🔎 Suzuki DF 40ATL2, DF 40ATLW2 Reference Library — Exploded parts diagrams (44 diagrams), specifications, common issues, and maintenance checklist.
The Suzuki DF 40ATL2, DF 40ATLW2 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 40ATL2, DF 40ATLW2:
-
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 40ATL2, DF 40ATLW2.
▶Fig. 111 - Cylinder Head (30 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 |
01550-0820C |
BOLT |
| 10 |
11119-87J00 |
Cylinder Head Bolt |
| 11 |
11141-88L00 |
Cylinder Head Gasket |
| 12 |
01550-08457 |
BOLT |
| 13 |
04211-13189 |
PIN |
| 14 |
11382-93J00 |
Oil Filler Cap |
| 15 |
09280-26006 |
O-Ring |
| 16 |
11170-88L10 |
Cylinder Head Cover |
| 17 |
11189-88L00 |
Cylinder Head Cover Gasket |
| 18 |
01547-0625C |
Bolt |
| 19 |
01547-0645C |
Bolt |
| 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 |
01550-0612C |
BOLT |
| 26 |
11194-88L10 |
Fuel Hose Guard |
| 27 |
01550-0616C |
BOLT |
| 28 |
09482-00446 |
NGK DCPR6E Spark Plug |
| 29 |
11115-73G01-001 |
Valve Guide |
| 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 |
01550-0820C |
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 |
12140-88L01 |
Piston Ring Set |
| 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 |
12140-88L01-050 |
Piston Ring Set (OS:0.50) |
| 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 |
12921-87J11 |
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 (16 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 |
01550-0830C |
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 |
01547-0616C |
BOLT,HARNESS B |
| 13 |
14141-88L10 |
COVER,EXHAUST |
| 14 |
14151-88L00 |
Exhaust Cover Gasket |
| 15 |
01550-0620C |
BOLT |
| 16 |
09160-06094 |
Washer (6.5x15x1.0) |
▶Fig. 136 - Ring Gear Cover (12 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11510-88L00 |
Ring Gear Cover |
| 2 |
01550-0630C |
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 |
01550-0625C |
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 (38 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 |
15610-88L01 |
CASE ASSY,VPR S |
| 26 |
15620-88L00 |
VST Upper Case |
| 27 |
01550-0630C |
BOLT |
| 28 |
09169-06075 |
Washer |
| 29 |
09160-06084 |
Washer (6.5x18x1.6) |
| 30 |
09320-09059 |
Cushion |
| 31 |
09352-50003-770 |
Hose (5x8.2x770) |
| 32 |
09401-08412 |
Clip |
| 33 |
18498-88L10 |
Evap Hose Protector (L:730) |
| 34 |
09320-08517 |
CUSHION,CABLE H |
| 35 |
09408-00043 |
Clamp |
| 36 |
09408-00121 |
Clamp (NLA) |
| 37 |
09408-00145 |
Clip |
| 38 |
55127-87D00 |
Hose Union |
▶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 |
01550-0625C |
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 |
01550-0616C |
BOLT |
| 10 |
15191-88L20 |
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 |
01550-0612C |
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 |
01550-0620C |
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 (12 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
13300-88L01 |
Throttle Body Assembly |
| 2 |
13353-99E00 |
Adjuster Assembly |
| 3 |
13315-88L00 |
Throttle Body Bracket (NLA) |
| 4 |
01550-0645C |
Bolt |
| 5 |
01550-0616C |
BOLT |
| 6 |
01550-0820C |
BOLT |
| 7 |
13510-88L00 |
Throttle Rod |
| 8 |
19120-88L01 |
Throttle Lever |
| 9 |
19131-95502 |
Connector |
| 10 |
09140-05005 |
Nut |
| 11 |
09160-06047 |
Washer (6.2x20x2) |
| 12 |
01550-0640C |
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 |
01550-0612C |
BOLT |
| 45689 |
11501-88L01-YAY |
Oil Pan |
| 45690 |
11501-88L01-Y5S |
Oil Pan (NLA) |
| 45809 |
11551-88L00-YAY |
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 |
01550-0616C |
BOLT |
| 4 |
01550-0630C |
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 |
01550-0612C |
BOLT |
| 15 |
23311-95J00 |
Clutch Rod Connector |
| 16 |
67341-88L01 |
Remocon Cable Holder |
| 17 |
01550-0616C |
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-YAY |
Propeller Shaft Bearing Housing |
| 45683 |
56130-87J12-YAY |
HOUSING,DRIVE S |
| 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 (19 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
31100-89L00 |
Starter Motor Assembly |
| 2 |
31150-98L00 |
Gear Case |
| 3 |
31170-89L00 |
Rear Housing |
| 4 |
31173-98L00 |
Brush Holder Assembly |
| 5 |
31191-63J00 |
Lever Assembly |
| 6 |
31220-89L00 |
Switch Assembly |
| 7 |
31311-63J00 |
Armature |
| 8 |
31192-92J00 |
Screw Set |
| 9 |
31261-75F10 |
Through Bolt |
| 10 |
31340-89L00 |
Starter Clutch Set |
| 11 |
31313-86030 |
Stopper Set |
| 12 |
31320-89L00 |
Pinion |
| 13 |
31341-89L00 |
Pinion Shaft |
| 14 |
31343-63J00 |
Internal Gear |
| 15 |
31344-63J00 |
Planetary Gear |
| 16 |
31912-88L00 |
Starter Motor Band |
| 17 |
31918-92J01 |
Lower Damper |
| 18 |
01550-06167 |
BOLT |
| 19 |
01550-0830C |
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 |
01550-0616C |
BOLT |
| 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 |
01550-0625C |
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 |
01550-0620C |
BOLT |
▶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 |
36610-88LM0 |
Wiring Harness Assembly |
| 4 |
33634-96J00 |
Service Connector Cap |
| 5 |
36668-87L00 |
Service Connector Cap |
| 6 |
09320-08510 |
Cushion (8.5x20x8) |
| 7 |
36737-98L00 |
Fuse Puller |
| 8 |
36721-98L00 |
Upper Cover O-Ring |
| 9 |
36738-98L00 |
Fuse Case Upper Cover |
| 10 |
38860-76F01 |
Relay |
| 11 |
38860-76F01 |
Relay |
| 12 |
09481-15504 |
15 Amp Fuse |
| 13 |
09481-30504 |
30 Amp Fuse |
| 14 |
09481-30403 |
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 |
36617-93J10 |
Harness Bracket |
| 23 |
01550-0612C |
BOLT |
| 24 |
09407-18402 |
Clamp (L:165) |
| 25 |
36617-88L20 |
Harness Bracket |
▶Fig. 326 - PTT Switch/Engine Control Unit (14 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 |
33940-88LJ0 |
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 |
| 14 |
09407-14407 |
Clamp (L:140) |
▶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 |
09160-12128 |
Washer (12.5x35x3) |
| 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-YAY |
Starboard Clamp Bracket |
| 45659 |
41111-88L20-Y5S |
Starboard Clamp Bracket |
| 45689 |
41121-88L10-YAY |
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-YAY |
Swivel Bracket (L) |
| 45659 |
43111-88L21-Y5S |
Swivel Bracket (L) |
| 45748 |
43750-88L22-YAY |
Steering Bracket (L) |
| 45749 |
43750-88L22-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 |
09116-10181 |
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 |
09160-12110 |
Washer (12.5x22x3.0) |
| 23 |
54121-88L00 |
Upper Thrust Front Mount |
| 24 |
54123-88L00 |
Upper Thrust Rear Mount |
| 45658 |
51110-88L10-YAY |
Engine Holder |
| 45659 |
51110-88L10-Y5S |
Engine Holder |
▶Fig. 405 - Drive Shaft Housing (18 parts)
| Ref |
OEM Part # |
Part Name |
| 2 |
09116-10181 |
Bolt (10x44) |
| 3 |
09202-08006 |
Knock Pin (8x12) |
| 6 |
09116-10181 |
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 |
09160-12110 |
Washer (12.5x22x3.0) |
| 45658 |
52111-88L10-YAY |
Drive Shaft Housing (L) |
| 45659 |
52111-88L10-Y5S |
Drive Shaft Housing (L) (NLA) |
| 45748 |
54221-88L20-YAY |
Lower Mount Stbd Cover |
| 45749 |
54221-88L20-Y5S |
Lower Mount Stbd Cover |
| 45778 |
54231-88L10-YAY |
Lower Mount Port Cover |
| 45779 |
54231-88L10-Y5S |
Lower Mount Port Cover |
| 45839 |
54211-87J30-YAY |
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-YAY |
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-YAY |
Starboard Side Cover |
| 45718 |
61811-88L20-Y5S |
Starboard Side Cover |
| 45748 |
61821-88L20-YAY |
Port Side Cover |
| 45749 |
61821-88L20-Y5S |
Port Side Cover |
| 45839 |
61831-88L10-YAY |
Front Panel |
| 45840 |
61831-88L10-Y5S |
Front Panel |
▶Fig. 420 - Engine Cover (28 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 |
68111-88L10 |
Emblem Mark (S) |
| 12 |
61620-95J00 |
Rear Fastener Bracket |
| 14 |
09229-04018 |
Rivet |
| 15 |
09229-04005 |
Rivet |
| 18 |
61458-90J01 |
Engine Cover Label |
| 19 |
09800-81812 |
Tool Set |
| 20 |
18210-88L00 |
Starter Knob Assembly |
| 21 |
990C0-65024 |
DF40A / DF50A / DF60A Genuine Engine Cover |
| 22 |
99011-88L80-03B |
Owners Manual DF40A/DF50A/DF60A - 2019 |
| 23 |
17917-87L00 |
Water Flush Connector |
| 45658 |
61400-88821-YAY |
Engine Cover Set |
| 45659 |
61400-88831-Y5S |
Engine Cover Set |
| 45673 |
61422-88L30 |
Front Emblem Mark (40) |
| 45674 |
61435-88L60 |
Emblem Mark (40) |
| 45689 |
61431-88L10-YAY |
Tilt Up Handle |
| 45690 |
61431-88L10-Y5S |
Tilt Up Handle |
| 45704 |
61422-88L60 |
Front Emblem Mark (40) |
| 45705 |
61435-88L90 |
Emblem Mark (40) |
| 45901 |
61443-88L20 |
Starboard Engine Cover Stripe |
| 45902 |
61443-88L30 |
Starboard Engine Cover Stripe |
| 45931 |
61453-88L20 |
Port Engine Cover Stripe |
| 45932 |
61453-88L30 |
Port Engine Cover Stripe |
▶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. 501 - Opt: Meter (36 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 |
| 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 |
18498-99EA1 |
Protector (L:80) |
| 7 |
09407-25402 |
Clamp (L:248) |
▶Fig. 521 - Opt: Harness (11 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 |
| 8 |
36667-96L20 |
Gauge Extension Wire |
| 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) (25 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
67200-88L02 |
Single Binnacle Control Box |
| 2 |
67261-88L10 |
Grip No.2 |
| 3 |
67261-88L00 |
Grip No. 1 |
| 4 |
37850-88L00 |
PTT Switch Assembly |
| 5 |
67296-88L00 |
Screw |
| 6 |
67288-92E20 |
Washer |
| 7 |
67212-88L00 |
Cover Plug (Single) |
| 8 |
68111-88L00 |
Emblem Mark (S) |
| 9 |
67257-88L00 |
Lever Cap |
| 10 |
67281-88L00 |
Decal (Single) |
| 11 |
67296-92E60 |
Screw |
| 12 |
67288-92E60 |
Washer |
| 13 |
67253-92E00 |
Washer |
| 14 |
67275-95600 |
Cable End |
| 15 |
67273-95600 |
Spacer |
| 16 |
67271-88L10 |
Remocon Lever Lower Cover |
| 17 |
67211-88L00 |
Top Binnacle Cover (Single) |
| 18 |
67264-88L00 |
Lever Design Cover |
| 19 |
67264-88L10 |
Lever Plating Cover |
| 20 |
67251-88L00 |
Handle Lever |
| 21 |
67500-88L00 |
Single Binnacle Box Spacer |
| 22 |
09125-05135 |
Screw (5x65) |
| 23 |
09160-05029 |
Washer (5.5x10x0.8) |
| 24 |
09140-05005 |
Nut |
| 25 |
67273-88L00 |
Grommet (Single) |
▶Fig. 545 - Opt: Top Mount Single (2) (47 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 |
67272-88L00 |
Waterproof Seal |
| 7 |
67291-92E00 |
Snap Ring (NLA) |
| 8 |
67221-92E00 |
Shift Assembly (NLA) |
| 9 |
67224-92E00 |
Brake Arm Assembly (NLA) |
| 10 |
09140-06020 |
Nut (6mm) |
| 11 |
37721-88L01 |
Neutral Switch Assembly |
| 12 |
67236-92E00 |
Roller (NLA) |
| 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 |
67230-88L00 |
Shift Arm Assembly |
| 21 |
09125-05042 |
Screw (5x10) |
| 22 |
67234-88L00 |
Gear Case |
| 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 |
67237-92E01 |
Spring (NLA) |
| 29 |
67269-92E00 |
Bracket (NLA) |
| 30 |
67296-88D10 |
Screw (5x16) |
| 31 |
67238-88L00 |
Drive Gear |
| 32 |
67231-88L00 |
Shift Gear |
| 33 |
67232-88L00 |
Shift Gear Bushing |
| 34 |
67241-88L00 |
Free Accel Rod |
| 35 |
67239-92E00 |
Pin |
| 36 |
67246-88L00 |
Remocon Drive Shaft |
| 37 |
67291-92E10 |
Snap Ring (NLA) |
| 38 |
67243-92E00 |
Grommet (NLA) |
| 39 |
67252-88L00 |
Remocon Drive Shaft Bushing |
| 40 |
67253-88L00 |
Washer |
| 41 |
67239-92E10 |
Shift Pin Plate |
| 42 |
67274-88L00 |
Cover Base Flange (Single) |
| 43 |
67296-95610 |
Screw |
| 44 |
67296-92E30 |
Screw |
| 45 |
09160-05024 |
Washer (5.5x16x1.5) |
| 46 |
67287-92E00 |
Nut |
| 47 |
67273-88L00 |
Grommet (Single) |
▶Fig. 570 - Opt: Tiller Handle (102 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
63002-88L24-YAY |
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 |
37820-87L10 |
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 |
63121-88L10 |
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 |
37112-88L91 |
Ignition Switch Label |
| 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 |
37864-88L91 |
Troll Mode Label |
| 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-YAY |
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-YAY |
Tiller Handle Housing |
| 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 |
▶Fig. 600 - Opt: Multi Function Gauge (23 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
34000-96L49 |
Single Engine Mech Multi Function Gauge Kit |
| 2 |
34011-96L42 |
SMG4 Multi Function Gauge |
| 3 |
34112-96L00 |
Gauge Nut |
| 4 |
34193-96L00 |
Gauge Bezel |
| 5 |
34211-96L00 |
Multi-Function Gauge Sun Cover |
| 6 |
34825-96L00 |
Gauge Packing |
| 7 |
36661-96L30 |
Mechanical Engine Adapter |
| 8 |
36615-96300 |
Resin Terminal |
| 9 |
36001-88L00 |
Wire Set |
| 10 |
990C0-88104 |
2' Extension cable |
| 11 |
990C0-88112 |
SMIS Power Cable |
| 12 |
990C0-88110 |
T-Connector |
| 13 |
990C0-88113 |
Terminating Resistor 120 ohm Female |
| 14 |
990C0-88114 |
Terminating Resistor 120 ohm Male |
| 16 |
990C0-88104 |
2' Extension cable |
| 17 |
990C0-88105 |
6' Extension cable |
| 18 |
990C0-88107 |
15' Extension cable |
| 19 |
990C0-88108 |
25' Extension cable |
| 20 |
990C0-88122 |
GPS Receiver Module |
| 21 |
990C0-88112 |
SMIS Power Cable |
| 22 |
990C0-88113 |
Terminating Resistor 120 ohm Female |
| 23 |
990C0-88114 |
Terminating Resistor 120 ohm Male |
| 24 |
990C0-88110 |
T-Connector |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Suzuki DF 40ATL2, DF 40ATLW2 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.
