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,.