🔎 Suzuki DF 4S Reference Library — Exploded parts diagrams (25 diagrams), specifications, common issues, and maintenance checklist.
The Suzuki DF 4S is a 4-Stroke OHV Single-Cylinder outboard motor. Designed for dinghies, inflatable boats, and small tenders where lightweight portability is essential.
Quick Reference Specifications
| Specification |
Value |
| Engine Type |
4-Stroke OHV Single-Cylinder |
| Horsepower |
4 HP |
| Displacement |
138 cc |
| Bore x Stroke |
60.4 x 48.0 mm |
| Spark Plug (Type & Gap) |
NGK CPR6EA-9 |
| Engine Oil Capacity |
1.0 L (with filter) |
| Recommended Engine Oil |
SAE 10W-40 |
| Gear Case Oil Capacity |
190 mL |
| Idle Speed (in gear) |
1250-1350 RPM |
| Full Throttle RPM Range |
4500-5500 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 4S:
-
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 4S.
▶Fig. 1 - Cylinder Head (17 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11110-91J30 |
Cylinder Head |
| 2 |
11114-90980 |
Valve Guide |
| 3 |
11141-91JL0 |
Cylinder Head Gasket |
| 4 |
11174-91J00 |
Breather Hose (NLA) |
| 5 |
11452-91J00 |
Reed Valve |
| 6 |
18498-91JL0-180 |
Protector (NLA) |
| 7 |
61827-91J00 |
Lower Cover Holder (NLA) |
| 8 |
11117-91JL0 |
Cylinder Head Bolt |
| 9 |
09401-11424 |
Clip |
| 10 |
01550-06167 |
BOLT |
| 11 |
02112-0612A |
SCREW |
| 12 |
04211-11169 |
PIN 11X16 |
| 13 |
11171-91J00 |
Cylinder Head Cover (NLA) |
| 14 |
11189-91J00 |
Cylinder Head Cover Gasket |
| 15 |
01550-06167 |
BOLT |
| 16 |
09482-00L04 |
NGK CPR6EA-9 Spark Plug |
| 17 |
17670-91J11 |
Thermostat (50c) |
▶Fig. 11 - Water Pump (21 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
17410-91JL0 |
Water Pump Case |
| 2 |
17415-98501 |
Water Pump Case Grommet |
| 3 |
17461-985M0 |
Water Pump Impeller |
| 4 |
17471-98610 |
Water Pump Plate (NLA) |
| 5 |
17472-91J00 |
Water Pump Plate Gasket |
| 6 |
17561-91JN0 |
Water Tube (S) |
| 7 |
17563-91J01 |
Water Tube Upper Grommet |
| 8 |
17564-98600 |
Water Tube Guide |
| 9 |
09108-06146 |
Stud Bolt (6x52) |
| 10 |
09116-06225 |
Bolt (6x16) |
| 11 |
29141-93J00 |
Nut (6mm) |
| 12 |
09160-06082 |
Washer (6.5x13x1.0) |
| 13 |
17412-91JL0 |
Water Pump Case Upper Plate |
| 14 |
17413-91JL0 |
Water Pump Case Sleeve |
| 15 |
09420-03002 |
Key |
| 16 |
56130-91J20 |
Drive Shaft Bearing Housing |
| 17 |
09282-10008 |
Oil Seal (10x21x4.5) |
| 18 |
56132-91J00 |
Drive Shaft Housing Gasket |
| 19 |
09116-06229 |
Bolt (6x25) |
| 20 |
25215-98601 |
Shift Rod Guide Stopper |
| 21 |
17400-986L2 |
Water Pump Repair Kit DF4/4A/6/6A |
▶Fig. 12 - Recoil Starter (14 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
18100-91JL2 |
Recoil Starter Assembly |
| 2 |
18120-91JL0 |
Reel |
| 3 |
18130-98130 |
Ratchet Set |
| 4 |
18142-92920 |
Spiral Spring |
| 5 |
18178-98310 |
Circlip |
| 6 |
18210-98130 |
Starter Grip |
| 7 |
99000-81157-50M |
Rope (NLA) |
| 8 |
18290-91J01 |
NSI Cable |
| 9 |
09103-06048 |
Bolt (6x20) (NLA) |
| 10 |
19183-91JL0 |
Throttle Cable Holder |
| 11 |
19183-91JM0 |
Throttle Cable Holder (NLA) |
| 12 |
01550-06167 |
BOLT |
| 13 |
69711-93E11 |
Label (S.I.G.P) |
| 14 |
61472-91J10 |
Recoil Starter Label (NLA) |
▶Fig. 13 - Oil Pump (5 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
16131-91J00 |
Oil Pump Inner Rotor |
| 2 |
16132-91J00 |
Oil Pump Outer Rotor |
| 3 |
16161-91J00 |
Oil Pump Rotor Plate |
| 4 |
16171-91J00 |
Oil Pump Plate Holder |
| 5 |
16510-91J00 |
Oil Filtering Screen |
▶Fig. 14 - Clutch Lever (15 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
21110-91JL0 |
Clutch Lever |
| 2 |
21120-91JL0 |
Clutch Notch Plate |
| 3 |
21216-91J00 |
Clutch Shaft Spacer |
| 4 |
23111-91J01 |
Clutch Rod |
| 5 |
23210-91J00 |
Clutch Rod Arm |
| 6 |
23212-91J00 |
Clutch Notch Pin |
| 7 |
23213-91J00 |
Clutch Notch Spring |
| 8 |
23310-91J00 |
Clutch Rod Connector |
| 9 |
23321-91J00 |
Clutch Rod Connector |
| 10 |
09116-06227 |
Bolt (6x20) |
| 11 |
09128-06014 |
Bolt (6x20) (NLA) |
| 12 |
09160-06145 |
Washer (6.2x19x3.0) |
| 13 |
09204-01002 |
Cotter Pin |
| 14 |
09280-16005 |
O-Ring |
| 15 |
09383-04002 |
E Ring |
▶Fig. 15 - Shift Rod (8 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
25100-91810 |
Shift Rod Set (S) |
| 2 |
25211-98601 |
Shift Rod Guide |
| 3 |
25222-91JL0 |
Shift Rod Boot |
| 4 |
25311-91J01 |
Shift Cam |
| 5 |
09160-05501 |
Washer (5.5x20x1.2) |
| 6 |
09205-02004 |
Spring Pin (2.5x12) |
| 7 |
09280-05008 |
O-Ring |
| 8 |
09280-15007 |
O-Ring |
▶Fig. 16 - Drive Shaft (33 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
57111-91J21 |
Drive Shaft (S) |
| 2 |
09181-10156 |
Washer |
| 4 |
09380-10003 |
Circlip |
| 5 |
57311-91J00 |
Pinion Gear |
| 7 |
09166-12L01 |
Washer (NLA) |
| 8 |
57510-91J00 |
Forward Gear |
| 9 |
57521-91J00 |
Reverse Gear |
| 11 |
09181-12111 |
Thrust Washer (1.00) |
| 14 |
57611-91J10 |
Propeller Shaft Assembly |
| 15 |
57621-986L0 |
Clutch Dog Shifter |
| 16 |
09202-04016 |
Pin |
| 17 |
09440-05039 |
Spring |
| 18 |
09440-24007 |
Clutch Dog Spring (NLA) |
| 19 |
57631-98601 |
Push Rod |
| 20 |
57632-97L00 |
Push Pin |
| 45670 |
09181-20162 |
Shim (0.80) (NLA) |
| 45701 |
09181-20164 |
Shim (0.90)(NLA) |
| 45729 |
09181-20167 |
Shim (1.00) |
| 45760 |
09181-20172 |
Shim (1.10) (NLA) |
| 45800 |
09181-20176 |
Shim (1.20) (NLA) |
| 45809 |
09160-10088 |
Washer (1.70) (NLA) |
| 45810 |
09160-10089 |
Washer (1.80) (NLA) |
| 45811 |
09160-10090 |
Washer (1.90) (NLA) |
| 45812 |
09160-10091 |
Washer (2.00) (NLA) |
| 45813 |
09160-10092 |
Washer (2.10) (NLA) |
| 45931 |
09181-12008 |
Thrust Washer (0.60) (NLA) |
| 45932 |
09160-12070 |
Thrust Washer (0.80) (NLA) |
| 45933 |
09181-12111 |
Thrust Washer (1.00) |
| 45992 |
09181-20159 |
Shim (0.60) (NLA) |
| 45993 |
09181-20160 |
Shim (0.70) (NLA) |
| 45994 |
09181-20162 |
Shim (0.80) (NLA) |
| 45995 |
09181-20164 |
Shim (0.90)(NLA) |
| 45996 |
09181-20167 |
Shim (1.00) |
▶Fig. 17 - Magneto (16 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
32102-91J20 |
Flywheel |
| 2 |
33410-91J50 |
Ignition Coil Assembly |
| 3 |
01550-06207 |
BOLT |
| 4 |
09159-12059 |
Nut (NLA) |
| 5 |
08341-31039 |
Woodruff Key |
| 6 |
29404-93J21 |
CLAMP |
| 7 |
33500-07H00 |
Spark Plug Cap |
| 8 |
33833-91J20 |
Switch Lead Tube (L:150) |
| 9 |
37830-91J21 |
Emergency Switch Assembly |
| 10 |
37823-97J00 |
Stop Switch Lanyard |
| 11 |
37826-92E00 |
Nut |
| 12 |
37835-91J00-YAY |
Stop Label |
| 13 |
33833-91J10 |
Switch Lead Tube (L:400) |
| 14 |
36991-91J00 |
Clamp |
| 15 |
09407-10404 |
Clamp (L:100) |
| 16 |
36617-91J00 |
Switch Lead Bracket (NLA) |
▶Fig. 18 - Clamp Bracket (15 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
41111-91J20-0EP |
Starboard Clamp Bracket |
| 2 |
41121-91J20-0EP |
Port Clamp Bracket |
| 3 |
41210-986L1 |
Clamp Screw Assembly |
| 4 |
41212-91J00 |
Clamp Handle |
| 5 |
41213-94J01 |
Clamp Plate |
| 6 |
09205-06007 |
Spring Pin (6x25) |
| 7 |
09100-06177 |
Bolt (6x140) |
| 8 |
09100-10321 |
Bolt (10x150) (NLA) |
| 9 |
29141-93J00 |
Nut (6mm) |
| 10 |
09159-10L07 |
Nut |
| 11 |
09160-06082 |
Washer (6.5x13x1.0) |
| 12 |
09160-10082 |
Washer (10.5x19x2.0) |
| 13 |
09180-06357 |
Spacer (6.5x10.5x104) |
| 14 |
45420-92DL0 |
Tilt Lock Pin |
| 15 |
69911-91J20 |
Clamp Bracket Mark (NLA) |
▶Fig. 19 - Swivel Bracket (19 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
45230-91JL0 |
Reverse Lock Arm |
| 2 |
43111-91J20-0EP |
Swivel Bracket |
| 3 |
43121-91J31-0EP |
Swivel Bracket Cover |
| 4 |
43211-91J00 |
Clamp Shaft Swivel Bushing |
| 5 |
43711-91J01 |
Upper Steering Bushing |
| 6 |
43751-91J20-0EP |
Steering Bracket |
| 7 |
43752-91J20-0EP |
Steering Bracket Cover |
| 8 |
09116-06099 |
Bolt (6x35) |
| 9 |
45211-98602 |
Reverse Lock Arm Spring |
| 10 |
45212-98602 |
Reverse Lock Arm Spring |
| 12 |
09116-06094 |
Bolt (6x15) |
| 13 |
43411-91J10 |
Steering Adjuster |
| 14 |
43410-91J20 |
Steering Adjuster Knob |
| 15 |
09204-01002 |
Cotter Pin |
| 16 |
45700-91JL0 |
Shallow Water Drive Assy |
| 17 |
45722-91J00 |
Shallow Water Drive Spring |
| 18 |
09160-08082 |
Washer (8.5x16x1.2) |
| 19 |
09200-08045 |
Shallow Water Drive Shaft (NLA) |
| 20 |
09204-01002 |
Cotter Pin |
▶Fig. 20 - Drive Shaft Housing (17 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
52110-91J00-0EP |
Drive Shaft Housing |
| 2 |
22511-99011 |
Grease Nipple |
| 3 |
52113-91J01 |
Drive Shaft Housing Gasket |
| 4 |
52115-98600 |
Clutch Adjust Hole Cover |
| 5 |
55321-87J01 |
Aluminum Anode |
| 6 |
09248-10008 |
Drain Plug |
| 7 |
09116-06189 |
Replaced by 09116-06238 |
| 8 |
09103-06281 |
Bolt (6x14) |
| 9 |
09168-10022 |
Drain Plug Gasket |
| 10 |
09168-12017 |
Gasket (12x17x1) |
| 11 |
09202-06015 |
Knock Pin |
| 12 |
09248-12007 |
Oil Drain Plug |
| 13 |
09320-04010 |
Bushing |
| 17 |
54132-91J10 |
Upper Rubber Mount |
| 18 |
54162-91J00 |
Lower Rubber Mount |
| 19 |
55181-95200 |
Flush Hose Attachment |
| 20 |
52117-92D00 |
Water Inspection Tube |
▶Fig. 21 - Gear Case (25 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
55100-91J30-0EP |
Gear Case Housing |
| 2 |
59311-91J00 |
Pinion Bushing |
| 3 |
09262-20106 |
Bearing (20x42x12) |
| 4 |
55321-87J01 |
Aluminum Anode |
| 5 |
09116-08156 |
Bolt (8x50) |
| 6 |
09103-06281 |
Bolt (6x14) |
| 7 |
09168-10022 |
Drain Plug Gasket |
| 8 |
09206-11006 |
Pin (8.4x11x8) (NLA) |
| 9 |
09248-10008 |
Drain Plug |
| 12 |
56120-91JM0-0EP |
Propeller Shaft Bearing Housing |
| 13 |
09167-23001 |
Washer |
| 14 |
09282-12L05 |
Oil Seal |
| 15 |
09262-12001 |
Bearing (12x28x8) |
| 16 |
09262-20106 |
Bearing (20x42x12) |
| 17 |
56122-98602 |
Oil Seal Protector |
| 18 |
56123-98600 |
Protector Washer |
| 19 |
09116-06225 |
Bolt (6x16) |
| 20 |
09280-49002 |
O-Ring |
| 22 |
58120-91JL0 |
Type C Propeller Bushing |
| 23 |
58130-91JL0 |
Propeller Nut |
| 24 |
57635-91JL0 |
Propeller Stopper |
| 25 |
09204-03003 |
Prop Nut Cotter Pin |
| 45678 |
58110-91JL0-019 |
C601 Propeller (3x7-1/2x6) |
| 45709 |
58110-91JM0-019 |
C611 Propeller (3x7-1/2x6-1/2) |
| 45737 |
58110-91JN0-019 |
C701 Propeller (3x7-1/2x7) |
▶Fig. 22 - Lower Cover (24 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
61100-91JA0-0EP |
Lower Cover Assembly |
| 2 |
65132-91J00 |
Cushion (NLA) |
| 4 |
09250-06005 |
Plug |
| 5 |
09250-12004 |
Plug (NLA) |
| 6 |
61155-94400 |
Water Inspection Tube |
| 7 |
61112-91J10 |
Lower Engine Cover Rubber |
| 8 |
61126-91J01 |
Lower Cover Plate Gasket |
| 9 |
61950-91J20 |
Carrying Handle |
| 10 |
09116-06225 |
Bolt (6x16) |
| 11 |
09116-08150 |
Bolt (8x27) |
| 12 |
09308-08011 |
Grommet |
| 13 |
61151-91J11 |
Cushion |
| 14 |
61151-91J20 |
Cushion |
| 15 |
09250-12016 |
CAP(OD:20) |
| 16 |
61611-91J11 |
Engine Cover Fastener |
| 17 |
61640-91J10 |
Fastener Lever |
| 18 |
09125-05132 |
Screw (5x14) (NLA) |
| 19 |
09140-05005 |
Nut |
| 20 |
09160-05029 |
Washer (5.5x10x0.8) |
| 21 |
63625-96300 |
Throttle Cable Grommet |
| 22 |
63624-91J00 |
Oil Level Gauge Grommet |
| 23 |
21131-94J00-YAY |
Clutch Shift Mark |
| 24 |
61211-91J80 |
Fuel Cock Mark |
| 25 |
61212-91J00 |
Oil Level Mark |
▶Fig. 24 - Engine Cover (9 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
61411-91J10-0EP |
Upper Engine Cover |
| 2 |
61622-91JL0 |
Recoil Starter Seal |
| 3 |
61435-91J70 |
Rear Emblem Mark DF4 |
| 4 |
61443-91J40 |
Starboard Engine Cover Stripe |
| 5 |
61453-91J40 |
Port Engine Cover Stripe |
| 6 |
61458-97J10 |
Engine Cover Label |
| 7 |
68111-99J00 |
S Emblem |
| 8 |
09800-01017 |
Tool Set |
| 9 |
61416-91J00 |
GUARD,AIR INTAK |
▶Fig. 26 - Tiller Handle (19 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
63111-91J30-0EP |
Tiller Handle |
| 2 |
63210-93E30 |
Handle Grip |
| 3 |
63221-91J10 |
Handle Rod |
| 4 |
63225-98601 |
Throttle Adjust Plate |
| 5 |
63241-986B0 |
Handle Rod Support |
| 6 |
63244-986A0 |
Throttle Adjust Knob |
| 7 |
63610-91J20 |
Throttle Cable Assembly |
| 8 |
63620-91J10 |
Throttle Cable Stopper |
| 9 |
63628-91J10 |
Throttle Cable Stopper Plate |
| 10 |
09116-08156 |
Bolt (8x50) |
| 11 |
09118-06123 |
Bolt (6x25) |
| 12 |
09126-06015 |
Screw (6x23) |
| 13 |
09136-05041 |
Screw (5x20) |
| 14 |
09140-08023-XC0 |
Nut (8mm) |
| 15 |
09148-06008 |
Nut |
| 16 |
09160-08082 |
Washer (8.5x16x1.2) |
| 17 |
09280-20004 |
O-Ring |
| 18 |
09306-08016 |
Bushing |
| 19 |
69714-91J20 |
Engine Start Mark |
▶Fig. 27 - Fuel Tank (12 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
65110-91J21 |
Fuel Tank |
| 2 |
65260-91J00 |
Fuel Tank Bracket (NLA) |
| 3 |
65281-91J11 |
Fuel Tank Grommet |
| 4 |
65284-91JL0 |
Fuel Tank Grommet Rubber |
| 5 |
65510-97J00 |
Fuel Tank Cap Assembly |
| 6 |
09103-06125 |
Bolt (6x16) (NLA) |
| 7 |
09169-06088 |
Washer (NLA) |
| 8 |
09320-09059 |
Cushion |
| 9 |
01550-06257 |
BOLT |
| 10 |
61151-91J20 |
Cushion |
| 11 |
66100-91JL0 |
Fuel Cock Assembly |
| 12 |
99011-91J30-03B |
Owners Manual DF4/DF6 - 2013 |
▶Fig. 29 - Opt: Electrical (23 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
32000-91J12 |
Battery Charging Kit |
| 2 |
32801-91J00 |
Rectifier Set |
| 3 |
32800-94620 |
Rectifier & Regulator |
| 4 |
32890-91J00 |
Rectifier Bracket (NLA) |
| 5 |
36740-95253 |
Fuse Case Assembly |
| 6 |
09481-20001 |
20 Amp Fuse |
| 7 |
37132-93700 |
Wire Connector |
| 8 |
09321-05019 |
Cushion |
| 9 |
09404-06435 |
Clamp (L:135) |
| 10 |
01550-06127 |
BOLT |
| 10A |
36617-91J10 |
Harness Bracket |
| 11 |
39600-91J12 |
Receptacle Lighting Set |
| 12 |
32102-91J30 |
Flywheel |
| 13 |
32120-91J10 |
Lighting Coil |
| 13A |
09407-14407 |
Clamp (L:140) |
| 13B |
12625-91J00 |
Stator Base |
| 13C |
01550-06167 |
BOLT |
| 14 |
39601-95D00 |
Lighting Receptacle Assembly |
| 15 |
36634-93910 |
Connector Cap |
| 16 |
39602-93900 |
Lamp Cord Plug Assembly |
| 17 |
02112-06207 |
CROSS SCREW,6X2 |
| 19 |
36990-87D00 |
Terminal & Sleeve Set |
| 45675 |
09404-06429 |
Clamp |
▶Fig. 3 - Cylinder Block (14 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11200-91J20 |
Cylinder Block Assembly |
| 2 |
09283-25098 |
Oil Seal (25x35x5) |
| 3 |
09262-25003 |
Bearing (25x52x15) |
| 4 |
11300-91J20 |
Crankcase Assembly |
| 5 |
11971-91J01 |
Oil Level Filler Lens |
| 6 |
09283-10009 |
Oil Seal (10x45x5) |
| 7 |
09283-25076 |
Oil Seal (25x45x5) |
| 8 |
11351-91J00 |
Crankcase Gasket |
| 9 |
11381-91J10 |
Oil Level Gauge (Yellow) |
| 10 |
09280-15007 |
O-Ring |
| 11 |
01550-06307 |
BOLT |
| 12 |
09168-10022 |
Drain Plug Gasket |
| 13 |
09248-10008 |
Drain Plug |
| 14 |
04211-09149 |
PIN 9X14 |
▶Fig. 30 - Opt: Fuel Tank (9 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
65000-99J01 |
3 Gallon Fuel Tank |
| 2 |
65700-91J28 |
Fuel Hose Assembly |
| 3 |
65750-87J11 |
Fuel Hose Connector |
| 4 |
65750-98506 |
Fuel Hose Connector (11mm) |
| 5 |
65770-94J04 |
Squeeze Pump |
| 6 |
65781-98500 |
Hose Clip |
| 7 |
65720-986L0 |
Fuel Connector |
| 8 |
09103-06237 |
Bolt (6x12.5) |
| 9 |
09160-06085 |
Washer (6.5x15x1.0) |
▶Fig. 32 - Opt: Remote Control (42 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
67200-94J21 |
67200-94J30 |
| 2 |
36628-92E00 |
Wire Harness Grommet |
| 3 |
37830-95D03 |
Emergency Stop Switch Assembly |
| 4 |
37823-92E02 |
Stop Switch Lanyard |
| 5 |
67212-95600 |
Washer (NLA) |
| 6 |
67220-95630 |
Plate Assembly |
| 7 |
67223-99E10 |
Brake Adjustment Knob |
| 8 |
67229-95600 |
Roller (NLA) |
| 9 |
67232-95600 |
Bushing |
| 10 |
67238-87D00 |
Drive Gear |
| 11 |
67241-99E10 |
Free Throttle Lever (NLA) |
| 12 |
67243-95600 |
Bushing (NLA) |
| 13 |
67244-95600 |
Wave Washer (NLA) |
| 14 |
67245-95600 |
Free Throttle Drum (NLA) |
| 15 |
67251-99E10 |
Handle Lever |
| 16 |
67252-95600 |
Bushing |
| 17 |
67253-95600 |
Washer (NLA) |
| 18 |
67255-99E00 |
Neutral Lock Arm |
| 19 |
67256-95600 |
Neutral Lock Holder |
| 20 |
67257-99E00 |
Lever Cap |
| 21 |
67258-99E00 |
Neutral Arm Bracket |
| 22 |
67259-87D00 |
Neutral Arm Spring (NLA) |
| 23 |
67261-99E00 |
Grip |
| 24 |
67296-94310 |
Screw |
| 25 |
67264-95600 |
Washer (NLA) |
| 26 |
67267-93J00 |
Wire Cover |
| 27 |
67273-95600 |
Spacer |
| 28 |
67275-95600 |
Cable End |
| 29 |
67288-92E00 |
Washer |
| 30 |
67292-94300 |
E Ring |
| 31 |
67294-95600 |
Spacer |
| 32 |
67296-90J10 |
Rear Cover Screw |
| 33 |
67296-94300 |
Screw (4x10) |
| 34 |
67296-95600 |
Screw |
| 35 |
67296-95610 |
Screw |
| 36 |
67297-95600 |
Washer |
| 37 |
68165-16B01-13L |
Suzuki Emblem |
| 38 |
09100-08232 |
Bolt (8x30) |
| 39 |
09126-05003 |
Screw (5x12) |
| 40 |
09140-06020 |
Nut (6mm) |
| 41 |
09160-06104 |
Washer (6.5x24x2) |
| 42 |
37859-90J00 |
Spacer |
▶Fig. 33 - Opt: Remote Parts Set (30 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
67130-91J02 |
Remote Control Parts Kit |
| 2 |
67110-91J00 |
Remocon Attachment |
| 3 |
09108-08130 |
Stud Bolt (8x20) |
| 4 |
09159-08059 |
Nut |
| 5 |
29162-93J10 |
Lock Washer |
| 6 |
63610-91J11 |
Throttle Cable Assembly |
| 7 |
67412-91J00 |
Remocon Throttle Lever |
| 8 |
67415-91J00 |
Remocon Throttle Drum |
| 9 |
67416-91J00 |
Remocon Throttle Bolt |
| 10 |
67430-91J00 |
Throttle Cable Guide |
| 11 |
67447-91J10 |
Throttle Cable Bolt |
| 12 |
67448-91J00 |
Remocon Cable Stopper |
| 13 |
67460-91J00 |
Remocon Throttle Bracket |
| 14 |
67466-95200 |
Cable Connector |
| 15 |
29141-93J00 |
Nut (6mm) |
| 16 |
09159-06079 |
Nut |
| 17 |
09159-06079 |
Nut |
| 18 |
09160-06104 |
Washer (6.5x24x2) |
| 19 |
09160-08082 |
Washer (8.5x16x1.2) |
| 20 |
09164-08017 |
Wave Washer |
| 21 |
09306-08002 |
Bushing (NLA) |
| 22 |
67447-91J00 |
Clutch Cable Pin (NLA) |
| 23 |
67467-93E01 |
Cable Connector |
| 24 |
09160-06082 |
Washer (6.5x13x1.0) |
| 25 |
09180-06097 |
Spacer |
| 26 |
36831-91J00 |
Stop Switch Lead |
| 27 |
65791-91J00 |
Hose & Cable Clamp Bracket |
| 28 |
29103-93J00 |
Bolt (6x12) |
| 29 |
09403-07325 |
Clamp |
| 30 |
09403-12314 |
Clamp (NLA) |
▶Fig. 4 - Crankshaft (26 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
12111-91J01-0B0 |
Piston |
| 2 |
12140-91J10 |
Piston Ring Set |
| 3 |
12151-90900 |
Piston Pin |
| 4 |
09381-18002 |
Piston Pin Circlip |
| 5 |
12160-91JL0-0A0 |
Connecting Rod Assembly |
| 6 |
12163-91JL0 |
Connecting Rod Bolt (NLA) |
| 7 |
12200-91JL0 |
Crankshaft Assembly |
| 8 |
08211-25361 |
Washer |
| 9 |
12711-91J20 |
Camshaft |
| 10 |
12951-91J01 |
Decompression Cam |
| 11 |
09106-02001 |
Bolt (2x9.8) |
| 12 |
08211-17251 |
Thrust Washer |
| 13 |
12894-91JL0 |
Push Rod |
| 14 |
12961-90900 |
Rocker Arm (NLA) |
| 15 |
12962-91JL0 |
Pivot (NLA) |
| 16 |
12966-91J00 |
Push Rod Guide |
| 17 |
09108-06126 |
Stud Bolt (NLA) |
| 18 |
09140-06021 |
Nut |
| 19 |
12891-87C00 |
Tappet |
| 20 |
12911-91J02 |
Intake Valve |
| 21 |
12915-91J02 |
Exhaust Valve |
| 22 |
12921-91J00 |
Valve Spring |
| 23 |
12931-89L00 |
Valve Spring Retainer (NLA) |
| 24 |
12932-24400 |
Valve Cotter |
| 25 |
12100-91J10-050 |
Piston & Ring Set (OS:0.50) (NLA) |
| 26 |
12140-91J10-050 |
Piston Ring Set (OS:0.50) (NLA) |
▶Fig. 5 - Intake Manifold (6 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
13111-91J90 |
Intake Manifold |
| 2 |
13119-91J00 |
Inlet Manifold Gasket |
| 3 |
01570-06357 |
BOLT |
| 4 |
13710-91J20 |
Flame Arrester |
| 5 |
13720-91J30 |
Flame Arrester Holder |
| 6 |
09180-06310 |
Spacer (6.5x10x10) |
▶Fig. 7 - Carburetor (35 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
13200-91JQ1 |
Carburetor Assembly |
| 2 |
13236-91J50 |
Main Nozzle (NLA) |
| 4 |
13371-91J20 |
Needle Valve |
| 5 |
13250-97J00 |
Carburetor Float |
| 6 |
13254-97J00 |
Float Pin |
| 7 |
13268-97J30 |
Spring |
| 8 |
13251-97J00 |
Float Chamber Gasket |
| 9 |
13245-97J00 |
Float Chamber |
| 10 |
13249-97J00 |
Gasket |
| 11 |
13247-97J00 |
Screw |
| 12 |
13268-97J10 |
Spring |
| 13 |
13616-97J00 |
Screw |
| 14 |
13267-97J00 |
Screw (NLA) |
| 16 |
13267-97J10 |
Screw |
| 17 |
09493-22L01 |
Main Air Jet #110 |
| 18 |
09493-95L01 |
Slow Air Jet #95 |
| 19 |
13249-97J10 |
Gasket |
| 20 |
13248-97J00 |
Plate (NLA) |
| 21 |
13268-97J20 |
Spring |
| 22 |
13534-97J10 |
Screw |
| 23 |
13267-97J20 |
Screw (NLA) |
| 24 |
13125-91J10 |
Carburetor Gasket |
| 25 |
13413-91JL0 |
Choke Rod |
| 26 |
13436-91J00 |
Choke Rod Connector |
| 27 |
13631-91J00 |
Choke Knob |
| 28 |
01547-06857 |
BOLT 6X85 |
| 29 |
08322-01067 |
Washer (6.5x13x1.0) |
| 30 |
44421-13ER0 |
Hose (5x10x600) |
| 31 |
13124-91JL0 |
Carburetor Insulator |
| 45672 |
09492-32011 |
Pilot Jet #32 |
| 45703 |
09492-34004 |
Pilot Jet #34 |
| 45717 |
09491-50L01 |
Main Jet #50 |
| 45718 |
09491-52L01 |
Main Jet #52 |
| 45719 |
09491-54L01 |
Main Jet #54 |
| 45731 |
09492-36L01 |
Pilot Jet #36 |
▶Fig. 9 - Fuel Pump (13 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
15100-91J03 |
Fuel Pump Assembly |
| 2 |
15170-91J02 |
Fuel Pump Diaphragm Set |
| 3 |
15251-91J00 |
Screw |
| 4 |
15410-98500 |
Fuel Filter |
| 5 |
18498-94JL0-130 |
Protector (L:130) (NLA) |
| 6 |
01550-06307 |
BOLT |
| 7 |
09280-27006 |
O-Ring |
| 8 |
09343-50L01-040 |
Hose (5x10x40) |
| 9 |
15191-91JM0 |
Fuel Hose (NLA) |
| 10 |
09343-50L01-300 |
Hose (5x10x300) |
| 11 |
59412-91J00 |
Fuel Hose Clip |
| 12 |
29404-93J11 |
Clamp (L:65) |
| 13 |
18498-94JL0-100 |
Protector (L:100) |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Suzuki DF 4S 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.
