 45840 |
54211-87J30-Y5S |
Lower Mount Bracket |
▶Fig. 407 - Gear Case (29 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
09263-22039 |
Bearing (22x30x30) |
| 3 |
09265-30004 |
Bearing (30x62x17.25) |
| 4 |
55125-95500 |
Trim Tab Zinc Anode |
| 5 |
09117-08109 |
Bolt (8x16) |
| 6 |
09248-10008 |
Drain Plug |
| 7 |
09168-10022 |
Drain Plug Gasket |
| 8 |
09116-08131 |
Bolt (8x45) |
| 10 |
58120-88L01 |
Propeller Bushing |
| 11 |
57632-95320 |
Propeller Stopper |
| 12 |
57633-94301 |
Propeller Nut Spacer |
| 13 |
09141-18005 |
Nut (18mm) |
| 14 |
09204-03003 |
Prop Nut Cotter Pin |
| 15 |
09160-18028 |
Washer (18.5x31x1.0) |
| 16 |
57630-94301 |
Propeller Hardware Kit DT40/DT55/DT65/
DF40/DF50/DF60A |
| 17 |
55181-95200 |
Flush Hose Attachment |
| 18 |
55300-95500 |
Zinc Anode |
| 19 |
55321-87J11 |
Magnesium Anode |
| 20 |
25700-88L03 |
Gear Case Seal Kit DT40c - DF40 / DF50 / 60A |
| 45658 |
55100-87J50-0EP |
Gear Case Housing |
| 45659 |
55100-87J50-Y5S |
Gear Case Housing |
| 45901 |
58100-88L03-019 |
S900 Propeller 3x11-1/2x9 * |
| 45902 |
58100-88LD0-019 |
S1000 Propeller 3x11-1/2x10 |
| 45903 |
58100-88LE0-019 |
S1100 Propeller 3x11-1/2x11 |
| 45904 |
58100-88LA0-019 |
S1200 Propeller 3x11-5/8x12 |
| 45905 |
58100-88LB0-019 |
S1301 Propeller 3x11-1/2x13 |
| 45906 |
58100-88LQ0-019 |
S1400 Propeller 3x11-3/8x14 |
| 45907 |
58100-88LR0-019 |
15P DF40A/50A/6 |
| 45908 |
58100-88L72-019 |
S1600 Propeller 3x11-1/8x16 |
| 45909 |
58100-88LF0-019 |
S1700 Propeller 3x11x17 |
▶Fig. 410 - Side Cover (28 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
61112-88L10 |
Side Cover Rubber |
| 2 |
61134-88L10 |
Side Cover Seal |
| 5 |
09139-06249 |
SCREW |
| 6 |
61151-88L00 |
Side Cover Cushion |
| 8 |
09116-08174 |
Bolt (8x38) |
| 9 |
09160-08039 |
Washer (8.5x19x2.3) |
| 10 |
09320-11023 |
CUSHION,FRONT P |
| 11 |
61412-88L00 |
Front Panel Hook |
| 12 |
03542-05169 |
SCREW |
| 13 |
61632-93J00 |
Engine Cover Hook Shaft |
| 14 |
61641-88L00 |
Engine Cover Hook |
| 15 |
09116-06127 |
Bolt (6x12) |
| 16 |
61633-88L00 |
Rear Hook Lever |
| 17 |
09160-13014 |
Washer (13.2x25x1.0) |
| 18 |
09164-14008 |
Wave Washer |
| 19 |
09202-04022 |
Hook Lever Pin |
| 20 |
09306-13007 |
Bushing |
| 21 |
09352-50901-600 |
Hose (5x9x600) |
| 22 |
61673-93J11 |
Hook Lever Latch |
| 23 |
09116-05010 |
Bolt (5x12) |
| 24 |
61124-88L11 |
Remocon Cable Grommet |
| 25 |
09407-25402 |
Clamp (L:248) |
| 45717 |
61811-88L20-0EP |
Starboard Side Cover |
| 45718 |
61811-88L20-Y5S |
Starboard Side Cover |
| 45748 |
61821-88L20-0EP |
Port Side Cover |
| 45749 |
61821-88L20-Y5S |
Port Side Cover |
| 45839 |
61831-88L10-0EP |
Front Panel |
| 45840 |
61831-88L10-Y5S |
Front Panel |
▶Fig. 420 - Engine Cover (26 parts)
| Ref |
OEM Part # |
Part Name |
| 3 |
61438-88L01 |
Tilt Up Handle Seal No 1 |
| 4 |
61439-88L01 |
Tilt Up Handle Seal No 2 |
| 5 |
03542-06169 |
SCREW |
| 6 |
61476-88L00 |
Air Vent Seal |
| 7 |
61610-95J00 |
Rear Fastener |
| 8 |
09159-06084 |
Nut (NLA) |
| 11 |
68111-18G20 |
Emblem Mark 'S' |
| 14 |
61458-90J01 |
Engine Cover Label |
| 15 |
61471-98J00 |
Lean Burn Decal |
| 16 |
09800-81812 |
Tool Set |
| 17 |
18210-88L00 |
Starter Knob Assembly |
| 18 |
68110-88L00 |
Weather Cover (NLA) |
| 19 |
99011-88L50-03B |
Owners Manual DF40A/DF50A/DF60A S/N 610001~ |
| 20 |
17917-87L00 |
Water Flush Connector |
| 45658 |
61400-88805-0EP |
Engine Cover Set |
| 45659 |
61400-88811-Y5S |
Engine Cover Set |
| 45670 |
61435-88L02 |
Emblem Mark (40) |
| 45689 |
61431-88L10-0EP |
Tilt Up Handle |
| 45690 |
61431-88L10-Y5S |
Tilt Up Handle |
| 45701 |
61435-88L30 |
Emblem Mark (40) |
| 45901 |
61443-88L02 |
Starboard Engine Cover Stripe |
| 45902 |
61443-88L10 |
Starboard Engine Cover Stripe |
| 45931 |
61453-88L02 |
Port Engine Cover Stripe |
| 45932 |
61453-88L10 |
Port Engine Cover Stripe |
| 45992 |
61435-88L02 |
Emblem Mark (40) |
| 45993 |
61435-88L30 |
Emblem Mark (40) |
▶Fig. 430 - Fuel Hose (9 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
65700-88L06 |
Fuel Hose |
| 2 |
65750-95501 |
Fuel Hose Connector (13mm) |
| 3 |
65770-90J04 |
Squeeze Pump |
| 4 |
61188-88L00 |
Fuel Hose Grommet |
| 5 |
09251-07003 |
Cap |
| 6 |
09367-08001 |
Hose Joint |
| 7 |
09401-11423 |
Clip |
| 8 |
09409-05312-6GS |
Clip |
| 9 |
65770-90J04 |
Squeeze Pump |
▶Fig. 442 - Drag Link (6 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
41161-94400 |
Steering Cable Seal |
| 2 |
67701-87J11 |
Drag Link Assembly |
| 3 |
67721-99E00 |
Drag Link Spacer |
| 4 |
67725-99E00 |
Drag Link Bolt |
| 5 |
67726-99E00 |
Lock Nut |
| 6 |
67728-99E00 |
Washer |
▶Fig. 502 - Opt: Meter (44 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
09471-12108 |
Bulb (12v 1.7w) |
| 4 |
09471-12028 |
Bulb (12v, 3.4w) |
| 5 |
34191-92E00 |
Water Pressure Tubing |
| 6 |
09407-14407 |
Clamp (L:140) |
| 7 |
36615-96300 |
Resin Terminal |
| 9 |
09471-12103 |
Bulb (12v, 3.4w) |
| 11 |
34310-92E00 |
Fuel Gauge Lead (NLA) |
| 12 |
34360-92E00 |
Adapter Harness (NLA) |
| 13 |
09471-12103 |
Bulb (12v, 3.4w) |
| 15 |
09471-12103 |
Bulb (12v, 3.4w) |
| 17 |
34191-92E00 |
Water Pressure Tubing |
| 18 |
09407-14407 |
Clamp (L:140) |
| 19 |
09471-12103 |
Bulb (12v, 3.4w) |
| 21 |
09471-12077 |
Bulb (12v, 1.7w) |
| 23 |
09471-12077 |
Bulb (12v, 1.7w) |
| 24 |
34190-95500 |
Speedometer Sensor (NLA) |
| 25 |
03112-06303 |
Screw (NLA) |
| 26 |
34190-87D00 |
Speedometer Sensor |
| 27 |
990C0-88108 |
25' Extension cable |
| 28 |
990C0-88112 |
SMIS Power Cable |
| 29 |
36663-98J00 |
Active Hub Power Harness Assy (NLA) |
| 30 |
09481-05501 |
5 Amp Fuse |
| 31 |
36663-98J10 |
Active Hub Power Harness Assy |
| 32 |
09481-05501 |
5 Amp Fuse |
| 33 |
990C0-88113 |
Terminating Resistor 120 ohm Female |
| 34 |
990C0-88114 |
Terminating Resistor 120 ohm Male |
| 45658 |
34800-93J02 |
Black Trim Gauge |
| 45659 |
34800-93J13 |
White Trim Gauge |
| 45671 |
34500-93J02 |
Black Hour Meter |
| 45673 |
34650-93J20 |
Black Water Pressure Gauge* |
| 45677 |
34200-93J02 |
Black Tachometer w/Monitor Function |
| 45679 |
34200-93J43 |
Black Tachometer w/Troll Mode Scale |
| 45702 |
34500-93J13 |
White Hour Meter |
| 45704 |
34650-93J33 |
White Water Pressure Gauge |
| 45708 |
34200-93J14 |
Tachometer w/Monitor - White |
| 45710 |
34200-93J54 |
White Tachometer w/Troll Mode Scale |
| 45717 |
34100-93J00 |
Black Speedometer 0-80 MPH |
| 45718 |
34100-93J00 |
Black Speedometer 0-80 MPH |
| 45719 |
34100-93J22 |
Black Speedometer 0-50 MPH |
| 45720 |
34100-93J33 |
White Speedometer 0-50 MPH |
| 45870 |
34600-93J02 |
Black Voltmeter |
| 45871 |
34600-93J13 |
White Voltmeter |
| 45931 |
34300-93J02 |
Black Fuel Gauge |
| 45932 |
34300-93J13 |
White Fuel Gauge |
▶Fig. 507 - Opt: Water Pressure Gauge Sub Kit (7 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
34660-90J04 |
Water Pressure Gauge Install Kit |
| 2 |
09352-50006-600 |
Hose (5x9x600) |
| 3 |
09352-50006-600 |
Hose (5x9x600) |
| 4 |
09367-06006 |
3 Way |
| 5 |
09401-08413 |
Clip |
| 6 |
18498-99EA0 |
Protector (L:80) (NLA) |
| 7 |
09407-25402 |
Clamp (L:248) |
▶Fig. 521 - Opt: Harness (10 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
36620-93J31 |
Replaced by 36620-93J32 |
| 3 |
38500-93J00 |
Warning Buzzer* |
| 5 |
09481-10501 |
10 Amp Fuse |
| 6 |
36990-87D00 |
Terminal & Sleeve Set |
| 7 |
36682-92E00 |
Wire Harness |
| 45658 |
36620-93J12 |
MAIN HARNESS EXT 6.5' |
| 45659 |
36620-93J42 |
HARNESS EXT 10' |
| 45748 |
36620-93J04 |
21' Main Wiring Harness |
| 45749 |
36620-93J54 |
16' Main Wiring Harness |
| 45750 |
36620-93J64 |
26' Main Wiring Harness |
▶Fig. 530 - Opt: Switch (53 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
37100-96J01 |
Ignition Switch Panel Assembly |
| 2 |
37110-93J02 |
Ignition Switch Assembly |
| 4 |
37143-99E01 |
Key Cap |
| 5 |
37149-93J00 |
Cylinder Body Cap |
| 6 |
37139-99E00 |
Ignition Switch Panel |
| 7 |
38500-93J90 |
Warning Buzzer |
| 8 |
09407-14403 |
Clamp (L:125) |
| 9 |
37803-93J06 |
Emergency Stop Switch Panel Assembly |
| 10 |
37820-93J05 |
Emergency Stop Switch Assembly |
| 11 |
37823-92E02 |
Stop Switch Lanyard |
| 12 |
37826-92J00 |
Nut |
| 13 |
37825-99E00 |
Emergency Switch Panel |
| 14 |
03122-05165 |
SCREW |
| 15 |
37805-93J00 |
PTT Switch Assembly |
| 16 |
37855-99E00 |
PTT Switch Panel |
| 17 |
37210-93J00 |
Lighting Switch Set (NLA) |
| 18 |
37212-93J00 |
Lighting Switch Panel (NLA) |
| 22 |
37143-99E01 |
Key Cap |
| 23 |
37149-93J00 |
Cylinder Body Cap |
| 24 |
37139-99E20 |
Ignition Switch Panel |
| 25 |
37820-93J05 |
Emergency Stop Switch Assembly |
| 26 |
37823-92E02 |
Stop Switch Lanyard |
| 27 |
37826-92J00 |
Nut |
| 28 |
03121-0516A |
SCREW |
| 29 |
38500-93J90 |
Warning Buzzer |
| 30 |
09407-14403 |
Clamp (L:125) |
| 31 |
37860-87L00 |
Trolling Mode Control Switch Assembly |
| 32 |
37862-87L00 |
Trolling Switch Panel |
| 33 |
09131-05004 |
Screw (5x16) |
| 45678 |
37141-99E00 |
(931) Ignition Key |
| 45709 |
37141-99E10 |
(932) Ignition Key |
| 45717 |
37141-99E00 |
(931) Ignition Key |
| 45718 |
37141-99E10 |
(932) Ignition Key |
| 45719 |
37141-99E20 |
(933) Ignition Key |
| 45720 |
37141-99E30 |
(934) Ignition Key |
| 45721 |
37141-99E40 |
(935) Ignition Key |
| 45722 |
37141-99E50 |
(936) Ignition Key |
| 45723 |
37141-99E60 |
(937) Ignition Key |
| 45724 |
37141-99E70 |
(938) Ignition Key |
| 45725 |
37141-99E80 |
(939) Ignition Key |
| 45726 |
37141-99E90 |
(940) Ignition Key |
| 45727 |
37141-99EA0 |
(941) Ignition Key |
| 45728 |
37141-99EB0 |
(942) Ignition Key |
| 45737 |
37141-99E20 |
(933) Ignition Key |
| 45768 |
37141-99E30 |
(934) Ignition Key |
| 45798 |
37141-99E40 |
(935) Ignition Key |
| 45829 |
37141-99E50 |
(936) Ignition Key |
| 45859 |
37141-99E60 |
(937) Ignition Key |
| 45890 |
37141-99E70 |
(938) Ignition Key |
| 45921 |
37141-99E80 |
(939) Ignition Key |
| 45951 |
37141-99E90 |
(940) Ignition Key |
| 45982 |
37141-99EA0 |
(941) Ignition Key |
| 46012 |
37141-99EB0 |
(942) Ignition Key |
▶Fig. 544 - 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. 545 - Opt: Top Mount Single (2) (45 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 |
67233-92E00 |
Spring (NLA) |
| 27 |
67235-92E00 |
Shift Lock Plate (NLA) |
| 28 |
67232-95620 |
Bushing (NLA) |
| 29 |
67269-92E00 |
Bracket (NLA) |
| 30 |
67296-88D10 |
Screw (5x16) |
| 31 |
09140-06020 |
Nut (6mm) |
| 32 |
67236-92E00 |
Roller (NLA) |
| 33 |
67237-92E01 |
Spring (NLA) |
| 34 |
67238-92E00 |
Drive Gear (NLA) |
| 35 |
67239-92E00 |
Pin |
| 36 |
67246-92E00 |
Drive Shaft |
| 37 |
67291-92E10 |
Snap Ring (NLA) |
| 38 |
67253-92E10 |
Washer |
| 39 |
67252-92E10 |
Bushing (NLA) |
| 40 |
67253-95600 |
Washer (NLA) |
| 41 |
67231-92E00 |
Shift Gear |
| 42 |
67232-95600 |
Bushing |
| 43 |
67241-92E10 |
Free Accel Rod (NLA) |
| 44 |
67243-92E00 |
Grommet (NLA) |
| 45 |
67239-92E10 |
Shift Pin Plate |
▶Fig. 570 - Opt: Tiller Handle (102 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
63002-88L21-0EP |
Tiller Handle Kit |
| 2 |
21110-88L00 |
Shift Lever (NLA) |
| 3 |
23230-88L00 |
Shift Cable |
| 4 |
36620-88L11 |
Handle Wire Harness |
| 5 |
37110-87L01 |
Ignition Switch Assembly |
| 7 |
37141-99E00 |
(931) Ignition Key |
| 8 |
37149-93J00 |
Cylinder Body Cap |
| 9 |
37820-87L02 |
Emergency Switch Assembly |
| 10 |
37823-92E02 |
Stop Switch Lanyard |
| 11 |
37826-92J00 |
Nut |
| 12 |
38500-93J90 |
Warning Buzzer |
| 13 |
37850-87L01 |
PTT Switch Assembly |
| 14 |
37852-87J00 |
Trim Switch Cap |
| 15 |
63121-88L00 |
Under Cover |
| 16 |
63210-88L00 |
Handle Grip |
| 17 |
63221-88L00 |
Throttle Shaft (NLA) |
| 18 |
63223-92D00 |
Handle Rod Stopper |
| 19 |
63225-88L00 |
Handle Rod Bushing (NLA) |
| 20 |
63227-93200 |
Handle Rod Pin |
| 21 |
63235-88L00 |
Throttle Shaft Plate |
| 22 |
63246-88L00 |
Throttle Adjust Stopper (NLA) |
| 23 |
63250-88L00 |
Throttle Arm Assembly (NLA) |
| 24 |
63251-87J00 |
Screw (6x12) |
| 25 |
63260-88L00 |
Shift Gear Assembly |
| 26 |
63272-87J00 |
Ball Guide Plate |
| 27 |
63273-87J00 |
Ball (NLA) |
| 28 |
63262-87J00 |
Shift Lever Bushing |
| 29 |
63271-87J00 |
Lock Plate |
| 30 |
63248-99J00 |
Throttle Adjuster Notch Plate |
| 31 |
63261-87J00 |
Shift Gear Bushing |
| 32 |
63274-87J00 |
E Ring (NLA) |
| 33 |
63610-88L00 |
Throttle Cable |
| 34 |
37853-88L90 |
PTT Switch Lead Grommet |
| 35 |
63626-88L00 |
Cable Grommet (NLA) |
| 36 |
67292-87J00 |
E Ring |
| 37 |
09126-06015 |
Screw (6x23) |
| 38 |
09163-06001 |
Lock Washer (6.4x12x0.5) |
| 39 |
09440-12027 |
Spring |
| 40 |
21112-88L00 |
Shift Lever Bolt |
| 41 |
09125-05047 |
Screw (5x14) |
| 42 |
63611-88L00 |
Clamp Bracket Bolt (NLA) |
| 43 |
63612-87J00 |
Clamp Bracket |
| 44 |
34200-87L00 |
Tachometer w/Monitor |
| 45 |
36617-88L90 |
Main Harness Clamp Bracket |
| 46 |
37112-88L90 |
Ignition Switch Label (NLA) |
| 47 |
37835-91J00-YAY |
Stop Label |
| 48 |
37851-88L90 |
PTT Switch Base |
| 49 |
37852-88L90 |
Guide Harness |
| 50 |
37861-87L10 |
Troll Mode Control Switch |
| 51 |
37864-88L90 |
Troll Mode Label (NLA) |
| 52 |
63244-99J00 |
Throttle Adjuster Knob |
| 53 |
63245-99J00 |
Throttle Adjuster Bushing |
| 54 |
63612-88L10 |
Clamp Shift Bracket (NLA) |
| 55 |
09260-10006 |
Ball |
| 56 |
19120-88L11 |
Throttle Lever |
| 57 |
21131-88L00 |
Clutch Shift Mark |
| 58 |
43761-88L01-0EP |
Tiller Handle Bracket |
| 59 |
43762-88L00 |
Tiller Handle Pivot Bolt |
| 60 |
43768-88L00 |
Tiller Handle Spacer |
| 61 |
09116-08137 |
Bolt (8x22) |
| 62 |
09159-12014 |
Nut (12x17) |
| 63 |
09160-12066 |
Washer (12.5x22x2.5) |
| 64 |
09160-12124 |
Washer (12.5x32x1.5) |
| 65 |
63115-88L01 |
Tiller Handle Bushing |
| 66 |
09164-13010 |
Washer |
| 67 |
63215-93110 |
Handle Grip Mark |
| 68 |
09116-10150 |
Bolt (10x55) |
| 69 |
63132-88L00 |
Tiller Handle Stopper |
| 70 |
63251-88L90 |
Bolt |
| 71 |
37855-88L90 |
Throttle Grip Screw |
| 72 |
37854-88L90 |
Throttle Grip Washer |
| 73 |
63258-88L00 |
Washer |
| 74 |
09440-06037 |
Spring |
| 75 |
03522-05169 |
Screw |
| 76 |
63247-99J00 |
Throttle Adjuster Knob Plate |
| 77 |
63111-88L00-0EP |
Tiller Handle Housing (NLA) |
| 78 |
33834-88L00 |
Protector |
| 79 |
65793-88L00 |
Fuel Hose Holder |
| 80 |
09116-06237 |
Bolt (6x15) |
| 81 |
22511-99011 |
Grease Nipple |
| 82 |
43411-88L00 |
Steering Adjuster |
| 83 |
43415-88L00 |
Steering Adjuster Plate |
| 84 |
43512-88L00 |
Steering Adjust Thread Shaft |
| 85 |
43513-88L00 |
Steering Adjust Bolt |
| 86 |
43514-88L00 |
Steering Adjust Friction Plate |
| 87 |
43515-88L00 |
Steering Adjust Friction Washer Plate |
| 88 |
43516-88L00 |
Steering Adjust Friction Washer |
| 89 |
43517-88L00 |
Steering Adjuster Spacer |
| 90 |
09159-08059 |
Nut |
| 91 |
09161-08011 |
Washer (8.2x18x1.2) |
| 45809 |
37141-99E00 |
(931) Ignition Key |
| 45810 |
37141-99E10 |
(932) Ignition Key |
| 45811 |
37141-99E20 |
(933) Ignition Key |
| 45812 |
37141-99E30 |
(934) Ignition Key |
| 45813 |
37141-99E40 |
(935) Ignition Key |
| 45814 |
37141-99E50 |
(936) Ignition Key |
| 45815 |
37141-99E60 |
(937) Ignition Key |
| 45816 |
37141-99E70 |
(938) Ignition Key |
| 45817 |
37141-99E80 |
(939) Ignition Key |
| 45818 |
37141-99E90 |
(940) Ignition Key |
| 45819 |
37141-99EA0 |
(941) Ignition Key |
| 45820 |
37141-99EB0 |
(942) Ignition Key |
▶Fig. 585 - Opt: Gasket Set (11 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11400-88872 |
Engine Gasket Set |
| 2 |
11141-88L00 |
Cylinder Head Gasket |
| 3 |
11189-88L00 |
Cylinder Head Cover Gasket |
| 4 |
11413-88L00 |
Upper Oil Seal Gasket |
| 5 |
14151-88L00 |
Exhaust Cover Gasket |
| 6 |
17472-96304 |
Water Pump Plate Gasket |
| 7 |
11433-88L00 |
Under Oil Seal Gasket |
| 8 |
11489-88L01 |
Oil Pan Gasket |
| 9 |
51211-88L00 |
Engine Holder Gasket |
| 10 |
51123-88L00 |
Mount Case Cover Gasket |
| 11 |
11552-88L00 |
Water Jacket Cover Gasket |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Suzuki DF 40ATL 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.
