3. INNER PARTS OF ASSEMBLY

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1 DT 5 (-00)

2 A PREFACE When it becomes necessary to replace parts on SUZUK OUTBOARD MOTORS, always use SUZUK GENUNE PARTS which have passed a strict inspection which guarantees qua i ty and performance. This parts catalogue covers the list of all service parts for SUZUK DT --' MODEL, DT5Y --' 0 MODEL... NSTRUCTONS FOR QUOTNG THE SATALOGUE DMENSONS Dimensions of the parts in this catalogue are indicated in unit millimeters. ABBREVATONS Abbreviations used in this catalogue are as follows: AR ASSY : E.No. : F.No. : d D OD L LH(P0RT) : RH(STD) : x x D OD As required NT : Number of teeth Assembl y OPT : Optional Engine number 0s : Over size Frame ilumber STD : Standard Diameter of materi a T : Thickness nside diameter us : Under size Outside diameter w : Width Length S, L,UL, LL : Transom type Left hand side 00 : MODEL:000 Ri ght hand side dl : MODEL:00 : Up to F.No : From F.l!a.OO * Figures in the description column T(or W,L) show the dimensions of parts.. NNER PARTS OF ASSEMBLY Parts number that have a period (. ) mark in front of the part description on a text page are separately serviced parts of the assembly.. HOOFECATON NOTCE A parts bulletin wi be sent to you on all occasions when changes in parts occur, i ncl udi ng i nterchangeabl e modi f i cati ons between new parts and ol d ones NOTE 5- There are some different parts from those of production models among spare parts for the administrative reasons and comn use of them with other models. 5-. n respect of rubber hoses and vinyl tubes, please be sure to use them by cutting off according to the length mentioned on parts catalogue or what is actually required on the vehicle. 5-. Note that the drawings on the illustration page are for ready reference of spare parts number, not to be used as an assembly manual. When assembl ins, use "SUZUK SERVCE MANUAL".. ENGNE NUMBER DT VJ (' MODEL) : DT VK (' MODEL) : VL 0 MDOEL) : ( J DT VM (' MDOEL) : DT VN (' MODEL) : DT VP (' MODEL) : ~ DT VS (' 5 MODEL) : DT VT (' MODEL) : 000-5lOOlb DT VV (' MODEL) : DT VW (' MODEL) : VR (' mn) : ~ o~oz-~~u~- DT5 YX (' MODEL) : DT5 YY (' 00 MODEL) : DT5 Y ('0 MODEL) : Q 00 American Suzuki Motor Corporation

3 FG FG. ( B-) CYLNDER (DTSY) Q'm REF.NO. PART NO. DESCRPTON REMARKS BOLT 5 -SAl-OED HEAD, CYLNDER (GRAY) -AO GASKET, CYLNDER HEAD - 00-AO-OED CYLNDER ASSY (GRAY) - 00-BO-OED CYLNDER ASSY (GRAY) M0DEL:Ol 5 O-5D0.VALVE, CHECK 0-00.DOWEL PN BOLT 055O-00.BOLT a0 COVER, WATER JACKET SCREW (5x) -0 GASKET, WATER JACKET 5-OO STOPPER, REED VALVE : 5-00 REED, VALVE 0-0 SCREW HOSE, LUBRCATON L: CLP DT5YE B

4 FG. - - FG. ( B-5) CRANKSHAFT (DTW Q'w REF-NO. PAFtT NO. DESCRPTON REMARKS AO AO AO A0 GiiO A AO O-O50 PSTON PSTON RNG SET, PSTON PN, PSTON CRCLP, PSTON PN BEARNG, PSTON PN CRANKSHAFT ASSY.ROD, CONNECTNG BEARNG, CRANK PN.PN, CRANK.CRANKSHAFT, UPPER.CRANKSHAFT, UNDER.BEARNG OL SEAL (0XX) OL SEAL, DRVE SHAFT UPPER THRUST WASHER (X5X) OL SEAL PSTONRNG SET (OS:0.5) PSTONRNG SET (OS:0.5) PSTONRNG SET (0S:OSO) PSTONRNG SET (OS:0.50) M0DEL:O OPT OPT,MODEL:O DT5YE B5

5 FG. ( B-) CARBURETOR (DTSY) FG., W-l5 - QW REF.0. PART NO. DESCWPTON REMARKS A OcaO a!noooo AO -AO 5-AO AO C 0 AO C O-C CARBURETOR kssy.sprng.screw. THROTTLE STOP.ADJUSTER SPRNG.ADJUSTER.PN.FLOAT.GASKET.GASKET.BOLT. DRAN.NEEDLE ASSY.ZHAMBER, FLOAT.NOZZLE, MAN.JET, PLOT (55).JET. MAN (0.5).JET, AR (0.).JET, AR (.) KNOB, STARTER GROMMET, CHOKE KNOB LEVER, CHOKE BOLT GASKET, CARBURETOR NSULATOR, CARBURETOR SPACER BOLT ' - DT5YE

6 FG. FG ( B-) FUEL PUMP (DTSul) Qn' REF.NO. PART NO. DESCRPTON REMARKS 5 0 if )o WMrn D PUMP ASSY, FUEL.DAPHRAGM, f UEL PUMP.SCRE'JV FLTER, FUEL BOLT (x0) HOSE (TANK TO CXK): HOSE (VACUUM) HOSE (COCK TO WAY) HOSE (FLTER TQ WAY} HOSE ( WAY TO PGMP] HUSE (PUMP TO *CARBJ HOSE (CONN TO FLTER) WAY CLP CLP SCREW (x) COCK ASSY, FUEL.CUP, FLTER.NET, FLTER.GASKET, FLTER CLAMP DT5YE B

7 ~~ FG 0 oi FG,0 ( El ) WATER PUMP (DT5Y) Q Ty REF.NO. PART NO. DESCRPTON REMARKS OA OOO B C 00- GROMMET, WATER TUBE TUBE, WATER (S) TUBE. WATER (L) GUDE, WATER TUBE BOLT (x) GROMMET, WATER PUMP OL SEAL PUMP CASE NUT LOCK WASHER STUD =tf (l.:oj CASE, WATER PUMP PN KEY MPELLER, WATER PUMP PANEL, WATER PUMP GASKET, PUMP PANEL HOUSNG, DRVE SHAFT BEARNG.SEAL GASKET, DRVE SHAFT HOUSNG BOLT (x5) STOPPER, SHlFF ROD GUDE KT, WATER PUMP REPAR OPT?- 5 0 DT5YE B

8 FG.? FG. ( -) RECOL STARTER (DTSY) O'TY - REFSO. PART NO. DESCRFTiON REMARKS - 00-AO STARTER ASSY, RECOL STARTER ASSY, RECOL REEL. STARTER -0.SPRNG, SPRAL 0-0.RATCHET SET GRP 0-AO.NS SET -AO CUP, STARTER -0 HOLDER. NTERLOCK CABLE 50-0 ARM, NTERLOCK 0 &5- RNG. SNAP -AO-OED BRACE, RECOL STARTER (GRAY) BOLT BOLT BOLT SCREW - -E00 LABEL, CAUTON - -E0 LABEL, CAUTON M0DEL:Ol l5 - DT5YE B

9 FG. \- 5 - Ti 5 - FG. ( -) CLUTCH (DT5Y) Q'n REF-NO. PART NO. DESCRPTON REMARKS a OOO E KNOB, CLUTCH LEVER LEVER, CLUTCH NUT NUT LOCKWASHER GREASE NPPLE, CLUTCH 0 RNG, CLUTCH LEVER SHAFT BALL. CLUTCH NOTCH SPRNG, CLUTCH NOTCH SHAFT, CLUTCH LEVER PN, CLUTCH LEVER ROD, CLUTCH (S) ROD, CLUTCH (L) COTTER PN CONNECTOR, CLUTCH ROD NO.l CONNECTOR, CLUTCH ROD N0. BOLT (x0) E RNG ROD ASSY, SHFT ROD ASSY, SHFT.GUDE, SHFT ROD.BOOT, SHFT ROD.CAM, SHFT.CAM, SHFT.WASHER (5.5x0X.) SPRNG PN.O RNG.O RNG BUSH, SHFT ROD M0DEL:Ol MODEL:-0 DT -MODEL: DT5Y -MODEL: DT5Y MODEL:-0 - DT5YE B

10 FG FG. ( C- ) MAGNETO (DT) REF-NO. PART NO. DESCRPTON Q W REMARKS 50-0 BRACKET, SWTCH 0-0 SCREW LOCK WASHER 0-00 WASHER NUT COL, GNlTlOFi PRMARY 0-E00 SWTCH ASSY. EMERGENCY & STOP MODEL: WASHER -E0 TUBE, SW WRE DT5YE c

11 FG. FG. ( C- 5) MAGNETO (DT5Y) Q'w REF.NO. PART NO. DESCRPTON REMARKS % U E00 -E00 -E00 -E FLYWHEEL COL, GNTON SCREW COL, LGHTNG SCREW.WASHER NUT KEY CLAMP COL PSSY, GNTON BOLT CLAMP CUSHON CAP, SPARK PLUG SWTCH ASSY. STOP.PLATE, LOCK.NUT TUBE, SW WRE PLUG, LOWER COVER WASHER LABEL, STOP SPARK PLUG (BPRHS) L: DT5YE c5

12 FG. FlG. ( C- ) CLAMP BRACKET Q'W REF.NO. PART NO. DESCRPTON REMARKS -WED BRACKET, CLAMP STBD -0-OED BRACKET, CLAMP PORT -00 PLATE, CLAMP -0 KNOB, TLT STOPPER BOLT (0X50) NUT WASHER BUSH 0-0 SCREW, CLAMP -0 PN, TLT STOPPER BUSH 0 lo5 BOLT (x0) ROD, CLAMP BRACKET LOWER DT,-MODEL:SS 000 LOCK WASHER NUT PN, TLT LOCK DT,MODEL:, PN DT,MODEL:, SPACER DT,MODEL:s DT5Y.MODEL:-0 50-DO PN, TLT LOCK DT,MODEL:0- DT5Y,MODEL: ZNC SET, PROTECTON DT,-MODEL: 000%.BOLT (x) DT,-MODEL: 0-%OO ZNC, PROTECTON DT,MODEL: DT5Y,MODEL: BOLT COLOR : OED (GRAY) DT5YE C

13 FG. FG. ( C- ) SWVEL BRACKET Q'W REENO. PART NO. DESCRPTON REMARKS 5 0 -M)ED -0-OED BRACKET, SWVEL COVER, SWVEL BRACKET BOLT (x0) GREASE NPPLE BUSHNG SET, STEERNG PLATE, UPPER BUSHNG ARM, REVERSE LOCK ARM PLATE, REVERSE LOCK BOLT (x) SPRNG, STBD SPRNG, PORT 500-# SHALLOW ORlVE ASSY ofjo SHAFf, SHALLOW WATER DRVE.SPRNG.PN ADJUSTER, STEERNG BOLT (x) SPRNG COLOR : OED (GRAY) DT5YE

14 FG. ( C- ) DRVE SHAFT HOUSNG FG. Q'W REF.NO. PART NO. DESCRPTON REMARKS aED HOUSNG, DRVE SHAFT (S) OED HOUSNG, DRVE SHAFT (L; KNOCK PN, NOTCH BALL 5-0 GASKET, DRVE SHAFT HOUSNG COVER, CLUTCH ADJUST HOLE PLUG, FLUSHNG GASKET, FLUSHNG PLUG BOLT (L:0) ZNC SET, PROTECTON.BOLT,X0 TUBE, YdATER HOSE CLP BOLT (x55) L:00+5 DT,- MODEL COLOR : OED (GRAY) 0 DT5YE C

15 FG.0 REF.NO. FG.0 ( C- ) PART NO. GEAR CASE DESCRPTON QTy REMARKS J's, OED CASE SET, GEAR BUSH 0 O-OO0.BEARNG, GEAR 0-00.BEARNG, GEAR OED PLUG, DRAN (0X.5) GASKET, DRAN PLUG BOLT (x5) PN BOLT (x0) 0 RNG (D:. ld:.) HOUSNG, PROP SHAFT BEARNG BEARNG, PROPELLER SHAFT.OL SEAL.WASHER.BEARNG, REVERSE GEAR.BEARNG, REVERSE GEAR BOLT (x) SHEAR PN BUSH, PROPELLER PROPELLER (X-X) PROPELLER (X-/X-/) PROPELLER (X-X) COTTER PN NUT FLTER, WATER SCREW PROTECTOR, OL SEAL WASHER ZNC SET, PROTECTON.BOLT (x) DT -MODEL:5 DT MODEL:- DT5Y MODEL:-0 DT -MODEL:5 DT MODEL%- DT5Y MODEL:-0 C00 C0 C00 COLOR : OED (GRAY) 0 (BUCK) DT5YE c

16 FG. - d - REENO l@? FG. ( C-0) PART NO 'M E GO TRANSMSSON DESCRPTON SHAFT, DRVE (S) SHAFT, DRVE (L) BUSH, DRVE SHAFT UPPER RNG, DRVE SHAFT SNAP THRUST WASHER (loxxl.o) ClRCLlP PNON GEAR, FORWARD GEAR, REVERSE THRUST WASHER WASHER ;.j WASHER (.) WASHER (.) WASHER (.0) WASHER (.) THRUST WASHER (0.) THRUST WASHER (0.) THRUST WASHER (.O) THRUST WASHER (.) SHM, FWD (.O) SHM, FWD (0.) SHM, FWD (0.) SHM, FWD (.O) SHM, MD (.) SHM, FWD (.) SHM, REV (0.) SHM, REV (0.) SHM, REV (0.) SHM, REV (0.) SHM, REV (.0) SHAFT, PROPELLER Q'W REMARKS : :w DT5YE c 0

17 FG. - REF.NO FiG. ( Gll) PART NO TRANSMSSON DESCRPTON SHFTER. CLUTCH DOG PN, CLUTCH DOG SPRNG SPRNG, DOG ROD, PUSH ROD, PUSH PN, PUSH QW REMARKS 0- f a -0 &&/. P 0 DT5YE c

18 FG. ( D- ) LOWER COVER (DT5Y) FG. &! 0 REF.NO. PART NO. DESCRPTON Q R REMARKS -VO-OED COVER, ENGNE LOWER (GRAY) - RUBBER, ENGNE LOWER COVER BOLT (x5) 00 BOLT (x) M0DEL:Ol - -0 FASTENER, ENGNE COVER FASTENER, ENGNE COVER M0DEL:Ol LEVER, FASTENER LEVER, FASTENER M0DEL:Ol 05-05O SCREW (5x) NUT 5-00 HOLDER, SHEAR PN PLUG NTERLOCK HOLE MARK, FUEL COCK (WHTE) 00-0 FASTENER SET -MODEL:00 DT5YE D

19 FG. [&j 0 Y FG. ( D- ) ENGNE COVER (DT5Y) REF.NO. PART KO. DESCRPTON Q n 0-AO-OEM COVER ASSY, ENGNE (GRAY) -00 SEAL, RECOL STARTER AZ -AO 5-A0-00-OJW 5-E MARK, ENGNE COVER RR STRPE, STBD STRPE, PORT EMBLEM, SUZUK (WHTE) MARK, SAFETY WARNNG MARK, WARNNG MARK, CLUTCH SHFT 5-0 0OO-OlOO LABEL, ENGNE COVER TOOL SET REMARKS -MODEL:OO -MODEL:OO M0DEL:Ol 0 DT5YE D

20 FG. FG. ( E- ) FUEL TANK Q'W REF.NO. PART NO. DESCRPTON REMARKS TANK, FUEL MODEL:, TANK, FUEL MODEL: CAP ASSY, FUEL TANK GASKET, FUEL TANK CAP 5-0 BRACKET, FUEL TANK BOLT (x5) LOCK WASHER ~a-00 CUSHON 0-00 CUSHON 5-0 GROMMET TOOL SET REFER TO FlG.0 (E-) FOR DT WlTANK MODEL- REFER TO FG. (E-) FOR DTW W/TANK REFER TO FG. (E-5) FOR PLASTC TANK DT5YE

21 FG. FG. ( E- ) FUEL TANK (DT5Y) Q Ty REF.NO. PART NO. DESCRPTON REMARKS ia00i TANK, FUEL TANK, FUEL CAP ASSY, FUEL TANK.GASKET, TANK CAP BOLT, FUEL TANK BOLT, FUEL TANK BRACKET, FUEL TANK M0DEL:Ol xM BRACKET. FUEL TANK GROMMET, FUEL TANK WASHER, FUEL TANK BOLT BOLT (x5) CUSHON NUT NUT BOLT BOLT WASHER (.5XX.) CUSHON NUT USED WTH 0-00() 0 - -MODEL: M0DEL:Ol M0DEL:Ol DT5YE

22 FG. REF.NO. FG. ( E- 5) PART NO. FUEL TANK (RESN) DESCRPTON Q'n 5ooO-00 TANK ASSY, FUEL (L) CAP ASSY, FUEL TANK 55-5DOO.GASKET, TANK CAP PLUG, FUEL CONNECTOR 5 5-5DOO.FLTER, OUTLET OUTLET ASSY O RNG 500-5D HOSE, FUEL SOCKET, FUEL HOSE PUMP, SQUEEZE CLP PLUG, FUEL REMARKS - DT5YE E5

23 FG.5 FG.5 ( E- ) TLLER HAFiDLE (DTU) Q'm REF.NO. PART NO. DESCRPTON REMARKS -0.OED HANDLE, TLLER (GRAY) 500 BUSH, TLLER HANDLE -0 MOUNT, TLLER HANDLE E A0-0 -A0 0-AO STOPPER, TLLER HANDLE GRP, HANDLE ROD, HANDLE PLATE, THROTTLE ADJ SUPPORT, HANDLE ROD SUPPORT, HANGLE ROD KNOB, THROTTLE ADJ KNOB, THROTTLE ADJ CABLE, THROllLE.GUDE, THRO itle CABLE SCREW, HANDLE GRP SCREW, HANDLE ROD SPRT NUT, THROTTLE ADJ KNOB 0 RNG, HANDLE GRP GROMMET, STOP SW LEAD GROMMET, THROTTLE CABLE CLAMP, THROTTLE CABLE BOLT, TLLER HANDLE STOPPER MARK. HANDLE GRP M0DEL:Ol M0DEL:Ol - DT5YE

24 FlG. FG. ( F- ) OPTONAL : ELECTRCAL (DT5Y) Q'TY R F.NO. PART NO. DESCRPTON REMARKS 00-0 RECEPTACLE SET 0-5[)00.RECEPTACLE ASSY, LGHTNG -0.CAP 0-W.PLUG GROMMET CLAMP (L:) ClAMP (L:5) COL SET, LGHTNG SCREW LOCK WASHER - DT5YE F

25 FG. FG. ( F- ) OPTONAL : ELECTRCAL (DTDTW) Q W REF.NO. PART NO. DESCRPTON REMARKS 0-0 RECTFER SET 00-5DO.RECTFER ASSY 0-00.BRACKET, RECTFER -00.CONNECTOR HOLDER. FUSE CASE 0-55.CASE ASSY, FUSE A FUSE (0A) BOLT (x) SCREW 00.SCREW LOCK WASHER 0-00.LOCK WASHER 0-00.LEAD, RECEPTACLE REGULATOR ASSY, VOLTAGE 0-00 SCREW LOCK WASHER 0-00 WASHER 0-DOO TERMNAL & SLEEVE SET 0 DT5YE

26 FG. FG. ( F- ) OPTONAL : FUEL TANK (RESN) Q TY REF.NO. PART NO. DESCRPTON REMARKS TANK ASSY, FUEL (L) CAP GASKET, TANK CAP PLUG, FUEL CONNECTOR 5 5-5DOO.FLTER, OUTLET OUTLET ASSY 5-5DOO.O RNG HOSE, FUEL SOCKET PUMP, SQUEEZE 5-5OO.CLP PLUG, FUEL CONNECTOR 0-05 GASKET b - DT5YE

27 FG. REF.NO FG. ( G- ) OPTONAL : REMOTE CONTROL ()(MODEL:-0) Q'W PART NO. DESCRPTON REMARKS 00-0-OED REMOTE CONTROL BOX ASSY 00- -OED 00--OED REMOTE CONTROL BOX ASSY -500.BUSH -50.BUSH -500.SCREW -500.SPACER WASHER NUT -50.BUSH WASHER BUSH BOLT -00.SCREW -50.LEVER, FREE THROTTLE (GRAY) SCREW -500.BUSH 0-50.PLATE ASSY END, CABLE -500.KNOB, BRAKE ADJ -00.E RNG -50.COVER, WRE (BLACK) -50.SCREW 5-50.CAP, LEVER (BLACK) HOLDER, NEUT LOCK 5-50.LEVER, HANDLE (GRAY) -500.WASHER -500 SPACER 0-E00 SWTCH ASSY, EMERGENCY FOR 00-0-OED 0-5DOO.SWTCH ASSY, EMERGENCY FOR 00--OED -E00..PLATE 55-5CO,ARM, NEUTRAL LOCK -50.GRP DRUM, FREE THROTTLE 5-WO.BRACKET, NEUTRAL ARM ATTACHMENT, TWN REMO-CON KT -50 DECAL, REMOCON BOX PORT DT5YE G

28 FG. FG. ( G- 5) OPTONAL : REMOTE CONTROL () Q n REF.NO. PART NO. DESCRPTON REMARKS BOX ASSY, REMO-CON STBD (ML-R) i NOT FOR U.S. MARKET 00-5 BOX ASSY, REMO-CON PORT (ML-L) NOT FOR U.S. MARKET 00-5 BOX ASSY, REMO-CON (ML-R,L) NOT FOR U.S. MARKET S-500.KNOB, CONTROL BOX NOT FOR U.S. MARKET HOLDER SET, REMO-CON CABLE NOT FOR U.S. MARKET DT5YE G5

29 FG.5 FG.5 ( G- ) REF.NO. PART NO. DESCRPTON OPTONAL : REMOTE CONTROL PARTS PARTS SET, REMOCON.LEVER, CLUTCH.SWTCH ASSY. ENGNE STOP.CABLE ASSY, THROTTLE.HOLDER, REMOCON CABLE.HOLDER, REMOCON CABLE SHAFT, REMOCON THROTTLE.LEVER, REMOCON THROTTLE.GUDE, CLUTCH CABALE.CONNECTOR, REMOCON CABLE BOLT (x).ball PVOT.NUT.NUT.NUT.NUT.WASHER (.5XXl.O).BUSH CLAMP Q'W REMARKS 5 -MODEL:OO M0DEL:Ol &lo DT5YE

30 FG. /EW A FG. ( G- ) OPTONAL : GASKET SET (DTSY) Q'W REF.NO. PART NO. DESCRPTON REMARKS 00-0 GASKET SET -AO.GASKET, CYLNDER HEAD -0.GASKET. WATER JACKET COVER 50C0.GASKET, CARBURETOR 5 -.GASKET, PUMP PANEL 5-0.GASKET, DRVE SHAFT HSG 5-0.GASKET. SHAFT BRG HSG EW B VEW 0 VEW C llew D J 5 DT5YE G

31 A a FG. ( G- ) OPTONAL Q'TY REF.NO. PART NO. DESCRPTON REMARKS SUZUK SLCONE SEAL (WG) GASKET, LQUD (OOG) GASKET, LQUD ( OOG) GASKET, LQUD (50G) SUZUK SUPER GREASE A (50G) THREAD LOCK '" (50G) THREAD LOCK SUPER '' 50G CEMENT, THREAD LOCK (00G) 0 --0A MANUAL, OWNERS 0 --0A 0-0A 0 -A 0-0-0A A 0 --0A 0-50A 0 --0A 0 --0A 0 -A MANUAL, OWNERS MANUAL, OWNERS MANUAL, C'JVNERS MANUAL, OWNERS MANUAL, OWNERS MANUAL, OWNERS MANUAL, OWNERS MANUAL, OWNERS MANUAL, OWNERS MANUAL, OWNERS FOR GEAR CASE FORGEARCASE FOR CRANK CASE FOR CRANK CASE FOR CRANK OL SEAL DT MODEL:0 CRAWNG NOT SHOWN DT MODEL: DT MODEL: DT MODEL DT MODEL% DT MODEL:5 DT MODEL DT MODEL: DT MODEL: DT5Y MODEL:,00 DTSY M0DEL:Ol 5 DT5YE