DT 40 (1983)

PREFACE

When it becomes neczssary t o r ep lace p a r t s on SUZUKI OUTBOARD MOTORS, always use SUZUKI GENUINE PARTS which have passed a strict inspec t ion which guarantees q u a l i t y and performance.

T h i s parts ca ta logue covers t h e list of a l l s e r v i c e p a r t s f o r SUZUKI DT40 QD.

INSTRUCTIONS FOR QUOTING T E CATALOGUE

1. DIENSIONS Dimensions o f t h e pa.rts i n t h i s ca ta logue a r e i n d i c a t e d i n u n i t millimeters.

2. ABBREVIATIOEVS Abbreviations used i a t h i s ca ta logue are as follows:

AR : As requi red ASSY : Assembly E.No. : Engine number F.No. : Frame number

NT : Number o f teeth O K : Optional 0s : Over s i z e STD : Standard

d

ID OD L

LH RH -123456 123456-

: Diameter of ma te r i a l T : Thickness : I n s i d e diameter us : Under s i z e : Outside diameter W : Width

: Length : Lef t hand s i d e : Right hand s i d e

: 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 i n the d e s c r i p t i o n column shw the dimensions o f parts. T 7 T

DT40 QD E 3 - 1 -

3. INNER PARTS OF ASSEMBLY P a r t s number t h a t have a per iod ( . I mark i n f r o n t o f t h e part desc r ip t ion

on a text page are s e p a r a t e l y se rv i ced p a r t s of t h e assembly.

4. MODIFICATION NOTICE A p a r t s b u i l e t i n w i l l be sent t o you on a l l occasions when changes i n

p a r t s occur , inc luding in te rchangeable modi f ica t icns between new p a r t s and o l d ones.

NOTE 5- - 5-1.

5-2.

5-3.

There are some d i f f e r e n t p a r t s from those of product ion models among s p a r e p a r t s for t h e admin i s t r a t ive reasons and common use of them w i t h o t h e r models.

I n r e s p e c t of rubber hoses and v iny l tubes, p l ease 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 ca ta logue or what is a c t u a l l y requi red on t h e vehic le .

Note t h a t t h e drawings on t h e i l l u s t r a t i o n page are f o r

ready reference of s p a r e parts number, no t t o be used as an assembly manual. When assembling, u se 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

1 4

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 . r l - 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, pis ton

12140-94300-025 RING SET, p i s % m (OS:O.25) 12140-94300-050 RING 5 3 3 , 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, p is ton

12140-94350-025 RING SET, pis ton (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 p i n

BEARING, p is ton p i n WASt-ER, connecting rod OIL SEAL, upper crankshaft

OIL SEAL, lmer crankshaft

OIL SEAL, d r ive shaf t upper

CRANKSHAfl ASSY

. ROD connecting

.BEARING, crank P i n

. WAStER

.PIN, crank

.CRANKSHN, upper

.WEEL, middle lmer

.SEAL, labyr in th

.WEEL, middle upper

.CRANKSHAFT , l a m

.BEARING, crankshaft

2 2 OPT 2 om 2 2 om 2 O M 2 om 2 O K

2 O K 2 O M 2 O M 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 W A S l f R

08322-21068 WASHER

08310-11068 NUT

12480-94300-02M CASE, i n l e t

13125-95200 GASKET, carburetor 01411-08208 STUO BOLT

0142 1-0 6258 STUD BOLT

13121-94301 GASKET, i n l e t 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, s i lencer

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 626500 2

13254-93010 13370-28110 09493-24007 13 61 2-94300

13613-94300 13268 -96110

13267-95211 01411-08208

13410-94300 0949140007

09491 -38007 094 91 -42003 094 91 -3 8008 13631 -93500

09305-04005

CARBURETOR ASSY

.JET, p i l o t (80)

.SPRIG, a i r screw SCREW, p i l o t a i r .NOZZLE

.FLOAT

.GASKET, f loa t chamber

.BaT, f loa t

PIN, f l oa t .VALVE ASSY, needle .JET, a i r .BOLT

.BOLT

.SPRIN;, stop screw

.SCREW, t h r o t t l e s top

.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 J u n . , '83 B5

1

2

4

5

5 01107-08258 BOLT

6 7

0832 1-21088 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, s t a r t i n g 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

094 01-09402

15410-93400

15415-93400

15412-93400

15413-93400

15416-93400

08322-21088

08310-22088 09343-05137

09404-06414

PUMP ASSY, f u e l .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, f u e l ( f i l ter-pump)

CLIP, f u e l hose

FILTER ASSY, f u e l

.O RING

.STHAIER

.CUP

.PACKING

WASER

WT HOSE, f u e l (connector - f i l te r )

CLAMP, f u e l 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 S T Y E

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, d r i vesha f t BRG 09289-17004 .OIL SEAL, d r i v e s h a f t 09263-25025 .BEARING, d r i v e 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, r e c o i l 1-2 18100-94320 STARTER ASSY, I E C O i l

2 18120-94300 . S E A = DRUM

3 18131-94302 .PAWL, dr ive

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

18 142-93000 .SPRING 18151-94300 .PLATE, dr ive

18153-95200 .SPRING, f r i c t i o n 18191-95202 .PLATE, guide 18192-95203 .RUBBER, guide p la te

18195-95200 .CLIP

18335-94300 18162-94300

.WASI-ER

.WASER, dr ive pla’te

.BUSHIM; 18155-94300 .SFRING, re tu rn

18124-94300 18332-94300 .BOLT

08310-11068 .KIT 18196-96301 .SPRING, guide p la te 18200-95202 .GRIP ASSY

18210-93001 . .GRIP

18281-96300 . LEVER, stopper 18282-96300 .ARM, stopper

.SPRIffi 18284-96300 18335-96300 . W A X R 18348-96300 . PIN

18290-94300 .CABLE, NSI

01517-08258 BOLT 01517-06258 8OLT

18411-94301 CUP, s ta r te r 01517-08168 B a T

18711-94301-02M BRACE, n?co i l starter RH 01107-06208 BOLT

08322-21068

18721-94301-02M BRACE, r e c o i l s ta r te r 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

FIG. 9

6

9 - 4 1

'1 --Q 12

8

1 2

3 4

5 6

7

8

9

10

11 12

13 14

15

16

17

18

19

20

21

Q'TY REMARKS REF.NO. PART NO. DESCRIPTION

1 19121-94300 LEVER, throttle control 19122-94300 LEVER, inter l i n k throttle CONT 1

6

1 L:187 19135-94300 ROD (inter link-starter) 19131-95501 CONNECTOR

19136-94301 ROD ( inter link-starter) 1 L:55

4 09119-05010 BALL PIVOT 6

08310-11058 NJT , connector 1 19151-94300-02M RETAINER, s t a to r 1

19161-94301 SPACER, stator 1 19172-94311 STOPPER, stator 2 01104-05108 BOLT 2 08322-21058 WASER 2

09320-07006 CUSHION 1 09111-08043 BOLT , throttle lever 1

1 1 19184-94301 BRACKET , t h r o t t l e cable 1

19185-94300 SPRING, throttle lever 1 19654-94300 ROD, CLUTCH NSI level 1

19851-96301 LEVER, NSI 1 19865-94300 STAY, NSI cable

09160-10040 WASHER

09160-08054 WASHER

I 17

3

OT40 QD

I

M40 PO E3 C2

FIG. 1 0 10

FIC.10 (C- 3) CLUTCH

19

25

Q'TY REMARKS REF.NO. PART NO. DESCRIPTION

1 2 3

4

5

6-1 6-2

7

8

9

10

11 12

13

14

15

16

17 18

19

20

21

22

23

24

25

26

27

28

29

21210-94301

09306-08003 W2r35-05010

23111-94301

09140-06004

25111-94310 25111-94350

09280-080'35

25211-95202 09280-11001

09205-03021

25311-94300

23311-94300

23131-94300

SHAFT, c l u t c h BUSHING, c l u t c h shaft c e n t e r PIN, c l u t c h rod ROD, c l u t c h NUT

ROD, s h i f t (L:244) ROD, s h i f t 0 RING (ID:7.6, d:1.8) GUIDE, s h i f t i n g rod 0 RING, s h i f t i n g rod guide PIN, s h i f t rod CAM, s h i f t TURNBUCKLE, c l u t c h rod BOOTS, c l u t c h rod

1 2 1 1

1 1 S T Y E 1 L TYPE 2

1 1

1 1 1 1 1 21111-94303-02M LEVER, Clutch

I

DT40 QO E3

09260 -10003

09440-07021

09306-10001

21120-94303

21212-94303

09205-04006

21241-94300

09204-01001. 25223-95200

09139-06003

09168-06002

25231-95501

25232-95501

09100-06020

09160-06015

BALL, c l u t c h notch SPRING, c l u t c h notch BUSHING , c l u t c h l e v e r shaf t PLATE, c l u t c h notch ARM, c l u t c h s h a f t c e n t e r PIN, c l u t c h s h a f t c e n t e r arm ROD, c l u t c h arm COTTER PIN, c l u t c h a r m rod D u g SEAL

SCREW, s h i f t cam s t o p GASKET HOLDER, magnet MAGNET

BOLT

WASER

1

1 2

1 1 1 1

2

1 1 1 1 1 1 1

DT40 QD

FIG.ll

11

12

13 3

/-

A

11 FIG.11 (C- 4) STARTING MOTOR

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

31100-96310

31310-96300

31320-96300 31312-96300

31360-96300

31173-96300

31131-96300

31132-96300

31135-96300

31281-93340

01107-08258

08321-21088 08322-11088

31800-95502

31805-94350

01107-06208

08321-21068

MOTOR ASSY, starter .ARMATURE

.PINION

.STOPPER SET, pinion

. WASI-ER

.HOLDER ASSY , brush

. .BRUSH (+>

. .BRUSH (->

. .SPRING

. BOLT BOLT

LOCK WASHER WASI-ER

RELAY, star ter BRACKET , starter relay BOLT

LOCK WASHER

1 1 1 1 1 1 1 1 2

2 2

2 2

1 1 1

1

DT40 QD 1

c4

DT40 QD E3

FIG. 1 2

11

12 FIG.12 (C- 5) MAGNETO

Q'TY REF.NO. PART NO. DESCRIPTION REMARKS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

32101-94314 32120-95301 02112-05258 08321-21058 32140-95301 02112-05208 08321-21058 32150-95302 02112-05108 08321-21058 32102-94312 02122-05128 08341-31059 09160-18011 09164-18001 08310-22188

12

STATOR ASSY .COIL, l i g h t i n g (12V,8OW) .scFEw .LOCK WASNR

.COIL, i g n i t i o n primary . S C R E W .LOCK W A S R .S€NSOR, i g n i t i o n t iming .SCAW .LOCK WASHR

FLYWHEEL SCFEW

KEY

W A X R (18.5~35~4) LOCK WASNR

NUT

1 1 2 2 1 2 2 2 4 4 1 3 1 1 1 1

DT40 QD

I

DT40 QD E3

FIG. 1 3

2 6

13 FIG.13 (C- 6) IGNITION

Q’TY REMARKS REF.NO. PART NO. DESCRIPTION

1 2

3 4

5

6 7 8

9

10

11 12

13 14

15

32900-94310 01517-06168

08310-11068

08321-21068

36650-94302

091 25-06020 36651-94300 36653-94301

33410-94310

33420-94310

01107-06208

08321-21068

33510-95510

09482-00198 09404-06401

C.D.I. U N n , i g n i t i m BOLT

NJT LOCK WASER

COVER, j unc t ion box

SCREW INSULATOR, Junct ion box f r o n t INSULATOR, j unc t ion box

C O I L ASSY, i g n i t i o n upper C O I L ASSY, i g n i t i o n lmer BOLT

LOCK WASI-ER

CAP, spark p lug

SPARK PLUG. (NGK RRHS) CLAMP, i g n i t i o n coil

1 1 1

1 1 MANJAL STARTER

4 MANUAL STARTER 1 irlANJALSTARTER 1 MANUAL STARTER

1

1 4

4

2

2

1

DT40 QD DT40 QD E3

FIG. 1 4

l6 -0 15-

14 FIG.^^ (c- 7) ELECTRICAL (1)

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

I

DT40 QD E3

32800-95720 02112-05258

G8310-11058 08321-21058

36740-95252 09481-20001 33810-96303

33811-96300

33885-94300 02152-06128 36612-94301 36632-95501

36613-94300

33812-94300 09404-06413 02152-06128

36899-94300

RECTIFIER ASSY

SCFEW

NUT LOCK WASHER

CASE ASSY, fuse .FUSE (20A) CABLE E S Y , s ta r t i ng motor G R O M M , battery cable

CLAMP, battery cable SCFEW GRCMIYET , harness connector CLAMP, connector grommet

GROMMZT, harness connector

CAP, battery cable CLAMP, stop lead wire SCEW

LEAD W I F E , stop

1 ELECTRIC STARTER

1

2 4 1 1 1 1 1. 1 TM-AL STARTER

15 F I G . 1 5 (C- 8) ELECTRICAL (2)

14

6

10 A //

Q’TY . ’ f?EF.NO. PART NO. DESCRIPTION REMARKS

1 2 3 4 5

6

7 8 9

10 11 12 13 14 15 16 17 18

3772 1-95252 37725-94301 37726-94302 01107-06168 08321-21068 38600-94351

09100-05102 09162-05002 09404-06412 36630-94320 36631-94300 36630-94330 38423-95501 33816-96300 03242-06259 09404-06413 37800-93351 02152-06128

SWITCH ASSY, neutral ACTUATOR, neutral switch BRACKET, neutral switch BOLT

LOCK WASHER

SOLENOID ASSY, choke BOLT LOCK WASHER

CLAMP, chdte solenoid WIRING HARNESS, remote control .CAP. remoto control harness W I R I G HARNESS remoto control T E E , remoto control harness CLAMP

SCREW

CLAMP, N.S.I. lead SWlTCH ASSY, stop S C R W

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

- E L E C T R I C S T A R T E R

1 TMWAL STARTER

D T 4 0 QD ...

I

OT40 QO E 3

FIG. 14

22 I

16 FIG. 16 (D- 2) CLAMP BRACKET 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 22

23 24 25 26 27 28

29

41120-94313-024 BRACKET , ClaIIIp, RHAH 41212-93000-02M HANDLE, clamp 09205-06007 41211-94301 41213-93002 09140-08003 09162-08003 091 60-08014 09100-08199 09100-08159 09160-08015 09180-09013 09162-08003 09140-08003 09159-22002 09160-22017 41130-94300 45420-94301 09140-10015 09162-10002

09111-10015 09111-12006 09448-29003 41222-94301 41223-94301 41226-94301 41141-94300 41222-94350 41223-94350

PIN SCREW

PLATE, clamp NUT L O X WASHER

WASFER (8.5x23x1.5) BOLT

BOLT (8x230) WASHER (8.5x16x1.6) SPACER (9.8~13.8~156) LOCK W A X R

NUT

WT W A S E R (22 .5~38~1) SHAFT, bracket PIN, tilt lock P U T . Li’Y W A S E R

BOi; (L:57) BOLT (L:27) SPRING ARM, tilt lock ARM, tilt stop SPACER, tilt s top arm ATTACHMENT, steering cable ARM, tilt lock ARM, tilt stop

2 2 2 2 2 2 2 4 2 1 2 1 1 1 1 2 1 1 2 2 2 2 1 1 1 1 1 1 1

OK OPT 7 Increases

T i 1 t Angle OrnJ By 8-

2

8

DT40 QO

I

DT40 PO E 3

17 FIG.17 (0- 3) SWIVEL BRACKET

Q’TY RENARKS . ’ REF.NO. PART NO. DESCRIPTION

FIG. 1 7

1 2

3

4

5 6

7 8

9

10

11 12

13

14

15 16

17

18

. 1.9 20

21 22

23 24

43750-94304-02M 09100-08163

09160-08015

09440-11013

09343-12004 09443-12021

4 5231-94300 43411-94300

09306-26006

43111-94303-02M

22511-99000 09306-26005

09161-26001

43241-93102

45255-93000

45261-94301

45254-94300 45250-94301

45243-94301 45241-94300

09160-08015

09100-08162

43754-94301-02M 03142-05109

BRA!XET , steering BOLT (8x35)

WASI-ER (8.5x16x1.6)

SPRING (d : l . 4ph i )

BOOTS (L:60-21) SPRING, reverse lock ARM, reverse lock ADJUSTER, steering BUSHING, upper BRACKl3, swivel

BUSHING, 1mer WASHER ( 2 6 . 7 ~ 4 8 ~ 2 )

MARK, release lower RUBBER, lever LEVER, release PIN, release arm LINK, release arm PIN, release lock am LINK, release lock WASHER (8.5x16x1.6)

BOLT (8x30)

COVER , bracket SCREW

GREASE NIPPLE

1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1

2

2

1 ELECTRIC START 2 ELECTRIC START

03

DT40 OD

D

DT40 QD E3

FIG. 08 18

14

. ' REF.NO. PART NO. DESCRIPTION REMARKS

1 2 3 4

5 6

7 8

9 10 11 12

13 14 15 16

11433-94302 11431-94303 52113-94300 52141-9431 1 09162-06001 09100-06058

54123-94300 54121-94300 09100-08163 09160-08015 54137-94300 54130-94300 09100-10148 09160-10040 09162-10002 09140-10015

GASKET 1 HOUSING, lmer o i l seal 1 GASKET, housing 1

T U E , exhaust LOCK WASHER BOLT (6x15)

PLATE MOUNTING, upper t h r u s t BOLT (8x35) WASER (8 .5~16~1 .6 ) CASE, upper mounting MOUNTING, upper BOLT (10x145) WASER ( 10.5~18~1.6) LOCK WASHER

NUT

1 6 6

1 1 4 4 2 2 2 4 2 2

13

Q'TY

I

DT40 QD €3 DT40 QD

FIG. 1 9

14

@-- 19 18

19 FIG.19 (0- 5) WIVESHAFT HOUSIK

Q'TY DESCRIPTION REMARKS REF.NO. PART NO.

1 2 3 4 5 6 7 8 9

10 11 12

13 14 15 16 17 18 19 20

PIN 09202-06015 09162-08003 LOCK W A W R

09160-08015 WASHER

09100-08160 BoL'r (8x45) 09100-08161 BOLT (8x65) 52111-94312-02M HOUSING, driveshaft 54125-94300 M O W I N G , t h r u s t reverse 54151-94300 MOUNTING, lower t h r u s t 54211-94303-02M COVER, laver mounting 09160-08015 WASHER (8 .5~16~1.6) 09162-08003 LOCK WASHER

09100-08095 BOLT (8x75)

54161-94300 Mom I S , lmer 54167-94300 MOUNTING, lower side 09205-10002 SPACER, housing 52131-94340-02M CASE, extension 09108-08110 STUD BOLT

NUT 09140-08003 09162-08003 LOCK WASHER

09206-11006 PIN

2 9 9 7 2 1 1 1 2 2 2

2

2 2 2 1. L T Y R

6 L TYPE

6 6 2

DT40 QD

I

OT40 QD E3

i 20 FIG. 1Q FIG.20 (0- 6) (TAR CASE Q'TY

REF.NO. PART NO. DESCRIPTION REMARKS

55100-94302-Om CASE SFT, gear 1 1 2 1 2

2 1 1 1 1 1 2

.BEARING, p in ion 09263-22029 09265-30004 .EEARING, propel ler shaft 17631-93402 FILTER, water

55122-94300 SEAL, gear case 03142-04259 SCAN

55125-95202-OD TRIM TAB 09162-08003 LOCK WASHER

55114-98502 COVER, gear case loder 09100-08090 BOLT (8x16)

03112-04109 TAPPING SCEW 55320-93142 ZINC, protect ion 1

3 3

09100-08101 BOLT (8x40) 6

6

13 09248-10004 PLUG, dra in 14 09168-10022 GASKET, dra in plug

15 09162-08003 LOCK WASHER 57632-95304 STOPAR, propel ler bushing 1

19-1 58100-94300-ClT PROPELLER (3~11-1/2~9) 1 smo 19-2 58100-95210-01T PROPELLER (3~11-1/2~10) 1 SlOOO

0-1 09160-32006 WASER (32.6~45~1)

1 S l l O O

19-4 58100-95351-01T PROPELLER (3~11-3/8~14) 1 51400 19-5 58100-94311-01T PROPELLER ( 3 ~ 1 L 1 / 2 ~ 1 3 ) 1 S1301 STD

19-3 58100-95220-OlT PROPELLER (3~11-1/4~11)

19-6 58100-95391-01T PROPELLER (3~11-5/8~12) 1 s1200 1

1 SPACER 57633-94300

57635-95300 WASER

0 9159 -l8004 k T 1

55300-95500 ZINC ASSY, protect ion 1 om

17

Q6 I

OT40 QO E3 DT40 QD ~

, F I G 2 1

a3

21 FIG.21 (D- 7) TRANSMISSION

Q'TY REMARKS ' REF.NO. PART NO. DESCRIPTION

1-1 57110-94313 SHAFT, d r i v e 1 S T Y E 1-2 57110-94350 SHAFr, d r i v e 1 L TYPE 2 57130-94301 BUSHING (17x27~24) 1 3 09205-03019 PIN 1 4-1 08221-30425 SHIM (T:0.5) 0-1 4-2 09181-30004 SHIM (T:0.6) 0-1

4-3 09181-30005 SHIM (T:0.7) 0-1 4-4 08221-30426 SHIM (T:0.8) 0-1

4-5 09181-30006 SHIM (T:0.9) 0-1 4-6 08211-30421 THRUST WASER (T :1) 0-1

5 09160-26008 WASHER (26~42x3) 1 6 0-969-25014 BEARING, t h r u s t 1 7 09440-27009 SPRING 1

8 08211-22303 THRUST W A W R 1 1 9 09169-22002

i

WASER

10 57133-94301 COLLAR 1 ' 11 57311-94310 PINION 1 12 09140-12021 NUT 1

0-1 13-1 08221-30425

13-2 09181-30004 SHIM (T:0.6) 0-1 13-3 09181-30005 SHIM (T:0.7) 0-1

SHIM (T:0.5)

13-4

13-5 13-6

14 15-1

15-2

16

-. 17

18

19

08221-30426 09181-30006 082 11-3042 1 57510-94310 08211-20263

08211-20264

57631-95200

09209-08016

57521-94301

09202-05019

S H I M (T:0.8) SHIM (T:0.9)

THRUST WASKR (T : 1) GEAR, forward THRUST WAStfR (T :2) THRUST WASHER (T:2.2)

ROD, push

PIN, push SHIFTER, c l u t c h dog PIN

0-1 0-1 0-1 1

0-1 0-1 1 1 1 1

I

13

~ DT40 QD M40 QD E3

FIG. 2 1 22 FIG.21 (0- 8) TRANSMISSION

Q'TY REF.NO. PART NO. DESCRIPTION REMARKS

8 - 2

4

5 .. i,

20 21

22 23-1 23-2 23-3

23-4 23-5

23-6 24

25-1 25-2

25-3 25-4

25-5 25-6

26 27

28 29

30 . 3 1

32

09440-38003 SPRING, dog . 09440-07018 SPRING, r e t u r n 57610-94301 SHAFT, propeller 09160-22018 THRUST WASHER (T : 1.8)

09160-22019 TIiUUST WASHER (T ~1.9) 09160-22020 THRUST WASHER (T :2.0)

09160-22021 THRUSF WASHER (T:2.1) 091.60-22022 THRUST WASHER (T t2.2)

09160-22023 THRUST WASHER (T ~2.3) 57521-94310 GEAR, reverse 09181-35003 SHIW (T:0.5) 09181~35009 S H I M (T:0.6)

09181-35010 SHIM (T:0.7) 09181-35011 SHIM (T:0.9)

09181-35001 SHIM (T:0.8) 09181-35002 SHIM (T:1.0)

09280-75001 0 RING

56120-94302-02M HOUSING, p r o p e l l e r shaft 08113-60070 .BEARING

.8EARII?G 09263-22020

09289-22006 .OIL SEAL

09160-08015 WASHER (8.5X16XP. 6)

09100-08112 aOLT (8x30)

1 1 1

0-1 0-1 0-1 0-1 0-1 0-1

1

0-1 0-1

0-1 0-1 0-1 0-1

1 1 1 2

1 2 2

I 13

DT40 QD DT40 QD E3

FBG. 22 23 FIG.22 (E- 2) LOWER COVER

Q'TY REMARKS

. . DESCRIPTION REF.NO. PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

61110-94306-02M COVER, lower 61113-94301 SEAL

09180-06112 SPACER (6.8xlOx11.5) 09320-10018 CUSHION

09160-06047 W A X R (6.5~22~2) 09162-06001 LOCK WASER

09100-06089 BOLT (6x25) 61139-94300 BLOCK 9 R H L H

01107-06108 BOLT 08322-21068 WASER

61631-98100 HOOK, lmer cover 09164-13005 WAVE WASER

09306-13002 BUSHING

67410-94301-02M S W , throttle 09306-10001 BUSHING

67417-94301-024 ARM, throttle 09205-04002 SPRING PIN

09119-05010 BAU, pivot

09250-30003 CAP, switch hole 39669-93502 CA?, consent 13625-94300 CAP, chcke rod guide

61633-96002-02M LEVER, hook

ROD 67413-94300

1 1 4 4 4 4 4 2 L:200

1 1

1 1 1 1 1 1 1 1 1 1 1 1 1

2

DT40 QD

b

DT40 40 E3

E2

FIG. 23

2 I

DT40 QD -

24 FIG.23 (E- 3) E N G I E COVER

Q'TY REF.NO. PART NO. DESCRIPTION REMARKS

1 61400-94870-02M COVER SET, engine 1 2 61431-94300-02M .HANDLE, tilt up 1 ' 3 09160-06036 .WASHER (6.5x18x1.5) 3

5 . 09100-06019 .BOLT (6x16) 3 6 61422-94360 .EM8LEM, f r o n t 1

7 61441-96300 .EMBLEM, side 2 8 61458-95201 .MARK, safety warning 1

? 61457-93002 . MARK, warning 1

10 61443-94360 .DECAL RH "40" 1 11 61453-94360 .DECAL LH "40" 1 12 61435-94360 .EMBLEM, rear I14Ott 1 13 21131-96003 .MARK, clutch s h i f t i n g 1 14 61112-94302 RUBBER, h e r cover 1

15 09800-81800 TOOL ASSY 1

3 .LOCK WASI-ER 4 09162-06001

. DT40 QD E3 c,

FIG. 24

'// 1-1 I 10

1

// i6

25 FIG.24 (E- 4) HANDLE (MANUAL START)

Q'TY REMARKS DESCRIPTION REF.NO. PART NO.

1 63121-96301-02M COVER, t i l l e r handle 1 2 63114-94300 SPACER 1 3 09108-08036 STUD BOLT 2 4 09162-08003 LOCK WAStER 2

5 09140-08003 NUT 2.

7 63111-96301-02M WNOLE, t i l ler 1 8 63115-96300 SPACER 1

9 6362 5-96300 GROMET 1 10-1 09404-06404 CLAMP 1

10-2 09404-06403 CLAMP 1

12 09125-06033 SCREW 1 13 63225-93200 BUSHING 1 14 63241-94300 ADJUSTER, g r i p 1 15 09160-06015 WASHER ( 6 . 5 ~ 1 3 ~ 1 ) 1 16 09100-06019 BOLT (6x16) 1 17 09440-12027 SPRING 1

19 63227-93200 PIN, handle rod (L:14) 1 20 63223-93200 STOPPER 1 21 09163-06001 LOCK WAStER 1 22 09126-06004 SCREW (6x20) 1 23 63210-93202 GRIP, handle 1

24,

6 63625-94300 GROMM 1 ELECTRIC START

11 63610-94300 CABE , t h ro t t l e (grip-lever) 2

1 63220-96300 ROO, handle 18

1 OPT 63300-94300 BAR ASSY, extension

DT40 QD

I

DT40 QO E 3

22 26

FIG.25 (E- 5) NEL TANK Q'TY

- 1

REMARKS DESCRIPTION REF.NO. PART NO. 1 6US.GAL. 1 65000-95200 TANK SET, f u e l (23L)

2 65510-98506 .CAP ASSY 1 3 65561-98502 . .GASKET 1

4 65871-93010 .GASKET, f u e l gauge 1

5 01107-06168 .BOLT 3

6 01107-06408 .BOLT 1 7 08322-21068 .WASl-ER 4

8 65850-95504 .GAUGE ASSY, fue l 1

10 65854-93001 . .GAS(ET, s t ra iner 1 11 65853-93001 .STRAINER 1 12 02112-04108 . .%FEW 2

13 65864-95200 . .FLOAT 1 14 65830-95500 . .FILTER, ou t l e t 1 15 09168-12001 . .GASKET ( 12.5~20~1) 1 16 65700-95205 HOSE, f u e l 1

17 65750-98505 .SOCKET 1 18 65750-93000 .SOCKET 1

19 65781-98500 .CLIP 4

20 65770-99702 .PUMP, squeeze 1

9 65740-95500 . .PLUG, tank s ide 1 M12,OD:13

1 om 21 65700-95271 HOSE, f u e l j o i n t 22 65720-98590 PLUG, f u e l cmnector 1 Om,MlZ-ll

DT40 QD

€5

DT40 QD E3

FIG. 26

'0 I 16 i

27 FIG.26 (E- 6) REMOTE CONTROL

Q'TY REF.NO. PART NO. DESCRIPTION REMARKS

1 2

3 4-1

4-2 4-3

4-4 4-5

4-6

5

6 7 8 9

. 10 11 12 13

14 15

16

67200-95550 67296-94300 37110-94301

37'141-93300

37141-93310 37141 -93 32 0

37141-93330 37141 -93340

37141-93350

67296-94310 36622-94300 36632-95501 3 6620 -94 310 67275-94300

37820-95254 37823-95251

67288-94300 67271-94300

67288-94310 09140-06004

09125-06012

I

DT40 QO E3

EMOTE CONTROL BOX ASSY .SCREW .SWITCH ASSY, i g n i t i o n

..KEY, spare (8511)

..KEY, spare (8512)

..KEY, spare (8513)

. .KEY, spare (8611)

..KEY, spare (8612)

..KEY, spare (8613)

.SCEW

.CLAMP

.CLAMP

.WIRING HARNESS, extension

.CABLE END

.SWTTCH, emergency

. .CAP

. W A X R

.HOLDER, cable

. WASt-ER

. NLJT

. % E W

1 (Electric S ta r t ) 4 1 1 1

1 1 1 1

4 1 1 1 2 1 1 2 1

3 3

3

DT40 QD E6

. . FIG.27 (E -7 ) OPT: ELECTRICAL (1)

FIG. 27

4 i

Q'TY REMARKS ,REF.NO. PART NO. DESCRIPTION

3 1 31101-94300 MOTOR SET, starting 1 I

2 33800-94302 CABLE & SWITCH SET. startins 1 I I -

3-1 32 102-94302 ROTOR ASSY 1

3-2 32 102-943 12 ROTOR ASSY 1

4 32801-94300 RECTIF IER SET 1

- I

Y 4

. .

- 2

.. . . .

DT 40 QD El

FIG.28 (E-8) OPT: ELECTRICAL 2 (MANUAL STARTER)

I 70

Q ' T Y REMARKS REF.NO. PART NO. D E S C R I P T I O N

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

1

3280 1- 9430 1

32800-95720

02 112-05258

08310-11058

0832 1-2 1058

36740-95252

09481-20001

36898-93300

37132-93700

36791-95200

39600-98300

39601-96712

02 1 12 -04 208

08322-21048

39602-99711

36898-93300

R E C T I F I ER S E T

. R E C T I F I E R ASSY

.SCREW

.NUT

.LOCK WASHER

.CASE ASSY, fuse

. .FUSE (20A)

.LEAD WIRE, c o n s e n t

. CONNECTOR, w i r e

.HOLDER, fuse case

SOCKET S E T

.SOCKET ASSY, l a m p

.SCREW

.WASHER

.PLUG ASSY, l a m p c o r d

.LEAD WIRE, c o n s e n t

1

1

.1

1

1

1

1

1

1

1

1

1

2

2

1

1

11

D T 40 QD El

E8

FIG.29 (E-9) OPT: ELECTRICAL 3

Q'TY REMARKS - REF.NO. PART NO. DESCRIPTION

1 32500-9572 1 REGULATOR ASSY, vol tage

2 01107-06208 BOLT 2

ELECTRIC STARTER

1

1

1

1

3 0832 1-2 1068 LOCK WASHER

4 08310-11068 NUT

5 36641-94701 ADAPTER, 0.N. (L:160)

6 36642-94702 ADAPTER, N.O. (L:300)

7 36632-95501 CLAMP, connector g r o m t

8 36639-94300 GROMMET, harness connector

9 36631-94300 CAP

8

DT 40 QD E l

DT40 QD El

E 9

FIG. 30 (E-10) OPTIONAL: REMOTE CONTROL PARTS I

FIG.30

1 3

8

7 :*

Q'TY REMARKS REF.NO. PART NO. DESCRIPTION

1 67130-94302-G2M REMOTE CONTROL PARTS

2 67341-9430 1

STD DT 40 E l e c t r i c 3

1

1

.HOLDER

3 67440-93701 .GUIDE, c lu tch cable

4 09 160-06015 .WASHER ( 6 . 5 ~ 1 3 ~ 1 )

5 09100-06058 .BOLT

6 67466-95200 .GUIDE, t h r o t t l e cab1.e

7 67414-9430C-02M .LEVER, t h r o t t l e

.BALL PIVOT 8 09119-06047

DT 40 QD E l

DT40 q0 E l

- .

-FIG.31

FIG.31 (E-11) OPT: METER (DT4OR)

Q'TY REF.NO. PART NO. DESCRIPTION REMARKS

1 99 105-00160 TACHOMETER ASSY 1

2 99105-00165 SPEED METER ASSY (knot) 1

3 34850-94700 THERMO UNIT ( Inc l grease) 1

4 34853-94301 SUPPORTER, heat switch 1

5

6

7

8

9

10

11

12

09404-08401

09160-08043

34854-95300

38500-95503

38501-95500

02112-05088

37820-95254

37823-95251

DT40 QD E l

CLAMP, heat switch lead wire 1

WASHER, heat switch 1

FILLER, heat switch 1

BUZZER ASSY, warning 1

BAND 1

SCREW 2

SWITCH ASSY, emergency 1

. CAP 1

OT40 OD E l El 1