Read Suzuki DT 4 (78) DT 4.5 (77) text version

DT 4 (1978) DT 4.5 (1977)

PREFACE T h i s p a r t s catalogue has been arranged to include all p r i o r modification as t h e final edtion. No revised edtion w i l l be issued a n y more and b e s u r e t o make use of t h i s in good keeping. Upon receipt o f t h i s f i n a l edtion, t h e old catalogue should b e t h r o w n away. T h i s p a r t s catalogue covers t h e l i s t o f all service p a r t s f o r SUZUKI R T b D T 9 (C, D, F. )

'

3.

INNER PARTS OF ASSEMBLY Parts number t h a t have a period (.) mark in f r o n t of t h e p a r t description on a t e x t page a r e separately serviced p a r t s of t h e assembly.

4.

MOD I FIC A T 1ON NOT IC E A p a r t s bulletin w i l l be sent t o you on all occasions when changes in p a r t s occur, i n c l u d i n g interchangeable modifications between new p a r t s and old ones.

A. INSTRUCTIONS FOR QUOTING THE CATALOGUE

5.

1.

DIMENSIONS .Dimensions o f ' t h e p a r t s in t h i s catalogue a r e indicated in unit millimeters.

NOTE

5-1.

-

There are some d i f f e r e n t p a r t s f r o m those of production models among spare p a r t s f o r t h e administrative reasons and common use o f them w i t h other models.

In respect of r u b b e r hoses a n d vinyl tubes, please be s u r e t o use them by c u t t i n g o f f according t o t h e length mentioned on p a r t s catalogue o r what i s actually required on t h e vehicle.

2.

ABBREVIATIONS

I ,

5-2.

Abbreviations used in t h i s catalogue are as follows: AR ASSY E.No. F.No. d ID OD

L

A5 r e q u i r e d

NT

0PT

: Number o f teeth

: Assemb Iy

: Engine Number

: Optional : O v e r Size : Standard : Thickness : U n d e r size

: Width

5-3.

0s

STD

: Frame Number

Diameter o f material Inside diameter Outside diameter

\

Note t h a t t h e drawings on t h e illustration page are f o r ready reference of spare p a r t s number, n o t t o b e used as an assembly manual. When assembling, use "SUZUKI SERVICE MANUAL".

T

6.

SPECIFICATION CODE T h i s catalogue contains t h e p a r t s f o r t h e model designed f o r t h e following spec. ; spec. code: DTZC ( E l , E28), DTED (El), DT2F (El), DT3.5F ( E l , E16) DT4.5C ( E l , E28), DT4D ( E l ) , DT5D ( E l , E3, E13), DT5F (El, E3, E13) DT7.5C ( E l , E13, E28), DT7.5D ( E l , E13), DT7.5F ( E l , E9, E13) DT9C ( E l , E13, E28, E37), DT9D ( E l , E13), DTSF ( E l , E9, E13)

us

W

Length L e f t hand side R i g h t hand side

S,L,UL,LL

: Transom t y p e

LH RH ,,

*lo0045 : U p t o F.No.-100045 100046- : From F No. -100046

.

F"7" I

ID OD

\

5.6

..--..a

Figures in t h e description column show the dimensions o f p a r t s .

7.

SERIAL FRAME NUMBER C-1 OOOl+, D - 1 0 0 0 1 ~F-10001'L ~

T ( o r W,L)

To 12340-56781 (Parts No.) : indicates t h a t t h e p a r t s number was changed t o 12345-56781 and thc; new p a r t s are interchangeable w i t h t h e former ones but t h e former ones are n o t interchangeable with new ones.

i6

From 12345-56781 (Parts No.) : indicstes t h a t t h e former and new p a r t s a r e interchangeable with each other and b o t h are usable. The number of l e t t e r shown below Q'ty indicate the MODEL NAME as shown right side. model C C

Q'ty DT2sDT9

JI

D

T

a

D

T

9

DT2sDT9

- 1 -

DT2*DT9

- 2 -

- . ...

..

..

,

. ..

. . ..

.. .- . .

.

. . .. . .. ..

,

,

. ..

. ...

FIG31

'IE-3

I +R9f.m.

1-1

7

1

FIG.31

CYLINDER

QtY

poro #a. 09482-00095

-wQn

SPARK PLUG ASSY SPARK PLUG ASSY SPARK PLUG ASSY CYLINDER HEAD

GASKET, cylinder head

C D 1

-

R d B-GHS,NGK S

-

1-2 1-3 2 3 4

09482-00088 09482-00088 11111-98003 11141-38005 01107-08358 08322-11088 08321-21 088 11300-98831 11300-98832 09100-06O32 09100-06033

1

-

1

from 09482-00048

BR-6HS,E28 BR-6HS

1 1

1 1

BOLT WASHER LOCK WASHER

4 4

4

4

5

4

6

4

4

7-1

2

CYLINDER/CRANKCASE ASSY 1

-

to (11300-98832) +

(12110-98006)

7-2 8 9

10 11

CYLINDER/CRANKCASE ASSY 1 *BOLT, cylinder 1 2 2

-

6x80

.BOLT, cylinder 2 =BOLT, cylinder 3 *DOWEL PIN *LOCK WASHER

2 2 2 2 2 2' 6 6

6x35

6x65

09100-06038 04211-09109

08321-21068

12

DT4.5C, DT4D

FIG. 32

I

1

L

3

FIG.32

REED VALVE

Qw

R6f.W.

1

M

14 2'

-

NO.

Dercripth

C D

R d S

from 12411-98809

2 3 4 5 6 7

8

12421-98002 02112-Q4128 m1-21048 08322-21048 12431-96001 12441-98030 12451-98000 12481-98002 01107-06308 08321-21068

VALVE ? reed STOPPER, reed valve SCREW LOCK WASHER WASHER PLATE, r e d valve SEAT, reed valve GASKET, valve seat CASE, inlet BOLT LOCK WASHER

1 1 1 1 3 3 3 3 3 3 1 1 1 1 2 2 7 1 2 2 2 2

9 10 11

DT4.5C. DT4D

~

~

,_.__ __ .

,

_. .

......

.:.

.

...

- . .

..

.

. . . . .

~

~..*

.........,

~

3

F G 33 B.

P

FIG. 33 CRANKSHAFT

Q'w

R8f.W. pat N . o 1-7 12110-98OQ5

mmuipnkn

P I STON PISTON PISTON PISTON RING SET, piston RING SET, piston R I N G SET, pistQn PIN, piston BEARING, piston pin CIRCLIP, piston pin CRANKSHAFT SET CRANKSHAFT SET CRANKSHAFT SET CRANKSHAFT SET -CRANKSHAFT, upper -CRANKSHAFT, lower =CRANKSHAFT, lower -CRANKSHAFT, lower -ROD, connecting -PIN, crank -BEARING, crank pin

C D

Runadco

1-2 1-3 1-4

2-1

12110-98000 12110-98006-025 12110-98006-050 12140-9801 3 12190-9801 3-025 12140-19610-050 12151-98OOO 09263- 12 0 3

09381-12001 12200-98820

1 - 1 - 1

7

to 12110-98OE

0 s: 0.25 ,OPT from 12110-98720

f rum 12110-98730

0 s :0.50, OPT

T:l.5

2-2 2-3 3 4

5

6-1

.c

,?,

7 1 - 1

1 1 1

0 s : 0.25, OPT from 12140-98720

0s:0.50,OPT from 12140-19760

12x15.7x15.8

1 1 2 2

1 -

.

6-2

12200-98821 12208-98822 12200-98823 12227-98003 12230-98000 12230-98001 12230-98002 1E l 61-35000 12211-98000 09263-1 6014 08221-20285 08113-62040 09283-2001 6 09283-2001 8 09160-38001 09280-15002

-

1

from 12200-98820

to 1220-98822

" 1 - 1 1 1

1 -

6-3 6-4 7 8-1 8-2

8-3 9

to 12280-98823

DT4D 10767%

-

to 12230-98001

to 12230-98802

-

1

- 1

1 1

DT4D-10767*

10 11

6-

1 1 1 1

1 -

12 13 14 15 16 17

=SHIM

-BEAR ING O I L SEAL, crankshah upper O I L SEAL, crankshaft lower THRUST WASHER

0

from 09263-16002 for 12230-98000 20x47~8 20x37~9 38x51x l .O

I D:15,d: 1.9

2 2

1 1

1 1 1 1

RING, lower crankshaft

a

1

DT4.5C. DT4D

.

IC._....

i

I

'

... ......_.. , .

...

.,. . . . . . . . . . . . . . . .

,

:. ....1

. . . . . . . . . . . .

. - ............... .

_ . -. ... . _ .

. . . . . . . . . . . . . . . . . . . . . . . . .

..

4

'BIG034

W.M.

1-2 1-3 2

3

pat

FIG.34

CARBURETOR

crtv

No.

Bkraopabn R ASSY

C D 1

-

RtlllWkS

13200-98019 13200-98020 13573-01010 13394-42110 13383-19600 13551-98012 09491-95001 09494-00071 13691-98010 09492-25Qo2 13392-01010 13370-23040 13370-98010 13252-0204 0 13254-01010 13269-01010 13267-98010 13268-95110 13251-98011 02112-04168 08321-21 048 13577-98011 13661-03010 13413-9801 0 13413-9801 1 13581-01 010 13631-99002 09305-04001 09491-2o001

CARBURETOR ASSY CARBURETOR ASSY -SPRING, throttle valve -CLIP, needle *NEEDLE, jet -VALWE, throttle *JET, main -NOZZLE, needle

*O RING, float chamber

-

1 1

to 13200-98015 to 13200-98020

DT4D-1173a

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 - 1 1 1 1 1 1 1 1 1

2 2

3J2

4 5

6

CA:2.0 95

1 -

......

24

/ :

.

I

7 8 9 10 11-1 11-2 12 13 14 15 16 17 18 19 20 =21 22-1 22-2 23 24 25

27

-JET, pilot GASKET, valve seat -VALWE ASSY, needle -VALVE ASSY, needle I=LOAT -PIN, float SCREW, pilot air -SCREW, throttle stop *SPRING, stop scqew -GASKET, float chamber -SCREW -LOCK WASHER -ADJUSTER, throttle cable -NUT, adjusting =LEVER, starter -LEVER, starter

25

DT4D 117 3 a

-

1 1 4 4 4 4 1 1 1 1 1 - 1

to 13413-98011

-SEAT, throttle valve spring- 1 1 KNOB, starter 1 1 BUSHING, starter guide JET, main JET, main

to 13631-93500

1 1 1 1 1 1

OPT, 90 OPT,100

2 6 ' 89491-90001

DTd-SC. DT4D

-..-...-.-.-....- ..-.. . . .

-....~...'.. . . . _....

*

_....,*

.... ..., ... -

..

.,.

..

.-. - ~.i

,

5

FIG.35

WATER PUMP

QtY

Raf.Ns. m. No. 1 17420-99002

2 3 4 09387-32001 09283-1 5001 09108-06025 09162-06001 09140-06004 17460-99002 09202-04002 09387-28001 17491-99000 09289-15001 09280-33002 09108-05002 09140-05001 17561-99102 17561-99202 09305 08007

M P t h

HOUSING, pinion shaft CIRCLIP, oil seal OIL SEAL, pinion shaft STUD BOLT, housing LOCK WASHER, housing NUT, housing IMPELLER, water pump

BIN, impeller

C D

1 1

1 1

R6ltUUkS

2 2 4 4 4 4 4 4

1 1

15x3ox7.5 6x30

5

6

7

0

910 1 1 12

13

1 1

1 1 1 1

1 1

4x24

CIRCLIP, impeller PLATE, water pump lower

OIL SEAL, lower [email protected] 0 RING, lower plate

15~30~7.5

ID: 33,d :2.2

1 1

STUD BOL'T, lower plate NUT, lower plate TUBE, water TUBE, water

BUSHING, water tube

2 2 2 2

1 1

5x4

S type,L:484

14 15 16 17

1 1

1 1

L type,L:637

from 09305-08005

-

8

'

DT4.5C, DT4D

FOG.36

,

j k

-

. . ...

.6

,

,

. -. ..

.

..

..

... ..

. .

I

FIG.36

ENGINE HOLDER

QW

M,No.

1

PW

1rsdlmm2

-

No.

-igHocr HOLDER , water tube

C D 1 1

W&S

2

3

4 5 6

09283-20022

OIL SEAL, water tuba holder

1 1

20x35~9 to 09283-20035 OD:9,L:20

7 8 9 10 11 12 13 14 15 16 17

17591-98004 ,09206-09003 511OO-~82OO-OI J 0905-165001 09100-06035 091~-06044 09160-06015 09162-06001 51211-98003 62111-98001-01J 01107-08308 09160-08015 62411-98701 -01J 01107-08308 09160-08815

GASKET, water tube holder 1 1 DOWEL PIN, water" tube holder 2 2 HOLDER , engine *DOWEL PIN BOLT, engine holder 2

BOLT, engine holder 3

1 1 1 1 6 6 6x40 6x65 6.5~11 SxO.8

2 2 8 8

WASHER, engine holder ,

LOCK WASHER, engine holder 8 GASKET, engine holder 1 1 GUARD, front BOLT WASHER BRACE, rear BOLT WASHER 1 1 2 2 2 2 1 1 2 2 8.5x16x1.2

-

2 2

8.5x16x1.2

DT4.5C, DT4D

7

FIG.37

STARTER

MA0 . l.

m t

No.

1-1 181OQ-SWW-OlT STARTER ASSY, recqil

1-2 l b 1 8 0 - ~ 5 - 0 7 T STARTER ASSY, recoil 2 18111-9884)l-OlT -CASE, starter -DRUM, sheave 3 l$l2l-§8OOl =PAWL, drive 4 18131-spKw)1 =FELT, oil 5 18125-98oOo

-

C jtD 1

-

R&8

ts 18100-98005-01T

- 1

1 1

1 1

3 3 1 1 2 2

1 1

6 7

18138-98000

a

-SPACER, spring -SPRING, recoiling -WASHEW, sheave drum -SPRING, pivot shaft -PLATE, drive -SPRING, return -CIRCLIP, drive plate -GRIP ASSY, starter -GRIP ASSY, starter -*GRIP, starter =-GRIP, starter -RUBBER, starter seal BOLT, starter case WASHER, starter case

CUP, starter

to 18138-98001

18142-980011

. 8

1 -

18143-98001 9 18145-98001 10 18151-98002 11 18155-98000 12 18163-98001 13-1 182W-93810 13-2 18200-93811 14-1 18210-93000 14-2 18210-93001 4 8251-98000 15 09100-06022 16

2 2 1 1

1 1

1 1 a 1 1 - 1

1 1

to 1820-93811 to 18200-93100

from 18271-98000 to -S8210-93001

1 1 3 3 3 3 1 1 3 3 3 3 1 1 1 - 1 1 1

.

6x35 6.5x11.5x0.8

11

*

4

17

091~-0691S 18411-98002 01107-06168 0832-l-21068 18511-9BOOO

18 19

BOLT LOCK WASHER SPACER, starter cup

20

21

22-1 32725-98000 22-2 32725-98400 23-1 61511-99611 19

INSULATOR, magneto I NSlJLATOR; magneto

MARK, start indicate

from 32725-98000

to 61511-9302

-Q

23-2

61517 -93602

MARK, start indicate

4 I

.

DT4.5C, DT4D

' .

DT4.5CI DT4D

.

.

8

FIG.38

MAGNETO

W.W. 9 2 3 4 5 6 7

lRrr

No.

32101-98036 32140-98035 02112-05203 08321-21058

MAGNETO ASSY *STATOR ASSY **SCREW

-

C D

1 1 1 2 2 1 1 1 1 2 1 2 2 1 1 1 1 1 1 2 2 1 1 1 1 2 1

:' I

Rafnmkt

to 32101-98038

**COIL, primary

**LOCK WASHER

32240-98034 32341-98030

02112-03088 02111-031 08 08321-21 038 08322-21038 02112-85128 08322-1 1058 08341-31039

**POINT, contact **CONDENSER **SCREW **SCREW

**LOCK WASHER

from 32240-98033

a

9

10 11 12 13 14 15 1 4 4 16

*WASHER

SCREW

2 2 1 1 1

WASHER KEY

08321-21 108 08310-1 2108

LOCK WASHER

NUT

44

!L-.10---10 9 8F

1

L,

DT4.5CI DT4D

F I G 39

-

9

FIG. 39 ELECTRICAL

OISalgtean

R8r.M. pprt wk. 1 32731-98002

2 . 33410-98030 08321-21 068 3 01421-06258 4 08310-1 1068 5 33510-41111 6 33510-28300 7 33543-98OOo 8 9-1 378OO-9!lO14 9-2 37800-99015 OWM-08413 10

C D

PLATE, magneto seal COIL ASSY, ignition LOCK WASHER STUD BOLT NUT CAP, spark plug CAP, spark plug BOOT, spark plug SWITCH ASSY, engine stop

1 1 1 1 2 2

2 2 2 2 1 - 1

to 33510-95510

1 1

1

SWITCH ASSY, engine stop CLAMP, stop switch read cord 1

-

-

1 1

to 37800-99015 t 37800-99016 o T:l .O

2

3

9

7

I

..

DT4.5C. DT4D

.. . . -., :

-

_._

,'

~

.- ....

. . -..

.". . . i . . . . . .. .-

F16.M

10

le-

12)

FIG.40

CLUTCH

Q'W

R ~ . N O . m NO. 1-1 29111-93100-01J

1-2 2 3 2ll11-9310l-OlJ 21112-93108 1-3 21111-93103-015

LEVER, clutch LEVER, clutch LEVER, clutch PLATE, clutch lever SCREW SHAFT, clutch lever WASHER WASHER LOCK. WASHER NUT, clutch lever

C D 1

-

1 1 1 1 2 2 1 1 1 1

R& to 21111-93101-01J to 21111-931 02-01J

f m 21111-93102-01 J

02122-04128 4 21To1-93100 5-1 08322-1101)$

5-2

L:72,to 21211-93'101

6

09160-08015 09162-08003

09140-08003 09280-o9003

1 1 1 1 2 2

1 1 1 1

7

8

0 RING, clutch lever shaft

BALL, clutch notch SPRING, clutch notch

I1

9

0926O-lO003

0940-87021

70

71 12

22511-99ooo 23111-99102

23111-99202

GREASE NIPPLE, clutch lever 1 1 1 1 ROD, clutch ROD, clutch BUSHING, push rod 2 ARM, clutch BOLT, clutch a m COTTER PIN, clutch rod WASHER, clutch rod CONNECTOR, clutch rod (1) CONNECTOR, clutch rod (2) BOLT, clutch rod

ROD, shifting

13 14 15 16 17

18.

1

3

s L

type,L:407

type,L:=

09305-06QM

23211-99002 09100-06019 09204-01 001

09160-06015 23311-99001

2 2 1 1 1 1 3 3 1 1 1 1 1 1 1 1

1 1

fi&m

23211-99001

ex16

OD:1.8,L:lO

6.5xll.5w0.8

t

19 12*-13 20 21 27 25 24 26 28

2332'9-99001 09100-06020

25111-99700

22 23 24 25 26

27 28

25111-99005 09280-06004 25217 -!Mo4 08212-861 51 09280-1 1001

25311-59004

08310-1 1068 09139-06003 09168-06002

ROD, shifting

0 RING, shifting pod

1 1

1 1 1 1 1 1

6x20 s type,L:345 h type,L:498 ID:5.8,d:3.5

I

GUIDE, shifting rod WASHER

0 RING, shifting rod guide

CAM, shifting NUT SCREW, shifting cam stop GASKET, cam stop screw

1 1 1 1 1 1 1 1

ID:ll,d:2.4

29

30 31

1 1

6.2XIZx1.5

_ -

-

_-

__

,

. ..

.__ . . . __.__._._-.~

.-

.. ..

- . .. . . '.

....

.

.

.

. . ~. . . .

....

. _, .

,

,

'91

FIG.41

HANDLE

- GRJP

(m

C D

RIlnarPu

1 1

1 1

wN .a

f

Ng.

63111-93102-01J

63112-93103

HANDLE, tiller GROfWWET, stop switch wire CUSHION, handle SEAT, handle rubber BUSHING, handle cushion WASHER, handle pivot SPACER, handle pivot BOLT, handle pivot NUT, handle GRIP ASSY, throttle

*GRIP, throttle

2 3 4

8

09321-07001 63321-99000 09305-12007 0916Q-10041

~ - 1 o 0 0 1

. 69100-10091

1 1 2 2 2 2 2 2 1 1

1 1

5 6

7

8 9 10

11

10.3x25x1.6 10.5~12.5~24

10x55

Q9140-10017 63200-93101

63210-93101 63214-931 00 63218-93100

1

1

1 1 1 1

ta 63200-93102 to 63210-93102

12

13

-PIECE, sliding -SCREW, cover MARK, handle grip MARK, handle grip CABLE ASSY, throttle CUSHION, hendle

1 1

2 2 1

-

14-1 63215-93100 14-2 63215-93101

-

to 63215-93101

1

15

16

63610-98002

63331-93lQO

1 1 . L:478,8:98.

1 1

to 63331-93101

DT4.5C,

DT4D

.-

.

.

~.

.

.__.

..

..

- _.... .

..

..

:.

.

.. .. -.

12

FIG.42

CLAMP BRACKET

Q'W

R8f.h. Pmt Mo. 1 41111 99003-01J 2 41124-99004-01J

3-1 3-2 4 5 41211-99001 41211-99700 41212-99OOO-OlJ

-

BRACKET, clamp RH BRACKET, c l ~ n p LH SCREW, clamp SCREW, clamp HANDLE, clamp PIN, clamp handle

C D 1 1 !I 1 1; 2 2 2 2 2 2 2 2

OPT

I

RQmasks

09205-05UOl

09181-05001 412l3-99001 09380-07063 09180-06Q68 09180-06007 08322-21068

5.2~18 from 09209-05005

14

1

I

6 7 8 9

10

SHIM

PLATE, clamp RING, clamp plate BOLT, clamp shaft SPACER, clamp shaft WASHER NUT, clamp shaft WASHER, clamp shaft BOLT, swivel shaft SPACER, swivel shaft BUSHING, swivel support SPACER, swivel bracket WASHER

AR (0-4) 5.2xl3xO.l

2 2 2 2 1 1 1 1 2 2 1 1 2 2 1 1 1 1 2 2 2 2 8.1~12~85 11.8~22~23 8.5~18~2

from 09159-06010

6x158 from 41311-9WOO 6.5~10.5~85

2

11 12 13 14 15 16 17 18 19

09159-0604 5

091M)-06013

6.5~18~2

I

09100-Q8080 09180-08Os9 09300-1 1003

09160-om7 m-11088

09159-08018

...

2 2

1 1

NUT, swivel bracket

DT4.5C, DT4D

_.

- __. -

DT4.5C.LDT4D

BIG.43

13

-'

FIG.43

SWIVEL BRACKET WtY C D

1 1 Rmuwks

W.W.

1

m NO. -iption 43111-99402-01 J BRACKET, swivel

22514 -99000 4341O-!mol 43711 -WOO0 43712-99001 43721-98000 W3OO-11004 45110-99080 09139-OW3 45211-96000 09300-08005 45231-99401 45212-99401 09200-Q8018 09204-01001 01107-08128 08322-11088 08321-31 088 45rll1-99O03 43221-98615 43224-98002 GREASE NIPPLE ADJUSTER, steering BUSHING, steering upper PLATE, steering upper BUSHING, steering lower BUSH I NG, steering adjuster LEVER, rack SCREW, sack lever SPRING, rack lever BUSHING, rack lever ARM, reverse lock

2

3

4 5

§

2 2 1 1

1 1 1 1

1 1

7 8 9 10

1 1

1 1

11.8x22x11.8 5x8 28x10~14

1 1 1 1

1 1

2 2

1 1

1 1

12 13 14 15 16 17 18 19 20 21-2

SPRING, reverse lock arm

PIN, rewerse lock arm CBTTER PIN BOLT WASHER LOCK WASHER BLOCK, thrust PLATE, name PLATE, name PLATE, name

1 1

OD:8,L:89 OD:1.8,L:10

2 2

1 1

1 1 1 1

1 1 1 1 -

21-1 43222-98000

- 1

6

DT4.5C,

DT4D

DT4.5C,

DT4D

-

.

, I , .I ^ _

.

_.-.

~

~

.-

- -

-~

.

I

14

PBG.4% (7

FIG.44

DRIVE SHAFT HOUSING

Qw

Raf. %- Pwt #a .. 752101 =I6 -01J

-

Qn m eu i HOUSING ASSY, driveshaft

HOUSING ASSY, driveshaft -STUD BOLT, housing

-WASHER , housing

-NUT, housing

0 RING, drive shaft housing

C D 1 1 1 1 4 4 4 4

4 4

[email protected]

2 3

4

52101-99817-01J 09108-06007 09960-06015 09140-06004 09280-50002 52112-39000 092SO-36001 53131-99000

6x25 6.5x11.5x0.5 ID:50,d:3.7

5

6 7 8

1 1 1 1 1 '1

GROMMET, drive shaft housing1 1

CAP, clutch adjusting hole

9

COVER, stud bolt

DT4.5C , DT4D

FIG.45

.

15

F16.45

GEAR CASE

- PROPELLER

cw

C D 1 1 1 1

1 1

1 1

R8f.b. Pure No. 1 55100 99830 -01J

-

osratptbn

CASE ASSY, gear *ZINC, protection *&EAR ING FILTER, water PLUG, water PLUG, drain GASKET, drain plug DOWEL PIN, gear case STUD BOLT, gear case 1 LOCK WASHER, gear case 1 NUT, gear case STUD BOLT, gear case 2 LOCK WASHER, gear case NUT, gear case COVER, water inlet GASKET, gear case 1 GASKET, gear case 2 GASKET, gear case HOUSl NG, bearing O I L SEAL, bearing housing BEARING 0 RING, bearing housing BOLT, bearing housing LOCK WASHER, bearing PROPELLER (STD) PROPELLER (STD) PROPELLER

Remerkr

55321-93141 08113-62OM

from 55321-93140 20x47~14

17631-99OQO 09243-12001 09248-70003, 09168-104

8 9 10

24 ?3

I

1 1 2 2 2 2

1 1

10~17~1.5

to 09168-10022

09205-11001

09108-08029

11x14 8x40

1 1

1 1 1 1

09162-08003

091N-08OO3

11

12 13 14 15 16 17

m08-06014 09162-06001

3 3

6x40

3

3

o9l4o-o6oo4

17641-99600 55311-99004 55312-99000 55313-99000 5611 -99002-01 J 1

3 3 1 1

1 1 1 1

ia

19 20 21 31

1 1 1 1

1 1

09289- 1 mi 08113-63020

09280-50002

09100-06020

15x30~9 15~42x13 ID:50,d:3.1 6x20

1 1

22 23 24

25-1

1 1

2 2 2 2

09162-06001

58111-99003-01T 58111-99004-01T 5811 -99720-07T 1

housing

1 - 1 t o 58111-99004-OlT

.

&-.13

25-2 14 26-1 26-2

@--

58111 -99721 -01T PROPELLER 1 27-1 5811 -98720-01T PROPELLER 1 27-2 5811 -98721 -01T PROPELLER . BUSHING, propeller 58120-99326 28 SHEAR PIN 09202-05013 29

30 31

- 1 2x210x140 1 - 1 5811 -99721-01 T to 1 - '0 3~280x150( F W ) 1 - to 58111-98721-01T - 1 3x200~130(F500)

1 1

1 1

1 1

5x27,3.6x38.2

09202-05020

58131-9900

09204-03001

NUT, propeller COTTER PIN, propeller

1 '0

DT4.5C, DT4D

DT4.5C,

DT4D

.

.

.

.......

_ _ .. - _

. . . . . . . . . . . . . .

.....,

~

rL

PlG.46

16

.

FIG. 46 TRANSMISSION

@w

SHAFT , drive

1.2-

-iauon

C D 1 1

Ranarks

2

3 4 5 6

57110-99206

57211-99903 08113-62020

SHAFT, drive

SHAFT, pinion

BEARING

1 1 1 1 1 1

1 1 2 2

S , type, L: 220 L

09180-12036 08331-31159

SPACER, pinion shaft

12x16~20

T:l.5 T:0.2

Cd RCLlP

5HIM, pinion shaft

7-1 7-2 8 9-1

9-2

10-1

08221-25353 08221-25354 09263-16007 08211-28382

08211-28381

08221-28383

AR(Oc3)

AR(b3)

S H I M , plnion shaft BEARING, pinion shaft THRUST WASHER, plnion

shaft

1 1 AR(b1)

AR(&l)

16X20X20 T:?.5

T:l .O

THRUST WASHER

, pinion

shaft

SHIM, pinion shaft

SHIM, pinion shaft

AR(063) AR(b3)

9 1

T:O. 1

10-2 08221-28384 11 57317 -99601

12 57510-99002 13-1 08211-1 2202 13-2 14-1 14-2

15-7

f:0.2

NT:13 NT:25

T:1.5

PINION

GEAR , forward THRUST WASHER, forward gear THRUST WASHER, forward

1 1 AR(b1)

AR(W1)

08211-12203

T:2.0

T:O. 1

08221- 12204

08221-20303

g-r

SHIM, forward gear

AR(Ch1)

08221 I2203

SHIM, forward gear

SHIM, forward gear back

AR(Ch2) AR(W1)

T:0.2 T:O. 1

15-2

15-3

16

08227 -20304 08221-20305

08217 -1 5261

08221-15263 08221-15264 08221-15266

SHIM, forward gear back

AR(b2)

T:0.2

T:0.5 T:1.0

SHIM, forward gear back AR(b1) THRUST WASHER, propeller A R ( b 1 )

shaft

17-1

17-2 17-3

SHIM, propeller shaft SHIM, propeller shaft SHIM, propeller shaft

AR(b1) AR(W2) AR(b1)

T:0.1 T:O.2

T:0.8

DT4.5CI DT4D

. -

.. ..

. -

.__... . _..

._..,.

.. .._...._._......

~

.

.

., 17 FIG .46 TRANSMISS ION

R~.NO. NO. 18 57320-99400

FIG. 46

m

Daraiptii GEAR, reverse

C D

1 1

R

NT:29 T:1.5 T:2.0

T:O. 1

d

1.2-

19-1 19-2 20-1 20-2 21

08211-15202 08211-15203 08221-15203 08221-15284 57611-99003 57621-99004 57630-99830 09440-07018 09209-04008

THRUST WASHER, reverse gear THRUST WASHER, reverse gear

SHIM,

AR(b1) AR(b1) AR(b1) AR(b2)

1 1

1 1

reverse gear

SHIM, reverse gear

T:O.2 Prom 57611-99002 from 57621-99003 from 57631-99003 4x35.5

SHAFT, propeller SHIFTER, clutch

ROD SET, push

I

I

3

22 23 24 25

1 1

1 1

SPRING, push rod r e t u r n PIN, clutch dog shifter

1 1

H

c

DT4.5C, DT4D

DT4.5Ct DT4D

~-icl

.)

~

_ ...

.!

...

.

.. .

.

..

.

FIG.49

.I

18

FIG.47

c

ENGINE COVER C D 1 1 1 - 1

Rd.Rlo. pot No. -=won 1 6 1 1 1 0 - ~ 3 - 0 1 J COVER, engine lower

Remarks

to 61211-99601

to 61212-99601

6x12 6.5x11.5x0.8

21 ; 2-2 3-1

61211-99600 61211-99601

MARK, fuel cock "OWt1 MARK, fuel cock "ON" MARK, fuel cock "OFF" MARK, fuel cock 'oOFF'l BOLT, lower cover

61212-99600 3-2 61212-99601 00100--~18 4

1 - 1 4 4 4 4

1 -

10

3

1

5 6-1 6-2 7 8 9 10-1 10-2 11

WASHER, lower cover 09160-06015 61410-98002-01 J COVER, engine front 61410-98M3-01 J COVER, engine front FASTENER, engine a v e r 61610-99020 BUSHING, fastener 61621-99000 WASHER 08322-21088

to 61410-98003-01 J

- 1 1 1 1 1 1 1 1 - 1 1 1

21131-SO00 21131-96001 61521-96000

MARK, clutch shifting MARK, clutch shifting HOLDER, shear pin

to 21131-96002 to 61521-98400

_.

I

DT4.§C, DT4D

,.._,__,-. (.__.._.___~__....____. L_L_____.^ .._. ._

,

,

.

.

.

. . . ,.....

. .

...-.-.....-

---.

.

---

19

POG.48

L

. I

FIG.48

FUEL TANK

cyty W.W.

1 2 3 4-1 4-2

5-1

IW

wo.

'

Dernfptlon

C D

Reenakr

to 61441-98500

8

6510Q-988W-OlT 61441-98400 61422-933M 6!j325-98601

.

TANK ASSY, fuel *EMBKEM, tank side *EMBLEM, front EMBLEM, tank rear

EMBLEM, tank rear

1 1 2 2 1 1 1 - 1 1 - 1 1 - 1 1 1 1 - 1 1 1 1 1

4 4 4 4 4 4 4 4 1 1

plastic

10

65325-98002 65328-98600

EMBLEM, tank side RH EMBLEM, tank side RH EMBLEM, tank side LH EMBLEM, tank side L W

MOULDING, tank side

8

65328-98000 65338-98600 6-2 65338-98800 6539-98001 7 8-1 60501-98806 8-2 65510-98820 09168-32001 9 65551-98001 10 09320-1 0002 11 09180-06006 12 09160-06046 13

5-2 6-1

CAP ASSY, fuel tank CAP ASSY, fuel tank GASKET, tank cap FILTER, fuel CUSHION, tank rubber

SPACER, tank cushton

to 65510-98820 to 65510-98402

32~48~2.5

6.5x10.5x11.5 from 09160-06020 6.5x20x1.5

WASHER NUT, tank STAY, tank RH STAY, tank LH BOLT BOLT, tank stay WASHER

.

14 15 16 17 18 'J9 09159-SQ75 65611-9801 65621-98001

01107-08258

1 1 2 2

2 2

I 7

65631-98MK) 08322-11088

4 4

DT4.5C , D1'4D _. ._

-,

.

..

... . . .

-_.. ...... .

I..

_..- .

._..._

. G

.. .. ,

-

.

-- . . L

20

FIG.49

FUEL COCK

Ref.W. plro No. 1 65341-98000 66100-98051

SPACER, fuel cock

COCK ASSY, fuel

.\

Qw

C D 1 1 1 1 1 1 1 1 1 1

R&t

44346-99050 66181-99050

66152-99050 66141-99050 66251-9801 O&'

*GASKET, cup *FILTER, cup FILTER -GASKET, joint .CAP, fuel cock

HOSE, fuel

.

1 1 1 1

09343-051$1 10 09344-080134 09401-08401

HOSE, air vent drain C L IP , fuel hose .

1 1 1 2 2

-

L:500+180

L:2W t o 09401-08403

8

DT4.5C. DT4D

.

DT4.5C, DT4D

FIG. 9

9

FIG.9 F4ef.b.

1

OPT : GASKET / TOOL SET

miptbor

m

No.

a 9

1 1

R

e

8

2

3-1 3-2 3-3

11400-$8840 11400-98820 llw-98830 11400-96832 11400-S8833 11400-96820 09880-00128 09880-00178

GASKET SET (ENGINE) GASKET SET (ENGINE) GASKET SET (ENGINE) GASKET SET (ENGINE) GASKET SET (ENGINE) GASKET SET (ENGINE) TOOL SET (DT3.SDT9) TOOL SET (DT2)

DT3.5 DT4,DT4.5 DTSD, t~ 1 4oO-98831 1

1

1 1

1

4

1 % 4

TDT5,

to 11400-98833

to 1'84100-98834

DT7.5, DT9 to 11800-96821

to 09800-00805 to 09800-00805

5-1 5-2

1

K'-

G A K E - S- T-

SET

DTaDT9

DTaDT9

10 FIG.10 OPT : LIGHTING COIL, EMERGENCY SWITCH

QtY

R d . k

4

2

M

No.

D.oEliptb

a 9

Remarks

322M4-98821

02192-05258 08321-21058 02112-04208 39601-963711 08322-21048 39602-99711

COIL SET, lighting

to (32200-98380)+(396Q0-98300)

*SCREW *LOCK WASHER *SCREW *SOCKET ASSY *WASHER *PLUG ASSY, lighting -LEAD WIRE, earth COIL SET, lighting

3

5 4 6 7

i)

2 2 1 1

DT2 DT3.5 DT4,DT4.5

g1

i e l8

r

8 9 10

36898-93300

3220-98832 32120-98520 02112-Q6258 Q8321-21068 39601-96714 02112-04258 08322-21048 3W2-99711

-COIL, lighting

*SCREW *LOCK WASHER *SOCKET ASSY *SCREW *WASHER -PLUG, lighting

.LEAD WIRE, earth

11 12

13 14 15

16

17 18 19 20 21 22 23 24-1 24-2 25 26

36898-93300

09308-10002 00407-12402 39601-95711 02112-04208 08322-21048 35602-99711 37800-93812 37800-93813 09925-04011 09162-04002

*GROMMET, lead wire *CLAMP, lead w i r e *SOCKET ASSY *SCREW *WASHER *PLUG, lighting SWITCH SET, emergency f m 37800-93811 SWITCH SET, emergency from 37800-93812 *SCREW *LOCK WASHER

4:.

2 1

1

DT5

1

1

T

2 1 2

DT7.5, DT9

2

DTi3DT9

DTaDT9

1

- __. ..... .... - .

.._

.

-

11

F1 . 1 1O B

I dh0 W.f.

1-1 1-2

pprt

FIG.ll

OPT : RECTIFIRE

QW

Mo.

Dacrwon

RECTIFIRE SET RECTIFIRE SET *WECTIFIRE ASSY

-STAY, wctiflre

3.s9 1

Rmur(u

32m-98810

32800-981811

to 3 2 8 0 0 - W l l to 32801-98300

2

3

i

!

32800-95220

32890-98000

4 5

6 7

Orll2-052m

08321-21058 08310-11058 36740-95252 094Ell-2O001 36791-95200 37132-93700 32800-96810 328oQ-s811 321800-95720 02112-05258 36740-95252 09481-20W 36791-95200 09125-8602Q 37132-93700 36898-93300

*SCRW -LOCK WASHER *NUT

*CASE ASSY, fuse from 36740-95251

DT3.5 1 1 1 1 1 )

tQ 3 2 m - w 1 1

OT5

8 9 10

11-1 11-2

f

**FUSE (20A) *HOLDER, fuse case =CONNECTOR RECTlFlRE SET RECTIFIRE SET =RECTIFIRE ASSY -SCREW *CASE ASSY, Pus0 from 36740-95251 **FUSE (20A) *HOLDER, fuse case -SCREW, fuse case *CONNECTOR

12 13

r

14

DT7.5,DTg 1

1

15

16 17 18 19

1 1 1

-LEAD WIRE, earth

13

14

F GB4 B,

FIG.14

OPTIONAL

[email protected] M . h . Part No. - =

1 950-31030 99000-3185G m-32040 99ooo-25160 990Oo-25170

GASKET, liquid GASKET, liquid CEMENT, thread lock GREASE, water resistant GREASE, water resistant GEAR OIL, outboard motor SUZUKI SUPER GREASE A SUZUKI LOCK SUPER HANGER, engine

2

3

QtY

2 e

1 1

ROlkMdU

for crankcase,lOOg

for gear case,100g

1

1 1

2WJ 2%

%I

4-1

4-2 5 6

7

99ooo-22540 !39ow-25010

99000-32030 099l4-399ll 99006-10205-01 J

1 1

mcc 4SQg,for crank oil seal

a

1

1 1

5Og (13036)

0

6 9

11

9-1 9-2 10-1 10-2 11-1 11-2 11-3 11-4 11-5 11-6

10

T 9WOO-lQ105-Ql PAINT

PAINT

(m)

99OOQ-10109-T)'TT PAINT (9oe) 99000-10209-Q9J PAINT (Wg)

1

1

1

99oo0-2l460

99000-21 145 99000-2l021 99000-21 150

CCI OIL (llx24,Mitsubishi)

CCI OIL (lEx24,Shell)

CCI OIL (4-6) CCI OIL

. .. . ---I"--'

1

(ma)

1 1 1

gsQo0-2l250

99006-2126Q

CCI SUPER OIL (lBx24) CCI SUPER OIL (4kx6)

DThDT9

DThDT9,.

Information

Suzuki DT 4 (78) DT 4.5 (77)

26 pages

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