Suzuki DF 40TLK7 (2007) Parts & Diagrams

🔎 Suzuki DF 40TLK7 Reference Library — Exploded parts diagrams (47 diagrams), specifications, common issues, and maintenance checklist.

The Suzuki DF 40TLK7 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 40TLK7:

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 40TLK7.

▶Fig. 1 - Cylinder Head (27 parts)

Ref	OEM Part #	Part Name
1	11100-87J23	Cylinder Head
2	11115-73G01-001	Valve Guide
3	09206-08001	Knock Pin (8x11)
4	11128-87J00	Camshaft Housing Bolt (NLA)
5	11119-87J00	Cylinder Head Bolt
6	11141-87J02	Cylinder Head Gasket
7	11116-87J30	Cylinder Head Bolt
8	04211-13189	PIN
9	11170-87J00	Cylinder Head Cover (NLA)
10	11173-87J01	Breather Plate
11	11179-73G00	Spark Plug Hole Gasket
12	11189-87J00	Cylinder Head Cover Gasket
13	11382-99E00	Oil Filler Cap
14	09280-26006	O-Ring
15	11176-87J00	Breather Hose Jet (NLA)
16	11174-99800	Breather Hose Set
17	09408-00140	Clamp
18	09401-20409	Clip
19	01547-06457	BOLT 6X45
20	01547-06257	BOLT 6X25
21	02142-0612A	SCREW
22	09482-00446	NGK DCPR6E Spark Plug
23	11261-93J00	Protection Anode Cover
24	09280-22019	O-Ring
25	55321-87J01	Aluminum Anode
26	09103-06281	Bolt (6x14)
27	01550-08207	BOLT

▶Fig. 10 - Silencer (22 parts)

Ref	OEM Part #	Part Name
1	13710-87J10	Flame Arrester (NLA)
2	13810-87J20	Silencer (NLA)
3	13816-87J00	Silencer Band
4	13851-87J10	Silencer Seal (NLA)
5	13852-87J00	Silencer Seal Plate
6	18145-84380	IAC Valve Silencer
7	18146-87J00	IAC Silencer Clamp
8	09169-06075	Washer
9	09320-08013	Grommet
10	09320-09059	Cushion
12	09116-06202	Bolt w/Washer (6x25)
13	18117-84380	IAC Valve
14	09169-06081	Washer
15	08316-10067	Nut
16	09352-70113-600	Hose (7x11x600)
17	44421-12FR0	Hose (6.5x11.5x600)
18	09401-11423	Clip
19	18141-87J00	ISC Hose (NLA)
20	09251-07003	Cap
21	09408-00105	Clamp
22	09403-13413	CLAMP
23	01550-06127	BOLT

▶Fig. 12 - Fuel Vapor Separator (37 parts)

Ref	OEM Part #	Part Name
1	15600-87J13	Fuel Vapor Separator Assembly
2	15650-99E00	Float
3	15654-99E00	Float Pin
4	13370-99E00	Needle Valve Assembly
5	02112-0408A	SCREW
6	13373-39110	Needle Valve Plate
7	15683-87J00	Drain Hose (L:120)
8	15627-99E00	Screw (L:70)
9	15628-99E00	Screw (L:15)
10	15629-99E10	Drain Screw
11	15641-99E01	Fuel Pump Filter
12	02112-0510A	SCREW
13	15626-99E00	O-Ring
14	15200-87J10	Fuel Pump Assembly
15	15760-87J00	Fuel Pressure Regulator
16	15642-87J00	Plate
16A	15612-99E01	Vapor Separator Cover
16B	15613-99E00	O-Ring
16C	15614-88L00	Screw
17	15410-98500	Fuel Filter
18	15661-87J01	Evaporation Hose Jet
19	18498-87JC1	Protector (L:450)
20	18498-87JC1	Protector (L:450)
21	18498-87JC1	Protector (L:450)
22	09320-20008	Cushion
23	44420-44AR0	Hose (5x8.2x600)
24	44420-44AR0	Hose (5x8.2x600)
25	44420-44AR0	Hose (5x8.2x600)
26	09359-40701-600	Hose (4x7x600)
27	09367-06002	3 Way
28	09401-08412	Clip
29	09408-00189	Clamp (NLA)
31	09320-09059	Cushion
33	09169-06075	Washer
34	09116-06202	Bolt w/Washer (6x25)
35	09404-06435	Clamp (L:135)
36	15660-87J00	Evaporation Hose Set

▶Fig. 13 - Fuel Injector (21 parts)

Ref	OEM Part #	Part Name
1	15410-87J00	H/P Fuel Filter
2	15710-87J00	Fuel Injector
2A	15761-94900	Upper O-Ring
2B	15771-94900	Lower O-Ring
3	15741-87J00	Fuel Injector Stopper
4	15751-94900	Fuel Injector Cushion
5	15830-87J10	Fuel Main Joint (NLA)
6	09160-06084	Washer (6.5x18x1.6)
7	09169-06062	Washer (6.3x17x1.6)
8	09320-08501	Cushion
9	18498-99E21	Hose Protector (L:450)
10	18498-99E21	Hose Protector (L:450)
11	15681-87J00	Fuel Hose
12	09356-75137-600	Fuel Hose (L:600)
13	09356-75137-600	Fuel Hose (L:600)
14	09401-11425	Clip
15	09403-18410	Clamp (NLA)
16	01500-06257	BOLT
17	01550-06127	BOLT
18	01550-08167	BOLT
19	07120-06167	BOLT

▶Fig. 14 - Fuel Pump (21 parts)

Ref	OEM Part #	Part Name
1	15100-87J03	Fuel Pump Assembly
2	15170-99E1V	Fuel Pump Diaphragm Set
3	15251-93E01	Screw
7	18498-99E11	Hose Protector (L:610)
8	18498-99E11	Hose Protector (L:610)
10	09280-26005	O-Ring
12	15682-87J10	Fuel Hose
13	09355-70129-600	Fuel Hose (7x12x600)
14	09401-11423	Clip
15	01550-06127	BOLT
16	01550-06257	BOLT
17	15191-87J11	Fuel Hose
18	18498-99E11	Hose Protector (L:610)
19	18498-99E11	Hose Protector (L:610)
20	09403-13413	CLAMP
21	29404-93J11	Clamp (L:65)
22	15410-87J30	Fuel Filter
23	15419-87J00	Fuel Filter Cap
24	09401-11423	Clip
25	15421-87J30	Fuel Filter Bracket
26	15422-96J01	Fuel Filter Clamp

▶Fig. 15 - Water Pump (24 parts)

Ref	OEM Part #	Part Name
1	17410-92L00	Water Pump Case
3	17461-96312	Water Pump Impeller
4	17471-94401	Water Pump Plate
5	17472-96304	Water Pump Plate Gasket
7	17563-94400	Water Tube Grommet
8	17565-94400	Water Tube Grommet
9	17566-94401	Water Tube Grommet
10	17631-96320	Water Filter
12	09108-06060	Stud Bolt (6x18)
13	09108-06061	Stud Bolt (6x35)
14	09125-05046	Screw (5x12)
15	29141-93J00	Nut (6mm)
16	29162-93J00	Lock Washer
17	09420-04006	Impeller Key
18	03142-04309	SCREW 4 X 30
19	09116-06094	Bolt (6x15)
20	56130-94431-0EP	Drive Shaft Bearing Housing
21	09263-25025	Bearing (25x33x15)
22	09282-17005	Oil Seal (16x32x6)
23	17400-96354	Water Pump Repair Kit DF25-50 DT20-40c
45809	17560-87J11	Water Tube (S) (NLA)
45810	17560-87J01	Water Tube (L)
45962	17635-87E00	Sub Water Filter
45963	17635-87E10	Gear Case Plate

▶Fig. 16 - Thermostat (20 parts)

Ref	OEM Part #	Part Name
1	11196-87J10	Water Return Hose
2	17615-87J00	Water Pressure Valve Cover
3	17616-87J00	Pressure Valve Cover Gasket
4	17621-87J00	Water Pressure Valve Case (NLA)
5	17660-99E01	Water Pressure Valve
7	17681-87J01	Thermostat Cover
8	17685-87D10	Thermostat Gasket
9	09116-06175	Bolt (6x42)
10	09352-50006-600	Hose (5x9x600)
12	09352-50006-600	Hose (5x9x600)
13	09352-50006-600	Hose (5x9x600)
14	09367-06002	3 Way
15	09401-08413	Clip
16	09401-25406	Clip
17	01550-06257	BOLT
18	01550-06407	BOLT
19	29404-93J11	Clamp (L:65)
45809	17670-94404	Thermostat (60c)
45810	17670-87J01	Thermostat (72c)
45963	09352-50006-600	Hose (5x9x600)

▶Fig. 17 - Throttle Body (14 parts)

Ref	OEM Part #	Part Name
1	13421-87J00	Throttle Body Gasket
2	13300-87J00	Throttle Body Assembly (NLA)
3	01550-06507	BOLT
4	13510-87J00	Throttle Rod
5	19121-87J00	Throttle Lever (NLA)
6	19131-95502	Connector
7	19148-87J00	Throttle Lever (NLA)
8	67473-89J00	Connector Pin
9	09119-05010	Pivot Ball
10	09140-05005	Nut
11	09160-06046	Washer (6.5x20x1.5)
12	09180-06186	Spacer (6.2x12.6x21)
13	01550-06357	BOLT
14	01550-06257	BOLT

▶Fig. 18 - Oil Pump (18 parts)

Ref	OEM Part #	Part Name
1	16100-87J11	Oil Pump Case Assembly
2	16130-70B01	Oil Pump Rotor Set
3	16150-60A20	Oil Pump Relief Valve Set
5	16161-87J00	Oil Pump Rotor Plate (NLA)
6	02112-0616A	SCREW
7	16520-87J00	Oil Pump Strainer (NLA)
8	29116-93J10	Bolt (8x35)
9	09160-18031	Exhaust Plug Gasket
10	11118-98J02	PLUG
11	09248-18010	Exhaust Plug
12	09280-16005	O-Ring
13	01570-0616A	BOLT
14	16510-87J02	Engine Oil Filter
15	04221-08149	PIN
16	16910-87J00	Oil Level Gauge
17	16930-87J01	Oil Level Gauge Guide (NLA)
18	09280-09008	O-Ring
19	01550-06127	BOLT

▶Fig. 19 - Oil Pan (14 parts)

Ref	OEM Part #	Part Name
1	11489-87J00	Oil Pan Gasket
2	11500-87J04-019	Oil Pan
3	61155-99E01	Water Indicator Tube
4	61150-99E01	Water Indicator Tube Cover
5	09280-09005	O-Ring
6	09108-10127	Stud Bolt (10x14)
7	29116-93J10	Bolt (8x35)
8	09116-08115	Bolt (8x95)
9	09116-10124	Bolt (10x150)
10	09160-10082	Washer (10.5x19x2.0)
11	09140-10031	Nut (10mm)
12	09168-12012	Oil Drain Plug Gasket
13	09248-12009	Oil Drain Plug
14	04221-08149	PIN

▶Fig. 2 - Cylinder Block (12 parts)

Ref	OEM Part #	Part Name
1	11291-87J00	Engine Hook (NLA)
2	01550-08207	BOLT
4	11301-87J30	Cylinder Block Set (NLA)
5	11117-89J10	Crankcase Bolt (NLA)
6	11261-87E10	Protection Anode Cover
7	11265-87E10	Protection Cover Gasket
8	55321-87J01	Aluminum Anode
9	09206-13019	Knock Pin
10	09246-08004	Plug (NLA)
11	01550-06207	BOLT
12	01550-08407	BOLT 8 X 40
13	09103-06281	Bolt (6x14)

▶Fig. 20 - Clutch (14 parts)

Ref	OEM Part #	Part Name
1	21211-87J00	Clutch Shaft
2	21210-87J00	Clutch Shaft Arm
3	21230-87J01	Clutch Shaft Side Arm
5	23115-87J00	Clutch Lever Link
6	23210-87J00	Clutch Control Lever
7	23311-95DL0	Clutch Rod Connector
8	67467-89J01	Cable Connector
9	67471-99E00	Remote Control Nut
10	29141-93J00	Nut (6mm)
11	09160-06055	Washer (7x12x1.0)
12	09385-06012	Clip
14	01550-06207	BOLT
45748	23111-87J00	Clutch Rod (L)
45749	23111-87J10	Clutch Rod (S)

▶Fig. 21 - Shift Rod (17 parts)

Ref	OEM Part #	Part Name
1	21121-93300	Clutch Notch Plate
3	25211-87J00	Shift Rod Guide
4	25212-94401	Shift Rod Lower Guide
5	25223-96J00	Seal, Shift Rod Dust
6	25311-94402	Shift Cam
7	09205-02004	Spring Pin (2.5x12)
8	09205-02013	Spring Pin (2.5x16)
9	09205-03021	Spring Pin (3.5x12)
10	09280-08005	O-Ring
11	09280-11005	Shift Rod O-Ring
14	09260-10005	Ball
16	08331-3115A	Circlip
17	25232-96302	Gear Case Magnet
45672	09440-07071	Spring
45689	25111-94412	Shift Rod (S) (NLA)
45690	25111-94442	Shift Rod (L)
45703	09440-07078	Spring

▶Fig. 22 - Transmission (48 parts)

Ref	OEM Part #	Part Name
1	56120-94321-0EP	Propeller Shaft Bearing Housing
2	09263-22020	Bearing (22.225x28.575.19.05)
3	09289-22007	Oil Seal (21.2x35x5)
4	09262-35070	Bearing (35x62x14)
5	09117-08047	Bolt (8x30)
6	09280-75001	O-Ring
8	57133-94400	Drive Shaft Spring Collar
9	09160-24020	Washer (24x33x2.5)
10	09160-26015	Washer (26.2x42x4.0)
11	09166-25006	Washer
12	09205-03019	Spring Pin (3x10)
13	09263-25062	BT 25x42x5 Bearing
14	09440-30005	Spring
16	57300-88810	Pinion & Gear Set
17	09140-12034	Pinion Nut
21	08211-20263	Thrust Washer (2.00)
22	57610-94403	Propeller Shaft Assembly
23	57621-87J03	Clutch Dog Shifter
24	09202-05022	Clutch Dog Shifter Pin
25	57634-88L00	Push Pin
27	09440-40002	Clutch Dog Spring
28	57631-95303	Push Rod
45672	09181-30186	Shim (0.50)
45675	08221-35455	Shim (0.50)
45676	09181-30186	Shim (0.50)
45677	09160-22018	Washer (1.80)
45683	09440-08034	Return Spring
45703	09181-30187	Shim (0.60)
45706	09181-35131	Shim (0.60)
45707	09181-30187	Shim (0.60)
45708	09160-22019	Washer (1.90)
45714	09440-08043	Return Spring
45731	09181-30188	Shim (0.70)
45734	09181-35132	Shim (0.70)
45735	09181-30188	Shim (0.70)
45736	09160-22020	Washer (2.00)
45762	09181-30190	Shim (0.80)
45765	08221-35456	Shim (0.80)
45766	09181-30190	Shim (0.80)
45767	09160-22021	Washer (2.10)
45792	09181-30192	Shim (0.90)
45795	09181-35136	Shim (0.90)
45796	09181-30192	Shim (0.90)
45797	09160-22022	Washer (2.20)
45826	08211-35451	Shim (1.00)
45828	09160-22023	Washer (2.30)
45839	57110-87J10	Drive Shaft (S) (NLA)
45840	57110-87J00	Drive Shaft (L)

▶Fig. 26 - Starting Motor (23 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	31190-94J00	Lever & Dust Cover Set (NLA)
8	31173-94J01	Brush Holder
9	31191-90J00	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	31912-87J00	Starting Motor Band (NLA)
18	31918-90J11	DAMPER,LWR
19	38860-76F01	Relay
20	38915-90J00	Relay Holder
21	01547-06207	BOLT 6 X 20
22	01550-08257	BOLT
23	09329-01007	Cushion

▶Fig. 29 - Magneto (12 parts)

Ref	OEM Part #	Part Name
1	32102-87J20	Flywheel
2	32120-87J20	Battery Charge Coil (NLA)
3	02112-05127	SCREW
4	32160-87L01	CKP/Ignition Timimg Coil
5	33220-76G02	Cam Position Sensor
6	01550-06167	BOLT
7	29404-93J11	Clamp (L:65)
8	02112-06307	SCREW, 6X30 CRO
9	01550-06127	BOLT
10	09103-14024	Flywheel Bolt (14x50)
11	09160-14065	Washer (14.5x36x4.5)
12	09420-04008	Key

▶Fig. 31 - Ignition Coil (11 parts)

Ref	OEM Part #	Part Name
1	01550-06127	BOLT
2	01580-06257	Bolt
3	32800-38F10	Rectifier Assembly
4	32890-87J21	Electric Parts Holder
5	09160-06054	Washer (6.5x22.1.6)
6	09320-12090	Cushion
7	32891-87J10	Electric Parts Holder Cover
8	33410-87J01	Ignition Coil Assembly
9	38410-93J12	PTT Relay Assembly
10	38415-93J00	PTT Relay Holder
11	01550-06207	BOLT

▶Fig. 32 - Harness (9 parts)

Ref	OEM Part #	Part Name
1	33810-87J10	Starter Motor Cable
1A	08316-10087	Nut
6	29404-93J11	Clamp (L:65)
7	01550-06127	BOLT
8	33634-99E00	Service Connector Cap
10	36610-87JG0	Wiring Harness Assembly
11	09481-30501	30 Amp Fuse
12	36656-87J00	Cable Grommet
21	01550-06167	BOLT

▶Fig. 33 - Engine Control Unit (14 parts)

Ref	OEM Part #	Part Name
1	37721-99E12	Neutral Switch Assembly
2	37725-95600	Switch Actuator
3A	37726-87J01	Neutral Switch Bracket
4	02162-06127	BOLT
5A	01550-06167	BOLT
6	37850-99E05	PTT Switch Assembly
7	29404-93J11	Clamp (L:65)
8	09250-12004	Plug (NLA)
12	33920-87JA4	Engine Control Unit
13	33925-87J00	ECU Cushion
14	38860-76F01	Relay
15	09404-08205	Clamp (L:62)
16	38915-90J00	Relay Holder
17	09408-00024	Clamp

▶Fig. 34 - Sensor (21 parts)

Ref	OEM Part #	Part Name
1	18133-61A01	Gas Filter
2	18590-80C40	MAP Sensor
3	33834-99E00	Hose Protector (NLA)
4	37820-99E02	Oil Pressure Switch
5	09355-35006-601	Hose (3.5x7.5x601)
6	09401-06406	Clip
7	01500-06127	BOLT
8	13650-52G00	Inlet Air Temp Sensor
9	13655-87J01	Air Temp Sensor Grommet
11	34830-87J20	Temp Sensor Assy
13	29404-93J11	Clamp (L:65)
14	01550-06127	BOLT
16	09471-12077	Bulb (12v, 1.7w)
17	18595-87J00	Pressure Sensor Bracket
18	01550-06127	BOLT
19	34801-99E05	Trim Sender
20	01550-06167	BOLT
45672	34200-93J02	Black Tachometer w/Monitor Function
45678	09407-14403	Clamp (L:125)
45703	34200-93J14	Tachometer w/Monitor - White
45709	09407-14407	Clamp (L:140)

▶Fig. 36 - Clamp Bracket (20 parts)

Ref	OEM Part #	Part Name
1	41111-89J21-0EP	Starboard Clamp Bracket
2	41121-89J15-0EP	Port Clamp Bracket
3	41130-87J10	Clamp Bracket Shaft
4	41151-94500	Clamp Bracket Shaft Cap
5	41152-94500	Clamp Bracket Shaft Plug
6	41153-94500	Transom Bolt Cap
7	55320-95311	Zinc Anode
8	09116-06094	Bolt (6x15)
10	09159-12014	Nut (12x17)
11	09159-22006	Nut
12	09160-12044	Washer (12.5x35x3.2)
13	09160-12110	Washer (12.5x22x3.0)
15	09162-12005	Lock Washer
16	45421-89J00	Tilt Lock Pin
17	09159-10050	Nut
18	09160-10082	Washer (10.5x19x2.0)
19	09160-12066	Washer (12.5x22x2.5)
21	41135-93J00	Clamp Bracket Shaft Washer
45901	09100-12093	Transom Bolt (12x100)
45902	09100-12091	Transom Bolt (12x115)

▶Fig. 38 - Swivel Bracket (26 parts)

Ref	OEM Part #	Part Name
1	22511-99011	Grease Nipple
2	36894-95201	Wire Lead (L:165)
3	36895-87D10	Wire Lead (L:310)
5	43211-87J00	Swivel Bracket Bushing
6	43711-89J10	Steering Bushing
7	43721-89J00	Steering Upper Plate
9	09125-05050	Screw (5x8)
10	09160-39002	Washer (39.5x58x1)
11	09160-39003	Washer (39.5x58x0.3)
13	09282-39001	Oil Seal (38x51x5)
14	09380-38003	Circlip
15	41226-97E00	Bushing
16	41230-97E10	Tilt Lock Spring
17	41270-89J04	Stbd Tilt Lock Lever
18	41280-89J04	Port Tilt Lock Lever
19	45731-96312	Spring Bracket
20	09116-06094	Bolt (6x15)
21	09205-03012	Spring Pin (3x16)
22	43417-89J00	Steering Adjuster
23	43412-93901	COVER,STEERING
24	09100-08227	Bolt (8x27) (NLA)
26	09160-08082	Washer (8.5x16x1.2)
28	29440-93J00	Steering Adjuster Spring
45748	43111-89J25-0EP	Swivel Bracket (L)
45749	43111-89J34-0EP	Swivel Bracket (S) (NLA)
45870	43750-87J40-0EP	BRACKET,STEERIN

▶Fig. 4 - Oil Seal Housing (18 parts)

Ref	OEM Part #	Part Name
1	11411-87J20	Upper Oil Seal Housing (NLA)
2	11413-87J00	Upper Oil Seal Housing Gasket
3	11431-87J00	Under Oil Seal Housing
4	11433-87J00	Under Oil Seal Housing Gasket
5	11510-87J12	Flywheel Magneto Cover
6	11174-99800	Breather Hose Set
7	11176-87J00	Breather Hose Jet (NLA)
8	11531-87J12	Magneto Cover Seal (NLA)
9	09320-08013	Grommet
10	09320-20008	Cushion
11	09401-20409	Clip
12	09117-06031	Bolt (6x20)
13	09282-17011	Oil Seal (16.5x28x6)
14	01550-06207	BOLT
15	01550-06507	BOLT
16	04221-04089	PIN 4X8
17	61472-93E33	LABEL,RECOIL,ST
18	69711-93E11	Label (S.I.G.P)

▶Fig. 42 - Power Trim (27 parts)

Ref	OEM Part #	Part Name
1	48000-87J42	Power Trim Assembly
2	48320-87J10	Up Pressure Valve
3	48330-87J10	Down Pressure Valve
4	48510-97E00	Gear Pump Assembly
5	48541-87J10	Bolt (NLA)
6	48541-87J20	Bolt (NLA)
7	48551-87J40	Manual Valve
7A	48553-88L00	Washer Seal
8	48557-87J10	O-Ring Set
9	48571-87J21	Resevoir Tank
10	48572-87J10	Plug
11	48582-97E01	Filter
12	48583-87J10	Drive Joint
13	48611-87J10	Joint (NLA)
14	48681-87J11	Circlip
15	48862-87J20	Reservoir Tank Bolt
16	47225-87J00	Tilt Cylinder Lower Collar (NLA)
17	48121-89J10	Tilt Cylinder Lower Shaft
18	48321-89J11	Tilt Cylinder Upper Shaft
19	48325-89J00	Tilt Cylinder Upper Bushing
20	48326-87J00	Tilt Cylinder Lower Bushing
21	55321-87J01	Aluminum Anode
22A	09116-10179	Bolt (10x35)
23	09125-06063	Screw (6x10)
24	09103-06281	Bolt (6x14)
26	09380-12002	Snap Ring
27	29404-93J11	Clamp (L:65)

▶Fig. 44 - PTT Motor (9 parts)

Ref	OEM Part #	Part Name
1	38100-87J21	PTT Motor Assembly
2	31111-87J10	Screw (NLA)
3	31123-97E10	O-Ring
4	31133-94910	Brush
5	31135-94900	Spring
6	31136-87J11	Breaker
7	31173-87J20	Brush Holder Assy
8	31311-87J10	Armature (NLA)
9	33799-97E00	Oil Seal

▶Fig. 45 - Engine Holder (16 parts)

Ref	OEM Part #	Part Name
1	51110-87J10-0EP	Engine Holder
2	51211-87J00	Engine Holder Gasket
3	04221-08149	PIN
5	09282-17011	Oil Seal (16.5x28x6)
6	54125-87J00	Upper Thrust Reverse Mount (NLA)
7	54130-87J40	Upper Mount (NLA)
8	54148-99E01-0EP	Stbd Upper Mount Cover
9	54149-99E01-0EP	Port Upper Mount Cover
10	54165-94400	Lower Damper
10A	54120-87J11	Upper Thrust Stopper (NLA)
11	54112-87J01	Upper Mount Bolt (NLA)
12	09116-08128	Bolt (8x40)
13	09116-08122	Bolt (8x30)
14	09159-12014	Nut (12x17)
15	09160-12110	Washer (12.5x22x3.0)
16	09160-12110	Washer (12.5x22x3.0)

▶Fig. 46 - Drive Shaft Housing (20 parts)

Ref	OEM Part #	Part Name
1	43112-94L01	Exhaust Pipe
3	09116-10176	Bolt (10x44)
4	09202-08006	Knock Pin (8x12)
5	36894-94401	Wire Lead (L:195)
6	54121-87E00	Replaced by 54121-87E01
7	54160-87J30	Lower Mount (NLA)
9	09140-12029	Nut
10	09160-13018	Washer (13x40x3) (NLA)
11	54151-87J10	Lower Thrust Mount
12	54211-87J30-0EP	Lower Mount Bracket
14	09117-08071	Bolt (8x35)
15	09159-12014	Nut (12x17)
16	09160-12110	Washer (12.5x22x3.0)
17	09125-05050	Screw (5x8)
19	54166-87J31	Lower Mount Bolt
20	09160-12107	Lower Mount Washer (NLA)
45670	54221-87J01-0EP	Lower Mount Cover
45689	52111-87J12-0EP	Drive Shaft Housing (S) (NLA)
45690	52111-87J20-0EP	Drive Shaft Housing (L)
45701	54221-95J00-0EP	Lower Mount Cover (NLA)

▶Fig. 47 - Gear Case (35 parts)

Ref	OEM Part #	Part Name
1	55100-87J50-0EP	Gear Case Housing
2	09263-22039	Bearing (22x30x30)
3	09265-30004	Bearing (30x62x17.25)
4	55122-88L00	Gear Case Seal Ring
5	55125-95500	Trim Tab Zinc Anode
6	09117-08109	Bolt (8x16)
7	09116-08131	Bolt (8x45)
8	09168-10022	Drain Plug Gasket
9	09202-06025	Pin (6x17)
10	09202-06027	Pin (6x23)
11	09248-10008	Drain Plug
13	58120-88L01	Propeller Bushing
14	57632-95320	Propeller Stopper
15	57630-94301	Propeller Hardware Kit DT40/DT55/DT65/ DF40/DF50/DF60A
16	09141-18005	Nut (18mm)
17	09160-18028	Washer (18.5x31x1.0)
18	57633-94301	Propeller Nut Spacer
19	09204-03003	Prop Nut Cotter Pin
20	25700-88L03	Gear Case Seal Kit DT40c - DF40 / DF50 / 60A
22	55300-95500	Zinc Anode
45992	58100-88L03-019	S900 Propeller 3x11-1/2x9 *
45993	58100-88LD0-019	S1000 Propeller 3x11-1/2x10
45994	58100-88LE0-019	S1100 Propeller 3x11-1/2x11
45995	58100-88LA0-019	S1200 Propeller 3x11-5/8x12
45996	58100-88LB0-019	S1301 Propeller 3x11-1/2x13
45997	58100-88LQ0-019	S1400 Propeller 3x11-3/8x14
45998	58100-88LR0-019	15P DF40A/50A/6
45999	58100-88L72-019	S1600 Propeller 3x11-1/8x16
46000	58100-88LF0-019	S1700 Propeller 3x11x17
46001	990C0-00501-12P	S/S Propeller 3x11-3/4x12 (NLA)
46002	990C0-00501-13P	S/S Propeller 3x11-3/4x13 (NLA)
46003	990C0-00501-14P	S/S Propeller 3x11-3/4x14 (NLA)
46004	990C0-00501-15P	S/S Propeller 3x11-3/4x15 (NLA)
46005	990C0-00501-16P	S/S Propeller 3x11-3/4x16 (NLA)
46006	990C0-00501-17P	S/S Propeller 3x11-3/4x17 (NLA)

▶Fig. 48 - Side Cover (27 parts)

Ref	OEM Part #	Part Name
1	61112-87J01	Engine Cover Lower Seal
2	61124-87J11	Remote Control Grommet
3	61135-87J01	Side Cover Seal (NLA)
6	61817-99E00	Side Cover Plug
8	61827-87J00	Side Cover Holder
9	61827-87J10	Side Cover Holder
10	61828-87J00	Side Cover Cushion (NLA)
11	61830-87J01-0EP	Front Panel
12	61833-87J00	Front Panel Bracket (NLA)
13	61851-87J00	Side Cover Protector (NLA)
16	01550-06127	BOLT
18	03542-05169	SCREW
19	61412-93E00	Engine Cover Hook
20	61610-90L00	Fastener
21	61616-93EL0	Lever Pin
22	09161-04012	Washer (4.2x11x1)
23	09385-04003	Snap Pin
24	03512-05169	SCREW
25	67341-99E00	Remocon Cable Holder
26	67343-99E01	Remocon Cable Stopper
27	01550-06207	BOLT
45671	09136-06144	Screw (6x30)
45702	09139-06249	SCREW
45778	61810-87810-0EP	Side Cover Set (NLA)
45779	61810-87J01-0EP	Starboard Side Cover
45839	61810-87810-0EP	Side Cover Set (NLA)
45840	61821-87J02-0EP	Port Side Cover

▶Fig. 5 - Crankshaft (18 parts)

Ref	OEM Part #	Part Name
1	12111-87J04	Piston
2	12140-87J01	Piston Ring Set
3	12151-87J00	Piston Pin
4	09381-18005	Circlip
5	12160-87J00	Connecting Rod Assembly
6	09159-08033	Nut
7	12181-87J00-0A0	Connecting Rod Bearing
8	12220-87J10	Crankshaft Assembly
10	12300-60840	Thrust Bearing Set
11	09283-35047	Oil Seal
12	12281-87J00	Oil Seal (39.3x44x7)
45670	12100-87J02	Piston & Ring Set
45701	12100-87J03-050	Piston & Ring Set (OS:0.50)
45901	12340-75FA0-0A0	Crankshaft Bearing Set (Green)
45902	12340-75FA0-0B0	Crankshaft Bearing Set (Black)
45903	12340-75F00-0C0	Crankshaft Bearing Set (Non)
45904	12340-75F00-0D0	Crankshaft Bearing Set (Yellow)
45905	12340-75F00-0E0	Discontinued

▶Fig. 50 - Engine Cover (15 parts)

Ref	OEM Part #	Part Name
1	61400-87Y41-0EP	Engine Cover Set
2	61431-87J00-0EP	Tilt Up Handle (NLA)
3	61631-99E00	Fastner Hook
4	09125-06025	Screw (6x20)
5	09145-06004	Nut
6	09160-06036	Washer (6.5x18x1.5)
7	03542-06169	SCREW
8	61443-87J51	Starboard Engine Cover Stripe
9	61453-87J51	Port Engine Cover Stripe
10	61446-87J01	EFI Decal
11	68271-87J00	Front Emblem Mark
12	61435-87J81	Rear Emblem Mark (DF40)
14	61458-99E31	Engine Cover Label
15	69716-99E14	Fuel Limitation Label
16	09800-81812	Tool Set

▶Fig. 52 - Fuel Tank (15 parts)

Ref	OEM Part #	Part Name
1	65000-95D01	6 Gallon Suzuki Fuel Tank (NLA)
2	65520-95D00	Fuel Tank Cap Assembly (NLA)
3	65561-95D00	Fuel Tank Cap Gasket
4	65740-95D01	Fuel Tank Connector (13mm)
5	65831-95D00	Fuel Outlet Filter
6	65890-95D00	Outlet Assembly
7	65892-95D00	Fuel Outlet O-Ring
8	65700-87J28	Fuel Hose
9	65750-87J11	Fuel Hose Connector
10	65750-95501	Fuel Hose Connector (13mm)
11	65770-95505	Squeeze Pump (NLA)
12	65781-98500	Hose Clip
13	65720-986L0	Fuel Connector
14	09103-06237	Bolt (6x12.5)
15	09160-06085	Washer (6.5x15x1.0)

▶Fig. 53 - Drag Link (16 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
7	67467-89J01	Cable Connector
8	09385-06012	Clip
9	09160-06055	Washer (7x12x1.0)
10	67600-90J00	Tie Rod Kit (NLA)
11	67631-90J00	Tie Rod Bracket
12	67725-99E10	Replaced by 67725-99E20
13	67726-99E00	Lock Nut
14	09100-12081	Bolt (12x25)
15	09160-12066	Washer (12.5x22x2.5)
16	09180-09022	Tie Rod Spacer (NLA)

▶Fig. 55 - Opt: Meter (34 parts)

Ref	OEM Part #	Part Name
2	09471-12103	Bulb (12v, 3.4w)
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	36615-96300	Resin Terminal
22	09471-12077	Bulb (12v, 1.7w)
23	34190-95500	Speedometer Sensor (NLA)
24	03112-06303	Screw (NLA)
25	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
45702	34500-93J13	White Hour Meter
45704	34650-93J33	White Water Pressure Gauge
45708	34200-93J14	Tachometer w/Monitor - White
45717	34100-93J00	Black Speedometer 0-80 MPH
45718	34100-93J13	White 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. 57 - Opt: Trim Sender (9 parts)

Ref	OEM Part #	Part Name
15	34804-94711	Trim Sender Set
16	34801-94710	Trim Sender
17	36658-95600	Cable Grommet (NLA)
18	36680-92E00	Trim Meter Wire Assembly (NLA)
19	36682-92E00	Wire Harness
20	01550-06167	BOLT
21	09125-06063	Screw (6x10)
45680	09407-14403	Clamp (L:125)
45711	09407-14407	Clamp (L:140)

▶Fig. 58 - Opt: Harness (10 parts)

Ref	OEM Part #	Part Name
4	36990-87D00	Terminal & Sleeve Set
11	36620-93J31	Replaced by 36620-93J32
12	34660-87J00	DF40/DF50 Water Pressure Gauge Install Kit
13	09352-50006-600	Hose (5x9x600)
14	09352-50006-600	Hose (5x9x600)
15	09367-06006	3 Way
16	09401-08411	Clip
17	09408-00024	Clamp
45931	36620-93J12	MAIN HARNESS EXT 6.5'
45932	36620-93J42	HARNESS EXT 10'

▶Fig. 6 - Timing Chain (12 parts)

Ref	OEM Part #	Part Name
1	12761-73G01	Timing Chain
2	12771-87J00	Timing Chain Guide
4	12776-85FA0	Timing Chain Guide Bolt
5	12811-87J00	Timing Chain Tensioner
6	12812-73G10	Timing Chain Tensioner Spacer
7	12813-73G00	Timing Chain Tensioner Pad
8	12821-87J01	Timing Chain Tensioner Link
9	12831-90J02	Tensioner Adjuster Assembly
10	09100-08260	Bolt (8x30)
11	09160-08123	Washer (8.5x20x1.2)
12	01550-0612A	BOLT
13	01550-0620A	BOLT

▶Fig. 61 - Opt: Switch (35 parts)

Ref	OEM Part #	Part Name
1	37100-96J01	Ignition Switch Panel Assembly
2	37139-99E00	Ignition Switch Panel
2A	38500-93J90	Warning Buzzer
2B	09407-14403	Clamp (L:125)
3	37803-93J06	Emergency Stop Switch Panel Assembly
4	37825-99E00	Emergency Switch Panel
5	37805-93J00	PTT Switch Assembly
6	37855-99E00	PTT Switch Panel
7	37210-93J00	Lighting Switch Set (NLA)
8	37212-93J00	Lighting Switch Panel (NLA)
10	37110-93J02	Ignition Switch Assembly
12	37143-99E01	Key Cap
13	37820-93J05	Emergency Stop Switch Assembly
14	37139-99E20	Ignition Switch Panel
15	03121-0516A	SCREW
16	38500-93J90	Warning Buzzer
17	09407-14403	Clamp (L:125)
19	37110-93J02	Ignition Switch Assembly
20	37820-93J95	Emergency Stop Switch Assembly
21	37139-99E10	Ignition Switch Panel
22	03121-0516A	SCREW
23	38500-93J90	Warning Buzzer
24	09407-14403	Clamp (L:125)
45962	37141-99E00	(931) Ignition Key
45963	37141-99E10	(932) Ignition Key
45964	37141-99E20	(933) Ignition Key
45965	37141-99E30	(934) Ignition Key
45966	37141-99E40	(935) Ignition Key
45967	37141-99E50	(936) Ignition Key
45968	37141-99E60	(937) Ignition Key
45969	37141-99E70	(938) Ignition Key
45970	37141-99E80	(939) Ignition Key
45971	37141-99E90	(940) Ignition Key
45972	37141-99EA0	(941) Ignition Key
45973	37141-99EB0	(942) Ignition Key

▶Fig. 65 - Opt: Remote Control (67 parts)

Ref	OEM Part #	Part Name
2	36646-93J00	PTT Switch Adapter Wire Asembly
3	36628-92E00	Wire Harness Grommet
4	37110-93J02	Ignition Switch Assembly
6	37143-99E01	Key Cap
7	37721-93J91	Neutral Switch Assembly
8	37820-93J05	Emergency Stop Switch Assembly
9	37823-92E02	Stop Switch Lanyard
10	37850-90J06	PTT Switch Assembly
11	38500-93J90	Warning Buzzer
12	67212-95600	Washer (NLA)
13	67213-92E00	Buzzer Bracket (NLA)
14	09125-05042	Screw (5x10)
15	67296-92E11	Screw (3x15)
16	67220-95630	Plate Assembly
17	67223-99E10	Brake Adjustment Knob
18	67229-95600	Roller (NLA)
19	67232-95600	Bushing
20	67238-87D00	Drive Gear
21	67241-99E10	Free Throttle Lever (NLA)
22	67243-95600	Bushing (NLA)
23	67244-95600	Wave Washer (NLA)
24	67245-95600	Free Throttle Drum (NLA)
25	67251-99E10	Handle Lever
26	67252-95600	Bushing
27	67253-95600	Washer (NLA)
28	67255-99E00	Neutral Lock Arm
29	67256-95600	Neutral Lock Holder
30	67257-99E00	Lever Cap
31	67258-99E00	Neutral Arm Bracket
32	67259-87D00	Neutral Arm Spring (NLA)
33	67261-99E00	Grip
34	67296-94310	Screw
35	67264-95600	Washer (NLA)
36	67267-95610	Wire Cover (Black)
37	67273-95600	Spacer
38	67275-95600	Cable End
39	67288-92E00	Washer
40	67292-94300	E Ring
41	67294-95600	Spacer
42	67296-90J10	Rear Cover Screw
43	67296-94300	Screw (4x10)
44	67296-95600	Screw
45	67296-95610	Screw
46	67297-95600	Washer
47	68165-16B01-13L	Suzuki Emblem
48	09100-08232	Bolt (8x30)
49	09126-05003	Screw (5x12)
50	09140-06020	Nut (6mm)
51	09160-06104	Washer (6.5x24x2)
51A	37859-90J00	Spacer
52A	09481-10501	10 Amp Fuse
53	67140-95600	Replaced by 67140-95601
18994	36620-93J04	21' Main Wiring Harness
19025	36620-93J54	16' Main Wiring Harness
19054	36620-93J64	26' Main Wiring Harness
45778	37141-99E00	(931) Ignition Key
45779	37141-99E10	(932) Ignition Key
45780	37141-99E20	(933) Ignition Key
45781	37141-99E30	(934) Ignition Key
45782	37141-99E40	(935) Ignition Key
45783	37141-99E50	(936) Ignition Key
45784	37141-99E60	(937) Ignition Key
45785	37141-99E70	(938) Ignition Key
45786	37141-99E80	(939) Ignition Key
45787	37141-99E90	(940) Ignition Key
45788	37141-99EA0	(941) Ignition Key
45789	37141-99EB0	(942) Ignition Key

▶Fig. 66 - 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. 67 - Opt: Top Mount Single (2) (48 parts)

Ref	OEM Part #	Part Name
1	67200-88L02	Single Binnacle Control Box
2	67222-92E00	Dual Plate
3	67223-92E00	Brake Adjust (NLA)
4	67288-92E00	Washer
5	67292-94300	E Ring
6	67288-92E10	Washer (NLA)
7	67291-92E00	Snap Ring (NLA)
8	67221-92E00	Shift Assembly (NLA)
9	67224-92E00	Brake Arm Assembly (NLA)
10	67294-92E00	Spacer (NLA)
11	37721-95500	Neutral Switch Assembly
12	67296-92E11	Screw (3x15)
13	67296-88D10	Screw (5x16)
14	67296-92E20	Screw (5x25) (NLA)
15	67226-92E00	Bolt (NLA)
16	67226-92E10	Bolt (NLA)
17	67240-92E00	Throttle Arm Assembly (NLA)
18	67228-92E00	Washer (NLA)
19	67286-92E00	Bolt (6x18) (NLA)
20	67230-92E00	Shift Arm Assembly (NLA)
21	09125-05042	Screw (5x10)
22	67234-92E00	Gear Case (NLA)
23	67245-92E00	Free Throttle Drum (NLA)
24	67227-92E00	Stopper (NLA)
25	09126-06006	Screw (6x20)
26	67225-92E00	Spring (NLA)
27	09125-04004	Screw (4x6)
28	67233-92E00	Spring (NLA)
29	67235-92E00	Shift Lock Plate (NLA)
30	67232-95620	Bushing (NLA)
31	67296-92E00	Screw (NLA)
32	67296-88D10	Screw (5x16)
33	09140-06020	Nut (6mm)
34	67236-92E00	Roller (NLA)
35	67237-92E01	Spring (NLA)
36	67238-92E00	Drive Gear (NLA)
37	67239-92E00	Pin
38	67246-92E00	Drive Shaft
39	67252-92E00	Bushing (NLA)
40	67291-92E10	Snap Ring (NLA)
41	67253-92E10	Washer
42	67252-92E10	Bushing (NLA)
43	67253-95600	Washer (NLA)
44	67231-92E00	Shift Gear
45	67232-95600	Bushing
46	67241-92E00	Free Accel Rod (NLA)
47	67243-92E00	Grommet (NLA)
48	67239-92E10	Shift Pin Plate

▶Fig. 68 - Opt: Top Mount Dual (1) (31 parts)

Ref	OEM Part #	Part Name
1	67200-88L12	Duel Binnacle Top Mount Control
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	67296-92E70	Screw
9	67288-92E40	Washer
10	67257-92E00	Lever Cap
11	67251-93J00	Handle Lever
12	67296-92E60	Screw
13	67288-92E30	Washer
14	67253-92E00	Washer
15	36890-93J10	Wire Harness
16	37220-92E00	Mode Changing Switch Assembly
17	67282-93J00	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	67273-92E10	Grommet (NLA)
24	67295-92E00	Screw
25	67271-92E00	Cover
26	67211-93J10	Top Binnacle Cover
27	67296-92E70	Screw
28	67500-93J10	Dual Binnacle Box Spacer
29	09125-05135	Screw (5x65)
30	09160-05029	Washer (5.5x10x0.8)
31	09140-05005	Nut

▶Fig. 69 - Opt: Top Mount Dual (2) (53 parts)

Ref	OEM Part #	Part Name
1	67200-88L12	Duel Binnacle Top Mount Control
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	37721-92E11	Neutral Switch Assembly
12	67296-92E11	Screw (3x15)
13	67296-88D10	Screw (5x16)
14	67296-92E20	Screw (5x25) (NLA)
15	67226-92E00	Bolt (NLA)
16	67226-92E10	Bolt (NLA)
17	67240-92E00	Throttle Arm Assembly (NLA)
18	67228-92E00	Washer (NLA)
19	67286-92E00	Bolt (6x18) (NLA)
20	67230-92E00	Shift Arm Assembly (NLA)
21	09125-05042	Screw (5x10)
22	67234-92E00	Gear Case (NLA)
23	67245-92E00	Free Throttle Drum (NLA)
24	67227-92E00	Stopper (NLA)
25	09126-06006	Screw (6x20)
26	67225-92E00	Spring (NLA)
27	09125-04004	Screw (4x6)
28	67296-95610	Screw
29	67233-92E00	Spring (NLA)
30	67235-92E00	Shift Lock Plate (NLA)
31	67232-95620	Bushing (NLA)
32	67269-92E00	Bracket (NLA)
33	67296-88D10	Screw (5x16)
34	09140-06020	Nut (6mm)
35	67236-92E00	Roller (NLA)
36	67237-92E01	Spring (NLA)
37	67238-92E00	Drive Gear (NLA)
38	67239-92E00	Pin
39	67246-92E00	Drive Shaft
40	67252-92E00	Bushing (NLA)
41	67291-92E10	Snap Ring (NLA)
42	67253-92E10	Washer
43	67252-92E10	Bushing (NLA)
44	67274-92E00	Flange
45	67253-95600	Washer (NLA)
46	67231-92E00	Shift Gear
47	67232-95600	Bushing
48	67241-92E00	Free Accel Rod (NLA)
49	67243-92E00	Grommet (NLA)
50	67239-92E10	Shift Pin Plate
51	67272-92E10	Flange Seal (NLA)
52	67287-92E10	Nut (NLA)
53	67296-92E80	Screw (NLA)

▶Fig. 7 - Camshaft (55 parts)

Ref	OEM Part #	Part Name
1	12710-87J20	Intake Camshaft
2	12720-87J00	Exhaust Camshaft (NLA)
3	12741-87J00	Camshaft Sprocket (NLA)
4	01550-0612A	BOLT
5	12891-73G01	Tappet
6	12911-73G01	Intake Valve
7	12915-73G20	Exhaust Valve
8	12921-87J10	Valve Spring
9	12931-78G00	Valve Spring Retainer
10	12932-24400	Valve Cotter
11	12933-51E00	Valve Spring Seat
12	09289-05006	Valve Stem Seal
13-13	12892-65H00-242	Tappet Shim (2.42)
13-14	12892-65H00-244	Tappet Shim (2.44)
13-15	12892-65H00-246	Tappet Shim (2.46)
13-16	12892-65H00-248	Tappet Shim (2.48)
13-17	12892-65H00-250	Tappet Shim (2.50)
13-18	12892-65H00-252	Tappet Shim (2.52)
13-19	12892-65H00-254	Tappet Shim (2.54)
13-20	12892-65H00-256	Tappet Shim (2.56) (NLA)
13-21	12892-65H00-258	Tappet Shim (2.58)
13-22	12892-65H00-260	Tappet Shim (2.60)
13-23	12892-65H00-262	Tappet Shim (2.62) (NLA)
13-24	12892-65H00-264	Tappet Shim (2.64) (NLA)
13-25	12892-65H00-266	Tappet Shim (2.66)
13-26	12892-65H00-268	Tappet Shim (2.68)
13-27	12892-65H00-270	Tappet Shim (2.70)
13-28	12892-65H00-272	Tappet Shim (2.72)
13-29	12892-65H00-274	Tappet Shim (2.74) (NLA)
13-30	12892-65H00-276	Tappet Shim (2.76) (NLA)
13-31	12892-65H00-278	Tappet Shim (2.78) (NLA)
13-32	12892-65H00-280	Tappet Shim (2.80) (NLA)
13-33	12892-65H00-282	Tappet Shim (2.82) (NLA)
13-34	12892-65H00-284	Tappet Shim (2.84) (NLA)
13-35	12892-65H00-286	Tappet Shim (2.86) (NLA)
13-36	12892-65H00-288	Tappet Shim (2.88) (NLA)
13-37	12892-65H00-290	Tappet Shim (2.90) (NLA)
13-38	12892-65H00-292	Tappet Shim (2.92) (NLA)
13-39	12892-65H00-294	Tappet Shim (2.94) (NLA)
13-40	12892-65H00-296	Tappet Shim (2.96) (NLA)
13-41	12892-65H00-298	Tappet Shim (2.98) (NLA)
13-42	12892-65H00-300	Tappet Shim (3.00) (NLA)
14	04221-05109	PIN
45670	12892-65H00-218	Tappet Shim (2.18)
45701	12892-65H00-220	Tappet Shim (2.20) (NLA)
45729	12892-65H00-222	Tappet Shim (2.22) (NLA)
45760	12892-65H00-224	Tappet Shim (2.24) (NLA)
45790	12892-65H00-226	Tappet Shim (2.26) (NLA)
45821	12892-65H00-228	Tappet Shim (2.28) (NLA)
45851	12892-65H00-230	Tappet Shim (2.30) (NLA)
45882	12892-65H00-232	Tappet Shim (2.32)
45913	12892-65H00-234	Tappet Shim (2.34)
45943	12892-65H00-236	Tappet Shim (2.36)
45974	12892-65H00-238	Tappet Shim (2.38)
46004	12892-65H00-240	Tappet Shim (2.40) (NLA)

▶Fig. 70 - Opt: Tiller Handle (72 parts)

Ref	OEM Part #	Part Name
1	63002-87J26-0EP	DF40/DF50 Tiller Handle Kit
2	21131-94J00-YAY	Clutch Shift Mark
3	23230-87J00	Clutch Cable
4	33833-91J00	Tube (6x8x250)
5	43761-87J30-0EP	Tiller Handle Bracket
6	21111-87J10-0EP	Clutch Lever
7	36620-87J20	Handle Wiring Harness (NLA)
8	37110-87J21	Ignition Switch Assembly
9A	37143-99E01	Key Cap
10	37820-87J03	Emergency Switch Assembly
11	37823-92E02	Stop Switch Lanyard
12	37826-92E00	Nut
13	37860-94610	Trim Switch Assembly
13A	37850-87J00	Trim Switch Assembly
14	37869-95590	Trim Switch Cap
14A	37852-87J00	Trim Switch Cap
15	38500-92X50	Warning Buzzer
16	63109-87J00-0EP	Tiller Handle Housing
17	63121-87J04	Under Cover
18	63210-93E30	Handle Grip
19	63221-87J00	Handle Rod
20	63223-92D00	Handle Rod Stopper
21	63225-93200	Handle Rod Bushing
22	63227-93200	Handle Rod Pin
23	63235-87J00	Throttle Shaft Plate (NLA)
24	63240-87J00	Throttle Adjuster (NLA)
25	63250-87J01	Throttle Arm Assembly
26	63260-87J02	Shift Gear Assembly
27	63261-87J00	Shift Gear Bushing
28	63262-87J00	Shift Lever Bushing
29	63271-87J00	Lock Plate
30	63272-87J00	Ball Guide Plate
31	63273-87J00	Ball (NLA)
32	63274-87J00	E Ring (NLA)
33	67263-99E00	Trim Switch Cover (NLA)
34	63610-87J00	Throttle Cable Assembly
35	63625-87J00	Throttle Cable Grommet (NLA)
36	63626-87J01	Handle Wire Grommet (NLA)
37	67292-87J00	E Ring
38	67473-89J00	Connector Pin
39	09126-06015	Screw (6x23)
40	09163-06001	Lock Washer (6.4x12x0.5)
41	09440-12027	Spring
42	09106-08099	Bolt (8x50) (NLA)
43	09125-05047	Screw (5x14)
44	63251-87J00	Screw (6x12)
45	09136-05008	Screw (5x12)
46	02142-05207	SCREW
53	09139-02003	Screw (2x6)
54	29404-93J30	Clamp (NLA)
55	63215-93110	Handle Grip Mark
56	09100-10264	Bolt (10x80)
57	09159-10050	Nut
58	09160-10114	Washer (10.5x22x1.5)
59	09306-10020	Bushing
60	09164-10016	Washer
61	43768-90J01	Spacer
62	09116-10176	Bolt (10x44)
63	63611-87J00	Clamp Bracket Bolt
64	63612-87J00	Clamp Bracket
45901	37141-99E00	(931) Ignition Key
45902	37141-99E10	(932) Ignition Key
45903	37141-99E20	(933) Ignition Key
45904	37141-99E30	(934) Ignition Key
45905	37141-99E40	(935) Ignition Key
45906	37141-99E50	(936) Ignition Key
45907	37141-99E60	(937) Ignition Key
45908	37141-99E70	(938) Ignition Key
45909	37141-99E80	(939) Ignition Key
45910	37141-99E90	(940) Ignition Key
45911	37141-99EA0	(941) Ignition Key
45912	37141-99EB0	(942) Ignition Key

▶Fig. 71 - Opt: Gasket Set (13 parts)

Ref	OEM Part #	Part Name
1	11400-87805	Engine Gasket Set
2	11141-87J02	Cylinder Head Gasket
3	11189-87J00	Cylinder Head Cover Gasket
4	11265-87E10	Protection Cover Gasket
5	11413-87J00	Upper Oil Seal Housing Gasket
6	11433-87J00	Under Oil Seal Housing Gasket
7	11489-87J00	Oil Pan Gasket
8	13421-87J00	Throttle Body Gasket
9	17472-96304	Water Pump Plate Gasket
10	17616-87J00	Pressure Valve Cover Gasket
11	17685-87D10	Thermostat Gasket
12	51211-87J00	Engine Holder Gasket
13	99011-87J08-03A	Owners Manual DF40/50 2007

▶Fig. 8 - Inlet Manifold (11 parts)

Ref	OEM Part #	Part Name
1	13111-87J03	Intake Manifold
2	13129-87J00	Intake Manifold Insulator
3	09168-12013	Gasket
4	09247-12104	Plug
5	01421-06407	Stud Bolt (NLA)
6	01421-08457	BOLT, STUD
7	01550-06407	BOLT
8	01550-06507	BOLT
9	01550-08557	BOLT
10	08316-10067	Nut
11	08316-10087	Nut

100-Hour / Annual Service Checklist

Regular maintenance keeps your Suzuki DF 40TLK7 running reliably season after season. Most of these tasks can be performed with basic tools and the factory service manual.

Replace water pump impeller and inspect wear plate
Change engine oil and oil filter (check drain plug washer)
Replace spark plugs and check ignition timing
Drain and refill lower unit gear oil; inspect for water contamination
Inspect fuel lines, primer bulb, and fuel filter for deterioration
Check and replace sacrificial anodes (zinc or aluminum)
Inspect propeller for damage; check shaft seal and cotter pin
Check valve clearance (refer to service manual for specifications)
Lubricate all grease points (steering, tilt tube, shift linkage)
Inspect control cables and throttle/shift linkage for smooth operation

Pro Tip: Always flush the engine with fresh water after saltwater use — even a quick 10-minute flush significantly extends component life.
Pro Tip: Use fuel stabilizer in the tank before winter storage, and fog the cylinders to prevent internal corrosion during extended periods of non-use.

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