96-01 SUZUKI4 Stroke OUTBOARDS 9.9 &15HP MASTER Parts Manual

Part s Book DF 99 (96-01) DF 15 (96-01)

PREFACE When it becomes necessary t o replace parts on SUZUKI OUTBOARD MOTORS, always ase SUZUKI GENUINE PARTS which have passed a s t r i c t inspection which guarantees quality and performance. This partscatalogue covers the list of all service parts for SUZUKI DF9.9/15 ' 96-' 01 MODEL, INSTRUCTIONS FOR QUOTING THE CATALOGUE 1. DIMENSIONS Dimensions of the parts i n this catalogue are indicated in unit millimeters. 2. ABBREVIATIONS Abbreviations used in this catalogue are as follows: AR : As required ASSY : Assenbl y E.No. : Engine number F.No. : Frame number d : Diameter of material ID : Inside diameter OD : Outside diameter L : Length LH(P0RT) : Left hand side RH(STBD) : Right hand side -1 23456 : Up to F. NO. 00991F-123456 123456- : From F. No. 00991F-123456 NT OPT : Optional os : Over s i z e STD : Standard T : Thickness us : Under s i z e W : Width W/ : With S,L,UL,LL: Transom type sus : Stainless steel I 00 : MODEL:2000 ' 01 : MODEL:2001 : Number of teet 1 12 x 34 x 5.s-.-.--- Figures in the description CO?UMI 777- show the dimensions of parts. ID OD T(or W,L) -12345-56781 (Parts No.) : indicates that the p a r t s number was changed to 12345-56781 and the new parts are interchangeable with the former ones but the former ones are not interchangeable with new ones. 3. INNER PARTS OF ASSEMBLY Part name with a dot (.) i n front as shown i n the description column indicates the component of the assembly also available individually. 4. MODIFICATION NOTICE A parts bulletin will be sent t o you on a l l occasions when changes in parts occur I i ncl udi ng i nterchangeabl e modi f i cati ons between new parts and old ones. 5. NOTE 5-17 There are some differen* parts frm thostz of i>rdccticn mde~s ;mng spare parts for the administrative :easons and c o m n use of them with other models. 5-2. In respect of rubber hoses and vinyl tubes, please be sure t o use t3em by cutting off according to the length mentioned on parts catalogue or what i s actually rgqcired on the vehicle. 5-3. Note that the drawings on the illustration page are for ready reference o f spare parts number, not t o be used as an assembly manual. When assembl ins, use "SUZUKI SERVICE MANUAL". 6. MODEL NAME AND ENGINE NUMBER YEAR'S TYPE TRANSOM ENGINE No. MODEL DF9.9ST '96 00991F S'L 00991F-651001- 00991F-652501- DF9.9ST '96 00991F S I L DF9.9SV '97 00991F S, L 00991F-751001- DF9.9SW '98 00991F S I L 0099lF-S61001 DF9.9SX '99 00991F SJ L 00991F-971001- DF9.9SY '00 00991F S'L 0099lF-030001- 00991F-151001- DF9.9SKl '01 00991F SI L '96 01501F s, L 01 501F-651001- DF15ST DFl5ST '96 01505F S'L 01 501F-652501- DF15SV '97 01501F S I L 01 501F-751001- DF15SW '98 01501F S, L 015OlF-861001- DF15SX '99 01501F S'L 01 501 F-971001 - DF15SY ' 00 01501F S'L 01 501 F-030001- DF15SK1 '01 01501F S'L 01501F-151001 N t12345-56781 (Parts No.) : indicates that the former and new parts are interchangeable with each other and both are usable. 0 2001 American Suzuki Motor Coiporation A1 ....... --_ .

F1G.l 15 11 ! k 2 16 CYLINDER HEAD FIG.l ( B-2) QTY. DFSCMPTION REMARKS REF.NO. PART NO. 1-1 1-2 2 3 4 5 6-1 6-2 7 8 9 10 11 11A 12 13 14 15 16 1 DF9.915 E3 ................. . . . -.- ........ 1 1 1 10-93EM-211 11110-93E04-OEP 11 141-93E10 09116-08110 04211-1 1129 1 1162-93EW 1 1 170-93E00-211 11 170-93EOMEP 09200-20810 09352-901 33-600 091 03-06 1 86 0948240446 1691 1 -92E20 1691 9-93E30 HEAD, CYLINDER HEAD, CYLINDER GASKET, CYLINDER HEAD BOLT (8x65) PIN GASKET, CYLINDER HEAD COVER COVER, CYLINDER HEAD COVER, CYLINDER HEAD CAP, OIL FILLER HOSE, BREATHER BOLT (6x16) PLUG, SPARK tXPR6E) PROTECTOR, BREATHER HOSE PROTECTOR, BREATHER HOSE 09401-12405 CLIP 0940448207 CLAMP 11291-91850 HOOK, ENGINE 01550-08207 BOLT 1 11 15-93EOM01 GUIDE, VALVE (OS0.30) COLOR : 211 (WHITE) OEP (BLACK) 1 1 1 9 2 1 1 1 1 1 6 2 1 1 2 1 1 1 4 MODEL:99-01 MODEL:99-01 L:600+320 L:540+340 L:350+280 MODEL:97-01 OPT OPT OPT B2

FIG.2 ( R3) CYLINDER BLOCK Qm. RF,F.NO. PART NO. DESCRIPTION REMARKS 1-1 1-2 1-3 2 3-1 3-2 3-3 4 5-1 5-2 6 7 8 11301-93E00-211 BLOCK ASSY, CYLINDER 11301-93E02-211 BLOCK ASSY, CYLINDER 11301-93E024EP BLOCK ASSY, CYLINDER 09205-1 0006 .PIN (1O.WlO) 01 550-06357 .BOLT 0 1 55046357 .BOLT 0 1 550-06357 .BOLT 0156048757 .BOLT 04221 -06129 .PIN 04211-11129 .PIN 01 421 -O6307 BOLT, STUD 0831 6-1 0067 NUT 16440-1 1 DO0 REGULATOR, ENGINE OIL COLOR 211 (WHITE) OEP (BLACK) 1 1 1 1 6 4 6 4 2 2 2 2 1 +I 1301-93E02-211 USED WITH 32160-93E10 0211236127(2) DF9.9 651600- DF15 651580- MODEL%-01 DF9.9 652501- DF15 652501 - -MODEL:OO M0DEL:Ol FOR 11301-93E00-Z11 DF9.9 651 600- DF15 651580- DF9.9 652501 - DF15 652501 - -MODEL:OO DF9.9 652501- DF15 652501- -MODELZOO 2 DF9.915 E3

2 FIG.3 ( B-4) CRANKSHAFT QW. REF-NO. PART N9. DESCRIPTION REMARKS 1 2 3 4 5-1 5-2 5-3 5-4 6 7 8-1 8-2 9-1 9-2 9-3 9-4 10 11 121 1 1 -93E00 PISTON 1 21 40-02ClO 12151-93E00 PIN, PISTON 09381 -14001 CIRCLIP RING SET, PISTON 12160-93EOMAO CONNROD ASSY 12160-93E10-OAO CONNROD ASSY 12160-93E004BO CWNROD ASSY 12160-93ElMBO CONNROD ASSY 121 63-32COO .BOLT, CONNROD 04221 -03053 .PIN 12200-93850 12220-93E11 CRANKSHAFT ASSY CRANKSHAFT SET 12229-33C004A0 BEARING, CRANKSHAFT 12229-33600-080 BEARING, CRANKSHAFT 1222933COO-OCO BEARING, CRANKSHAFT 12229-33C00-0DO BEARING, CRANKSHAFT 09283-32039 SEAL, CRANKSHAFT OIL 12100-93E00-050 PISTON SET (OS:O.50) 3 DF9.9 15 E3 -~ 2 2 2 4 1 1 1 1 4 4 1 1 4 4 4 4 2 2 MARK 1 DF9.9 651600- DF15 651580- MARK 2 DF9.9 651600- DFt5 651580- DF9.9 651600- DF15 651580- GREEN BLACK BROWN OPT YELLOW OPT B4

FIG.4 ( 55) TIMING BELT QTY- DEscmIord REMARKS FIG.$ REF.NO. PART NO. PULLEY, CRANKSHAFT GUIDE, TIMING BELT (UPPER) GUIDE, TIMING BELT (LOWER) NUT, TIMING PULLEY WASHER, PULLEY NUT LOCK PULLEY, CAMSHAFT WASHER (6.5X20X1.2) 7-2 09160-06138 WASHER(6.5X22X2.3) 4 DF9.9 15 E3

1 &5 ' . ... FIG.5 ( B-6) CAMSHAFT QTY. REF.NO. PART NO. DFSCRIITION REMARUS 1 DF9.9 1-1 1271 1-93E00 CAMSHAFT 1-2 1271 1 -93E10 CAMSHAFT 1 OF1 5 2 09283-25009 SEAL, CAMSHAFT OIL 1 3 12840-93E01 ARM ASSY. ROCKER 4 4 1284249201 SCREW, TAPPET ADJUSTING 4 .NUT, TAPPET ADJUSTING 4 5 12843-27AW 6 12861 -93E00 SHAFT, ROCKER ARM 1 7 091 60-1301 0 WASHER 1 8 09164-14012 WASHER, WAVE 1 9 09440-1 5037 SPRING 1 10 12911-93E00 VALVE, INTAKE 2 11 1291593E00 VALVE, EXHAUST 2 12 1 2921 -93E00 SPRING, VALVE 4 13 12931 -78G00 RETAINER, VALVE SPRING 4 14 1832.24400 COTTER, VALVE 8 15 12933-71 COO SEAT, VALVE SPRING 4 16 09289-0501 2 SEAL, VALVE STEM 4 REFER TO FIG.6 (8-7) FOR DF9.9 652501-/OF15 652501- 5 DF9.9 15 E3 B6 .- - _. . . . .

FIG.6 17 & F- -1 l4 f?14 FIG.6 ( 57) CAiWSHAFT QTY. REF.NO. PART NO. DESIRIPTION REMARKS 1-1 1-2 2 3 4 5 6 -. I 8 9 10 11 12 13 14 15 16 17-1 17-2 12700-93E01 12700-93E11 09283-25009 12840-93E01 1284249201 12843-27AOO 12861 -93EOO 09160-13OlO 091 64-1 401 2 09440-1 5037 12911-93E00 1291 5-93E00 12921 -93E00 1 2931 -78GOO 12932-24400 12933-71COO 09289-0501 2 12711-93E01 12711-93E11 @-5J 6 DF9.9 15 E3 .--.I-.- - . ......... CAMSHAFT ASSY CAMSHAFT ASSY SEAL, CAMSHAFT OIL ARM ASSY, ROCKER .SCREW, TAPPET ADJUSTING .NUT, TAPPET ADJUSTING SHAFT', ROCKER ARM WASHER WASHER, WAVE SPRING VALVE, INTAKE VALVE, EXHAUST SPRING, VALVE RETAINER, VALVE SPRING COTER, VALVE SEAT, VALVE SPRiNG SEAL, VALVE STEM CAMSHAFT CAMSHAFT 1 1 1 4 4 4 1 1 1 1 2 2 4 4 8 4 4 1 1 DF9.9 MANUAL STARTER W/DECOMP DF15 MANUAL STARTER W/DECOMP DF9.9 ELECTRIC STARTER WECOMP OF15 ELECTRIC STARTER N/DECOMP B7 _.

FIG.? INLET MANIFOLD DESCBII"IB)N REMARKS FIG.7 ( 58) QTY. REF.NO. PAW NO. 1-1 13111-93EO4-Pl1 MANIFOLD, INLET 1 1-2 2 3 4 5-1 5-2 5-3 6 7 I3 9 10 131 1 1 -93E044EP MARIFOLD, INLET GASKET. INLET MANIFOLD 131 19-93EOO Qf 550-08407 BOLT 131 16-93EW CAP, INLET MANIFOLD 13800-93E00 SILENCER ASSY 13800-93E12 SILENCER ASSY 13800-93E20 SILENCER ASSY 13694-92W .PLATE, CHOKE SPRING 93511-oAo83 .SCREW 09250-1 201 2 .CAP ? 38 1 5-93E00 .CAP, SILENCER .ARRESTER, FLAME 13710-93E00 COLOR : Z11 (WHITE) OEP (BL4CK) 1 1 2 1 1 1 1 1 1 1 1 1 MODEL:99-01 DF9.9 652501- DT15 652501 - M0DEL:Ol -MODEL:96 DF9.9 652840- DF15 653178- FOR 13800-93E20 ! 7 DF9.915 E3 B8

FIG8 25 1 I 15 31 2 29 I 17 A -7.3 FIG.8 ( B-9) CARBURETOR QTV. DEXRIPTIQN REMARKS REF.NO. PART NO. 1 2 2A 28 3 4 5 6 7-1 7-2 8-1 8-2 9-1 9-2 43 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1312595D30 13413-93EQO 09403-04306 13413-93E10 1 363 1 -93501 09140-04007 09320-04009 01550-06957 13200-93EO2 13200-93E40 13200-93E11 132W93EXI 1323-95020 13235-95020 132S93ElO 13239-95OoO 13245-93E01 13250-95DOl 13251-95000 13254-98300 13267-93900 13268-9291 0 13268-961 1 I 13370-95000 133734671 0 13493-2OE20 13495-09400 13495-18E00 13496-2oE20 GASKF3,CARBURETOR ROD, CHOKE COSJNECTOR, CHOKE ROO ROD, WOKE KNOB, STARTER NUT BUSH 90LT CARBURETOR CAR8URETOR CARBURETOR CARBURETOR .NOZZLE, MAIN .NOZZLE, MAIN .NOZZLE, MAIN ,CAP, MAIN NOZZLE .CHAMBER, FLOAT .FLOAT .GASKET, FLOAT CHAMBER .PIN, FLOAT .SCREW .SPRING SPFiihiG .VALVE ASSY, NEEDLE .PLATE .PLUNGER .CAP .CAP .GUIDE, HOLDER 1 1 1 1 f 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 df15 DF9.9652501 a2501 - . BF9.9 652501 - 0f1 5 652501 - DF9.9 DF15 0f9.9 DF9.9 MODEL:%01 OF15 MODEL%-01 DF9.9115 MODEL:98-01 OF15 -MODEL:97 8 DF9.9 15 E3 B9

You're Reading a Preview

96-01 SUZUKI4 Stroke OUTBOARDS 9.9 &15HP MASTER Parts Manual

Description

Reviews

Q&A

Recently Viewed