Suzuki DT 140TCLG, DT 140TCXG (1986) Parts & Diagrams

OEM and aftermarket replacement parts for Suzuki DT 140TCLG, DT 140TCXG. Scroll down for exploded parts diagrams (64), specifications, and maintenance reference.

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Ignition Key Switch – Fits Suzuki 8 - 225 HP Outboard Engines (Replaces 37110 - 99E02) - JLM Marine Boat Parts Limited
37110-92E01 Control Box Ignition Key Switch for Suzuki DT25 DT30 DT40 DT50 DT55 DT60 DT65 DT75 DT85 DT90 DT100 DT115 DT140 DT150 DT175 DT200 DT225 | JLM Marine
$17.50
$17.50
files/37110-92E01_07ff13e8-97a4-48d3-938d-e5bfeac45186.pngDefault Title
$17.50
Fuel Filter Element – Fits Mercury/Mariner 6-70 HP (Replaces 35-87946A3, 35-87946Q04)
Fuel Filter Element – Fits Mercury/Mariner 6-70 HP (Replaces 35-87946A3, 35-87946Q04)
$16.99
$16.99
files/23FF046_1.jpgDefault Title
$16.99
32800-94610 32800-94620 Voltage Regulator Rectifier for Suzuki DF4 DF5 DF6 DF9.9 DF15 DT50 DT55 DT60 DT65 DT90 DT100 DT115 DT140 | JLM Marine
32800-94610 32800-94620 Voltage Regulator Rectifier for Suzuki DF4 DF5 DF6 DF9.9 DF15 DT50 DT55 DT60 DT65 DT90 DT100 DT115 DT140 | JLM Marine
$27.54
$27.54
files/Se460c3c0db4d44a59a4c3ef265fb1420Y.jpg_200x200_53c6e157-43c1-4284-bb07-6e5accf7e243.webpDefault Title
$27.54
Water Pump Impeller Repair Kit – Fits Suzuki DT115/DT140 (Replaces 17400 - 94611) - JLM Marine Boat Parts Limited
Water Pump Impeller Repair Kit – Fits Suzuki DT115/DT140 (Replaces 17400-94611)
$34.50
$35.00
$34.50
files/Water_Pump_Impeller_Repair_Kit_for_Suzuki_DT_115_140_18-3256_-_JLM_MARINE-8286581.jpgDefault Title
$34.50

Suzuki DT 140TCLG, DT 140TCXG (1986) Parts & Diagrams

🔎 Suzuki DT 140TCLG, DT 140TCXG Reference Library — Exploded parts diagrams (64 diagrams), specifications, common issues, and maintenance checklist.

The Suzuki DT 140TCLG, DT 140TCXG is a 2-Stroke V4 outboard motor. Powers center-console boats, larger pontoons, and offshore-capable fishing craft.

Quick Reference Specifications

Specification Value
Engine Type 2-Stroke V4
Horsepower 140 HP
Displacement 1332 cc
Bore x Stroke 82.0 x 63.0 mm
Spark Plug (Type & Gap) NGK BR8HS
Engine Oil Capacity —
Recommended Engine Oil TC-W3 Certified 2-Stroke Oil
Gear Case Oil Capacity 1100 mL
Idle Speed (in gear) 700–750 RPM
Full Throttle RPM Range 5000-5500 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 DT 140TCLG, DT 140TCXG:

  • 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
  • Fuel System Issues / Hard Starting: Stale fuel and ethanol-related deposits are common in 2-stroke carbureted engines. Clean or rebuild carburetors and replace fuel lines if deteriorated. → Recommended: Carburetor Repair Kit, Fuel Line Assembly
  • Spark Plug Fouling: 2-stroke engines are prone to spark plug fouling from oil residue, especially at low RPM. Replace plugs at each annual service. → Recommended: OEM Spark Plugs
  • 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
  • Thermostat Failure: A stuck thermostat can cause overheating or poor warm-up. Replace if operating temperature is inconsistent. → Recommended: Thermostat Assembly

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 DT 140TCLG, DT 140TCXG.

▶Fig. 1 - Crankcase (57 parts) Fig. 1 - Crankcase
Ref OEM Part # Part Name
1 11151-94620-0ED Cylinder Head Upper Cover (NLA)
2 11161-94620-0ED Cylinder Head Lower Cover
3 11162-94630 Cylinder Head Cover Gasket (NLA)
4 01560-10807 BOLT
5 09160-08054 Washer
6 01550-06307 BOLT
7 01550-08807 BOLT
8 09246-04005 Plug
9 17670-95303 Thermostat (42c)
10 17681-94612-0ED Thermostat Cover
11 17685-94610 Thermostat Gasket
12 01550-06407 BOLT
13 17660-94601 Water Pressure Valve
13A 17665-94600 Pressure Valve Cover (NLA)
13B 17666-94600 Pressure Valve Plug (NLA)
13C 09128-06021 Bolt (6x14)
16 11141-94620 Cylinder Head Gasket
17 11181-94501 Cylinder Head Connector
18 11182-94500 Cylinder Head Connector Insert
19 11171-94501 Cylinder Head Connector
20 11172-94500 Cylinder Head Connector Insert
23 11231-94602-0ED Cylinder Water Jacket Cover (NLA)
24 11232-94610 Water Jacket Cover Gasket (NLA)
25 01570-06207 BOLT
27 04211-11129 11 X 12 DOWEL P
30 01560-10557 BOLT
31 01560-10757 Bolt (NLA)
32 01550-08407 BOLT 8 X 40
33 16351-94610 Drive Gear Stopper (NLA)
34 11315-94600 Crankcase Plug (NLA)
35 11316-94600 Crankcase Plug (NLA)
36 16361-94600 Oil Gear Plug (NLA)
37 09108-10026 Stud Bolt (NLA)
38 08322-01107 Washer
39 09162-10005 Lock Washer
40 09140-10031 Nut (10mm)
42 34875-94660 Cooling Water Sensor Gasket (NLA)
44 09404-10206 Clamp
45 09352-50006-600 Hose (5x9x600)
46 09401-08411 Clip
48 11130-94600 Zinc Anode
14977 34870-94630 Cooling Water Sensor
15008 34870-94630 Cooling Water Sensor
15036 34820-94610 Cylinder Sensor Assembly (NLA)
15707 03212-0512B SCREW
15738 03121-0516A SCREW
45671 11111-94610-0ED Upper Cylinder Head (NLA)
45672 11121-94610-0ED Lower Cylinder Head (NLA)
45678 11291-94600 Engine Hook (NLA)
45679 01550-08207 BOLT
45683 11301-94625-0ED Cylinder/Crankcase Assembly (NLA)
45702 11111-94620-0ED Upper Cylinder Head (NLA)
45703 11121-94620-0ED Lower Cylinder Head
45709 11291-94600 Engine Hook (NLA)
45710 01550-08207 BOLT
45714 11301-94910-0ED Cylinder/Crankcase Assembly (NLA)
45742 11301-94920-0ED Cylinder/Crankcase Assembly (NLA)
▶Fig. 10 - Throttle Body(DT140EFI - 1997 to 2001) (9 parts) Fig. 10 - Throttle Body(DT140EFI - 1997 to 2001)
Ref OEM Part # Part Name
1 13125-94900 Throttle Body Gasket
2 13300-94910 Throttle Body Assembly (NLA)
3 37810-94900 Throttle Valve Sensor Assembly
4 13381-94900 Throttle Sensor Screw (NLA)
5 13391-94900 Adjust Screw (NLA)
6 09140-05005 Nut
7 09160-05029 Washer (5.5x10x0.8)
8 01550-08557 BOLT
9 09404-08205 Clamp (L:62)
▶Fig. 11 - Fuel Pump(1986 to 1994) (21 parts) Fig. 11 - Fuel Pump(1986 to 1994)
Ref OEM Part # Part Name
1 15100-94604 Fuel Pump Assembly (NLA)
2 15100-7281V Fuel Pump Diaphragm Set
3 15165-93010 Fuel Pump O-Ring
4 01421-06307 BOLTSTUD
5 08316-10067 Nut
5A 01550-06307 BOLT
6 15322-93000 Fuel Pump Insulator(NLA)
7 09280-12012 O-Ring
8 44421-12FR0 Hose (6.5x11.5x600)
9 44421-12FR0 Hose (6.5x11.5x600)
10 44421-12FR0 Hose (6.5x11.5x600)
12 44421-12FR0 Hose (6.5x11.5x600)
13 08310-00087 Nut (8mm)
14 08322-01087 Washer
15 15410-95541 Fuel Filter Assy
17 15415-93400 Fuel Strainer O-Ring
18 15413-93400 Fuel Strainer Cup (NLA)
45673 15430-93412 Fuel Filter Strainer Set
45704 15430-93411 Fuel Filter Strainer Set
45962 09401-11403 Fuel Hose Clip
45963 09401-11415 Clip
▶Fig. 12 - Fuel Pump(1995 to 1996) (25 parts) Fig. 12 - Fuel Pump(1995 to 1996)
Ref OEM Part # Part Name
1 15100-94604 Fuel Pump Assembly (NLA)
2 15100-7281V Fuel Pump Diaphragm Set
3 15165-93010 Fuel Pump O-Ring
4 01550-06307 BOLT
5 15322-93000 Fuel Pump Insulator(NLA)
6 09280-12012 O-Ring
9 44421-12FR0 Hose (6.5x11.5x600)
10 44421-12FR0 Hose (6.5x11.5x600)
11 09401-11415 Clip
12 44421-12FR0 Hose (6.5x11.5x600)
13 08310-00087 Nut (8mm)
14 08322-01087 Washer
15 15410-95541 Fuel Filter Assy
16 15430-93411 Fuel Filter Strainer Set
16A 15415-93400 Fuel Strainer O-Ring
17 15413-93400 Fuel Strainer Cup (NLA)
18 09367-08005 3 Way
19 15410-95541 Fuel Filter Assy
20 15430-87D10 Fuel Filter Strainer Set
21 15413-87D10 Fuel Strainer Cup
22 09408-00024 Clamp
45839 44421-12FR0 Hose (6.5x11.5x600)
45840 44421-12FR0 Hose (6.5x11.5x600)
45870 44421-12FR0 Hose (6.5x11.5x600)
45871 44421-12FR0 Hose (6.5x11.5x600)
▶Fig. 13 - Fuel Pump(DT140EFI - 1997 to 2001) (20 parts) Fig. 13 - Fuel Pump(DT140EFI - 1997 to 2001)
Ref OEM Part # Part Name
1 15100-94911 Fuel Pump Assembly (NLA)
2 15100-7281V Fuel Pump Diaphragm Set
3 15165-93010 Fuel Pump O-Ring
4 15322-93000 Fuel Pump Insulator(NLA)
5 15410-95541 Fuel Filter Assy
6 15430-87D10 Fuel Filter Strainer Set
7 15413-87D10 Fuel Strainer Cup
8 16911-92E20 Protector
9 09280-12012 O-Ring
10 44421-12FR0 Hose (6.5x11.5x600)
11 44421-12FR0 Hose (6.5x11.5x600)
12 44421-12FR0 Hose (6.5x11.5x600)
13 09401-11415 Clip
14 09408-00024 Clamp
15 01550-06307 BOLT
16 08310-00087 Nut (8mm)
17 08322-01087 Washer
18 65793-94600 Fuel Hose Holder (NLA)
19 09100-08215 Bolt (8x16)
20 09160-08082 Washer (8.5x16x1.2)
▶Fig. 14 - Fuel Vapor Separator(DT140EFI - 1997 to 2001) (18 parts) Fig. 14 - Fuel Vapor Separator(DT140EFI - 1997 to 2001)
Ref OEM Part # Part Name
1 15412-92E00 Fuel Filter
2 15600-94901-0ED Fuel Vapor Separator Assembly (NLA)
3 13370-92E00 Needle Valve Assembly
4 13392-16600 Needle Valve Gasket
5 09246-04009 Plug
6 15620-94900-0ED Fuel Vapor Separator Cover (NLA)
7 15626-92E12 Fuel Sep Cover Gasket
8 15650-87D00 Float
9 15654-92E00 Float Pin (NLA)
10 02112-06167 SCREW 6X16
11 15670-94901 Vapor Separator Bracket (NLA)
12 09169-06067 Washer (6.8x19x1.6)
13 09320-09059 Cushion
14 01500-08207 BOLT
15 09160-08054 Washer
16 01550-06257 BOLT
17 09355-35755-600 Hose (L:600)
18 09401-06405 Clamp
▶Fig. 15 - Fuel Injector(DT140EFI - 1997 to 2001) (27 parts) Fig. 15 - Fuel Injector(DT140EFI - 1997 to 2001)
Ref OEM Part # Part Name
1 15100-94900 Fuel Pump Assembly
2 15710-94900 Fuel Injector
2A 15751-94900 Fuel Injector Cushion
3 15741-94900 Fuel Injector Stopper (NLA)
4 15760-92E01 Fuel Pressure Regulator
5 15765-88D20 Fuel Pressure Regulator Holder (NLA)
6 16911-92E20 Protector
7 16911-94900 Protector (NLA)
8 16911-92E20 Protector
9 16911-92E20 Protector
10 09160-06084 Washer (6.5x18x1.6)
11 09168-12013 Gasket
12 09169-06062 Washer (6.3x17x1.6)
13 09354-10173-600 Hose (10x17x600)*
14 09355-35755-600 Hose (L:600)
15 09356-75137-600 Fuel Hose (L:600)
16 09356-75137-600 Fuel Hose (L:600)
17 09356-75137-600 Fuel Hose (L:600)
18 09360-12008 Union Bolt
19 09363-08004 Union
20 09401-06405 Clamp
21 09401-18404 Clip
22 09401-11414 Clip
23 09408-00024 Clamp
24 01550-06357 BOLT
25 02162-06127 BOLT
26 02162-06257 SCREW
▶Fig. 16 - Oil Pump(1986 to 1994) (46 parts) Fig. 16 - Oil Pump(1986 to 1994)
Ref OEM Part # Part Name
1 16100-94605 Oil Pump Assembly (NLA)
2 16191-94600 Air Vent Bolt (NLA)
3 16192-94600 Air Vent Washer (NLA)
4 09401-06405 Clamp
6 09401-08411 Clip
7 08310-00067 Nut
8 09162-06006 Lock Washer
9 01421-06257 BOLT, STUD
10 16340-94610 Driven Gear Retainer (NLA)
11 16731-95520 Oil Pump Retainer Gasket (NLA)
12 16331-94601 Oil Pump Driven Gear (NLA)
13 09209-05017 Connector
14 19131-95502 Connector
15 16411-94601 Oil Pump Control Rod (NLA)
16 09140-05005 Nut
17 09360-06012 Union Bolt
18 09168-06023 Gasket
19 09363-02002 Union
20 16710-92E01 Oil Check Valve (Single)
21 16710-94641 Oil Check Valve (Double)
22 09351-50803-00B Hose (5x8x2000)
23 16911-92E20 Protector
25 16911-92E20 Protector
26 09351-50803-00B Hose (5x8x2000)
28 16911-92E20 Protector
29-2 09355-25705-600 Hose (2.5x7x600)
30 16911-92E20 Protector
31-2 09355-25705-600 Hose (2.5x7x600)
32 09351-50803-00B Hose (5x8x2000)
35 16911-92E20 Protector
36 16810-95501 Oil Filter
37 09408-00024 Clamp
38 09404-08205 Clamp (L:62)
39 16250-94710 Oil Filter/Flow Sensor
12055 09351-50803-00B Hose (5x8x2000)
12086 09352-50006-600 Hose (5x9x600)
12420 09351-50803-00B Hose (5x8x2000)
12451 09352-50006-600 Hose (5x9x600)
45681 09351-25703-600 Hose (2.5x7x600)
45684 09351-25703-600 Hose (2.5x7x600)
45686 09351-25703-600 Hose (2.5x7x600)
45688 09351-25703-600 Hose (2.5x7x600)
45712 09355-25705-600 Hose (2.5x7x600)
45715 09355-25705-600 Hose (2.5x7x600)
45778 09401-08409 Clamp
45779 09401-08409 Clamp
▶Fig. 17 - Oil Pump(1995 to 1996) (27 parts) Fig. 17 - Oil Pump(1995 to 1996)
Ref OEM Part # Part Name
1 16100-94620 Oil Pump Assembly
1A 16091-94900 Bolt (NLA)
1B 16092-92440 Gasket (NLA)
1C 16198-87D00 Oil Pump O-Ring
2 16331-94601 Oil Pump Driven Gear (NLA)
3 16340-94610 Driven Gear Retainer (NLA)
4 16411-94601 Oil Pump Control Rod (NLA)
5 19131-95502 Connector
6 08310-00057 Nut
7 16731-95520 Oil Pump Retainer Gasket (NLA)
8 09209-05017 Connector
9 07130-06307 BOLT
10 16250-94710 Oil Filter/Flow Sensor
11 16710-94641 Oil Check Valve (Double)
12 16911-92E20 Protector
13 16911-92E20 Protector
14 16911-92E20 Protector
15 09351-50803-00B Hose (5x8x2000)
16 09352-50006-600 Hose (5x9x600)
17 09352-50006-600 Hose (5x9x600)
18 09355-25705-600 Hose (2.5x7x600)
19 09367-08005 3 Way
20 09401-06405 Clamp
21 09401-08409 Clamp
22 09401-08411 Clip
23 09404-08205 Clamp (L:62)
24 09408-00024 Clamp
▶Fig. 18 - Oil Pump(DT140EFI - 1997 to 2001) (24 parts) Fig. 18 - Oil Pump(DT140EFI - 1997 to 2001)
Ref OEM Part # Part Name
1 16100-94900 Oil Pump Assembly (NLA)
2 16191-94900 Screw (NLA)
3 16092-92440 Gasket (NLA)
4 16198-87D00 Oil Pump O-Ring
5 16331-94601 Oil Pump Driven Gear (NLA)
6 16340-94610 Driven Gear Retainer (NLA)
7 16420-94900 Oil Pump Cable (NLA)
8 16431-94900 Oil Pump Cable Bracket (NLA)
9 16731-95520 Oil Pump Retainer Gasket (NLA)
10 07130-06307 BOLT
11 16250-94710 Oil Filter/Flow Sensor
13 16911-92E20 Protector
14 16911-92E20 Protector
15 16911-92E20 Protector
16 09351-50803-00B Hose (5x8x2000)
17 09352-50006-600 Hose (5x9x600)
18 09352-50006-600 Hose (5x9x600)
19 09355-25705-600 Hose (2.5x7x600)
20 09401-06405 Clamp
21 09401-08409 Clamp
22 09401-08411 Clip
23 09404-08205 Clamp (L:62)
45992 16710-94641 Oil Check Valve (Double)
45993 16710-92E01 Oil Check Valve (Single)
▶Fig. 19 - Water Pump(1986 to 1996) (25 parts) Fig. 19 - Water Pump(1986 to 1996)
Ref OEM Part # Part Name
1 17563-94502 Water Tube Bushing
3 09306-16002 Bushing
4 17567-94510 Water Tube Gasket (NLA)
5 09320-16011 Bushing
7 09162-06006 Lock Washer
8 09140-06020 Nut (6mm)
9 09117-08062 Bolt (8x70)
10 09117-08063-XC0 Bolt (8x50)
12 09202-04008 Dowel Pin (4x9)
13 17411-94601 Water Pump Case (NLA)
15 17461-90J01 Water Pump Impeller
16 17471-94600 Water Pump Plate
17 17472-94510 Water Pump Plate Gasket
18 09126-06006 Screw (6x20)
19 56130-94502 Drive Shaft Bearing Housing (NLA)
20 09282-24003 Oil Seal (24x36x6)
21 09280-55002 O-Ring
22 09263-26010 Bearing (26x34x20)(NLA)
23 17400-94611 Water Pump Repair Kit DT115 / DT140
45671 09420-05005 Key (NLA)
45689 17560-94521 Water Tube (L)
45690 17560-94531 Water Tube (X) (NLA)
45702 09420-05009 Water Pump Key
45809 09108-06060 Stud Bolt (6x18)
45810 09108-06063 Stud Bolt (6x12)
▶Fig. 2 - Crankshaft(1986 to 1995) (34 parts) Fig. 2 - Crankshaft(1986 to 1995)
Ref OEM Part # Part Name
2 12140-87D02 Piston Ring Set
3 12151-94601 Piston Pin
4 09381-22004 Circlip
5 09263-22063 Bearing (22x28x30)
6 09181-22251 Washer
7 09283-35030 Oil Seal (35x58x8)
8 12200-94900 Crankshaft Assembly (NLA)
9 12161-94900 Connecting Rod
10 12211-94610 Crankshaft Pin Upper
12 12221-94603 Upper Crankshaft (NLA)
13 12231-94602 Middle Upper Wheel (NLA)
14 12232-94601 Middle Under Wheel (NLA)
15 12240-94601 Under Crankshaft (NLA)
16 12322-94600 Inner Seal
17 12323-94600 Ring Seal (NLA)
18 16321-94600 Oil Pump Drive Gear
19 09160-30034 Washer
20 09262-40003 Bearing (40x80x18) (NLA)
21 09263-30019 Bearing (32x40x22)
22 09269-40003 Bearing (40x65x37) (NLA)
23 09421-10002 Key (NLA)
24 09181-35167 Washer (NLA)
25 09181-35240 Washer (NLA)
26 08331-3135A Circlip
27 09263-40010 RC 40x62x27 Bearing
28 09283-40024 Oil Seal (40x26x8)
29 09390-80002 C-Ring
30 04221-04089 PIN 4X8
31 11431-94600 Under Oil Seal Housing (NLA)
32 09280-70005 O-Ring
33 09282-24003 Oil Seal (24x36x6)
45658 12110-94611 Piston
45659 12100-94611-025 Piston & Ring Set (OS:0.25) (NLA)
45660 12100-94611-050 Piston & Ring Set (OS:0.50) (NLA)
▶Fig. 20 - Water Pump(DT140EFI - 1997 to 2001) (31 parts) Fig. 20 - Water Pump(DT140EFI - 1997 to 2001)
Ref OEM Part # Part Name
1 17563-94502 Water Tube Bushing
3 09306-16002 Bushing
4 17567-94510 Water Tube Gasket (NLA)
5 09320-16011 Bushing
6 09108-06063 Stud Bolt (6x12)
7 09162-06006 Lock Washer
8 09140-06020 Nut (6mm)
9 09117-08062 Bolt (8x70)
10 09117-08063-XC0 Bolt (8x50)
11 17522-94520 Gear Case Plug Plate (NLA)
12 09202-04008 Dowel Pin (4x9)
13 17411-94601 Water Pump Case (NLA)
14 09420-05009 Water Pump Key
15 17461-90J01 Water Pump Impeller
16 17471-94600 Water Pump Plate
17 17472-94510 Water Pump Plate Gasket
18 17523-94510 Sub Water Tube Gasket
19 17564-94500 Sub Water Tube Bushing
20 17631-94600 Water Filter
21 17635-94500 Sub Water Filter
22 09117-06040-XC0 Bolt (6x15)
23 09125-05046 Screw (5x12)
24 03112-04309 SCREW 4X30
25 09126-06006 Screw (6x20)
26 56130-94502 Drive Shaft Bearing Housing (NLA)
27 09282-24003 Oil Seal (24x36x6)
28 09280-55002 O-Ring
29 09263-26010 Bearing (26x34x20)(NLA)
30 17400-94611 Water Pump Repair Kit DT115 / DT140
45689 17560-94521 Water Tube (L)
45690 17560-94531 Water Tube (X) (NLA)
▶Fig. 21 - Throttle Link (10 parts) Fig. 21 - Throttle Link
Ref OEM Part # Part Name
1 19111-94602 Throttle Control Lever
2 09116-06127 Bolt (6x12)
3 19131-94503 Cable Rod Retainer
4 19137-94500 Cable Link Rod
5 09159-05011 Turnbuckle
6 19131-95502 Connector
7 09140-05005 Nut
9 09119-05010 Pivot Ball
45870 19136-94600 Throttle Rod (NLA)
45871 19136-94900 Throttle Rod (NLA)
▶Fig. 22 - Clutch (44 parts) Fig. 22 - Clutch
Ref OEM Part # Part Name
1 21210-94500 Clutch Shift Shaft (NLA)
2 09160-08090 Washer
3 21311-94503 Clutch Shaft Holder
4 21312-94500 Clutch Shaft Bushing (NLA)
6 09117-06049 Bolt (6x25)
7 09383-08004 E Ring
12 09204-01002 Cotter Pin
13 25141-94503 Shift Rod Housing Guide (NLA)
14 25141-94510 Shift Rod Housing Guide
15 25142-94560 Shift Guide Gasket
16 25142-94520 Shift Guide Gasket
17 04221-05109 PIN
18 09117-08071 Bolt (8x35)
20 09280-08008 O-Ring
21 09280-15003 O-Ring
22 25211-94501 Shift Rod Guide
23 09160-09015 Washer (9x19x1.0)
24 25205-94501 Shift Rod Spring Collar
25 25311-94510 Shift Cam
26 09160-09010 Washer (9x30x1.6)
27 09205-02004 Spring Pin (2.5x12)
28 09205-02006 Spring Pin (2x12)
29 09205-03021 Spring Pin (3.5x12)
30 09260-10005 Ball
31 09284-08003 Dust Seal
32 09440-07033 Cam Notch Spring
33 21121-93300 Clutch Notch Plate
34 09440-12025 Spring
35 08331-41309 Circlip
36 25230-94300 Gear Case Magnet Set
37 25232-94300 Gear Case Magnet
45676 25111-94503 Shift Rod (L) (NLA)
45707 25111-94503 Shift Rod (L) (NLA)
45735 25111-94511 Shift Rod (X)
45766 25111-94511 Shift Rod (X)
45870 09140-06020 Nut (6mm)
45871 09140-08019 Nut (8mm)
45872 09140-08023-XC0 Nut (8mm)
45901 23110-94502 Clutch Rod (L) (NLA)
45902 23110-94510 Clutch Rod (X) (NLA)
45931 23315-94503 Clutch Rod Connector (L)
45932 23315-94510 Clutch Rod Connector (X)
45962 23313-87D00 Clutch Rod Connector Pin (L)
45963 23313-99E01 Clutch Rod Connector Pin
▶Fig. 23 - Starting Motor(1986 to 1999) (28 parts) Fig. 23 - Starting Motor(1986 to 1999)
Ref OEM Part # Part Name
1 08321-01087 Lock Washer
3 07130-08407 BOLT
5 09180-08097-XC0 Spacer
6 31100-94610 Starter Motor Assembly (NLA)
7 31173-95310 Brush Holder
8 31131-95310 Brush (+)
9 31131-95241 Brush
10 31135-95310 Spring (NLA)
11 31281-94510 Through Bolt
12 31312-94601 Pinion Stopper Set
13 31320-95240 Pinion Assembly (NLA)
14 31360-87D00 Washer Kit (NLA)
15 31310-94600 Armature (NLA)
16 31916-94500 Starter Motor Upper Damper
17 31917-94500 Starter Motor Middle Damper (NLA)
18 31918-94600 Lower Damper (NLA)
19 09407-14403 Clamp (L:125)
20 31911-94620-0ED Starter Motor Bracket
21 01580-08257 BOLT
22 31912-94600 Starting Motor Band (NLA)
23 01550-08167 BOLT
24 09407-14403 Clamp (L:125)
25 33820-94600 Cable Assembly (NLA)
26 01550-08167 BOLT
45689 01500-0835B BOLT
45690 09117-08087 Bolt (8x40) (NLA)
45748 09160-08062 Washer
45749 09160-08054 Washer
▶Fig. 23A - Starting Motor(2000 to 2001) (20 parts) Fig. 23A - Starting Motor(2000 to 2001)
Ref OEM Part # Part Name
1 31100-94610 Starter Motor Assembly (NLA)
2 31131-99E00 Brush (+)
3 31135-99E00 Spring
4 31173-99E00 Brush Holder
5 31281-94510 Through Bolt
6 31310-99E00 Armature (NLA)
7 31312-87J00 Pinion Stopper Set (NLA)
8 31320-94600 Pinion Assembly (NLA)
9 31360-99E10 Washer Kit (NLA)
10 31916-94500 Starter Motor Upper Damper
11 31917-94500 Starter Motor Middle Damper (NLA)
12 09160-08054 Washer
13 09180-08097-XC0 Spacer
14 07130-08407 BOLT
15 31911-94620-0ED Starter Motor Bracket
16 01580-08257 BOLT
17 31912-94600 Starting Motor Band (NLA)
18 31918-94600 Lower Damper (NLA)
19 01550-08167 BOLT
20 33820-94600 Cable Assembly (NLA)
▶Fig. 24 - Magneto(1986 to 1988) (27 parts) Fig. 24 - Magneto(1986 to 1988)
Ref OEM Part # Part Name
1 32102-94600 Flywheel (NLA)
2 32140-94600 Primary Coil #1 (NLA)
3 32140-94610 Primary Coil #2 (NLA)
4 02112-06207 CROSS SCREW,6X2
5 08321-01067 Lock Washer
6 32120-94600 Battery Charge Coil #1 (NLA)
7 32120-94610 Battery Charge Coil #2 (NLA)
8 02112-06257 6X25CROSS SCREW
9 08321-01067 Lock Washer
10 32160-94610 Pulser Coil #1
11 32170-94610 Pulser Coil #2 (NLA)
12 32180-94610 Pulser Coil #3
13 32190-94610 Pulser Coil #4 (NLA)
14 32150-94600 Gear Counter Coil
15 02112-75107 Screw (NLA)
16 02112-35127 SCREW 5X12
17 09140-18007 Nut (NLA)
18 09160-18011 Washer
19 08341-31059 Woodruff Key 5mm
20 11511-94603 Ring Gear Cover (NLA)
22 02142-05087 SCREW 5X8 CROSS
23 33833-91J00 Tube (6x8x250)
24 11521-94602-0ED Ring Gear Case
25 11523-94610 Ring Gear Case Gasket (NLA)
26 02112-06167 SCREW 6X16
27 02142-05167 SCREW 5X16 CROS
28 04221-04089 PIN 4X8
▶Fig. 25 - Magneto(1989 to 1996) (27 parts) Fig. 25 - Magneto(1989 to 1996)
Ref OEM Part # Part Name
1 32102-94613 Flywheel (NLA)
2 32140-94620 Primary Coil #1
3 32140-94630 Primary Coil #2 (NLA)
4 02112-06207 CROSS SCREW,6X2
5 08321-01067 Lock Washer
6 32120-94621 Battery Charge Coil #1
7 32120-94630 Battery Charge Coil #2
8 02112-06257 6X25CROSS SCREW
9 08321-01067 Lock Washer
10 32160-94610 Pulser Coil #1
11 32170-94610 Pulser Coil #2 (NLA)
12 32180-94610 Pulser Coil #3
13 32190-94610 Pulser Coil #4 (NLA)
14 32150-87E20 Gear Counter Coil (NLA)
15 02112-75107 Screw (NLA)
16 02112-35127 SCREW 5X12
17 09140-18007 Nut (NLA)
18 09160-18011 Washer
19 08341-31059 Woodruff Key 5mm
20 11511-94603 Ring Gear Cover (NLA)
22 02142-05087 SCREW 5X8 CROSS
23 33833-91J00 Tube (6x8x250)
24 11521-94602-0ED Ring Gear Case
25 11523-94610 Ring Gear Case Gasket (NLA)
26 02112-06167 SCREW 6X16
27 02142-05167 SCREW 5X16 CROS
28 04221-04089 PIN 4X8
▶Fig. 26 - Magneto(DT140EFI - 1997 to 2001) (18 parts) Fig. 26 - Magneto(DT140EFI - 1997 to 2001)
Ref OEM Part # Part Name
1 32101-94620 Stator Coil
2 32102-94620 Flywheel (NLA)
3 02112-35127 SCREW 5X12
4 02112-36257 SCREW
5 32160-94620 Igntion Timing Coil
6 32156-94610 Igntion Timing Coil Band (NLA)
7 32150-94630 Gear Counter Coil
8 32156-94600 Gear Counter Coil Band
9 09140-18007 Nut (NLA)
10 09160-18011 Washer
11 08341-31059 Woodruff Key 5mm
12 11511-94603 Ring Gear Cover (NLA)
14 33833-91J00 Tube (6x8x250)
15 11521-94900-0ED Ring Gear Case
16 11523-94610 Ring Gear Case Gasket (NLA)
17 01550-06167 BOLT
18 02142-05167 SCREW 5X16 CROS
19 04221-04089 PIN 4X8
▶Fig. 27 - Ignition(1986 to 1996) (31 parts) Fig. 27 - Ignition(1986 to 1996)
Ref OEM Part # Part Name
1 32890-94610 Electric Parts Holder (NLA)
1A 32890-94810 Electric Parts Holder Set (NLA)
2 32890-94640 Electric Parts Holder (NLA)
3 37933-94600 Reset Bracket (NLA)
4 01550-0625A BOLT
5 01550-0616A BOLT
6 09159-14014 Nut (10mm)
7 08316-1006B Nut
8 09160-06052 Washer
10 02142-0625A SCREW
11 32890-94640 Electric Parts Holder (NLA)
12 01500-08307 BOLT
13 09160-08054 Washer
14 09180-08193 Spacer (NLA)
15 09320-12028 Cushion (NLA)
16 32895-94630 Parts Holder Cover (NLA)
17 03211-0520A SCREW
18 03212-0530B SCREW
19 33410-94621 Ignition Coil Assembly (NLA)
20 09309-06007 Grommet (NLA)
21 03211-0520A SCREW
24 33810-94601 Starter Motor Cable
25 36830-94600 Ignition Coil Wiring (NLA)
26 09404-08205 Clamp (L:62)
27 09407-14403 Clamp (L:125)
28 09250-12005 Plug
29 01550-08167 BOLT
45679 33510-95520 Spark Plug Cap
45680 09482-00198 NGK B8HS Spark Plug
45710 33510-87D20 Spark Plug Cap
45711 09482-00370 NGK BR8HS Spark Plug
▶Fig. 28 - Ignition(DT140EFI - 1997 to 2001) (17 parts) Fig. 28 - Ignition(DT140EFI - 1997 to 2001)
Ref OEM Part # Part Name
1 32890-94640 Electric Parts Holder (NLA)
2 01500-08307 BOLT
3 09160-08054 Washer
4 09180-08193 Spacer (NLA)
5 09320-12028 Cushion (NLA)
6 32895-94630 Parts Holder Cover (NLA)
7 03211-0520A SCREW
8 03212-0530B SCREW
9 33410-94630 Ignition Coil Assembly
10 09309-06007 Grommet (NLA)
11 03211-0520A SCREW
12 33510-87D20 Spark Plug Cap
13 09482-00370 NGK BR8HS Spark Plug
14 33810-94601 Starter Motor Cable
15 09404-08205 Clamp (L:62)
16 09407-14403 Clamp (L:125)
17 01550-08167 BOLT
▶Fig. 29 - Electrical(1986 to 2000) (63 parts) Fig. 29 - Electrical(1986 to 2000)
Ref OEM Part # Part Name
1 32800-94601 Rectifier & Regulator (NLA)
2 03212-0530B SCREW
3 08322-01057 Washer
4 32800-87E00 Rectifier & Regulator (NLA)
5 32800-94620 Rectifier & Regulator
6 32805-94600 Rectifier & Regulator Plate (NLA)
8 32800-95D02 Rectifier & Regulator Assembly
9 03212-05253 Screw (NLA)
10 08322-01057 Washer
12 03212-0516B SCREW
13 08322-01057 Washer
14 37920-87D00 Ignition Timing Switch Assembly
15 37920-94621 Ignition Timing Switch Assembly (NLA)
16 37922-94610 Knob
17 02112-04087 SCREW 4X8
18 03212-0512B SCREW
19 09160-05024 Washer (5.5x16x1.5)
20 37940-94701 Ignition Timing Resistor (NLA)
22 03241-0510A SCREW
24 03242-05253 Screw (NLA)
25 38410-94540 PTT Relay Assembly (NLA)
26 38410-94552 PTT Relay Assembly
28 36740-94720 Fuse Case Assembly (NLA)
29 09481-20001 20 Amp Fuse
30 03212-0512B SCREW
31-2 09404-08206 Clamp (L:82)
32 36740-94771 Fuse Case Assembly (NLA)
33 09481-25001 25 Amp Fuse
34 36740-94620 Fuse Case Assembly (NLA)
35 09481-10001 10 Amp Fuse
36 36791-87E00 Fuse Case Holder (NLA)
37 09408-00043 Clamp
38 09407-14403 Clamp (L:125)
39 09408-00021 Clamp (NLA)
41 37930-94706 Oil Warning Reset Switch Assembly (NLA)
42 33831-94630 Trim Relay Cable Assembly (NLA)
43 02112-36207 Screw (NLA)
44 08310-00067 Nut
45 02112-36207 Screw (NLA)
46 08310-00067 Nut
47 34820-94600 Engine Temp Sensor (NLA)
48 34853-94600 Engine Temp Support (NLA)
49 33832-94601 Trim Cable Assembly (NLA)
50 34850-94610 Heat Sensor Assy
51 34853-94700 Heat Sensor Supporter
52 09125-06069 Screw (6x12)
54 36630-92E00 Instrument Wire Assembly
55 36682-92E00 Wire Harness
14611 36610-94600 Wiring Harness Assembly (NLA)
14642 36610-94631 Wiring Harness Assembly (NLA)
14671 36610-94640 Wiring Harness Assembly (NLA)
14702 36610-94670 Wiring Harness Assembly (NLA)
14732 36610-94680 Wiring Harness Assembly (NLA)
19360 36810-94601 Rectifier Extension Lead (NLA)
19391 36810-94610 Rectifier Extension Lead (NLA)
45680 32900-94602 CDI Unit Assembly
45688 09404-08205 Clamp (L:62)
45711 32900-94640 CDI Unit Assembly (NLA)
45839 01550-06257 BOLT
45840 01550-06207 BOLT
45962 37875-94611 Low Oil Warning Unit (NLA)
45963 37875-94630 Low Oil Warning Unit (NLA)
45964 37875-94641 Low Oil Warning Unit
▶Fig. 29A - Electrical(2001) (18 parts) Fig. 29A - Electrical(2001)
Ref OEM Part # Part Name
1 32800-94620 Rectifier & Regulator
2 09404-08205 Clamp (L:62)
3 09407-14403 Clamp (L:125)
4 01550-06207 BOLT
5 36610-94680 Wiring Harness Assembly (NLA)
7 36630-92E00 Instrument Wire Assembly
8 33831-94630 Trim Relay Cable Assembly (NLA)
9 33832-94601 Trim Cable Assembly (NLA)
10 37801-98300 Lead (NLA)
11 36810-94610 Rectifier Extension Lead (NLA)
12 36740-94620 Fuse Case Assembly (NLA)
13 09481-10001 10 Amp Fuse
14 36740-94771 Fuse Case Assembly (NLA)
15 09481-25001 25 Amp Fuse
16 09408-00043 Clamp
17 38410-94552 PTT Relay Assembly
45809 09404-08205 Clamp (L:62)
45810 09404-08206 Clamp (L:82)
▶Fig. 3 - Crankshaft(1996 to 2001) (35 parts) Fig. 3 - Crankshaft(1996 to 2001)
Ref OEM Part # Part Name
1 12110-94611 Piston
2 12140-87D02 Piston Ring Set
3 12151-94601 Piston Pin
4 09381-22004 Circlip
5 09263-22063 Bearing (22x28x30)
6 09181-22251 Washer
7 09283-35030 Oil Seal (35x58x8)
8 12200-94900 Crankshaft Assembly (NLA)
9 12161-94900 Connecting Rod
10 12211-94610 Crankshaft Pin Upper
11 12221-94900 Upper Crankshaft (NLA)
12 12232-94900 Middle Under Wheel (NLA)
13 12231-94900 Middle Upper Wheel (NLA)
14 12240-94900 Under Crankshaft (NLA)
15 12323-94600 Ring Seal (NLA)
16 16321-94600 Oil Pump Drive Gear
17 09160-30034 Washer
18 09262-40003 Bearing (40x80x18) (NLA)
19 09263-30019 Bearing (32x40x22)
20 09269-40003 Bearing (40x65x37) (NLA)
21 09421-10002 Key (NLA)
22 09181-35167 Washer (NLA)
23 09181-35240 Washer (NLA)
24 08331-3135A Circlip
26 09263-40010 RC 40x62x27 Bearing
27 09283-40024 Oil Seal (40x26x8)
28 09390-80002 C-Ring
29 04221-04089 PIN 4X8
30 11431-94600 Under Oil Seal Housing (NLA)
31 09280-70005 O-Ring
32 09282-24003 Oil Seal (24x36x6)
33 12100-94611-025 Piston & Ring Set (OS:0.25) (NLA)
34 12140-95320-025 Piston Ring Set (OS:0.25)(NLA)
35 12100-94611-050 Piston & Ring Set (OS:0.50) (NLA)
36 12140-95320-050 Piston Ring Set (OS:0.50)
▶Fig. 30 - Sensor & Meter(DT140EFI - 1997 to 2001) (18 parts) Fig. 30 - Sensor & Meter(DT140EFI - 1997 to 2001)
Ref OEM Part # Part Name
1 34200-92E02 Tachometer (NLA)
2 34700-92E11 Monitor Gauge Assembly (NLA)
3 34830-92E00 Temp Sensor
4 34853-94700 Heat Sensor Supporter
5 09125-06069 Screw (6x12)
6 34830-94600 Air Temp Sensor (NLA)
7 34853-94700 Heat Sensor Supporter
8 09125-06069 Screw (6x12)
9 34876-92E00 Water Sensor Hole Plug
10 03121-0516A SCREW
11 18590-94600 MAP Sensor
12 09160-06052 Washer
13 09169-06062 Washer (6.3x17x1.6)
15 02162-06257 SCREW
16 09403-17304 Clamp
17 02162-06127 BOLT
45675 34881-94600 Air Pressure Sensor Bracket (NLA)
45706 34881-92E00 Air Pressure Sensor Bracket (NLA)
▶Fig. 31 - Engine Control Unit(DT140EFI - 1997 to 2001) (5 parts) Fig. 31 - Engine Control Unit(DT140EFI - 1997 to 2001)
Ref OEM Part # Part Name
2 36615-96300 Resin Terminal
3 01550-0640A BOLT
4 08310-0006A Nut
45658 33920-94610 Engine Control Unit (NLA)
45659 33920-94640 Engine Control Unit (NLA)
▶Fig. 32 - Solenoid (14 parts) Fig. 32 - Solenoid
Ref OEM Part # Part Name
2 02112-75207 SCREW
3 38617-94600 Choke Solenoid Plate (NLA)
4 38615-94600 Choke Solenoid Cushion (NLA)
5 38616-94600 Choke Solenoid Cushion (NLA)
6 09180-06248 Spacer
7 38600-94810 Choke Solenoid Assembly (NLA)
8 31800-94401 Starter Relay
9 38412-94500 PTT Bracket (NLA)
10 38422-94520 Relay Damper (NLA)
11 33833-91J00 Tube (6x8x250)
12 02112-06167 SCREW 6X16
13 01500-06167 BOLT
13A 01580-06167 BOLT
14 08321-01067 Lock Washer
▶Fig. 33 - Clamp Bracket(1986 to 1995) (31 parts) Fig. 33 - Clamp Bracket(1986 to 1995)
Ref OEM Part # Part Name
3 41130-95541 Clamp Bracket Shaft
4 41151-94500 Clamp Bracket Shaft Cap
5 41152-94500 Clamp Bracket Shaft Plug
6 55320-95311 Zinc Anode
7 09116-06094 Bolt (6x15)
8 09100-12093 Transom Bolt (12x100)
9 09140-12028 Nut
10 41153-94500 Transom Bolt Cap
11 09159-22006 Nut
12 09160-12044 Washer (12.5x35x3.2)
13 09160-12066 Washer (12.5x22x2.5)
14 09162-12005 Lock Washer
15 09100-10155 Bolt (10x50)
16 09100-10264 Bolt (10x80)
17 09162-10005 Lock Washer
18 45420-95500 Tilt Lock Pin
19 09441-24002 Spring (NLA)
20 36894-95201 Wire Lead (L:165)
21 09125-05050 Screw (5x8)
22 09161-05114 Washer (5.2x11x1.0)
23 41161-95250 Steering Cable Seal (NLA)
24 41161-94400 Steering Cable Seal
25 09160-22046 Washer (NLA)
45658 41111-94511-02M Starboard Clamp Bracket (NLA)
45659 41111-95602-0ED Starboard Clamp Bracket (NLA)
45660 41111-94511-01T Starboard Clamp Bracket (NLA)
45689 41121-94531-02M Port Clamp Bracket (NLA)
45690 41121-94532-02M Port Clamp Bracket (NLA)
45691 41121-94531-01T Port Clamp Bracket (NLA)
45692 41121-94532-01T Port Clamp Bracket (NLA)
45693 41121-95610-0ED Port Clamp Bracket (NLA)
▶Fig. 34 - Clamp Bracket(1996 to 2001) (26 parts) Fig. 34 - Clamp Bracket(1996 to 2001)
Ref OEM Part # Part Name
3 41130-95541 Clamp Bracket Shaft
4 41153-94500 Transom Bolt Cap
5 55320-94900 Protection Anode Set
6 09116-06121 Bolt (6x25)
7 09100-12093 Transom Bolt (12x100)
8 09125-06063 Screw (6x10)
9 09140-12028 Nut
10 09159-22006 Nut
11 09160-12044 Washer (12.5x35x3.2)
12 09160-12066 Washer (12.5x22x2.5)
13 09162-12005 Lock Washer
15 09408-00113 Clamp (NLA)
16 45421-87D03 Tilt Lock Pin
17 09106-10065 Bolt (10x20)
18 09159-14020 Nut (14mm)
19 09160-10082 Washer (10.5x19x2.0)
20 41161-94400 Steering Cable Seal
21 34801-94720 Trim Sender (NLA)
22 09100-06113 Bolt (6x16)
24 09125-06063 Screw (6x10)
25 09407-14403 Clamp (L:125)
26 09159-12014 Nut (12x17)
45658 41111-95E03-0ED Starboard Clamp Bracket
45659 41111-94901-0ED Starboard Clamp Bracket (NLA)
45689 41121-95E05-0ED Port Clamp Bracket (NLA)
45690 41121-94901-0ED Port Clamp Bracket (NLA)
▶Fig. 35 - Swivel Bracket(1986 to 1995) (21 parts) Fig. 35 - Swivel Bracket(1986 to 1995)
Ref OEM Part # Part Name
1 43111-94521-0ED Swivel Bracket (NLA)
2 43211-95510 Bushing (NLA)
3 22511-99011 Grease Nipple
4 09306-36002 Bushing (NLA)
5 43740-94505-0ED Pilot Shaft (NLA)
6 09140-33002 Nut (NLA)
7 09160-33002 Lower Washer (NLA)
8 09160-36004 Upper Washer (NLA)
9 09181-36005 Shim (0.3) (NLA)
10 09166-33002 Washer (NLA)
11 09421-05006 Key (NLA)
12 09140-08023-XC0 Nut (8mm)
13 09162-08007 Lock Washer (8.2x15.4x2.0)
14 48311-94501 Trim Cylinder Ram Pad
15 41220-95501-0ED Tilt Lock Lever (NLA)
16 09443-10029 Tilt Lock Lever Spring (NLA)
17 09111-12008 Bolt (NLA)
18 41225-94502 Release Arm Pin
19 36894-94401 Wire Lead (L:195)
20 09125-05050 Screw (5x8)
21 09161-05114 Washer (5.2x11x1.0)
▶Fig. 36 - Swivel Bracket(1996 to 2001) (28 parts) Fig. 36 - Swivel Bracket(1996 to 2001)
Ref OEM Part # Part Name
1 22511-99011 Grease Nipple
2 36894-94401 Wire Lead (L:195)
3 36894-95201 Wire Lead (L:165)
4 43111-94901-0ED Swivel Bracket (NLA)
5 43211-95510 Bushing (NLA)
6 43740-94505-0ED Pilot Shaft (NLA)
7 09140-33002 Nut (NLA)
8 09125-05050 Screw (5x8)
9 09160-33002 Lower Washer (NLA)
10 09160-36004 Upper Washer (NLA)
11 09161-05114 Washer (5.2x11x1.0)
12 09166-33002 Washer (NLA)
13 09181-36005 Shim (0.3) (NLA)
14 09306-36002 Bushing (NLA)
15 09421-05006 Key (NLA)
16 41220-95E13 Starboard Tilt Lock Lever
17 41221-95E40 Port Tilt Lock Lever
18 41224-95E01 Tilt Stopper Rod Bushing
19 41225-94400 Tilt Lock Arm Rubber
20 41228-95E00 Tilt Lock Lever Spring (NLA)
21 41230-95E00 Tilt Lock Lever Link
21A 09160-06082 Washer (6.5x13x1.0)
22 41233-95E10 Tilt Lock Spring Bracket
23 09125-06063 Screw (6x10)
24 09140-10032 Nut
25 09204-01006 Cotter Pin
26 09440-19028 Spring
27 09160-12067 Washer (12.5x23x1.0)
▶Fig. 37 - Tilt Cylinder(1986 to 1995) (18 parts) Fig. 37 - Tilt Cylinder(1986 to 1995)
Ref OEM Part # Part Name
1 48400-94511-0ED Tilt Cylinder Assembly (NLA)
2 48401-94501 Piston & Rod Sub Assembly
3 48427-94500 Tilt Piston O-Ring (NLA)
4 48433-94500 O-Ring (NLA)
5 48441-94510 Cylinder Tube (NLA)
6 22511-99011 Grease Nipple
7 48720-94521 Tilt Inlet Tube (NLA)
8 48730-94521 Tilt Outlet Tube (NLA)
9 48740-94521 Trim Inlet Tube (NLA)
10 48750-94521 Trim Outlet Tube (NLA)
11 48321-94510 Tilt Cylinder Shaft
12 09306-16003 Bushing
13 09380-16003 Circlip
14 09407-14403 Clamp (L:125)
15 48720-94580 Tilt Inlet Tube (NLA)
16 48730-94580 Tilt Outlet Tube (NLA)
17 48740-94580 Trim Inlet Tube (NLA)
18 48750-94580 Trim Outlet Tube (NLA)
▶Fig. 38 - Power Unit(1986 to 1989) (32 parts) Fig. 38 - Power Unit(1986 to 1989)
Ref OEM Part # Part Name
2 09168-10022 Drain Plug Gasket
3 09248-10008 Drain Plug
4 48502-94530 Pump & Valve Body (NLA)
5 48550-94600 Manual Valve Release
6 09136-05041 Screw (5x20)
7 48592-94500 Washer (NLA)
8 48585-94520 Valve Body O-Ring
9 09280-70005 O-Ring
10 48570-94600-0ED Reservoir Assembly (NLA)
11 31281-94510 Through Bolt
12 31170-94520-0ED Upper Cover (NLA)
13 31173-94521 Brush Holder Assembly (NLA)
14 31133-94521 Brush (NLA)
15 31110-94520-0ED Yoke Assembly (NLA)
16 31311-94600 Armature (NLA)
18 09407-14403 Clamp (L:125)
19 48583-94520 Drive Joint
20 09282-08003 Oil Seal (NLA)
21 33861-95600 PTT Cable (NLA)
22 09108-08130 Stud Bolt (8x20)
23 09100-08219 Bolt (8x20) (NLA)
24 09140-08023-XC0 Nut (8mm)
25 09162-08007 Lock Washer (8.2x15.4x2.0)
26 33833-91J00 Tube (6x8x250)
27 48131-95200 Power Unit Spacer (NLA)
28 09108-08137 Stud Bolt (8x40)
29 09140-08023-XC0 Nut (8mm)
30 09162-08007 Lock Washer (8.2x15.4x2.0)
31 38410-94552 PTT Relay Assembly
32 33832-94601 Trim Cable Assembly (NLA)
45658 48500-94620-0ED Power Trim Power Unit Assembly (NLA)
45659 48500-94690-0ED Power Trim Power Unit Assembly (NLA)
▶Fig. 39 - Power Unit(1990 to 1995) (29 parts) Fig. 39 - Power Unit(1990 to 1995)
Ref OEM Part # Part Name
2 09280-09005 O-Ring
3 48511-95500 Oil Filler Plug (NLA)
4 48502-94530 Pump & Valve Body (NLA)
5 48550-94600 Manual Valve Release
6 48581-94500 PTT Pump Filter (NLA)
7 48583-94520 Drive Joint
8 48585-94520 Valve Body O-Ring
9 09136-05041 Screw (5x20)
10 48586-94500 Plug
11 09280-70005 O-Ring
12 31281-94610 Through Bolt (NLA)
13 31170-94610-0ED PTT Motor Cover (NLA)
14 31173-94620 Brush Holder
15 31133-94610 Brush
16 31110-94610-0ED Yoke Assembly (NLA)
17 31311-94610 Armature (NLA)
18 48570-94610-0ED Reservoir Assembly (NLA)
19 33799-94610 Oil Seal
19A 33899-94600 PTT Cable Seal Set (NLA)
20 09108-08130 Stud Bolt (8x20)
21 09140-08023-XC0 Nut (8mm)
22 09162-08007 Lock Washer (8.2x15.4x2.0)
23 09117-08074 Bolt (8x22) (NLA)
24 48131-95200 Power Unit Spacer (NLA)
25 09108-08137 Stud Bolt (8x40)
26 09140-08023-XC0 Nut (8mm)
27 09162-08007 Lock Washer (8.2x15.4x2.0)
45658 48500-94620-0ED Power Trim Power Unit Assembly (NLA)
45659 48500-94690-0ED Power Trim Power Unit Assembly (NLA)
▶Fig. 4 - Intake/Exhaust Cover (18 parts) Fig. 4 - Intake/Exhaust Cover
Ref OEM Part # Part Name
1 13125-95210 Carburetor Gasket
2 08316-10087 Nut
3 01421-08357 BOLT,STUD
5 13121-94510 Inlet Case Gasket (NLA)
6 13150-94502 Reed Valve Assembly (NLA)
7 13152-94501 Reed Valve Stopper (NLA)
8 13153-94500 Reed Valve (NLA)
9 02112-3308A SCREW
11 13156-94511 Reed Valve Gasket (NLA)
12 14151-94510 Exhaust Cover Gasket
13 14131-94503 Exhaust Plate
14 14141-94500-0ED Exhaust Cover (NLA)
15 01550-06357 BOLT
16 36895-94400 Wire Lead (NLA)
17 09404-08205 Clamp (L:62)
18 09404-08206 Clamp (L:82)
45748 13110-94601 Inlet Case (NLA)
45749 13110-946V1 Inlet Case (NLA)
▶Fig. 40 - Power Unit(1996 to 2001) (21 parts) Fig. 40 - Power Unit(1996 to 2001)
Ref OEM Part # Part Name
1 38100-94900-0ED PTT Motor Assembly (NLA)
2 31111-94900 Yoke Screw
3 31311-94900 Armature (NLA)
4 31173-94920 Brush Holder Assembly
5 31133-94910 Brush
6 31135-94900 Spring
7 31136-94900 Breaker (NLA)
8 31110-94900 Yoke Assembly (NLA)
9 31123-87D60 O-Ring
10 33799-97E00 Oil Seal
11 48585-95E00 O-Ring
12 48583-95E00 Drive Joint
13 48502-94901 PTT Pump Assembly
14 48582-95E01 Filter
16 48862-95E00 Bolt
17 48862-95E10 Bolt
18 31281-95E00 Through Bolt
19 09403-17304 Clamp
20 02162-06127 BOLT
45672 48864-94910 Manual Valve Set (NLA)
45703 48864-94911 Manual Valve Set
▶Fig. 41 - Trim Cylinder(1986 to 1995) (8 parts) Fig. 41 - Trim Cylinder(1986 to 1995)
Ref OEM Part # Part Name
1 48600-94511-0ED Trim Cylinder Assembly (NLA)
2 48601-94501 Piston & Piston Rod Assembly (NLA)
3 48627-94500 Trim Piston O-Ring
4 48633-94500 Trim Cylinder O-Ring
5 48641-94510 Trim Cylinder (NLA)
6 48630-94500 Trim Cylinder Head
7 48760-94501 Trim Cylinder Outlet Tube (NLA)
8 48121-94510 Tilt Cylinder Lower Shaft (NLA)
▶Fig. 42 - Trim Cylinder(1996 to 2001) (24 parts) Fig. 42 - Trim Cylinder(1996 to 2001)
Ref OEM Part # Part Name
1 48503-94900-0ED Manifold Sub Assembly (NLA)
2 48401-94900 Piston Assembly (NLA)
3 48627-95E00 O-Ring Set
4 48630-94900 Trim Cylinder Head
5 48633-94900 O-Ring Set (Pack of 2)
6 48601-94900 Piston & Ram Assembly
7 48627-95E00 O-Ring Set
8 48641-94900-0ED PTT Manifold (NLA)
9 48650-94900 Free Piston
10 48405-87D00 Tilt O-Ring Set
11 48615-97E00 Piston Ring Set
12 48861-95E00 Reservoir Bolt (NLA)
13 48570-95E01 Reservoir Assembly
14 48572-95E00 Cap
15 48588-94900 O-Ring (Pack of 6)
16 48121-95E00 Tilt Cylinder Shaft (NLA)
17 48311-94501 Trim Cylinder Ram Pad
18 48321-87D03 Tilt Cylinder Upper Shaft
19 48326-95E00 Tilt Cylinder Lower Bushing
20 09140-08023-XC0 Nut (8mm)
21 09162-08007 Lock Washer (8.2x15.4x2.0)
22 09306-17001 Bushing
23 09380-17009 Circlip
24 09380-22015 Circlip
▶Fig. 43 - Engine Holder (26 parts) Fig. 43 - Engine Holder
Ref OEM Part # Part Name
1 51111-94510-0ED Engine Holder
2 09206-11016 Pin (11x12) (NLA)
3 51211-94530 Engine Holder Gasket (NLA)
4 09206-13017 Pin (13x20)
6 09108-12002 Stud Bolt
7 09140-12029 Nut
8 09162-12005 Lock Washer
9 54136-94503 Upper Mount Stopper (NLA)
12 51112-94502 Upper Mount Cover (NLA)
13 09117-08038 Bolt (8x45)
14 52171-94510 Exhaust Housing
15 52172-94541 Exhaust Housing Gasket
16 52173-94502 Exhaust Housing Seal
17 09117-06049 Bolt (6x25)
18 09117-06032 Bolt (6x30)
19 14211-94622 Exhaust Tube
20 09284-08004 Seal (NLA)
21 09319-08043 Bushing (NLA)
22 09117-06049 Bolt (6x25)
23 09117-08047 Bolt (8x30)
45778 54130-94501 Upper Mount
45779 54130-94511 Upper Mount (NLA)
45931 54141-94501 Upper Front Mount
45932 54141-94510 Upper Front Mount (NLA)
45962 54142-94502 Upper Rear Mount (NLA)
45963 54142-94510 Upper Rear Mount (NLA)
▶Fig. 44 - Drive Shaft Housing (45 parts) Fig. 44 - Drive Shaft Housing
Ref OEM Part # Part Name
1 52111-94511-0ED Driveshaft Housing (NLA)
2 09117-08056-XC0 Bolt (8x40)
3 09117-08071 Bolt (8x35)
4 09206-11016 Pin (11x12) (NLA)
5 52121-94502-0ED Drive Shaft Housing Cover (NLA)
6 52121-94520-0ED Drive Shaft Housing Cover (NLA)
7 01550-06657 BOLT
8 09160-06082 Washer (6.5x13x1.0)
11 54166-94501 Lower Mount Stopper (NLA)
12 54211-94510-0ED Lower Mounting Bracket (NLA)
13 09104-14002 Bolt (14x55) (NLA)
14 09162-14004 Lock Washer (NLA)
15 09118-10039 Bolt (10x130)
16 52131-94511-0ED Extension Case (X) (NLA)
17 09108-10117 Stud Bolt (NLA)
18 09116-10176 Bolt (10x44)
19 09140-10031 Nut (10mm)
20 09162-10005 Lock Washer
21 09206-11016 Pin (11x12) (NLA)
22 52161-94500 Bushing Housing (NLA)
23 57130-94501 Drive Shaft Bushing
24 09117-08047 Bolt (8x30)
26 09387-45001 Set Ring (SUS)
27 04221-05109 PIN
28 52122-94500 Cover Spacer (NLA)
29 09103-06118 Bolt (6x60)
30 52181-94500 Over Flow Tube (NLA)
31 52190-94500 Water Outlet Tube (NLA)
32 52194-94510 Water Outlet Tube Gasket
33 52195-94500 Water Outlet Tube Grommet
34 09117-06038 Bolt (6x16) (NLA)
35 36894-95201 Wire Lead (L:165)
36 09125-05050 Screw (5x8)
37 09161-05114 Washer (5.2x11x1.0)
38 55127-87D00 Hose Union
39 09362-09008 Nipple
41 09407-14403 Clamp (L:125)
43 09100-06131 Bolt (6x12)
14611 09355-40805-600 Hose (4x8x600)
14642 09355-40805-600 Hose (4x8x600)
14671 09355-40805-00B Hose (4x8x2000)
45901 54161-94503 Lower Mount (NLA)
45902 54161-94510 Lower Mount (NLA)
45931 54165-94504 Lower Thrust Mount (NLA)
45932 54165-94510 Lower Thrust Mount (NLA)
▶Fig. 45 - Gear Case (67 parts) Fig. 45 - Gear Case
Ref OEM Part # Part Name
2 09263-28016 Bearing (28.6x38x31.8)
3 17631-94600 Water Filter
4 03112-04309 SCREW 4X30
5 17635-94500 Sub Water Filter
6 09125-05046 Screw (5x12)
7 09116-10142 Bolt (10x100) w/Washer
8 09116-10176 Bolt (10x44)
9 09162-10005 Lock Washer
10 55125-94502 Zinc Anode
11 55320-95311 Zinc Anode
12 09116-06094 Bolt (6x15)
13 55332-94510 Exhaust Seal Rubber (NLA)
14 55333-94510 Exhaust Seal Plate
15 17520-94500 Sub Water Tube (NLA)
16 17523-94510 Sub Water Tube Gasket
17 17564-94500 Sub Water Tube Bushing
18 09117-06040-XC0 Bolt (6x15)
19 55334-94500 Exhaust Seal Cover
20 09108-06062 Stud Bolt (6x12)
21 09140-06020 Nut (6mm)
22 09162-06006 Lock Washer
23 09168-10022 Drain Plug Gasket
24 09248-10008 Drain Plug
25 09206-11016 Pin (11x12) (NLA)
27 57633-95501 Propeller Nut Spacer
28 57635-95300 Propeller Nut Washer
29-2 57635-94511 Propeller Bushing Stopper
30 57633-94500 Propeller Nut Spacer
31 57634-94500 Propeller Nut Washer (NLA)
32 09159-18004 Nut
33 09141-18005 Nut (18mm)
34 09204-03003 Prop Nut Cotter Pin
35 09160-18028 Washer (18.5x31x1.0)
37 58120-95500 Type U Propeller Bushing
39 58120-94520 Propeller Bushing (NLA)
40 55181-95200 Flush Hose Attachment
41 55300-95500 Zinc Anode
42 17500-94520 Exhaust Seal Assembly (NLA)
43 17636-94500 Sub Water Tube Plug (NLA)
44 55182-95200 Flush Hose Attachment (NLA)
45 17500-94510 Cooling Tube Set (NLA)
46 17600-94500 Sub Water Tube Plug Kit (NLA)
47 55116-94511 Gear Case Plug (NLA)
49 25700-94500 Gear Case Seal Kit DT115 / DT140 (NLA)
50 25141-94510 Shift Rod Housing Guide
51 25142-94520 Shift Guide Gasket
52 52121-94520-0ED Drive Shaft Housing Cover (NLA)
53 09103-06118 Bolt (6x60)
54 09284-08003 Dust Seal
13150 58100-95511-019 U1700 Propeller 3x13-1/4x17 (NLA)
13181 58100-95550-019 U1800 Propeller 3x13x18 (NLA)
13210 58100-95521-019 U1900 Propeller 3x13x19 (NLA)
13881 99105-00100-14P S/S Propeller 3x13-1/4x14 (NLA)
13912 99105-00100-16P S/S Propeller 3x13-1/14x16 (NLA)
13940 99105-00100-18P S/S Propeller 3x13-1/4x18 (NLA)
13971 99105-00101-20P S/S Propeller 3x13-1/4x20 (NLA)
14001 58100-94500-019 V1500 Propeller 3x13-1/2x15
14032 58100-94512-019 V1700 Propeller 3x13-3/4x17
14062 58100-94522-019 V1900 Propeller 3x13x19
14093 58100-94532-019 V2100 Propeller 3x13x21
17533 57630-94500 Propeller Hardware Kit DT75 / DT85 / DT90 / DT100 / DT115 / DT140/DF60 / DF70 V-Style
17564 57630-95500 Propeller Hardware Kit DT75 / DT85 / DT90 / DT100 / DT115 / DT140/DF60 / DF70 U-Style
45658 55100-94530-0ED Gear Case Housing
45659 55100-94530-0ED Gear Case Housing
45683 57635-95503 Propeller Bushing Stopper
45686 57635-94502 Propeller Bushing Stopper
45714 57635-95510 Propeller Bushing Stopper
▶Fig. 46 - Transmission (66 parts) Fig. 46 - Transmission
Ref OEM Part # Part Name
3 09205-04019 Pin
4 57133-94502 Drive Shaft Spring Collar (NLA)
5 09166-30006 Thrust Washer (2.50)
6 09160-30031 Thrust Washer (2.50) (NLA)
7 09160-32005 Thrust Washer (4.25)
9 09263-30046 Bearing (30x52x8)
10 57300-94832 Pinion & Gear Set (NLA)
11 09140-16021 Pinion Nut
12 09209-12007 Push Pin
13 57631-94501 Push Rod (L:77) (NLA)
14 56140-94510 Forward Gear Bearing Housing (NLA)
15 09205-05011 Spring Pin (5x14)
16 09263-50001 Bearing (50x62x25)
18 09269-70001 Bearing (70x95x4.0)
19 09160-70002 Thrust Washer (5.25)
21 09440-11020 Spring
22 09202-07002 Pin (7x48)
23 09440-50002 Clutch Dog Spring
24 57621-94520 Clutch Dog Shifter
26 09181-25030 Shim (3.00)
28 56120-94513-0ED Propeller Shaft Bearing Housing (NLA)
29 09263-28013 Bearing (28x37x20)
30 09280-97001 O-Ring
31 09282-28002 Oil Seal
32 09387-52001 Set Ring (SUS)
33 08113-60097 B1 45X75X16 BEA
34 09117-08047 Bolt (8x30)
45658 57100-94540 Drive Shaft (L)
45659 57100-94540 Drive Shaft (L)
45660 57100-94550 Drive Shaft (X) (NLA)
45661 57100-94550 Drive Shaft (X) (NLA)
45674 09181-70008 Shim (0.55)
45677 09181-45003 Shim (1.00)
45682 57610-94506 Propeller Shaft Assembly (NLA)
45684 09181-28015 Shim (0.90)
45689 09440-31003 Drive Shaft Spring
45690 09440-36002 Drive Shaft Spring (NLA)
45705 09181-70006 Shim (0.60)
45708 09181-45004 Shim (1.10)
45713 57610-94520 Propeller Shaft Assembly
45715 09181-28016 Shim (1.00)
45733 09181-70009 Shim (0.65)
45736 09181-45005 Shim (1.20)
45743 09181-28017 Shim (1.20)
45764 09181-70001 Shim (0.70)
45767 09181-45006 Shim (1.30)
45774 09181-28018 Shim (1.30)
45794 09181-70010 Shim (0.75)
45797 09181-45007 Shim (1.40)
45804 09181-28019 Shim (1.40)
45825 09181-70002 Shim (0.80)
45828 09181-45008 Shim (1.50)
45835 09181-28020 Shim (1.60)
45855 09181-70011 Shim (0.85)
45858 09181-45009 Shim (1.60)
45870 09181-30299 Shim (0.60) (NLA)
45871 09181-30300 Shim (0.70)
45872 09181-30302 Shim (0.80) (NLA)
45873 09181-30304 Shim (0.90) (NLA)
45874 09181-30306 Shim (1.00) (NLA)
45875 09181-30312 Shim (1.10) (NLA)
45876 09181-30316 Shim (1.20)
45877 09181-30321 Shim (1.30)
45886 09181-70003 Shim (0.90)
45917 09181-70012 Shim (0.95)
45947 09181-70004 Shim (1.00)
▶Fig. 47 - Lower Cover (69 parts) Fig. 47 - Lower Cover
Ref OEM Part # Part Name
1 61110-94X53-0ED Lower Engine Cover (NLA)
2 61155-94500 Water Inspection Tube
3 61131-94502-0ED Engine Holder Starboard Cover (NLA)
4 61141-94503-0ED Engine Holder Port Cover
6 13979-37400 Drain Tube Retainer (NLA)
7 61112-94502 Lower Cover Upper Seal (NLA)
8 61113-94503 Lower Cover Lower Seal
11 09160-06082 Washer (6.5x13x1.0)
12 09128-06052 Bolt (6x26) (NLA)
14 61138-94601 Water Cover
15 09122-86003 Bolt (6x16) (NLA)
17 33816-94600 Clamp (NLA)
18 01421-06127 BOLT, STUD
20 08316-10067 Nut
21 36616-94600 Harness Connector Holder (NLA)
22 09125-06069 Screw (6x12)
23 01550-06127 BOLT
24 36895-95300 Lead (NLA)
27 09162-08007 Lock Washer (8.2x15.4x2.0)
28 61142-94502 Grommet (NLA)
29 09250-09008 Plug
30 09250-10012 Cap (NLA)
31 09308-08013 Grommet
32 36656-94900 PTT Cable Grommet (NLA)
33 67271-94500 Remocon Cable Holder
34 67276-94502 Remocon Cable Holder Plate (NLA)
35 01421-06127 BOLT, STUD
36 01421-06307 BOLTSTUD
37 08316-10067 Nut
38 36656-94612 Cable Grommet (NLA)
39 36661-95210 PTT Cable Cap (NLA)
40 13851-95210 Cushion (NLA)
41 13851-95210 Cushion (NLA)
42 61240-94610-70G Lower Cover Decal Set (NLA)
43 61231-94600-26G Port Lower Cover Decal (NLA)
46 61610-95514 Fastener
47 01500-06127 BOLT
48 01550-06167 BOLT
49 08321-01067 Lock Washer
50 08322-01067 Washer (6.5x13x1.0)
51 37850-95612 PTT Switch Assembly
52 09407-25402 Clamp (L:248)
54 09250-20006 Cap
55 37930-95612 Oil Warning Reset Switch Assembly
56 37935-95602 Low Oil Warning Reset Label (NLA)
57 17911-94611 Flush Connector Grommet (NLA)
58 17912-94610 Flush Hose Connector
59 17913-94610 Flush Connector Plug
60 59291-94J00 O-Ring
61 09355-90145-600 Hose (9x14x600)
62 09401-13416 Clip (NLA)
64 17917-94600 Flush Water Connector
16072 61116-94601 Engine Cover Hook Bracket (NLA)
16103 61116-94601 Engine Cover Hook Bracket (NLA)
16438 09117-06046 Bolt (6x20) (NLA)
16469 09117-06046 Bolt (6x20) (NLA)
16497 09116-06204 Bolt (6x20)
45673 09125-06069 Screw (6x12)
45682 09117-08056-XC0 Bolt (8x40)
45683 09160-08081 Washer (8.5x23x1.5)
45704 02142-06127 SCREW 6X12
45713 09116-08174 Bolt (8x38)
45714 09160-08082 Washer (8.5x16x1.2)
45778 61139-94511 Drain Tube
45779 61139-94901 Drain Tube
45901 61631-94602 Engine Cover Hook (NLA)
45902 61631-94602 Engine Cover Hook (NLA)
45931 09117-06040-XC0 Bolt (6x15)
45932 01550-06167 BOLT
▶Fig. 48 - Engine Cover(1986 to 1987) (44 parts) Fig. 48 - Engine Cover(1986 to 1987)
Ref OEM Part # Part Name
1 61403-94810-02M Engine Cover Set (NLA)
2 61421-94601-2CS Front Emblem (NLA)
3 61422-94600-26N Front Emblem Mark (NLA)
4 68181-17D00-019 Suzuki Emblem
5 61442-94600-019 Oil Injection Mark (NLA)
11 61443-94630-70G Starboard Engine Cover Stripe
12 61453-94630-70G Port Engine Cover Decal (NLA)
13 61641-94501 Engine Cover Hook (NLA)
14 61651-95501 Hook Spring Holder (NLA)
15 61641-95500 Release Hook (NLA)
16 61652-95500 Hook Spring Holder Packing (NLA)
17 61652-94501 Grommet (NLA)
18 61653-95501 Release Hook Shaft (NLA)
19 61653-94502 Latch Release Rod (NLA)
20 61660-95500 Hook Knob (NLA)
21 61661-94501 Lower Cover Latch Lever (NLA)
22 09383-03001 E Ring
23 03241-0616C SCREW
24 08322-01067 Washer (6.5x13x1.0)
25 61431-94503-0ED Tilt Up Handle (NLA)
26 61654-95500 Nut (NLA)
27 19131-95502 Connector
28 09209-05017 Connector
29 09443-06040 Spring (NLA)
30 09125-06067 Screw (6x16)
31 09140-06020 Nut (6mm)
32 09160-06055 Washer (7x12x1.0)
33 61642-95500 Pin (NLA)
34 09441-12001 Spring (SUS)
35 09385-06003 Pin (NLA)
36 09301-06005 Bushing (NLA)
37 61481-94504-0ED Oil Tank Filler Lid (NLA)
38 61482-94510 Oil Filler Lid Hinge
39 61485-94500 Oil Filler Lid Spring
40 61544-94500 Oil Filler Pad
41 61486-94600 Engine Cover Cap (NLA)
42 61487-94602 Front Emblem Inner Cover (NLA)
43 03241-0516A SCREW
45809 03241-0516A SCREW
45810 03241-0510A SCREW
45839 61435-94600-70G Rear Emblem Mark (NLA)
45840 61435-94600-8EH Rear Emblem Mark (NLA)
45870 61443-94620-70G Starboard Engine Cover Decal (NLA)
45871 61443-94620-8EH Starboard Engine Cover Decal (NLA)
▶Fig. 49 - Engine Cover(1988) (39 parts) Fig. 49 - Engine Cover(1988)
Ref OEM Part # Part Name
1 61420-94882-0ED Engine Cover Set (NLA)
2 61421-94601-2CS Front Emblem (NLA)
3 61422-94600-26N Front Emblem Mark (NLA)
4 68181-17D00-019 Suzuki Emblem
5 61442-94600-019 Oil Injection Mark (NLA)
11 61443-94630-70G Starboard Engine Cover Stripe
12 61453-94630-70G Port Engine Cover Decal (NLA)
13 61641-94501 Engine Cover Hook (NLA)
14 61641-94600 Front Hook (NLA)
15 61645-94600-0ED Front Hook Lever (NLA)
16 09100-06131 Bolt (6x12)
17 09160-06036 Washer (6.5x18x1.5)
18 09162-06006 Lock Washer
19 09164-13005 Wave Washer
20 61652-94501 Grommet (NLA)
21 61653-94502 Latch Release Rod (NLA)
22 61661-94501 Lower Cover Latch Lever (NLA)
23 09383-03001 E Ring
24 03241-0616C SCREW
25 08322-01067 Washer (6.5x13x1.0)
26 61431-94503-0ED Tilt Up Handle (NLA)
27 19131-95502 Connector
28 09209-05017 Connector
29 09443-06040 Spring (NLA)
30 09125-06067 Screw (6x16)
31 09140-06020 Nut (6mm)
32 09160-06055 Washer (7x12x1.0)
33 61642-95500 Pin (NLA)
34 09385-06003 Pin (NLA)
35 09301-06005 Bushing (NLA)
36 61481-94504-0ED Oil Tank Filler Lid (NLA)
37 61482-94510 Oil Filler Lid Hinge
38 61485-94500 Oil Filler Lid Spring
39 61544-94500 Oil Filler Pad
40 61486-94600 Engine Cover Cap (NLA)
41 61487-94602 Front Emblem Inner Cover (NLA)
42 03241-0516A SCREW
45809 03241-0516A SCREW
45810 03241-0510A SCREW
▶Fig. 5 - Intake Manifold(DT140EFI - 1997 to 2001) (5 parts) Fig. 5 - Intake Manifold(DT140EFI - 1997 to 2001)
Ref OEM Part # Part Name
1 13111-94900-0ED Intake Manifold (NLA)
2 13121-94510 Inlet Case Gasket (NLA)
3 01421-08357 BOLT,STUD
4 08316-10087 Nut
5 09404-08206 Clamp (L:82)
▶Fig. 50 - Engine Cover(1989 to 1994) (49 parts) Fig. 50 - Engine Cover(1989 to 1994)
Ref OEM Part # Part Name
1 61420-94882-0ED Engine Cover Set (NLA)
6 61435-94630-70G Rear Emblem Mark (NLA)
9 03241-0512A SCREW
11 61443-94630-70G Starboard Engine Cover Stripe
13 61453-94630-70G Port Engine Cover Decal (NLA)
14 61641-94501 Engine Cover Hook (NLA)
15 61641-94600 Front Hook (NLA)
16 61645-94600-0ED Front Hook Lever (NLA)
17 09100-06131 Bolt (6x12)
17A 09118-06095 Bolt (6x12)
18 09162-06006 Lock Washer
19 09160-06036 Washer (6.5x18x1.5)
20 09164-13005 Wave Washer
21 61652-94501 Grommet (NLA)
22 61653-94502 Latch Release Rod (NLA)
23 61661-94501 Lower Cover Latch Lever (NLA)
24 09383-03001 E Ring
25 03541-0616A SCREW
26 08322-01067 Washer (6.5x13x1.0)
27 61431-94503-0ED Tilt Up Handle (NLA)
28 19131-95502 Connector
29 09209-05017 Connector
30 09443-06040 Spring (NLA)
31 09125-06067 Screw (6x16)
32 09160-06055 Washer (7x12x1.0)
33 09140-06020 Nut (6mm)
34 61642-95500 Pin (NLA)
35 09385-06003 Pin (NLA)
36 09301-06005 Bushing (NLA)
37 61481-94504-0ED Oil Tank Filler Lid (NLA)
38 61482-94510 Oil Filler Lid Hinge
39 61485-94500 Oil Filler Lid Spring
40 61544-94500 Oil Filler Pad
41 61486-94600 Engine Cover Cap (NLA)
42 61487-94602 Front Emblem Inner Cover (NLA)
43 03241-0512A SCREW
44 61651-94602 Front Hood Holder (NLA)
45 09229-04027 Rivet (NLA)
46 08322-01057 Washer
47 61644-94502 Cover Locating Bracket (NLA)
48 09229-04014 Rivet (NLA)
49 61670-94600 Oil Lid Striker Assy (NLA)
50 09250-12012 Cap (NLA)
51 03241-0410A SCREW
52 09800-01016 Tool Set
45839 61441-94600-764 Suzuki Emblem (NLA)
45840 68181-17D00-019 Suzuki Emblem
45870 61442-94600-764 Oil Injection Mark
45871 61442-94600-019 Oil Injection Mark (NLA)
▶Fig. 51 - Engine Cover(1995 to 1996) (28 parts) Fig. 51 - Engine Cover(1995 to 1996)
Ref OEM Part # Part Name
1 61420-94810-0ED Engine Cover Set (NLA)
2 61651-94602 Front Hood Holder (NLA)
3 09229-04027 Rivet (NLA)
4 08322-01057 Washer
5 61431-94503-0ED Tilt Up Handle (NLA)
6 61481-94504-0ED Oil Tank Filler Lid (NLA)
7 61482-94510 Oil Filler Lid Hinge
8 61485-94500 Oil Filler Lid Spring
9 61486-94600 Engine Cover Cap (NLA)
10 61544-94500 Oil Filler Pad
11 61641-94600 Front Hook (NLA)
11A 61631-94610 Rear Hook (NLA)
12 61645-94600-0ED Front Hook Lever (NLA)
13 61670-94600 Oil Lid Striker Assy (NLA)
14 09118-06095 Bolt (6x12)
15 09125-06067 Screw (6x16)
16 09140-06020 Nut (6mm)
17 09160-06082 Washer (6.5x13x1.0)
18 09164-13005 Wave Washer
19 09250-12012 Cap (NLA)
20 03241-0410A SCREW
21 03541-0616A SCREW
22 08322-01067 Washer (6.5x13x1.0)
23 61440-94660 Engine Cover Stripe Set (NLA)
24 68111-42031-1RR Suzuki Mark
26 61435-94670 Rear Mark "140" (NLA)
27 61581-98620 Engine Cover Label
28 09800-01016 Tool Set
▶Fig. 52A - Engine Cover(DT140EFI - 1997 to 2001) (33 parts) Fig. 52A - Engine Cover(DT140EFI - 1997 to 2001)
Ref OEM Part # Part Name
1 61420-94882-0ED Engine Cover Set (NLA)
2 61651-94602 Front Hood Holder (NLA)
3 09229-04032 Rivet (NLA)
4 08322-01057 Washer
5 61431-94503-0ED Tilt Up Handle (NLA)
6 61481-94504-0ED Oil Tank Filler Lid (NLA)
7 61482-94510 Oil Filler Lid Hinge
8 61485-94500 Oil Filler Lid Spring
9 61486-94600 Engine Cover Cap (NLA)
10 61544-94500 Oil Filler Pad
11 61641-94600 Front Hook (NLA)
12 61631-94610 Rear Hook (NLA)
13 61645-94600-0ED Front Hook Lever (NLA)
14 61670-94600 Oil Lid Striker Assy (NLA)
15 09118-06095 Bolt (6x12)
16 02142-06167 6 X 16 CROSS SC
17 09140-06020 Nut (6mm)
18 09164-13005 Wave Washer
19 03241-0410A SCREW
20 03541-0616A SCREW
21 08322-01067 Washer (6.5x13x1.0)
22 61443-94910 Starboard Engine Cover Stripe
23 61453-94910 Port Engine Cover Decal (NLA)
24 68111-42031-1RR Suzuki Mark
25 61463-94910 Engine Cover Rear Decal
26 61421-94601-2TN Engine Cover Emblem
27 61422-94640-019 Front Emblem Mark (NLA)
28 61487-94602 Front Emblem Inner Cover (NLA)
29 03241-0512A SCREW
30 03241-0512A SCREW
31 69711-93E11 Label (S.I.G.P)
32 61581-98620 Engine Cover Label
33 09800-01016 Tool Set
▶Fig. 53 - Oil Tank (15 parts) Fig. 53 - Oil Tank
Ref OEM Part # Part Name
1 69110-94602 Oil Tank
2 69200-94510 Suzuki Oil Tank Cap
3 69241-94500 Oil Tank Cap Gasket
4 69311-94610 Oil Tank Support (NLA)
5 01550-08167 BOLT
6 69312-94600 Upper Cushion (NLA)
7 09329-12004 Cushion
8 69361-94602 Oil Tank Cushion
9 34860-94621 Oil Level Sensor (NLA)
45931 34701-92X50 Monitor Gauge Assembly (NLA)
45932 34700-92E11 Monitor Gauge Assembly (NLA)
45962 36660-94610 Monitor Gauge Harness (21 ft) (NLA)
45963 36660-94690 Monitor Wiring Harness (NLA)
45964 36660-95610 Monitor Gauge Harness (21 ft)
45965 36660-92E90 Monitor Gauge Harness (6 ft) (NLA)
▶Fig. 54 - Fuel Tank (44 parts) Fig. 54 - Fuel Tank
Ref OEM Part # Part Name
1 65800-92823 Fuel Tank Set (NLA)
2 65510-92D00 Fuel Tank Cap Assembly
3 65561-92D00 Tank Cap Gasket
4 02112-16167 SCREW
8 65850-92D01 Fuel Gauge Assembly (NLA)
11 65853-92D00 Lens (NLA)
13 03222-04083 Screw (NLA)
14 65864-92D00 Float (NLA)
15 65866-92D00 Push Nut (NLA)
16 65871-92D00 Gasket (NLA)
17 65700-87D16 Fuel Hose (NLA)
18 65750-94404 Fuel Hose Connector
20 65781-98500 Hose Clip
21 65720-94411 Fuel Connector (NLA)
22 09161-12004 Washer
24 09161-12004 Washer
25 65700-87D85 Fuel Hose
26 65750-95501 Fuel Hose Connector (13mm)
27 65750-98506 Fuel Hose Connector (11mm)
28 65770-95540 Squeeze Pump (NLA)
29 65781-98500 Hose Clip
30 65700-87D32 Fuel Hose (NLA)
31 65750-95501 Fuel Hose Connector (13mm)
32 65770-95540 Squeeze Pump (NLA)
33 65781-98500 Hose Clip
35 65700-87D23 Fuel Hose
37 65781-98500 Hose Clip
38 09401-10409 Clip
12420 09407-14403 Clamp (L:125)
12451 09407-25402 Clamp (L:248)
45680 65720-955L1 Fuel Connector
45711 65721-87D00 Fuel Connector (NLA)
45778 09168-06004 Washer
45779 09168-06026 Gasket
45809 65720-94411 Fuel Connector (NLA)
45810 65740-95501 Fuel Tank Connector (13mm)
45839 09168-12001 Gasket
45840 09168-12015-XC0 Gasket (12.2x21x0.8)
45901 65855-92D00 Gauge Cover (NLA)
45902 65855-92D10 Gauge Cover (NLA)
45931 65854-92D10 Lens Gasket (NLA)
45932 65854-92D20 Lens Gasket (NLA)
45992 65854-92D00 Lens Gasket (NLA)
45993 65854-92D30 Lens Gasket (NLA)
▶Fig. 55 - Remote Control(1986 to 1992) (56 parts) Fig. 55 - Remote Control(1986 to 1992)
Ref OEM Part # Part Name
1 67200-87D61 Side Mount Control Box (NLA)
2 67232-95600 Bushing
3 67232-95620 Bushing (NLA)
4 67296-95600 Screw
5 67294-95600 Spacer
6 09160-06104 Washer (6.5x24x2)
7 09140-06020 Nut (6mm)
8 67232-95610 Bushing (NLA)
9 67253-95600 Washer (NLA)
10 67252-95600 Bushing
11 09100-08232 Bolt (8x30)
12 67238-87D00 Drive Gear
13 67296-94300 Screw (4x10)
14 37721-94601 Neutral Switch Assembly
16 09126-05003 Screw (5x12)
17 67243-95600 Bushing (NLA)
18 67220-95620 Plate Assembly
19 67275-95600 Cable End
20 67223-95600 Brake Adjustment Knob
21 67292-94300 E Ring
23 67296-95610 Screw
25 67256-95600 Neutral Lock Holder
27 37110-99E02 Ignition Switch Assembly
29 67297-95600 Washer
30 67273-95600 Spacer
31 38500-92X50 Warning Buzzer
32 36620-92E00 21' Main Wire Harness (NLA)
33 37820-92E05 Emergency Stop Switch Assembly
34 37823-94401 Emergency Stop Switch Cap
35 67255-95600 Neutral Lock Arm
36 67261-95600 Handle Grip for PTT
37 37860-94610 Trim Switch Assembly
38 67263-95600 Grip Cap
39 09139-02003 Screw (2x6)
40 37869-95590 Trim Switch Cap
41 67245-95600 Free Throttle Drum (NLA)
42 67258-87D00 Neutral Arm Bracket
43 67259-87D00 Neutral Arm Spring (NLA)
44 67140-95600 Replaced by 67140-95601
45 67282-95610 Port Decal (Black) (NLA)
45672 67241-95600 Free Throttle Lever (White) (NLA)
45679 67267-95600 Wire Cover (Blue) (NLA)
45681 67257-95600 Lever Cap (Blue)
45683 67251-95600 Handle Lever (White) (NLA)
45685 37141-94401 (101) Ignition Key
45703 67241-95650 Free Throttle Lever (Silver) (NLA)
45710 67267-95610 Wire Cover (Black)
45712 67257-95610 Lever Cap (Black)
45714 67251-95680 Handle Lever (Gray) (NLA)
45716 37141-94410 (102) Ignition Key
45740 67257-95620 Lever Cap (Burgundy) (NLA)
45742 67251-95680 Handle Lever (Gray) (NLA)
45744 37141-94420 (103) Ignition Key*
45775 37141-94431 (104) Ignition Key
45805 37141-94440 (105) Ignition Key
45836 37141-94450 (106) Ignition Key*
▶Fig. 56 - Remote Control(1993 to 2001) (54 parts) Fig. 56 - Remote Control(1993 to 2001)
Ref OEM Part # Part Name
1 67200-87D61 Side Mount Control Box (NLA)
2 67232-95600 Bushing
3 67232-95620 Bushing (NLA)
4 67296-95600 Screw
5 67294-95600 Spacer
6 09160-06104 Washer (6.5x24x2)
7 09140-06020 Nut (6mm)
8 67232-95610 Bushing (NLA)
9 67253-95600 Washer (NLA)
10 67252-95600 Bushing
11 09100-08232 Bolt (8x30)
12 67238-87D00 Drive Gear
13 67296-94300 Screw (4x10)
14 37721-94601 Neutral Switch Assembly
15 67241-95680 Free Throttle Lever (Gray) (NLA)
16 09126-05003 Screw (5x12)
17 67243-95600 Bushing (NLA)
18 67220-95620 Plate Assembly
19 67275-95600 Cable End
20 67223-95600 Brake Adjustment Knob
21 67292-94300 E Ring
22 67267-95610 Wire Cover (Black)
23 67296-95610 Screw
24 67257-95610 Lever Cap (Black)
25 67256-95600 Neutral Lock Holder
26 67251-95680 Handle Lever (Gray) (NLA)
27 37110-99E02 Ignition Switch Assembly
29 67297-95600 Washer
30 67273-95600 Spacer
31 38500-92X50 Warning Buzzer
32 36620-92E00 21' Main Wire Harness (NLA)
33 37820-92E05 Emergency Stop Switch Assembly
34 37823-92E02 Stop Switch Lanyard
35 67255-95600 Neutral Lock Arm
36 67261-95600 Handle Grip for PTT
37 37860-94610 Trim Switch Assembly
38 67263-95600 Grip Cap
39 09139-02003 Screw (2x6)
40 37869-95590 Trim Switch Cap
41 67245-95600 Free Throttle Drum (NLA)
42 67258-87D00 Neutral Arm Bracket
43 67259-87D00 Neutral Arm Spring (NLA)
44 67140-95600 Replaced by 67140-95601
45 67282-95610 Port Decal (Black) (NLA)
45685 37141-92E00 (11) Ignition Key
45716 37141-92E10 (12) Ignition Key
45744 37141-92E20 (13) Ignition Key
45775 37141-92E30 (14) Ignition Key
45805 37141-92E40 (15) Ignition Key
45836 37141-92E50 (16) Ignition Key
45866 37141-92E60 (17) Ignition Key
45897 37141-92E70 (18) Ignition Key
45928 37141-92E80 (19) Ignition Key
45958 37141-92E90 (20) Ignition Key
▶Fig. 57 - Opt: Meter (31 parts) Fig. 57 - Opt: Meter
Ref OEM Part # Part Name
1 34200-92E02 Tachometer (NLA)
2 09471-12179 Bulb (Red)
3 34800-92E00 Trim Meter Assembly (NLA)
4 09471-12180 Bulb (NLA)
5 36682-92E00 Wire Harness
7 09471-12179 Bulb (Red)
8 34191-92E00 Water Pressure Tubing
9 09407-14407 Clamp (L:140)
10 36615-96300 Resin Terminal
11 34190-95500 Speedometer Sensor (NLA)
12 34190-87D00 Speedometer Sensor
13 03112-06303 Screw (NLA)
14 34300-92E00 Fuel Gauge Set (NLA)
14B 34320-92E00 Fuel Gauge (NLA)
15 34310-92E00 Fuel Gauge Lead (NLA)
16 34360-92E00 Adapter Harness (NLA)
17 09471-12180 Bulb (NLA)
18 34500-92E00 Hour Meter (NLA)
19 09471-12108 Bulb (12v 1.7w)
20 34600-92E00 Volt Meter (NLA)
21 09471-12108 Bulb (12v 1.7w)
22 34650-92E00 Water Pressure Gauge (NLA)
23 34191-92E00 Water Pressure Tubing
24 09407-14407 Clamp (L:140)
25 34652-92E00 Union (NLA)
26 36658-95600 Cable Grommet (NLA)
27 09471-12180 Bulb (NLA)
28 09320-08028 Grommet
29 36990-87D00 Terminal & Sleeve Set
45809 34100-92E00 Speedometer (80mph) (NLA)
45810 34100-92E10 Speedometer (50mph) (NLA)
▶Fig. 58 - Opt: Switch Panel (13 parts) Fig. 58 - Opt: Switch Panel
Ref OEM Part # Part Name
1 34804-94720 Trim Sender Set (NLA)
2 34801-94720 Trim Sender (NLA)
3 36680-92E00 Trim Meter Wire Assembly (NLA)
4 36682-92E00 Wire Harness
5 09100-06113 Bolt (6x16)
9 37100-92E00 Ignition Switch Panel Assembly (NLA)
10 37139-92E01 Single Ingition Switch Panel
11 37803-92E00 Emergency Stop Switch Assembly (NLA)
12 37825-92E00 Emergency Switch Panel
45839 09407-14403 Clamp (L:125)
45840 09407-14407 Clamp (L:140)
45870 36660-94400 Meter Extension Harness (NLA)
45871 36660-94480 Trim Wire Harness (6 ft) (NLA)
▶Fig. 59 - Opt: Wire Harness (9 parts) Fig. 59 - Opt: Wire Harness
Ref OEM Part # Part Name
1 34109-94500 Extension Lead (NLA)
2 36640-95500 Trim Relay Harness (NLA)
3 36615-96300 Resin Terminal
5 36631-94300 Cap
6 36620-92E00 21' Main Wire Harness (NLA)
7 36820-95560 Neutral Switch Lead (NLA)
8 37862-95201 Trim Switch Lead Extension (NLA)
45748 36620-87D20 Wiring Harness Extension (NLA)
45749 36620-95302 Wiring Harness Extension (NLA)
▶Fig. 6 - Carburetor(1986 to 1996) (48 parts) Fig. 6 - Carburetor(1986 to 1996)
Ref OEM Part # Part Name
5 13269-95210 Pilot Air Screw
6 13271-93311 Air Screw Spring
8A 13237-94400 Upper Nozzle
9 13392-58600 Valve Seat Gasket
10 13370-28110 Needle Valve Assembly
11 13254-98300 Float Pin
12 13250-93012 Carburetor Float
13 13251-95220 Float Chamber Gasket
14 08321-0105A Lock Washer
15 09125-05050 Screw (5x8)
16 13616-94500 Drain Bolt
17 13271-93311 Air Screw Spring
19 02112-0416A SCREW
20 08321-0104A Lock Washer
23 13534-95D00 Screw
24 13268-96111 Spring
25 13245-95210 Float Chamber (NLA)
26 01411-08207 Stud Bolt (NLA)
27 08316-10087 Nut
28 09352-50006-600 Hose (5x9x600)
29 09401-08411 Clip
30-2 09491-29010 Main Jet #147.5
31 13510-94600 Throttle Rod Assembly (NLA)
32 13910-94400 Carburetor Repair Kit
45658 13201-94660 Top Carburetor Assembly (NLA)
45659 13201-946B4 Top Carburetor Assembly (NLA)
45675 37810-94601 Throttle Valve Sensor Assembly (NLA)
45678 09491-31007 Main Jet #157.5 (NLA)
45679 09491-30010 Main Jet #150
45687 09491-29006 Main Jet #145 (NLA)
45689 13202-94660 2nd Carburetor Assembly (NLA)
45690 13202-946B4 2nd Carburetor Assembly (NLA)
45706 37810-95606 Throttle Valve Sensor Assembly
45709 09491-31014 Main Jet #155
45710 09491-32012 Main Jet #160
45717 13203-94660 3rd Carburetor Assembly (NLA)
45737 09491-32008 Main Jet #162.5
45746 09491-30009 Main Jet #152.5 (NLA)
45748 13204-94660 4th Carburetor Assembly (NLA)
45749 13204-946B4 4th Carburetor Assembly (NLA)
45768 09491-31014 Main Jet #155
45777 09491-32012 Main Jet #160
45807 09491-33007 Main Jet #167.5 (NLA)
45839 09492-80005 Pilot Jet #80
45840 09492-85001 Pilot Jet #85
45841 09492-80005 Pilot Jet #80
45870 13235-95210 Main Nozzle
45871 13236-94600 Main Nozzle (NLA)
▶Fig. 60 - Opt: Drag Link (19 parts) Fig. 60 - Opt: Drag Link
Ref OEM Part # Part Name
1 67701-94502 Drag Link Assembly (NLA)
2 67721-94510 Spacer (NLA)
3 67725-99E00 Drag Link Bolt
4 67726-99E00 Lock Nut
5 67728-99E00 Washer
6 43764-95500 Nut (NLA)
7 67701-94511 Drag Link Assembly (NLA)
8 67721-94510 Spacer (NLA)
9 67726-99E00 Lock Nut
10 67728-99E00 Washer
12 43764-95500 Nut (NLA)
13 09407-14403 Clamp (L:125)
15 67721-94520 Spacer (NLA)
16 67726-99E00 Lock Nut
17 67728-99E00 Washer
18 67725-94520 Drag Link Bolt (NLA)
19 43764-95500 Nut (NLA)
45671 67701-94530 Drag Link Assembly (NLA)
45702 67701-94900 Drag Link Assembly (NLA)
▶Fig. 61 - Opt: Gasket Set (20 parts) Fig. 61 - Opt: Gasket Set
Ref OEM Part # Part Name
1 11410-94812 Engine Gasket Set
2 11141-94620 Cylinder Head Gasket
3 11162-94630 Cylinder Head Cover Gasket (NLA)
4 17685-94610 Thermostat Gasket
5 11232-94610 Water Jacket Cover Gasket (NLA)
6 13125-95210 Carburetor Gasket
7 13121-94510 Inlet Case Gasket (NLA)
8 13156-94511 Reed Valve Gasket (NLA)
9 14151-94510 Exhaust Cover Gasket
11 13855-95210 Silencer Gasket
12 13853-94510 Silencer Gasket (NLA)
13 16731-95520 Oil Pump Retainer Gasket (NLA)
14 11523-94610 Ring Gear Case Gasket (NLA)
15 17567-94510 Water Tube Gasket (NLA)
16 17472-94510 Water Pump Plate Gasket
17 25142-94560 Shift Guide Gasket
18 25142-94520 Shift Guide Gasket
19 51211-94530 Engine Holder Gasket (NLA)
20 52172-94541 Exhaust Housing Gasket
21 52194-94510 Water Outlet Tube Gasket
▶Fig. 62 - Optional (4 parts) Fig. 62 - Optional
Ref OEM Part # Part Name
1 99000-31010 Liguid Gasket 150 (NLA)
2 93691-80030 Suzuki Silicone Seal
4 99000-25520 Water Resistant Grease
5 99000-25490 Suzuki Ecstar Super Grease C
▶Fig. 8 - Silencer(1986 to S/N 231403) (18 parts) Fig. 8 - Silencer(1986 to S/N 231403)
Ref OEM Part # Part Name
2 13855-95210 Silencer Gasket
3 13811-94601 Silencer Case (NLA)
4 08322-01067 Washer (6.5x13x1.0)
5 08321-01067 Lock Washer
6 09100-06038 Bolt (6x50)
7 08321-01067 Lock Washer
8 01550-06167 BOLT
9 13853-94510 Silencer Gasket (NLA)
10 13812-94504 Silencer Cover (NLA)
11 02142-05207 SCREW
12 02142-05357 SCREW
13 09250-15010 Plug
14 01550-05457 BOLT 5X45
15 09401-06405 Clamp
16 09355-30001-600 Hose (3x7x600)
17 09355-30001-600 Hose (3x7x600)
18 09404-08420 Clamp
19 16710-95211 Check Valve
▶Fig. 9 - Silencer Case(S/N 231404 to 1996) (10 parts) Fig. 9 - Silencer Case(S/N 231404 to 1996)
Ref OEM Part # Part Name
1 13811-94601 Silencer Case (NLA)
2 09116-06160 Bolt (6x16)
3 13812-94601 Silencer Cover (NLA)
4 09125-06095 Screw (6x25)
5 08310-00067 Nut
6 09401-06405 Clamp
7 09355-30001-600 Hose (3x7x600)
8 09355-30001-600 Hose (3x7x600)
9 16710-95211 Check Valve
10 09404-08205 Clamp (L:62)
▶Fig. 9B - Lubrication Hose(DT140EFI - 1997 to 2001) (16 parts) Fig. 9B - Lubrication Hose(DT140EFI - 1997 to 2001)
Ref OEM Part # Part Name
1 09355-30001-600 Hose (3x7x600)
2 09355-30001-600 Hose (3x7x600)
3 09355-35755-600 Hose (L:600)
4 09355-35755-600 Hose (L:600)
5 09355-35755-600 Hose (L:600)
6 09355-35755-600 Hose (L:600)
7 09355-35755-600 Hose (L:600)
8 09355-35755-600 Hose (L:600)
9 09355-35755-600 Hose (L:600)
10 16911-92E20 Protector
11 09367-04010 3 Way (NLA)
12 09401-07101 Clip (NLA)
13 16710-95211 Check Valve
15 09401-06405 Clamp
45671 09404-08207 Clamp (L:97)
45702 09404-08205 Clamp (L:62)

100-Hour / Annual Service Checklist

Regular maintenance keeps your Suzuki DT 140TCLG, DT 140TCXG running reliably season after season. Most of these tasks can be performed with basic tools and the factory service manual.

  1. Replace water pump impeller and inspect wear plate
  2. Inspect and clean carburetor(s); check fuel mixture settings
  3. Replace spark plugs and check ignition timing
  4. Drain and refill lower unit gear oil; inspect for water contamination
  5. Inspect fuel lines, primer bulb, and fuel filter for deterioration
  6. Check and replace sacrificial anodes (zinc or aluminum)
  7. Inspect propeller for damage; check shaft seal and cotter pin
  8. Decarbonize exhaust ports and piston crown if needed
  9. Lubricate all grease points (steering, tilt tube, shift linkage)
  10. 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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