17400-91860 17400-91830 Maintenance Service Kit for Suzuki DF4 DF5 DF6 | JLM Marine

17400-91860 17400-91830 Maintenance Service Kit for Suzuki DF4 DF5 DF6

This comprehensive maintenance service kit is designed for Suzuki DF4, DF5, and DF6 outboard engines (2002-2016). It provides all essential components needed for routine servicing and ensures your outboard continues to run reliably season after season.

This kit directly replaces OEM part numbers 17400-91860, 17400-91830, and 17400-91891, offering a complete maintenance solution in one package.

• Includes water pump repair kit, fuel filter, anodes, and critical seals
• Designed for DF4/DF5/DF6 models from 2002 to 2016
• Complete service kit for comprehensive outboard maintenance

Part Number Cross-Reference

Use this table to confirm equivalent part numbers across OEM and aftermarket brands.

Compatible Engine Models

Confirm your engine model/year in the table below. For Suzuki owners, you can review exploded diagrams here to verify part numbers: Suzuki Parts Diagrams & Catalog.

Technical Specifications

Package Contents

This comprehensive service kit includes the following components:

• 1 x Water Pump Repair Kit 17400-98661
  • 17471-98610 Plate
  • 17472-91J00 Gasket
  • 09420-03002 Key
  • 17461-98501 Impeller
• 1 x Fuel Filter 15410-98500
• 2 x Anode 55321-87J01
• 1 x Cotter Pin 09204-03003
• 3 x Oil Drain Seal 09168-10022

Installation Guide

1. Ensure the outboard engine is off and cool before beginning any maintenance work. Disconnect the fuel line and tilt the engine to the full up position for easy access.
2. Remove the lower unit by loosening the mounting bolts. Carefully slide the lower unit downward and away from the mid-section.
3. Access the water pump housing by removing the cover plate. Remove the old impeller, plate, and gasket from the housing.
4. Install the new impeller (17461-98501) with blades oriented correctly, ensuring proper rotation direction. Apply a light coating of marine grease to the impeller and housing.
5. Install the new gasket (17472-91J00) and plate (17471-98610), aligning all bolt holes properly. Insert the key (09420-03002) into its designated slot.
6. Replace the old anodes with the new ones (55321-87J01) to protect against corrosion. Ensure they are securely fastened.
7. Locate the fuel filter housing and remove the old fuel filter. Install the new fuel filter (15410-98500) and ensure all connections are tight.
8. Drain the engine oil completely and replace the oil drain seals (09168-10022) to prevent leaks. Refill with fresh marine engine oil to the recommended level.
9. Reinstall the lower unit onto the mid-section, ensuring proper alignment of the drive shaft. Secure all mounting bolts to the manufacturer's torque specifications.
10. Install the cotter pin (09204-03003) in the appropriate location as per your engine's service manual. Double-check that it is properly secured.
11. Reconnect the fuel line and check all connections for tightness. Start the engine and check for proper water flow from the cooling system.
12. Allow the engine to run at idle for several minutes and inspect for any leaks or unusual sounds. Verify that all maintenance items have been properly installed before operating at higher RPMs.

Troubleshooting & FAQ

Q: How do I confirm this kit fits my Suzuki outboard?
A: Check the compatible engine models table above to verify your model (DF4, DF5, or DF6) and year (2002-2016). You can also cross-reference the OEM part numbers 17400-91860, 17400-91830, or 17400-91891 with your engine's service manual or parts diagram.

Q: How often should I perform this maintenance service?
A: Suzuki recommends performing routine maintenance annually or every 100 hours of operation, whichever comes first. In saltwater or heavy-use environments, more frequent servicing may be required.

Q: What are signs that my water pump impeller needs replacement?
A: Common symptoms include reduced or no water flow from the cooling system tell-tale, engine overheating, steam from the engine, or visible damage to the impeller blades. If you notice any of these signs, replace the impeller immediately.

Q: Can I install this maintenance kit myself or do I need a professional?
A: If you have mechanical experience and the proper tools, you can perform this service yourself following the installation guide and your engine's service manual. However, professional installation is recommended if you're unfamiliar with outboard maintenance to ensure safety and proper performance.

Q: What's the difference between this aftermarket kit and the OEM version?
A: This listing is an aftermarket replacement part (not an OEM component). We build to OEM specifications using comparable-grade materials. Production is done in an ISO9002-certified facility, and each batch is inspected for consistent performance.

Q: How fast do you ship and how much does it cost?
A: We offer fast global shipping—typically 5–15 days worldwide—and standard shipping is free. Expedited options are available at checkout depending on your location.

Q: What is your warranty and return policy?
A: This product includes a 1-year warranty against manufacturing defects under normal use. If something goes wrong, contact our support team with your order details. Returns are accepted within our standard return window (unused & in original condition); please see our policy page or reach out for instructions.

Important Notes

• Verify that the product images and specifications match your original part. If discrepancies exist—even if your model is listed—do not proceed with the purchase.
• This product is an aftermarket replacement part and is not an OEM component.
• Professional installation is recommended to ensure safety and optimal performance.

Why Choose JLM MARINE?

• Quality Assured: As a trusted manufacturer for over 20 years, we supply top marine brands globally.
• Fast Global Shipping: Free delivery worldwide in 5–15 days.
• Direct from Manufacturer: Competitive pricing without compromising quality.