Suzuki Outboard Engine DT-40 Parts Catalogue [EN]

PREFACE When it becomes neczssary to replace parts on SUZUKI OUTBOARD MOTORS, always use SUZUKI GENUINE PARTS which have p a s s e d a strict inspection which guarantees quality and performance. This parts catalogue covers the list of all service parts for SUZUKI DT40 QD. INSTRUCTIONS FOR QUOTING T E CATALOGUE 1. DIENSIONS Dimensions of the pa.rts in this catalogue are indicated in unit millimeters. 2. ABBREVIATIOEVS Abbreviations used ia this catalogue are as follows: AR : As required ASSY : Assembly E.No. : Engine number F.No. : Frame number NT : Number of teeth OK : Optional 0s : Over s i z e STD : Standard d ID OD L LH RH -123456 123456- : Diameter of material T : Thickness : Inside diameter us : Under size : Outside diameter W : Width : Length : Left hand side : Right hand side : From F.No.4001-301234 S,L,UL,LL : Transom type : Up t o F.No.4001-301234 12 x 34 x 5.6 .*.*-.-. Figures in the description column shw the dimensions of parts. T 7 T DT40 QD E3 -1- 3. INNER PARTS OF ASSEMBLY Parts number that have a period (.I mark in front of the part description on a text page are separately serviced parts of the assembly. 4. MODIFICATION NOTICE A parts builetin will be sent t o you on all occasions when changes in parts occur, including interchangeable modificaticns between new parts and old ones. NOTE 5- - 5-1. 5-2. 5-3. There are some different parts from those of production models among spare parts for the administrative reasons and common use of them with other models. In respect of rubber hoses and vinyl tubes, please be sure to use them by cutting off according to the length mentioned on parts catalogue or what is actually required on the vehicle. Note that the drawings on the illustration page are for ready reference of spare parts number, not to be used as an assembly manual. When assembling, use 18SUZUKI SERVICE 6. ENGINE NUMBER DT40 QD, DT40R QD : 4001-300001- DT40 QD E3 -2-

FIG. 1 1 FIG.1 (B- 2) CYLINDER Q'TY REMARKS DESCRIPTION REF.NO. PART NO. -6 -7 -9.10 - 6 -7 -9 - 10 '6 -7 14 1 2 3 4 5 6 f 8 9 10 11 12 13 14 15-1 15-2 16 17 18 19 20 21 22 23 11161-94301-02M COVER, cylinder head 11162-94300 GASKET, cylinder head cover 11141-94302 GASKET, cylinder head 01107-08658 BOLT 08321-21088 LOCK WASER 08322-11088 WASI€R 01107-06258 BOLT 38321-21068 LOCK WASHER 08322-21068 WASI-ER 11291-94301 HOOK, engine 01517-08208 BOLT 11111-94300-024 CYLINIER *AD 11301-94304-02M CYLIN)ER/CRANKCASE ASSY 04211-09109 .PIN 01107-10558 .BOLT 01107-10658 .BOLT 01107-06258 .BOLT 08321-21108 .LOCK WASI-ER 08322-11108 .WASHER 17670-94300 THERMOSTAT 09343-02026 HOSE, lubrication (L:300) 09401-06403 CLIP 09404-06414 CLAMP, lubrication hose 11400-94818 GASKET SET 1 1 1 1 10 10 10 4 4 4 1 2 1 2 6 2 4 8 8 1 1 2 1 1 OPT I OT40 QD E3 B2 DT40 QD

12 - FBG.2 9--@ - 22 4- 1 . rl-5 2 FIG.2 (6- 3) CRANKSHAFF Q'TY DESCRIPTION REMARKS REF.NO. PART NO. 1-1 1-2 1-3 2-1 2-2 2-3 ' 3-1 3-2 3-3 4-1 a-2 4-3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 12110-94301 PISTON 12110-94301-025 PISTON (OS:C.25) 12110-94301-050 PISTON (0s: 0.5) 12140-94300 RING SET, piston 12140-94300-025 RING SET, pis%m (OS:O.25) 12140-94300-050 RING 533, Piston (0S:O. 5) 12110-94352 PI ST ON 12110-94352-025 PISTON (0s :0.25) 12110-94352-050 PISTON (OS:O.5) 12140-94350 RING SET, piston 12140-94350-025 RING SET, piston (05:0.25) 12140-94350-050 RING SET, Piston (OS:O.5) 12151-97500 09381-18002 09263-18015 09169 - 18004 09283-30011 09283 -30042 09282-17004 12200-94304 12161-94300 09263-25028 08211-25322 12211-94302 12221-94300 12232-94300 12321-94301 12231-94300 12240-94300 09262-30055 PIN, p i s t m CIRCLIP, Diston pin BEARING, p i s t o n p i n WASt-ER, connecting rod OIL SEAL, upper crankshaft OIL SEAL, lmer crankshaft OIL SEAL, drive shaft upper CRANKSHAfl ASSY . ROD connecting .BEARING, crank Pin . WAStER .PIN, crank .CRANKSHN, upper .WEEL, middle lmer .SEAL, l a b y r i n t h .WEEL, middle upper .CRANKSHAFT , lam .BEARING, crankshaft 2 2 OPT 2 om 2 2 om 2 OM 2 om 2 OK 2 OK 2 OM 2 OM 2 om 2 4 2 4 1 30x55~10 1 1 17x28~6 1 2 2 4 2 1 1 1 1 1 3 30x72~19 DT40 QD I DT40 QD E3 B3

8343.3 3 FIG.3 (6- 4) INLET CASE - EXHAUST COVER Q'TY .. REF.NO. PART NO. DESCRIPTION REMARKS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 01517-06308 BOLT 08321-31068 LOCK WASlfR 08322-21068 WASHER 08310-11068 NUT 12480-94300-02M CASE, inlet 13125-95200 GASKET, carburetor 01411-08208 STUO BOLT 01421-0 6258 STUD BOLT 13121-94301 GASKET, inlet case 13122-94300 GASKET, valve sheet 13150-94301 VALVE ASSY, reed 02122-06168 SCREW 08310-22088 NIT 08322-11088 WASNR 14151-94300 GASKET, exhaust cover RATE, exhaust 14141-94300-02M COVER, exhaust 01517-06258 BOLT CASE, silencer 14131-94300 13811-94300 02112-06458 SCREW 08322-21068 WASNR 8 2 2 2 1 1 1 2 1 1 1 1 2 2 2 1 1 14 1 2 2 I c DT40 QD OT40 QD E3

FIG.4 1 3 \\ 2.2 .. 1 r .* _? FIG.4 (6- 5) CAWRETOR Q'TY . REF.NO. PART NO. DESCRIPTION REMARKS 1 2 3 4 5 6 7 8 9 10 1 .I. 12 13 14 13 16 17 18 19 20 -1 20-2 20 -3 21 ' 22 13200-94310 09492-80003 13271-93311 13269-95210 13235-95210 13250-93012 13251 -95 210 13611-95211 0 91 6265002 13254-93010 13370-28110 09493-24007 13 61 2-94300 13613-94300 13268 -96110 13267-95211 01411-08208 13410-94300 0949140007 09491 -38007 09491 -42003 09491 -3 8008 13631 -93500 09305-04005 CARBURETOR ASSY .JET, pilot (80) .SPRIG, air screw SCREW, pilot air .NOZZLE .FLOAT .GASKET, float chamber .BaT, float PIN, float .VALVE ASSY, needle .JET, air .BOLT .BOLT .SPRIN;, stop screw .SCREW, throttle stop .STUD BOLT .ShAFT ASSY .LOCK WASHER .JET, main (200) JET, main (190) JET, main (210) JET, main (195) KNOB, starter BUSHIN;, starter rod 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 1 1 1 OPT 1 OPT 1 OPT 1 1 DT40 QD Revised 1 Jun., '83 DT40 QD E3 Revised 1 Jun., '83 B5

1 2 4 5 5 01107-08258 BOLT 6 7 08321-21088 LOCK WASER WASER 08322-11088 5 FIG.5 (B- 6) UPPER OIL SEAL HOUSING Q’TY REMARKS DESCRIPTION REF.NO. PART NO. 1 11411-9431JO HOUSING, upper oil seal 1 2 11413-94300 GASKET 1 3 02122-06208 SCEW 5 4 31911-94311-02M BRACKET, starting moto;. 1 6 4 4 T DT40 QD I DT40 QO E3

FlG.6 @- 19 @- 78 12 I 12 -Q - 13 1 I 6 FIG.6 (6- 7) FUEL PUMP Q'TY . REF.NO. PART NO. DESCRIPTION REMARKS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 15100-94301 15170-943 11 15181.-94301 15183-94301 15186-94300 15851-94300 01107-06408 08321-21068 15321-99700 09343-05137 09343-05137 09401-09402 15410-93400 15415-93400 15412-93400 15413-93400 15416-93400 08322-21088 08310-22088 09343-05137 09404-06414 PUMP ASSY, fuel .DIARiRAGM SET .PLATE, f u e l pump .SCREW .NJT .SCREW BOLT LOCK WASER GASKET, f u e l pump HOSE, f u e l (pump-carburetor) HOSE, fuel (filter-pump) CLIP, fuel hose FILTER ASSY, fuel .O RING .STHAIER .CUP .PACKING WASER WT HOSE, fuel (connector-filter) CLAMP, fuel hose 1 1 2 2 2 3 2 2 1 1 L:500-240 1 L:500-180 6 1 1 1 1 1 1 1 1 L:500-350 1 L:80 21 DT40 QD 7 B7 DT40 QD E3

FIG.7 . 7 FIG.7 (6- 8) WATER FUMP Q'TY REMARKS ' REF.NO. PART NO. DESCRIPTION 1 STYE 1 L TYPE 1 4 1-1 17560-94310 TUBE, water 1-2 17560-94340 TUBE, water 2 17411-95204 CASE, water pump 3 09162-08003 LOCK WASHER 4 5 6 7 8 9 10 . 11 12 09100-08139 BOLT 09420-04005 KEY 17461-95200 IMPELLER, w&er pump 17471-95203 PLATE, pump case h e r 55130-94302-02M HOUSING SET, driveshaft BRG 09289-17004 .OIL SEAL, drive shaft 09263-25025 .BEARING, drive shaft 17472-95300 GASKET 09206-11005 PIN (11x20) 2 DT40 00 OT40 PO E3

FIG. 8 25 8 FIG.8 (8- 9) STARTER Q’TY DESCRIPTION REMARKS REF.NO. PART NO. 1 1 M40R 1 1 1-1 18100-94315 STARTER ASSY, recoil 1-2 18100-94320 STARTER ASSY, IECOil 2 18120-94300 .SEA= DRUM 3 18131-94302 .PAWL, drive 4 5 6 7 .8 .9 1Q 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 18142-93000 .SPRING 18151-94300 .PLATE, drive 18153-95200 .SPRING, friction 18191-95202 .PLATE, guide 18192-95203 .RUBBER, guide plate 18195-95200 .CLIP 18335-94300 18162-94300 .WASI-ER .WASER, drive pla’te .BUSHIM; 18155-94300 .SFRING, return 18124-94300 18332-94300 .BOLT 08310-11068 .KIT 18196-96301 .SPRING, guide plate 18200-95202 .GRIP ASSY 18210-93001 . .GRIP 18281-96300 . LEVER, stopper 18282-96300 .ARM, stopper .SPRIffi 18284-96300 18335-96300 .WAXR 18348-96300 . PIN 18290-94300 .CABLE, NSI 01517-08258 BOLT 01517-06258 8OLT 18411-94301 CUP, starter 01517-08168 BaT 18711-94301-02M BRACE, n ? c o i l starter RH 01107-06208 BOLT 08322-21068 18721-94301-02M BRACE, recoil starter LH 01517-08258 BOLT WA!S+ER 1 1 1 1 1 1 1 1 1 1 1 M40R 1 M40R 1 M4OR 1 DT40R 1 DR40R 1 DT40R 1 2 1 3 1 2 2 1 Manual Starter 3 Manual Starter DT40 QD M40 QD E3 B9