Suzuki DT 40 (83) - Browns Point83).pdf · PREFACE When it becomes neczssary to replace parts on...
Transcript of Suzuki DT 40 (83) - Browns Point83).pdf · PREFACE When it becomes neczssary to replace parts on...
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