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Suzuki DT 115 1986-2001

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1. 1 02 NSMISSION 6 08 PT GASKET SET J 06 Ill CYLINDER F 12 PT METER 5 02 PUMP D 02 PT PANEL SWITCH J 03 1 FNGINE COVER H 05 IINTAKE MANIFOLD B 08 b P T T I E ROD J 05 IkTARTING MOTOR E 02 I FlG 46 7 9 c 2 FIG 46 G 9 TRANSM SSION REF EO PART NO DESCRIPTION QTY REMARKS 4 3 6 4 21 23 I I 14 15 16 17 1 7 2 7 3 7 4 7 5 7 6 17 7 17 8 1 7 9 17 10 18 19 20 1 20 2 20 3 20 4 20 5 20 6 20 7 21 22 25 24 25 1 25 2 26 56 140 9451 0 092054501 1 09263 50001 09 1 8 1 70008 09 1 8 1 70006 091 81 7OOO9 091 81 70001 091 81 7001 0 091 81 70002 09181 70011 09 1 8 1 70003 091 81 70012 091 81 70004 09269 70001 091 60 70002 091 81 45003 091 81 4904 091 81 45005 091 81 45006 091 81 45007 091 81 45008 09181 45009 09440 1 1020 09202 07002 09440 5GGG2 57621 9451 2 5761 0 94506 5761 0 94520 091 81 25030 HOUSING FORWARD GEAR BEARING 1 PIN L 14 1 BEARING SOX62X25 1 SHIM T 0 55 0 1 SHIM T 0 6 0 1 SHIM T0 65 0 1 SHIM T 0 7 0 1 SHIM T 0 75 0 1 SHIM T 0 8 0 1 SHIM T 0 85 0 1 SHIM T 0 90 0 1 SHIM T 0 95 0 1 SHIM T 1 O 0 1 BEARING 70X95X4 1 THRUST WASHER T5 25 1
2. K OR SEPARATO E FIG 41 F 12 TRIM CYLINDER QTY FIG 41 REF NO PART NO DESCRIPTION REMARKS 1 2 4 1 48600 9451 1 OED TRIM CYLINDER ASSY 1 2 48601 94501 PISTON amp PISTON ROD ASSY 3 48627 94500 O RING PISTON 48641 94510 CYLINDER TRIM 5 6 48630 94500 1 1 4 48633 94500 O RING HEAD 4 I 1 HEAD TRIM CYLINDER 2 7 48760 94501 TUBE TRIM CYLINDER OUTLET 1 8 48 1 2 1 9451 0 SHAFT TILT CYLINDER LOWER 1 6 COLOR OED GRAY REFER TO FIG 42 F 13 FOR MODEL96 01 CARBURETOR B 09 ENGINE HOLDER 6 02 CLAMP BRACKET F 02 EXHAUST COVER E 07 CLUTCH D 05 FUEL INJECTOR C 10 CRANKCASE B 02 FUEL PUMP C 05 CRANKSHAFT B 05 FUEL TANK 1 03 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 ELECTRICAL E 09 GEAR CASE 6 05 ENGINE CONTROL UNIT E 14 IGNITION E 07 _ I_ LUBRICATION HOSE C 02 AGNETO E 04 I L PUMP C 11 GASKET SET J 06 PT METER J 02 PT PANEL SWITCH 5 03 56 DT115I140 E3 PTIONAL J 07 OWER UNIT F 08 EMOTE CONTROL BOX 1 05 ENSOR amp METER E 13 ILENCER CASE B 14 ILENCER 8 13 OLENOID E 15 F 12 SWIVEL BRACKET F 05 THROTTLE BODY
3. F 07 SILENCER CASE 8 14 TR In CYLINDER F 12 SOLENOID E 15 SENSOR amp METER E 13 TR ANSMISSION 6 08 SILENCER B 13 dATER PUHP D 02 I 1 ii ENGINE COVER H 05 INTAKE MANIFOLD B 08 bPT T I E ROD J 05 IbTARTING MOTOR E 02 1 FIG 9 6 10 7 I 1 6 FIG9 B 14 SILENCER CASE PIASTIC QTY REF NO PART NO DESCRIPTION REMARKS 1 1 1 2 2 1 2 2 3 4 5 6 7 8 9 10 1 381 1 9461 1 13811 94601 091 16 06160 091 16 06160 13812 94601 09 1 25 06095 08310 00067 09401 06405 09355 30705 600 09355 3r3701m 1671 0 9521 1 09404 08205 CASE SILENCER CASE SILENCER BOLT BOLT COVER SILENCER SCREW 6x25 NUT CLIP ID 6 8 HOSE 3XrX600 HOSE 3WXsoO CHECK VALVE CLAMP L 45 1 1 12 8 1 1 I 4 1 1 1 1 DT115 DT140 DT115 DT140 DT115 14O DT1151140 DT1151140 DT115 115S 140 L 600 400 L 600 12O DTll5 231515 MODEL 97 DT140 231404 MODEL 96 DT140 MODEL96 I_ I_ _ I I__ I _ CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 CLAMP BRACKET F 02 EXHAUST COVER E 07 LUBRICATION HOSE C 02 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 CRANKCASE B 02 FUE
4. H 02 OPT WIRING HARNEW 5 04 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 THROTTLE LINK D 04 CRANKCASE B 02 FUEL PUMP C 05 31L PUMP C 11 MOTE mNTROL BOX 1 05 T I L T CYLINDER F 07 CRANKSHAFT B 05 FUEL TANK 1 03 31L TANK 1 02 NSOR L METER E 13 TR ANSMISSION 6 08 In CYLINDER F 12 METER J 02 ILENCER B 13 ATER PUMP D 02 F PANEL SWITCH J 03 IE OLENOID E 15 GASKET SET J 06 ILENCER CASE B 14 I __ __ _ _ _ ENGINE COVER H 05 IINTAKE MANIFOLD B 08 bPT T I E ROD 5 05 IbTARTING MOTOR E 02 I F16 29 FIG 29 I 1 ELECTRICAL M0DEL OO QTY REF NO PART NO DESCRIPTION REMARKS 49 33832 94601 CABLE ASSY TRIM RELAY GROUND 1 50 3489 94600 SENSOR ASSY HEAT 1 MODEL 92 97 SUPPORT HEAT SENSOR 1 MODEL92 97 51 34853 94700 1 MODEL 92 97 52 091 25 06069 SCREW 53 1 36810 34601 LEAD RECTIFIER EXT 1 MODEL 94 97 53 2 368 10 9461 0 LEAD RECTIFIER EXT 1 DTl15S1140EFI 54 36630 92E00 WIRE ASSY INSTRUMENT 1 MODEL 93 00 55 36682 92E00
5. E 07 PT PANEL SWITCH J 03 NGINE COVER H 05 i INTAKE MANIFOLD B 08 PT T I E ROD J 05 FIG 32 E 15 SOLENOID FIG 32 15 QTY REF NO PART NO DESCRIPTION REMARKS 9 4 5 6 7 8 9 10 11 12 13 13A 14 I5 38600 948 10 021 12 75207 38617 94600 3861 5 94600 3861 6 94600 091 80 06248 36600 94821 31 800 94401 384 12 94500 38422 94520 38423 955 10 021 12 06167 01 500 061 67 01580 06167 08321 01 067 09404 06432 11 45 DT115 140 E3 CARBURETOR B 09 ENGINE HOLDER 6 02 CLAMP BRACKET F 02 EXHAUST COVER 8 07 CLUTCH D 05 FUEL INJECTOR C 10 CRANKCASE B 02 CRANKSHAFT B 05 DRIVEWAFT HOUSING 6 03 LECTRICAL E 09 NGINE CONTROL UNIT E 14 LUBRICATION HOSE C 02 AGNETO E 04 I L PUMP C 11 PT GASKET SET J 06 PT METER J 02 PT PANEL SWITCH J 03 bPT WIRING HARNEW J 04 OPTIONAL 5 07 POWER UNIT F 08 REMOTE CONTROL BOX 1 05 SENSOR amp METER E 13 SILENCER B 13 SILENCER CASE B 14 SOLENOID E 15 SOLENOID SET CHOKE SCREW PLATE CHOKE SOLENOID CUSHION r 3KE SOLENOID CUSHION CHOKE SOLENOID SPACER CHOKE SOLENOID SOLENOID SET CHOKE RELAY ASSY STARTER BRACKET STARTER RELAY DAMPER STARTER RELAY TUBE
6. E 15 DT115 740 E03 07 6 OIL PUMP 94 27 1 27 2 28 29 1 29 2 30 31 1 31 2 32 33 1 33 2 34 1 34 2 35 36 37 38 39 09351 25703 600 09355 25705 600 1691 1 92E20 09351 25703 600 09355 25705 600 1691 1 92E20 09351 25703 600 09355 25705 600 09351 50803 00A 09351 50803 00A 09352 50903 600 09351 50803 0OA 09352 50903 600 1691 1 92E20 16810 95501 09408 00024 09404 08205 16250 9471 0 HOSE 2 5X7X600 1 HOSE 2 5xIX600 1 PROTECTOR 1 HOSE 2 5X7X600 1 HOSE 2 5xIX600 1 PROTECTOR 1 HOSE 2 5xIXsOO 1 HOSE 2 5X7X600 HOSE 5X8XlOOO HOSE INLET 5X8XlOOQ HOSE 5X9X600 HOSE INLET 5X8XlOOO HOSE 5X9X600 PROTECTOR FILTER OIL L 600 270 MODEL86 90 L 600 270 MODEL91 94 L540 240 L 600 160 MODEL86 90 L 600 160 MODEL 91 M L 540 130 L 600 120 MODEL 86 87 L 600 1 00 MODEL88 L 600 100 MODEL 91 94 L 1000 130 MODEL 86 87 L l QQQ 26Q MQDEL88 90 L 600 260 MODEL 91 94 L 1000 45 MODEL 88 L 600 45 MODEL 9i 94 L 540 90 DT115 609018 DT140 609260 CLIP D 23 1 CLAMP L 50 2 SENSOR OIL 1 24 DTl15 140 E3 c 12 _ _ ENGINE COVER H 05 IINTAKE MANIFOLD B 08 bPT T I E ROD 5 05 IkTARTING MOTOR E 02 1 I I FIG 17 C 13 OIL PUMP MODEL 95 97 QTY REF NO PART NO DESCRIPTION REMARKS FIG 17 1 1 1 2 1 6 1 00 946
7. AFT AFT HOUSING R SEPARATO OIL T METER FIG 45 21 A FIG 45 G 6 GEAR CASE QTY REF NO PART NO DESCRIP fION REMARKS I ___ __ CARWIRETOR B 09 CLAMP BRACKET F 02 CLUTCH D 05 CRANKCASE B 02 CRANKSHAFT B 05 gt RIVESHAFT HOUSING 6 03 ELECTRICAL E 09 ENGINE CONTROL UNIT E 14 i ENGINE HOLDER 6 02 EXHAUST COVER B 07 FUEL INJECTOR C 10 FUEL PUMP C 05 FUEL TANK 1 03 FUEL VAPOR SEPARATO C 09 GEAR CASE 6 05 IGNITION E 07 LUBRICATION HOSE C 02 AGNETO E 04 I L PUMP C 11 I L TANK 1 02 PT GASKET SET 5 06 PT PANEL SWITCH 5 03 PT HETER 5 02 26 1 26 2 27 28 29 1 29 2 30 31 32 33 34 35 36 1 36 2 36 3 37 38 1 38 3 38 4 38 5 38 6 38 7 38 8 39 40 57635 95503 57635 9551 0 57635 95300 57633 95501 57635 94502 57635 9451 1 57633 94500 57634 94500 091 59 1 8004 091 41 1 8C05 09204 03003 09160 18028 58100 9551 1 019 58 1 00 95550 0 1 9 58 100 95521 01 9 581 20 95500 58100 94554 STOPPER STOPPER SPACER WASHER STOPPER STOPPER SPACER WASHER NUT NUT
8. 1 02 GEAR CASE 6 05 OPT METER J 02 FIG 20 D 3 WATER PUMP DT115S1140EFI QTY REF 30 PART NO DESCRIPTION REMARKS 1 2 1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 19 2 20 21 1 21 2 22 23 24 25 26 27 28 29 30 17563 94501 17560 94521 17560 94531 09306 1 6002 17567 MlO 09320 16011 091 08 06063 091 62 06006 091 40 06020 091 17 08062 091 1748063 17522 94520 09202 04008 1741 1 94601 09420 05r 06 1 7461 9451 0 17471 94600 17472 9451 0 17523 9451 0 17564 94520 17564 94500 17631 94600 17635 94521 17635 94500 091 17 06040 091 25 05046 031 12 04303 091 2646006 56130 94502 09282 24003 09280 55002 09263 26010 17400 94602 28 DTll5 140 E3 BUSHING UPPER TUBE WATER L TUBE WATER X BUSHING GUIDE GASKET WATER TUBE BUSH STUD BOLT 6x20 LOCK WASHER 6 1X12 2X1 5 NUT BOLT 8x70 BOLT 8x50 PLATE GEAR CASE PLUG DOWEL PIN D 4 L 9 CASE WATER PUMP KEY B 5 D 23 H 7 IMPELLER PANEL UNDER GASKET UNDERPANEL GASKET SUB WATER TUBE PLUG GEAR CASE BUSH SUB WATER TUBE FILTER WATER PIATE GEAR CASE FILTER WATER SUB BOLT 6x1 5 SCREW 5x12 SCREW SCREW 6x20 HOUSING DRIVESHAFT BEARING OIL SEAL 24X36X6 O RING 0 3 1 1D 54 5 BEARING 26X34X20 WA
9. E 09 GE AR CASE 6 05 ENGINE CONTROL UNIT E 14 IGNITION E 07 FIG 19 D 2 WATER PUMP QTY REF NO PART NO DESCRIPTION REMARKS 1 2 1 2 2 3 4 5 6 1 6 2 7 8 9 10 12 13 14 1 14 2 15 16 17 18 19 20 21 22 23 1 23 2 17563 94501 17560 94521 1 7560 9453 1 OM06 16002 17567 945 10 09320 1601 1 09108 06060 09108 06063 091 62 06006 09140 06020 091 17 08062 091 17 08063 09202 04008 1741 1 94601 09420 05005 09420 05006 1 7461 9451 0 17471 94600 17472 9451 0 09126 06006 56130 94502 09282 24003 09280 55002 09263 2601 0 17400 94600 17400 94602 BUSHING UPPER TUBE WATER L TUBE WATER X BUSHING GUIDE GASKET BUSH STUD BOLT 6x1 8 STUD BOLT 6x20 LOCK WASHER 6 1X12 2X1 5 NUT BOLT 8x70 BOLT 8x50 DOWEL PIN D 4 L9 CASE WATER PUMP KEY B 5 D 19 H 7 5 KEY B 5 D 23 H 7 IMPELLER PANEL UNDER GASKET UN3ER PANEL SCREW 6x20 HOUSING DRIVESHAFT BEARING OIL SEAL 24X36X6 O RING D 3 1 10 54 5 BEARING 26X34X20 WATER PUMP REPAIR KIT WATER PUMP REPAIR KIT REFER TO FIG20 D 3 FOR DTl1551140EFI 1 1 1 1 1 1 2 2 2 2 2 2 1 1 1 1 1 1 1 4 1 2 1 1 1 1 DT115 709357 DTl40 709489 DT115 709358 DT140 709490 DT115 812174 DT
10. F 12 WATER PUMP D 02 FIGS7 J 2 OPT METER QW REF NO PART NO DESCRLPTION REMARKS FlG 57 10 I IT j2 14 v I 22 1 I 27 RBURETOR B 09 LAMP BRACKET F 02 LUTCH D 05 RANKCASE B 02 RANKSHAFT B 05 RIVESHAFT HOUSING 6 03 LECTRICAL E 09 NGINE CONTROL UNIT E 14 ENGINE HOLDER 6 02 XHAUST COVER E 07 UEL INJECTOR C 10 UEL PUMP C 05 UEL TANK 1 03 UEL VAPOR SEPARATO C 09 GEAR CASE 6 05 IGNITION E 07 r INTAKE MANIFOLD B 08 1 34200 92E02 TACHOMETER 2 09471 1 21 79 BULB 3 4 5 6 1 6 2 6 3 7 8 9 10 11 12 13 14 149 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 34800 92E00 09471 1 21 80 36682 92E00 34100 92E00 34100 92ElO 341 00 92E20 09471 12179 3441 9 92EO0 09407 1 4407 3661 5 96300 34190 95500 34 190 87D00 031 12 06303 34300 92E00 34320 92E00 34310 92E00 34360 92E00 09471 1 21 EO 34500 92E00 09471 12180 34600 32E00 09471 1 mo 34650 92E00 34191 92E00 09407 14307 34652 92E00 36658 95600 09471 1 21 80 09320 08028 36990 87DOO METER ASSY TRIM BULB WIRE TRIM GAUGE EXT SPEEDOMETER SPEEDOMETER SPEEDOMETER BULB TUBE BAND TERMINAL RESIN SENDER ASSY SP
11. 0141 1 08207 0831 6 10087 09352 50903 600 09352 50903 600 09401 08411 09491 250 14 09491 2601 6 09491 27007 135 10 94600 1391 0 94701 SPRING WASHER CHAMBER ASSY FLOAT CHAMBER ASSY FLOAT JET PILOT 82 5 JET PILOT 65 STUD BOLT NUT HOSE UPPER 5X9X600 HOSE LOWER SX9X600 CLIP JET MAIN 125 JET MAIN 1 30 JET MAIN 137 5 ROD THROlTLE CONTROL REPAIR KIT CARBURETOR 1 4 3 1 4 4 8 8 1 1 4 4 4 4 2 1 1 2 3 4 MODEL2 438 MODEL 89 97 L600 135 L 600 270 OPT OPT OPT OPT NOT SHOWN 4 9 DT115 140 E3 B 10 LOWER COVER H 02 LUBRICATION HOSE C 02 MAGNETO E 04 OIL PUWP C 11 O I L TANK 1 02 OPT z METER J 02 OPT GASKET SET J 06 OPT PANEL SWITCH J 03 _ I_ bPT WIRING HARNEW J 04 OPTIONAL 5 07 OOWER UNIT F 08 REMOTE CONTROL BOX 1 05 SENSOR amp METER E 13 SILENCER CASE B 14 ILENCER B 13 LENOIL E 15 _ I_ __ _ _ _ _ I _I_ _ I _ _ SWIVEL BRACKET F 05 THROTTLE BODY C 04 THROTTLE LINK D 04 T I L T CYLINDER F 07 TRANSMISSION 6 08 TRIH CYLINDER F 12 WATER PUMP D 02 FSG 7 31 31 28 2 9 29 18 1 3 I 3 7 28 I e 8A 27 10 x t8 t4
12. 1 1 1 2 2 4 4 2 MODEL36 92 MODEL 93 01 MODEL 86 92 MODEL 93 01 MODEL L 58542 L 585 30 FOR OED MODEL86 88 FOR 02M MODEL 88 94 MODEL95 01 MODEL88 94 MODEL19598 MDOEL 99 01 MODEL 88 01 H 3 l b P T WIRING HARNEW J 04 BWIVEL BRACKET F 05 I PTIONAL J 07 ROTTLE BODY C 04 OWER UNIT F 08 ROTTLE LINK D 04 CYLINDER F 07 ENSOR amp METER E 13 ANSMISSION 6 08 ILENCER CASE B 14 I CYLINDER F 12 PUMP D 02 OLENOID E 15 FlG 47 R B U R E T O R B 09 CLAMP BRACKET F 02 CLUTCH D 05 CRANKCASE 8 02 CRANKSHAFT B 05 DRIVESHAFT HOUSING G 03 10 42 FIG 47 H 4 LOWER COVER QTY DESCRIPTION REMARKS REF NO PART NO 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 XHAUST COVER B 07 UEL INJECTOR C 10 UEL TANK 1 03 UEL VAPOR SEPARATO C 09 AGNETO E 04 I L PUMP C 11 GASKET SET 5 06 Pi PANEL SWITCH J 03 METER J 02 69 DT1151140 E3 01500 06127 0155046167 08321 01067 08322 01067 37850 95602 09407 25402 09404 06432 09250 20006 37930 9561 2 37935 95601 17911 94611 1791 2 9461 0 179 13 9461 0 09280 1 9006 09355 901 45 600 09401 1341 6
13. 2 1 1 1 1 1 4 4 1 1 H 12 I ___ SWIVEL BRACKET F 05 THROTTLE BODY C 04 THROTTLE LINK D 04 T I L T CYLINDER F 07 TRANSMISSION 6 08 TRIM CYLINDER F 12 WATER PUMP D 02 1 I _ _ gNGINE COVER H 05 IINTAKE MANIFOLD B 08 OPT TIE ROD 0 J 05 I b T k T I N G MOTOR E 02 I FIG 52A 5 I 12 9T115GjO E03 052A ENGl N E C0VER DT i 40EFI FIG 52A H 13 ENGINE COVER DT140EFI QTY REF NO PART NO DESCRIPTION REM ARKS 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 30 31 32 1 32 2 33 78 DT115 140 E3 61420 948824ED 61651 94602 09229 04032 08322 01057 6 1431 945034ED 6 1481 945044ED 61482 94510 6 1485 94500 614a6 94600 6 1544 94500 61641 94600 61 631 946 10 61 645 94600 OED 6 1670 94600 091 18 06095 02142 06167 091 40 06020 091 64 13005 03242 041 03 03542461 63 08322 01 067 6 143 9491 0 6 1453 9491 0 631 11 42031 1 RR 61463 94910 61421 94601 2TN 6 14Z M64O O19 61487 94602 03242 051 23 03242 051 23 69711 93E10 61 581 9861 0 61581 98620 09800 01001 COVER SET ENGINE GRAY HOLDER HOOK RIVET WASHER HANDLE TILT UP GRAY LID OIL TANK FiLLER GRAY HIN
14. 26 27 28 61420 94810 OED 6 1651 94602 09229 04027 0832241 057 6 1431 94503 0ED 61481 945044ED 61482 94510 61 485 94500 6 1486 94600 61544 94500 amp f WKI 6 1631 9461 0 6 1645 94600 OED 6 1670 94600 091 18 06095 091 25 06067 09 1 40 06020 091 6046082 091 64 13005 09250 1 20 12 03242 041 03 03542 061 63 08322 01 067 61440 94660 681 11 42031 1 RR 6 1435 94660 61435 94670 61 581 9861 0 09800 01001 COVER SET ENGINE HOLDER HOOK RIVET WASHER HANDLE TILT UP LID OIL TANK FILLER HINGE OIL FILLER LID SPRING OIL FILLER LID CAP ENGINE COVER PAD OIL FILLER LID t lOCX FROM HOOK REAR LEVER HOOK STRIKER OIL FILLER LID BOLT SCREW NUT WASHER WASHER WAVE CAP SCREW SCREW WASHER STRIPE SET MARK SUZUKI MARK EMBLEM RR MARK EMBLEM RR MARK SAFETY WARNING TOOL ASSY COLOR OED GRAY 1 RR GOLD DT115 MODEL195 97 DT140 MODEL 95 96 1lA 76 DTl15 140 E3 RBURETOR B 09 NGINE HOLDER G 02 LOWER COVER H 02 LAMP BRACKET F 02 XHAUST COVER B 07 LUBRICATION HOSE C 02 LUTCH D 05 UEL INJECTOR C 10 MAGNETO E 04 RANKCASE B 02 UEL PUMP C 05 OIL PUMP C 11 RANKSHAFT B 05 UEL TANK 1 03 I L TANK 1 02 UEL VAPOR SEPARATO C 09
15. 67232 9561 0 67253 95600 67252 25640 091 00 08232 672 1 4 95600 6729694300 37721 94600 67241 95600 67241 95650 091 26 05003 67243 95600 67220 95620 67275 95600 67223 95600 67292 94300 67267 95600 67267 95618 67296 956 10 BUSH BUSH SCREW SPACER WASHER NUT BUSH WASHER BUSH BOLT 8x30 ACTUATOR SCREW SWITCH NEUTRAL LEVER FREE THROTTLE LEVER FREE THROllLE SCREW 5x12 BUSH PLATE ASSY END CABLE KYOB BRAKE ADJUST E RING COVER WIRE COVER WIRE SCREW 67200 87D12 02M BODY SlLVER DECAL BLUE 67200 87Dll OlT BODY WHITE DECAL BLACK 67200 87D12 0ED B0DY GRAY DECAL BLACK REFER TO FIG 56 1 7 FOR MODELz93 01 1 1 3 3 3 3 1 1 1 1 1 3 1 1 1 2 1 1 2 1 3 1 1 7 82 DT115 140 E3 _ _ II _ __ I __ _ __ ROTTLE BODY C 04 AGNETO E 04 ROTTLE LINK D 04 I L PUMP C 11 NSOR amp METER E 13 TR ANSHISSION 6 08 Ill CYLINDER F 12 PT METER 5 02 I L TANK 1 02 PT GASKET SET J 06 PT PANEL SWITCH J 03 WHITE SILVER BLUE BLACK _ _ I I ENGINE COVER H 05 IbTARTIN6 MOTOR E 02 IXNTAKE MANIFOLD B 08 bPT TIE ROD 5 05 1 I 1 FIGS5
16. D 04 CRANKCASE 91 02 FUEL PUMP C 05 O I L PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 DRIVESHAFT HOUSING G 03 FUEL VAPOR SEPARATO C 09 OPT GASKET SET 5 06 SILENCER CASE B 14 TR I M CYLINDER F 12 ENGINE CONTROL UNIT E 14 IGNITION E 07 OPT PANEL SWITCH J 03 SOLENOID E 15 FNGINE COVER H 05 INTAKE MANIFOLD B 08 QPT T I E ROD 5 05 STARTING MOTOR E 02 CRANKSHAFT B 05 FUEL TANK 1 03 OIL TANK 1 02 SE NSOR amp METER E 13 TRANSMISSION 6 08 ELECTRICAL e E 09 GEAR CASE 6 05 OPT METER J 02 SILENCER B 13 WATER PUWP D 02 8 FIG 13 C 8 FUEL PUMP DT115S1140EFl QTY REMARKS DESCRIPTION REF NO PART NO 1 14 7 13 I 12 I I I 1 ___ CARBURETOR B 09 CLAMP BRACKET F 02 CLUTCH D 05 CRANKCASE B 02 CRANKSHAFT 8 05 DRIVESHAFT HOUSING 6 03 ELECTRICAL E 09 ENGINE CONTROL UNIT E 14 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 1 51 00 9491 0 1 51 00 728 12 151 65 930 10 15322 93000 1 54 10 95540 1543O 87D10 1 W3 87DlO 1691 1 92E20 09280 12012 09355 701 25 600 09355 701 25600 09355 701 25 600 09401 1 1407 09408 00024 0 15
17. FIG 7 B 11 CARBURETOR DT140 MODEL QTY REF NO PART NO DESCRIPTIOPi REMARKS 1 1 1 2 2 1 2 2 3 1 3 2 4 1 4 2 4 3 5 6 7 1 7 2 7 3 8 1 8 2 8A 9 10 11 12 13 14 15 16 17 18 1 18 2 13201 94660 13201 94684 13202 946CO 13202 94684 13203 94660 13203 94684 13204 94601 13204 94660 13204 94684 13269 9521 0 13271 933 1 1 09492 80005 09492 85001 09492 80005 13235 9521 0 13236 94600 13237 94400 13392 58600 13370 281 10 13254 98300 13250 9301 2 i 3251 95220 08321 01 057 091 25 05050 1361 6 94500 13271 9331 1 3781 0 9460 1 3781 0 95606 10 DTl15 14O E3 CARBURETOR TOP CARBURETOR TOP CARBURETOR 2ND CARBURETOR 2ND CARBURETOR 3RD CARBURETOR 3RD CARBURETOR 4 M CARBURETOR 4TH 1 CARBURETOR 4TH ADJUSTOR SPRING JET PILOT 80 JET PILOT 85 JET PILOT 80 NOZZLE NOZZLE MAIN NOZZLE GASKET VALVE SEAT VALVE NEEDLE PIN FLOAT GASKET LOCK WASHER SCREW SCREW DRAIN SPRING SENSOR ASSY THROTTLE LEVER SENSOR ASSY THROiTLE LEVER CARBURETOR B 09 6 02 LOWER COVER H 02 CLAMP BRACKET F 02 8 07 LUBRICATION HOSE C 02 CLUTCH D 05 C 10 MAGNETO E 04 CRANKCASE B 02 C 05 31L PUMP C 11 CRANKSHAFT B 05 1 03 O I L TA
18. SHIM T3 0 1 SHIM T l l 1 SHIM T 1 2 1 SHIM T 1 3 1 SHIM T 1 4 1 SHIM T l 5 1 SHIM T l 6 1 SPRING D 1 8 1 PIN 7x48 1 SPRING 1 SHIFTER CLUTCH DOG 1 SHAFT PROPELLER 1 SHAFT PROPELLER SHIM 25X32X3 1 1 MODEL 92 01 G 9 0 7 9 A j c 4 2 4 jT 6 5 5 21 FIG 46 G 10 TRANSMISSION QTY REF NO PART NO DESCRIPTION REMARKS 23 I I A 27 1 27 2 27 3 274 27 6 28 29 30 31 32 33 34 27 5 09181 28015 09181 28016 091 ai 280 i 7 09181 28018 091 81 2801 9 091 81 28020 56120 945104ED 09263 28013 09280 97001 09282 28002 09387 52001 081 13 60097 091 1748047 THRUST WASHER T O 9 THRUST WASHER T 1 O THRUST WASHER T 1 2 THRUST WASHER T l 3 THRUST WASHER TA 4 TURUST WASHER TA 6 HOUSING PROPELLER SHAFT BEARING 28X37X20 O RING D 3 5 10 95 OIL SEAL 28X50X6 SING BEARING BOLT 8x30 0 2 0 2 0 2 0 2 0 2 0 2 1 2 1 2 1 2 COLOR OED GRAY 66 DT1151140 E3 G 10 R SEPARATO 61G 47 17 h 37 43 W FIG 47 H 2 LOWER COVER QTY REF NO PART NO DESCRIPTION REMARKS 1 2 3 4 5 1 5 2 6 7 8 9 1 9 2 10 1 1
19. 091 66 30006 09160 30031 09160 32005 09181 30299 09181 30300 091 81 30302 091 8 1 30304 031 81 30306 09 181 3031 2 09181 3031 6 091 81 30321 09269 3001 3 57300 94832 09140 1 6021 09209 1 2007 57631 94501 64 DTl151140 E3 I _ SHAFT ASSY DRIVE L SHAFT ASSY DRIVE L SHAFT ASSY DRIVE X SHAFT ASSY DRIVE X SPRING DRIVE SHAFT SPRING DRIVE SHAFT PIN COLLAR DRIVE SHAFT SPRING THRUST WASHER T 2 5 THRUST WASHER T 2 5 THRUST WASHER T 4 25 SHIM T 0 6 SHIM T 0 7 SHIM T 0 8 SHIM T 0 9 SHIM T l Oj SHIM T l I SHIM T 1 2 SHIM T 1 3 BEARING 30X52X7 5 PlNlONlGEAR SET NUT PIN PUSH 1D 7 ROD PUSH L 77 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 DT115 812288 DT140 811649 USED WITH 09420 05006 D i l l 5 8 1 2289 DT140 811650 DT115 812288 DT140 811649 57100 94550 USED WITH 09420 05006 DT115 812289 DT140 811650 4 7 1 00 94540 MODEL 96 01 6 8 I __ I I___ _ _ I __ _ LOWER COVER H 02 bPT WIRING HARNEW 5 04 VEL BRACKET F 05 LUBRICATION HOSE C 02 OPTIONAL J 07 ROTTLE BODY C 04 MAGNETO E 04 POWER UNIT F 08 ROTTLE LINK D 04 I L PUMP C 11 T CYLINDER F 07 I L TANK
20. 09404 06432 1 79 1 7 94600 _I PT WIRING HARNEW 5 04 PTIONAL J 07 OWER UNIT F 08 NSOR amp METER E 13 ILENCER B 13 OLENOID E 15 BOLT 1 BOLT 1 LOCK WASHER 1 WASHER 1 SWITCH ASSY TILT 1 CLAMP L 187 1 CLAMP L 80 1 CAP RESET SWITCH HOLE 1 SWITCH ASSY OIL WARNING RESET 1 LABEL LOW OIL WARNING RESET 1 GROMMET FLUSH CONNECTOR 1 CONNECTOR FLUSH HOSE 1 PLUG FLUSH CONNECTOR 1 0 RING 1 HOSE 1 CLIP 2 CLAMP 2 CONNECTOR FLUSH WATEFl 1 MODEM 93 MODEL 94 01 MODELM 93 MODELB 93 MODEL 89 01 MODEL 01 MODEL 89 01 MODEL 89 01 MODEL 98 01 MODEL98 01 MODEL 98 01 MODEL98 01 MODEL198 01 MODEL198 01 MODEL198 01 H 4 SWIVEL BRACKET F 05 THROTTLE BODY C 04 THROTTLE LINK D 04 TILT CYLINDER F 07 TRANSMISSION G 08 TRIM CYLINDER F 12 WATER PUMP R 02 I ENGINE COVER H 05 IINTAKE MANIFOLD B 08 b P T TIE ROD J 05 IkTARTING MOTOR E 02 I FIG 48 H 5 ENGINE COVER MODEL 86 87 DESCRIPTION REMARKS REF NO PART NO 1 DT115 41420 94682 0ED USED WITH 09162 06006 01500 06127 61 61 0 95514 08321 O1067 08322 01067 09100 06122 61116 94601 1 DT140 41420 94682 0ED 08322 01067 61116 94601 09162 06006 616i0 95514 01 500 061 27 08321 01 067 09100 06122 61402 9487042M COVER SET
21. 09481 10001 36740 94771 0948 1 25001 09408 00043 38410 94551 42 DT115 140 E3 RECT amp REGULATOR ASSY CLAMP CLAMP BOLT HARNESS ASSY WIRING CLAMP L 62 CLAMP L 82 WIRE INSTRUMENT CABLE TRIM RELAY CABLE TRIM RELAY GND LEAD REGULATOR GND LEAD RECT EXT CASE ASSY FUSE FUSE IOA CASE ASSY FUSE FUSE 25A HOLDER FUSE CASE RELAY ASSY PTT UP 8 DN 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 E 12 ECTOR P K OR SEPARATO E FIG 38 n FIG 30 E 13 SENSOR 8 METER DT1 15W40EFI QTY REF NO PART NO DESCRIPTION REMARKS 1 2 16 L J 9 10 11 1 11 2 it5 4 amp 3 14 j Q CARBURETOR 0 9 CLAMP BRACKET F 02 CRANKCASE amp 02 CRANKSHAFT B 05 DRIVESHAFT HOUSING 6 03 ENGINE CONTROL UNIT E 14 CLUTCH 0 05 ELECTRICAL E 09 I ENGINE HOLDER 6 02 EXHAUST COVER 8 07 FUEL INJECTOR C 10 FUEL PUMP C 05 FUEL TANK 1 03 GEAR CASE 6 05 FUEL VAPOR SEPARATO C 09 IGNITION E 07 I 12 1 12 2 13 14 15 16 17 18 1 18 2 34200 92E02 34700 92E11 34830 92E00 34853 94700 091 25 06069 34830 94600 34853 9470
22. 1 DT115 FOR 02M 1 DTll5 FOR 01T 1 DT115 FOR 02M 1 DT115 FOR 01T 1 DT140 FOR 02M 1 DT140 FOR 02M 1 1 1 1 1 1 1 1 FOR 02M COLOR 02M SILVER 70G 764 019 26M BURGUNDY G1T WHITE 8EH 26tvV764 2CS 02M12914764 26G BLACK 2CT OlT 291 764 26N BLACK 291 BLACK 26P BURGUNDY 764 GOLD OED GRAY 72 DT115 140 E3 M 7 CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 OPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 OPTIONAL 5 07 TH ROTTLE BODY C 04 POWER UNIT F 08 TH ROTTLE LINK D 04 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 SENSOR amp METER E 13 TR ANSMISSION 6 08 SILENCER CASE B 14 TR In CYLINDER F 12 ELECTRICAL E 09 GEAR CASE 6 05 bPT METER J 02 IBILENCER 4 B 13 b T E R PUMP D 02 I I FIG 49 15 FIG 49 H 8 ENGINE COVER MODEL188 22 QTY REF NO PART NO DFSCRIPTION REMARKS 21 22 23 24 25 26 27 28 29 3e 31 32 33 34 35 36 37 38 39 40 41 42 6 1 653 9502 61661 94501 09383 03001 03242 061 63 08322 01067 6 1431 94503 OED 191 31 3502 O92
23. 5 24 COLOR OED GRAY d 6 7 8 9 10 11 12 13 14 20 15 I 16 7 17 18 19 20 21 22 23 24 25 41161 94400 34801 94720 09100 06113 09404 06432 091 25 06063 09407 14403 SENDER ASSY TRIM BOLT CLAMP SCREW 6x10 CLAMP 48 DT115 140 E3 I _ _ _ __ LOWER COVER H 02 bPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 LUBRICATION HOSE C 02 OPTIONAL J 07 M ROTTLE BODY C 04 MAGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK 0 04 31L PUMP C 11 REHOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 TANK 1 02 SENSOR L METER E 13 TRANSMISSION 6 08 PT GASKET SET J 06 SILENCER CASE B 14 TR I N CYLINDER F 12 PT METER J 02 SILENCER B 13 HATER PUMP D 02 PT PANEL SWITCH J 03 SOLENOID E 15 ZARBURETOR B 09 CLAMP BRACKET F 02 CRANKCASE B 02 CRANKSHAFT B 05 DRIVESHAFT HOUSING 6 03 ELECTRICAL E 09 ENGINE CONTROL UNIT E 14 CLUTCH D 05 XHAUST COVER 8 07 UEL INJECTOR C 10 UEL PUMP C 05 UEL VAPOR SEPARATO C 09 IGNITION E 07 UEL TANK 1 03 FIG36 5 i I_ FIG36 F 6 SWIVEL BRACKET MODEL 96 01 QTY REFJO PART NO DESCRIPTION REMARKS 2
24. 7 FIG l2A C 7 FUEL PUMP DT115TC MODEL97 QTY REF NQ PART NO DESCRIPTION REMARKS 1 15100 94610 PUMP ASSY FUEL 1 2 15100 72812 DIAPHRAGM SET 1 3 1 51 42 680 10 GASKET FUEL PUMP 1 4 151 82 6801 1 SPRING 1 5 1 51 65 9301 0 O RING 1 6 15322 93000 INSULATOR 1 7 15410 95540 FILTER FUEL 1 8 15413 87D10 CUP 1 9 1 543O 87D10 ELEMENT SET 1 10 1691 1 92EX PROTECTOR 11 09280 1 201 2 0 RING 1 12 09355 70125 600 HOSE FUEL FILTER TO 3 WAY 1 L 6 0 0 4 13 09355 70125 600 HOSE FUEL 3 WAY TO PUMP 1 L 600 160 L 600 230 L 600 320 2 L 540 145 14 09355 70125 600 HOSE FUEL CONN TO FILTER 1 15 09355 70125 600 HOSE FUEL PUMP TO CARB 1 16 09355 70125 600 HOSE FUEL PUMP TO CARB 1 L 6 0 0 4 0 17 09401 1 1407 CLIP 10 18 09408 00024 CLIP 1 19 01550 06307 BOLT 2 20 21 08310 00087 NUT 08322 01087 WASHER 19 DT115 140 E3 c 7 I _ ___l lll l I__ _ _l____ll____ __ _ _ __ ____I_ CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 bPT WIRING HARNEW J 0 4 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 OPTIONAL J O f ROTTLE BODY C 04 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK
25. C 04 THROTTLE LINK D 04 T I L T CYLINDER F 07 TRANSHISSION 6 08 TRIH CYLINDER F 12 WATER PUHP D 02 FIG 42 FIG 42 F 13 TRIM CYLINDER MODEL 01 QTY 22 20 s 2 1 1 REF NO PART NO DESCRIWION REMARKS CARBURETOR B 09 ENGINE HOLDER 6 02 CLUTCH D 05 FUEL INJECTOR C 10 CRANKCASE C 05 CRANKSHAFT B 05 FUEL TANK 1 03 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 ENGINE CONTROL UNIT E 14 IGNITION E 07 CLAMP BRACKET F 02 EXHAUST COVER 8 07 B 02 FUEL PUMP ELECTRICAL E 09 GEAR CASE 6 05 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 37 23 24 COLOR OED GRAY 48503 94900 0ED 48401 94900 48627 95E00 48630 94900 48633 94900 48601 94900 48627 95E00 48641 94900 OED 48650 94900 w05 87Dco 4861 5 97E00 48861 95E00 48570 95E00 48572 95E00 48588 94900 481 21 95E00 4831 1 94501 48321 87D02 48326 95E00 09140 08016 091 62 08007 09306 17001 09380 1 7009 09380 2201 5 MANIFOLD SUB ASSY PISTON ASSY O RING SET HEAD TRIM CYLINDER O RING SET HEAD PISTON amp RAM ASSY O RING SET MANIFOLD P l l PISTON FREE C RING SET RING SET PI
26. COTTER PIN D 3 6 L 25 WASHER PROPELLER 3X13 1 4X17 PROPELLER 3X13X18 PROPELLER 3x1 3x1 9 BUSH PROPELLER 3X13 112X15 58100 94581 PROPELLER 3x1 3 114x17 58100 94561 PROPELLER 3X13X19 58100 94571 PROPELLER 3X13X21 582 0 945 J 019 PROPELLER 3X13 liW15 581 00 9451 2 01 9 PROPELLER 3x1 344x1 7 58100 94522 019 PROPELLER 3X13XlQ 58100 94532 019 PROPELLER 3X13X21 58120 94520 BUSH 55181 95200 ATTACHMENT FLUSH HOSE 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 TYPE U MODEL 86 91 TYPE U MODEL 92 00 NPE U TYPE U MODEL 91 TYPE V MODEL 86 91 TYPE V MODEL 92 01 TYPE V TYPE V MODEL91 MODEL 86 91 MODEL 92 01 MODEL 92 01 U 1 700 U 1 800 u1900 TYPE U VS1500 STAINLESS SEE NOTE VS1700 STAINLESS SEE NOTE NOT FOR U S MARKET VS1900 STAINLESS SEE NOTE NOT FOR US MARKET VS2100 STAINLESS SEE NOTE NOT FOR US MARKET V15W V1700 V1900 DT115 STD V2100 DT140 SiD NOT FOR U S MARKET 38 2 TYPE V COLOR 019 BLACK REFER TO ACCESSORY CATALOG FOR APPLICABLE PROPS 62 DT1 i 5 140 E3 C 6 _ _ I PT WIRING HARNEW 5 04 SWIVEL BRACKET F 05 PTIONAL 5 07 TH ROTTLE BODY C 04 OWER UNIT F 08 TH ROTTLE LINK D 04 EMOTE CONTROL BOX 1 05 T I L T CYLINDER F Of ENSOR L HETE
27. J 02 FIG 62 J 7 OPTIONAL FIG 62 4 QW DESCRIPTION REMARKS REFSO PART NO 4 3 1 1 1 2 2 3 4 5 6 1 6 2 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 7 9 7 10 7 1 1 7 1 2 7 1 3 7 14 7 15 7 1 6 991 04 33 140 99000 31 120 93691 80030 99000 32040 99000 25 160 99000 2501 0 99000 32050 99000 32020 9901 1 94529 03 9901 1 94530 03A 9901 1 94531 03A 9901 1 94532 03A 9901 1 94533 03A 9901 1 94534 03A 9901 1 94535 03A 9901 1 94537 03A 9901 1 94539 03A 9901 1 94900 03A 9901 1 94902 03A 9901 1 94910 03A 9901 i 9491 1 03A LIQUID GASKET SILICONE SEAL SILICONE SEALANT CEMENT THREAD LOCK GREASE WATER RESISTANT SUPER GREASE A THREAD LOCK CEMENT THREAD LOCK CEMENT SUPER MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS W11 94913 03A MANUAL OWNERS 9901 1 94914 03A MANUAL OWNERS 9901 1 94915 03A MANUAL OWNERS 91 DT115 140 E3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 FOR CRANKCASE 50G FOR GEAR CASE 100G FOR GEAR CASE 2006 2506 450G FOR CRANK OIL SEAL 50G 1342 50G 13338 MODEL 8
28. TERMINAL RESIN 4 4 1 36620 87D20 WIRE ASSY REMOCON EXT 1 L 5000 WIRE ASSY REMOCON EXT 1 L 2W 4 2 36620 95302 5 36631 94300 CAP 1 6 36620 92E00 WIRE ASSY REMOCON EXT 1 L 5000 7 36820 95560 LEAD NEUTRAL SWITCH 1 L 700 a 37862 95201 LEAD TRIM SWITCH EXT 1 88 DT115 140 E3 J4 _ _ _ _I__ __ I I__ CARBURETOR 8 09 OWER COVER H 02 QPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 UBRICATION HOSE C 02 OPTIONAL J 07 M ROTTLE BODY C 04 CLUTCH D 05 AGNETO E 04 POWER UNIT F 08 ROTTLE LINK D 04 CRANKCASE B 02 CRANKSHAFT B 05 I L TANK 1 02 SE NSOR L flETER E 13 TR ANSMISSION G 08 TlRIVESHAFT HOUSING 6 03 PT GASKET SET 5 06 SILENCER CASE B 14 TR In CYLINDER F 12 ELECTRICAL E 09 PT METER J 02 SILENCER B 13 WATER PUMP D 02 ENGINE CONTROL UNIT E 14 P l PANEL SWITCH J 03 SOLENOID E 15 P i T I E ROD J 05 STARTING MOTOR E 02 I L PUMP C 11 FEHOTE CONTROL BOX 1 05 E L T CYLINDER F 07 amp NGINE COVER 0 5 FlG 60 3 6 12 a 9 Q 13 FIG 60 J 5 OPT DRAG LINK QW REF NO PART NO DESCRIPTION RElMARKs 1 2 3 4 5 6
29. 01560 10807 BOLT 091 60 081 24 WASHER 8 5X20X1 6 01550 06307 BOLT 01 550 08807 09246 04005 17670 95302 17681 946124ED 1 7685 6 10 01 550 06407 17660 94600 17665 94600 17666 94600 091 28 06021 11 111 94610 OED BOLT PLUG PT 118x8 THERMOSTAT 42C COVER THERMOSTAT GASKET BOLT 6x40 VALVE PRESSURE COVER PRESSURE VALVE PLUG PRESSURE VALVE SCREW CYLINDER HEAD UPPER 11 1 11 946204ED CYLINDER HEAD UPPER 11 1 11 949004ED CYLINDER HEAD UPPER 11121 94610 OED CYLINDER HEAD LOWER 11 121 946204ED CYLINDER HEAD LOWER 11 121 94900 OED CYLINDER HEAD LOWER 11 141 94620 1 11 81 94501 GASKET CYLINDER HEAD CONNECTOR HEAD 1 11 82 94500 INSERT 11 171 94501 CONNECTOR HEAD 1 1 172 94500 INSERT 1 1291 94600 1 1291 94600 01 550 08207 BOLT 01 550 08207 BOLT COLOR OED GRAY HOOK ENGINE REAR HOOK ENGINE REAR 1 DT115 140 E3 CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 CRANKCASE B 02 FUEL PUMP C 05 O I L PUMP e e C 11 CRANKSHAFT B 0 5 FUEL TANK 1 03 O I L TANK 1 02 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 OPT 6ASKET SET J 06 ELECTRICAL E 09
30. 19 20 21 22 1 22 2 23 1 23 2 24 25 26 27 28 29 32890 94610 32890 94810 32890 94640 37933 94600 0 1 550 06253 0 1 550 06 1 63 091 59 1 4014 0831 6 1 0063 09160 06079 091 80 06264 02142 06253 32890 94640 OX00 08307 091 60 08054 091 80 081 93 09320 1 2028 32895 94630 03212 05203 0321 2 05303 3341 0 9620 09309 06007 03212 05203 3351 0 95520 33510 87D20 09482 00151 09482 00464 3381 0 94601 36830 94600 09404 08205 09407 1 4403 09250 1 2005 0 1550 081 67 HOLDER ELECTRIC PARTS 1 HOLDER SET ELECTRIC PARTS 1 HOLDER ELECTRIC PARTS 1 BRACKET RESET 2 BOLT 2 BOLT 2 NUT 1 NUT 5 WASHER 2 1 SPACER SCREW 1 HOLDER ELECTRIC PARTS 1 BOLT 4 WASHER 8 5X20X1 6 4 SPACER 8 5X12X17 4 CUSHION ID 12 OD 2O L17 5 4 COVER HOLDER PARTS 1 SCREW 5 SCREW 1 COIL ASSY IGNITION 4 GROMMET D1 6 8 4 SCREW 8 CAP SPARK PLUG 4 CAP SPARK PLUG 4 SPARK PLUG B8HS 4 SPARK PLUG BR8HCS 4 CABLE ASSY STARTER 1 WIRING IGN COIL 1 CLAhlP L 50 1 CLAMP L 125 4 PLUG D1 12 02 17 1 BOLT 1 REFER TO FIG 28 E 8 FOR DT115S1140EFI 37 DT115 14O E3 3289O 94810 MODEL MODEL 96 97 MODEL 86 88 MODEL39 97 MODEL 86 88 MODEL 91 96 7 XRBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 CLAMP
31. 7 8 9 10 67701 94502 67721 94510 6772599E00 67728 99E00 67726 BE00 43764 95500 67701 9451 1 67721 94510 67726 99EOO 6772am10 i 2 437634 95500 13 09407 14403 14 1 67701 94530 14 2 67701 94900 15 67721 94520 16 67726 99E00 17 6772a99 00 18 67725 9520 19 43764 95500 DRAG LINK ASSY SPACER H 13 BOLT L 45 NUT WASHER NUT DRAG LINK ASSY SPACER H 7 NUT WASHER K i i i CLAMP DRAG LINK ASSY DRAG LINK ASSY SPACER NUT WASHER BOLT DRAG LINK NUT DWG LINK 1 1 1 1 3 1 1 1 2 3 1 1 1 1 1 1 4 1 1 6701 94530 STD 467701 94530 STD STD STD STD MODEL 93 95 STD MODEL 96 01 STD MODEL 93 01 STD MODEL 93 01 STD MODEL 93 01 STD MODEL 93 01 STD MODEL 93 01 J5 I_ CARBURETOR B 09 OWER COVER CLAHP BRACKET F 02 UBRICATION HOSE C 02 CLUTCH D 05 AGNETO E 04 ROTTLE LINK D 04 CRANKCASE B 02 CRANKSHAFT B 05 I L TANK 1 02 ANSHISSION 6 08 DRIVESHAFT HOUSING 6 03 PT GASKET SET 5 06 P I L PUMP C 11 ENGINE CONTROL UNIT E 14 E 07 bPT PANEL SWITCH J 03 LECTRICAL E 09 AR CASE 6 05 E PT METER J 02 FIG 61 2 3 I IEW A a VIEW C FIG 61 J 6 OP
32. C e l l PT GASKET SET J 06 PT PANEL SWITCH J 03 PT 8 METER J 02 QTY REF NO PART NO DESCRIPTION REMARKS 1 2 2A 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 151 00 94900 157 10 94900 15751 94900 15741 94900 15760 E01 15765 68920 1691 1 92E20 1691 1 94900 1691 1 92E20 1691 1 92E20 091 60 06084 09168 12013 091 69 06062 09354 10173 600 09355 357 55 600 09356 751 37 600 09356 751 37 600 09356 75 137 600 09360 12008 09363 08004 09401 06405 09401 18404 09401 1 1 41 4 09408 00024 01 550 06357 021 62 061 27 G2162 06257 09160 06084 PUMP ASSY FUEL 1 INJECTOR ASSY FUEL 4 INSULATOR FUEL INJECTION 8 STOPPER FUEL INJECTOR 4 REGULATOR FUEL PRESSURE 1 HOLDER FUEL PRESS RGLTR 1 PROTECTOR 1 PROTECTOR L 480 1 PROTECTOR 1 PROTECTOR 1 WASHER 2 GASKET 4 WASHER 6 HOSE FUEL SEPARATOR TO PUMP 1 1 HOSE RGLTR HOSE FUEL PUMP TO INJECTOR 1 HOSE FUEL INJECTOR TO RGLTR 1 HOSE FUEL RGLTR TO 1 SEPA TOR BOLT UNION 2 UNION FUEL 2 CLIP 2 CLIP 2 CLIP 6 CLAMP 1 BOLT 2 BOLT 4 BOLT 2 WASHER 2 L 540 310 L 540 180 L 540 145 L 600460 L 600 380 L 600 170 L 600 190 L 600 3 10 22 DT115 140 E3 c 10 __ bPT WIRING HARNEW J 04 OP
33. CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 PT WIRING HARNEW J 04 SWIVEL BRACKET F 05 CLAHP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 PTIONAL J 07 TH ROTTLE BODY C 04 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 OWER UNIT F 08 TH ROTTLE LINK 0 04 CRANKSHAFT 8 05 FUEL TANK 1 03 I L TANK 1 02 SENSOR amp METER E 13 TR ANSMISSION 6 08 DRIVESHAFT HOUSING G 03 FUEL VAPOR SEPARATO C 09 PT GASKET SET 5 06 SILENCER CASE B 14 TR I H CYLINDER F 12 FLECTRICAL E 09 GEAR CASE 6 05 PT HElER J 02 SILENCER B 13 WATER PUHP 1 02 CRANKCASE B 02 FUEL PUMP C 05 OIL PUMP C 11 EMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 I I FNGINE COVER H 05 IINTAKE MANIFOLD B 08 bPT T I E ROD J 05 IETARTING MOTOR E 02 I FIG l FIG l B 2 CRANKCASE QTY REMARKS DESCRIPTION REF NO PART NO 1 2 3 4 5 6 7 8 9 10 11 12 13 13A 138 13C 14 1 14 2 14 3 15 1 15 2 15 3 16 17 18 19 20 21 1 21 2 22 1 22 2 1 1 151 9462M ED 11 161 94620 OED 11 162 94630 COVER CYLINDER HEAD UPPER COVER CYLINDER HEAD LOWER GASKET COVER
34. D 02 I FlG 33 4 1 f 21 22 I I 20 FIG 33 F 3 CLAMP BRACKET MODEL 95 QTY I REF NO PART NO DESCRIPTION REMARKS 8 09100 12039 BOLT 12x100 4 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 091 40 12028 41153 94500 091 5422003 09160 12044 091 60 1 2066 09162 12005 08100 10155 09100 10264 091 62 1 0005 45420 95500 ow1 24002 36894 95201 091 25 05050 09161 051 14 41 161 95250 NUT CAP NUT WASHER 1 2 5X35X32 WASHER 12 5X22X2 5 WASHER 12 2X21 5X3 0 BOLT 1 0x50 BOLT 1 0x80 WASHER 10 2X18 4X2 5 PIN TILT LOCK SPRING LEAD LA 65 SCREW 5x8 WASHER 52x1 1x1 SEAL STEERING CABLE 41 161 WOO SEAL STEERING CABLE 091 60 22046 WASHER 22 5X44Xl O 1 2 1 OPT 1 MODEL 87 95 1 DT115 608866 DT140 609070 MODEL 86 47 DT115 140 E3 F 3 _I_I I_ I _ I CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 CLUTCH D 05 FUEL INJECTOR C 10 AGNETO E 04 CRANKCASE e B 02 FUEL PUMP C 05 I L PUMP C 11 CRANKSHAFT B 05 FUEL TANK 1 03 9IL TANK 1 02 LECTRICAL E 09 GEAR C A S E 6 05 OPT METER 5 02
35. E 13 TR ANSHISSION 6 08 DRIVESHAFT HOUSING G 03 GASKET SET J 06 SILENCER CASE B 14 TRIM CYLINDER F 12 METER J 02 SILENCER B 13 WATER PUMP D 02 ENGINE CONTROL UNIT E 14 PANEL SWITCH J 03 SOLENOID E 15 ELECTRICAL E 09 H 6 1 FIG 49 22 FIG H 7 ENGINE COVER MODELl88 QTY REMARKS REF NO PART NO DESCRIPTION 1 2 3 4 5 6 1 6 2 7 1 7 2 8 1 8 2 9 1 9 2 11 12 13 14 15 16 17 18 19 20 61410 94910 0ED COVER ASSY ENGINE 6142144601 2CS EMBLEM FRONT 61422 94600 26N MARK UPPER 68181 17000 019 EMBLEM SIDE 61442 94600 019 MARK OIL INJECTION 03242 051 63 03242 051 03 SCREW SCREW 61435 94600 706 EMBLEM REAR 61435 94600 634 EMBLEM REAR 61443 94620 7OG DECAL ENGINE COVER STBD 61443 94620 8EH DECAL ENGINE COVER STBD 61453 94620 706 DECAL ENGINE COVER PORT 61453 94620 8EH DECAL ENGINE COVER PORT 61443 94639 706 DECAL ENGINE COVER STBD 61453 94630 706 DECAL ENGlNE COVER PORT 61641 94501 HOOK COVER RELEASE 61647 94600 HOOK FRONT 61645 94600 OED LEVER FRONT HOOK 091 00 06 1 3 1 091 6046036 WASHER 6 5X18X1 5 091 62 06006 LOCK WASHER 09164 13005 WASHER 13 2X24X0 6 61652 94501 GROMMET LATCH RELEASE ROD BOLT 6x25 1 61420 94682 0ED 1 1 2 2 3 1 1 DT115 FOR 02M 1 DT115 FOR 01T
36. ENGINE 61403 9481042M COVER SET ENGINE USED WITH 61421 94601 2CS EMBLEM FRONT 1 FOR02M 61422 94660 26N MARK UFPER 1 FOR02M 68181 17DOO 015 EhlBLEM SIDE 61442 94600 019 MARK OIL INJECTION 61435 94600 70G EMBLEM REAR 614255 94600 8EH EMBLEM REAR 1 FOR01T 61443 94620 70G DECAL ENGINE COVER ST3D 1 FOR02M i FOR01T 61453 94620 706 DECAL ENGINE COVER PORT 1 DT115 FOR 02M 61453 94620 8EH DECAL ENGINE COVER PORT 1 DT115FOROlT 61443 94630 706 DECAL ENGINE COVER STBD 1 DT140FOR02M 1 DT140FOR02M 61443 94620 8EH DECAL ENGINE COVER STBD 61453 94630 706 DECAL ENGINE COVER PORT REFER TO FlG 52A H 13 FOR DTI4OEFl COLOR 02M SILVER 26N BURGUNDY 01T WHITE 291 BLACK 2CS 02M91 764 764 GOLD 26N BLACK 26M BURGUNDY 70G 7641019 OED GRAY 8EH 26M64 70 DTl15 140 E3 METER o a FIG 48 21 FIG 48 H 6 ENGINE COVER MODEL 86 87 QTY REF NO PART NO DESCRIPTION REMARKS 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 61 641 94501 61651 95501 6 1641 95500 6 1652 95500 61652 94501 61653 95501 61 653 94502 61 660 95500 61 661 94501 09383 03001 03242 061 63 08322 01067 61431 94503 0ED 61 654 95500 191 31 95502 092O9 050 1
37. FUEL HOSE FUEL CONNECTOR FUEL PUMP SQUEEZE CLIP CONNECTOR FUEL WASHER CONNECTOR FUEL CONNECTOR FUEL WASHER 1 1 1 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 4 1 1 1 1 1 6 3 U S GAU5 2 IMP GAL MODEL 86 88 MODEL 89 95 DT115 231153 DT140 231137 MODEL 86 88 MODEL 89 95 365850 921300 MODEL 86 88 MODEL 89 95 MODEL 86 88 MODEL 89 95 MODEL 86 88 MODEL 89 95 DT115 231153 DT140 231137 MODEL 97 01 DT115 231153 DT140 231137 MODEL 96 NOT FOR U S MAR1 NOT FOR U S MARKET 1 3 I I I_ LOWER COVER H 02 PT WIRING HARNEW J 04 SWIVEL BRACKET F 05 LUBRICATION HOSE C 02 PTIONAL J 07 M ROTTLE BODY C 04 MAGNETO E 04 OWER UNIT F 08 TH ROTTLE LINK D 04 I L TANK 1 02 SENSORS METER E 13 TR ANSMISSION 6 08 PT GASKET SET J 06 SILENCER CASE B 14 TR IM CYLINDER F 12 PT METER J 02 SILENCER B 13 dATER PUMP 0 02 PT PANEL SWITCH J 03 SO LENOIL E 15 O I L PUMP C 11 EHOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 bNGINE COVER H 05 IINTAKE MANIFOLD B 08 bPT T I E ROD 5 05 IkTARTING MOTOR E 02 I FIG 54 22 1 i F I G S I 4 FUEL TANK
38. I 1 PTIONAL J 07 OWER UNIT F 08 EMOTE CONTROL BOX 1 05 I ENSOR amp METER E 13 1 ILENCER CASE B 14 1 i ILENCER 8 13 ROTTLE BODY C 04 ROTTLE LINK D 04 CYLINDER F 07 ANSMISSION 6 08 IM CYLINDER F 12 PUMP D 02 FIG 48 19 1 FIG 40 F 11 POWER UNIT MODEL96 01 QTY REFSO PART NO DESCRIPTION REMARKS J 18 r8 LW 3 U 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 15 2 16 17 18 19 20 38100 94900 OED 31 11 1 94900 31311 94900 31 173 94900 31 133 94900 31 135 94900 3 1 136 94900 31 110 9490 31 123 87060 33799 97EQQ 48585 95E00 48583 95E00 48502 9490 1 48582 95E00 48864 94910 48864 9491 1 48862 95E00 48862 95E 10 31 281 95E00 09403 1 7304 021 62 061 27 MOTOR ASSY PTT SCREW ARMATURE HOLDER ASSY BRUSH BRUSH SPRING BREAKER ASSY YOKE 0 RING OIL SEAL 0 RING JOINT PUMP FILTER VALVE SET MANUAL VALVE SET MANUAL BOLT BOLT BOLT THROUGH CLAMP BOLT COLOR OED GRAY 2 1 1 1 2 i 1 1 1 1 1 1 1 1 1 MODEL 99 01 1 2 4 1 1 15 55 DT1151140 E3 F 11 _ _ _ _ x _ ROTTLE BODY ROTTLE LINK P L T CYLINDER
39. PT GASKET SET J 06 1 2 10 10 1 1 1 1 1 1 1 1 2 1 2 2 2 2 2 1 2 4 2 1 2 1 DT 15 1 DT140 1 1 MODEL H 11 bPT WIRING HARNEW 5 04 SWIVEL BRACKET F 05 OPTIONAL 5 07 TH ROTTLE BODY C 04 POWER UNIT F 08 TH ROTTLE LINK D 04 SENSOR amp METER E 13 TR ANSMISSION 6 08 SILENCER CASE B 14 TR In CYLINDER F 12 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 TER PunP 0 2 FOG 52 c LAMP BRACKET F 02 LUTCH D 05 LECTRICAL E 09 _ __ _ _ ENGINE HOLDER 6 02 EXHAUST COVER B 07 FUEL INJECTOR C 10 FUEL PUMP C 05 FUEL TANK 1 03 FUEL VAPOR SEPARATO C 09 GEAR CASE 6 05 IGNITION E 07 FIG 52 H 12 ENGINE COVER DT115Sj QTY REMARKS DFSCRIPTION REF NO PART NO 1 2 3 4 5 6 7 8 9 10 5 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 6 1420 94843 0ED 61 651 94602 09229 04032 08322 01057 6 1431 94503 OED 61 481 945M OED 61482 94510 6 1485 94500 6 1 486 94600 61 544 94500 61 641 946130 61531 9461 0 61 645 94600 OED 6 1670 94600 091 18 06095 0214261 67 0
40. 06 SILENCER CASE B 14 TR I t 4 CYLINDER F 12 CRANKCASE B 02 FUEL PUMP C 05 31L PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 ELECTRICAL E 09 GEAR CASE 6 05 3PT METER J 02 SILENCER B 13 d amp TER PUMP D 02 NGINE CONTROL UNIT E 14 NITION E 07 OPT PANEL SWITCH J 03 SOLENOID E 15 fNGINE COVER H 05 I I N T E MANIFOLD B 08 OPT TIE ROD 3 05 EiARTING MOTOR E 02 FIG 25 17 18 19 27 20 1 24 a4 a 16 9 1 4 FIG 25 E 5 MAGNETO MODEL 89 97 QTY 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 28 321 02 9461 3 321 40 94620 321 40 94630 021 12 06207 08321 01 067 321 20 94621 321 20 94630 02 1 12 06257 08321 01067 321 60 9461 0 321 70 9461 0 321 80 946 10 321 90 9461 0 321 50 87E20 021 12 75107 021 12 35127 09140 18007 091 60 1801 1 08341 31059 1 151 1 94603 09404 06432 02142 05087 38423 9551 0 1 1521 94602 OED 11523 94610 02112 06167 02142 051 67 04221 04089 FLYWHEEL COIL MAGNETO PRIMARY NO l COIL MAGNETO PRIMARY N0 2 SCREW LOCK WASHER COIL BTRY CHARGING NO 1 COIL BTRY CHARGING N0 2
41. 12323 94600 1 6321 94600 091 60 30034 09262 40003 09263 30019 09269 40003 09421 10002 091 81 351 67 09181 35240 08331 31356 09263 40010 09283 40024 09390 80002 04221 04089 11431 94600 09280 70005 09282 24003 RING SET PISTON PIN CIRCL P BEARING WASHER OIL SEAL 35X58X8 CRANKSHAFT ASSY CONNECTING ROD PIN CRANK CRANKSHAFT UPPER WHEEL MIDDLE UPPER WHEEL MIDDLE UNDER CRANKSHAFT UNDER SEAL INNER SEAL RING GEAR OIL PUMP DRIVE WASHER 3OX5OXl BEARING UNDER 4OX8OX18 BEARING 30X40X22 BEARING MIDDLE 40X65X37 KEY B 2 5 H 1OIL 17 5 WASHER OIL PUMP DRIVE UNDER WASHER OIL PUMP DRIVE UPPER CIRCLIP DRIVE GEAR BEARING UPPER SEAL UPPER 40X6W8 C RING ID 76 8 OD 86 TI 9 4 4 4 4 4 8 4 8 1 1 4 4 1 3 3 1 3 6 1 8 1 4 3 1 1 1 1 1 1 1 KNOCK PIN CRANKSHAFT BEARING 4 HOUSING OIL SEAL 1 0 RING D 3 1 JD69 4 1 OIL SEAL 24X36X6 2 REFER TO FIG 3 8 6 FOR MODEL 96 01 4 DT115 140 E3 OPT OPT B5 _ I__ _ I ll_ l _ _ _ _ _ _ I 1 ___ ENGINE HOLDER 6 02 LOWER COVER H 02 OPT WIRING HARNEW 5 04 SWIVEL BRACKET F 05 GEAR CASE 6 05 PT METER 5 02 SILENCER B 13 WATER PUHP D 02 IGNITION E 0
42. 141 I 12 19 2 19 3 19 4 21210 94500 09160 081 19 21311 94503 21 31 2 94500 09i 17 06039 09383 08004 091 40 06020 09140 08019 091 40 0801 6 091 40 08003 231 10 94502 23 1 10 945 10 2331 5 94503 2331 5 94510 2331 3 87wO 2331 3 9451 0 09204 01 002 251 41 94503 25141 94510 25142 94560 25142 94520 04221 051 09 091 17 08071 251 1 1 94502 251 1 1 94503 251 11 94510 251 11 9451 1 30 DT1151140 E3 ENGINE HOLDER 6 02 EXHAUST COVER 8 07 FUEL INJECTOR C 10 FUEL PUMP C 05 FUEL TANK 1 03 FUEL VAPOR SEPARATO C 09 GEAR CASE 6 05 IGNITION E 07 LUBRICATION HOSE C 02 AGNETO E 04 I L PUMP C 11 GASKET SET 5 06 PT PANEL SWITCH J 03 PT METER e J 02 OPT WIRING HARNEW J 04 OPTIONAL J 07 POWER UNIT F 08 SENSOR amp METER E 13 SILENCER CASE B 14 SILENCER B 13 SOLENOID E 15 REMOTE CONTROL BOX 1 05 SHAFT CLUTCH SHIFT WASHER HOLDER SHAFT BUSH BOLT 6x25 E RING NUT M6 NUT M8 NUT M8 NUT ROD CLUTCH L ROD CLUTCH X CONNECTOR CLUTCH ROD L CONNECTORl CLUTCH ROD X PIN CONNECTOR L PIN CONNECTOR X COTTER PIN D1 1 8 L 15 HOUSING SHIFT ROD GUIDE HOUSING SHIFT ROD GUIDE GASKET SHIFT GUIDE HOUSING GASKET SHIFT GUI
43. 17 08056 3 09117 08071 BOLT 8x40 BOLT 8x35 4 09206 11016 PIN 11x12 5 52121 94502 OED COVER DRIVE SHAFT HOUSING 6 52121 94520 OED COVER DRIVE SHAFT HOUSING 7 09100 06118 BOLT 6x65 8 9 1 9 2 9 3 10 1 10 2 11 12 13 14 15 16 17 18 19 09160 06082 WASHER 6 5X13Xl 54 16 1 94503 MOUNT LOWER 54 16 1 9451 0 MOUNT LOWER 541 6 1 9451 0 MOUNT LOWER 54 16 x4504 MOUNT LOWER THRUST 54165 9451 0 MOUNT LOWER THRUST 54 1 66 94501 STOPPER LOWER MOUNT 5421 1 94510 OED BRACKET LOWER MOUNT 09104 14002 BOLT 14x55 09 162 14004 LOCK WASHER 14 2X24 5X3 5 BOLT 00x1 30 09 1 18 1 0039 52131 94511 OED CASE EXTENSION X 09108 10117 STUD BOLT L 166 5 091 17 10034 BOLT 1 0x45 09140 10031 NUT 20 09162 10005 LOCK WASHER 10 2X18 02 5 21 09206 11016 PIN 1 l OX8 4X12 22 52161 94500 HOUSING BUSHING 23 57130 94500 BUSHING DRIVESHAFT 24 091 17 08047 BOLT 8x30 COLOR OED GRAY QW REMARKS 1 2 4 2 1 DT115 709842 DT140 709964 1 DTl15 709843 DT140 709965 1 DT115 709842 DT 140 YG9964 1 2 DTl15 140 140EFI 2 DTll5S 0PT HARD TYPE 2 t 1 0PT HARD TYPE 1 1 2 2 8 1 a 1 8 4 59 DT1151140 E3 G 3 I I I OPT WIRING HARNEW 5 04 SWIVEL BRACKET F 05 OPTIONAL J 07 TH ROTTLE BODY C 04
44. 54 141 94501 MOUNT UPPER FRONT 10 2 54141 94510 MOUNT UPPER FRONT 1 DTll5S 1 0PT HARD TYPE 10 3 54141 94510 MOUNT UPPER FRONT 11 1 54142 94502 MOUNT UPPER REAR 2 DT115 1401140EFI 11 2 54142 94510 MOUNT UPPER REAR 2 DTll5S 11 3 54142 94510 MOUNT UPPER REAR 2 0PT HARD TYPE 12 51 1 12 94502 COVER UPPER MOUNT 1 13 091 17 08038 BOLT 8x45 5 14 521 71 94510 HOUSING EXHAUST 1 15 521 72 94541 GASKET EXHAUST HOUSING 1 16 52173 944502 SEAL EXHAUST HOUSING 1 17 091 17 06039 BOLT 6x25 6 18 091 17 06 41 BOLT 6x30 1 19 1 1421 1 9461 2 TUBE EXHAUST 1 DT115 19 2 1421 1 94622 TUBE EXHAUST 1 DT1401140EFI 19 3 142 1 1 94900 TUBE EXHAUST 1 DT115S 20 09284 08004 SEAL 6 8X45Xll 1 21 09319 08043 BUSHING 4 22 091 17 06039 BOLT 8x25 2 23 091 17 08075 BOLT 8x30 4 2 DT115 140 140EFI 2 0PT HARD TYPE 58 DT1151140 E3 G 2 ___ __I __ _ _ _I_ _ _ _ B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 PT WIRING HARNEW J 04 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 PTIONAL J 07 TH ROTTLE BODY C 04 LUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 THROTTLE LINK D 04 RANKCASE B 02 FUEL PUMP c 05 I L PUMP C 11 REMOTE CONTROL BOX 1 05 TILT C
45. 55100 945304ED 09263 2801 6 17631 94600 031 1244303 17635 94500 17635 94521 091 25 05046 091 00 1 0 158 091 17 10034 091 62 10005 55125 94502 55320 95310 091 1646094 55332 94510 55332 94520 55333 94510 55333 94520 17520 94500 17523 9G 10 17564 94500 091 17 06040 55334 94500 091 08 06062 091 40 06020 091 62 06006 09168 10022 09248 1 OOO amp 09206 1 101 6 CASE ASSY GEAR SILVER CASE ASSY GEAR GRAY BEARING 28 6X38X31 8 FILTER WATER SCREW FILTER WATER SUB PLATE GEAR CASE SCREW 5x12 BOLT 1OXlOO BOLT 10x45 LOCK WASHER 1 0 2X18 4X2 5 TRIM TAB ZINC PROTECTION BOLT 6x15 RUBBER EXHAUST SEAL RUBBER EXHAUST SEAL PLATE PLATE TUBE WATER SUB GASKET SUB WATER TUBE BUSH BOLT 6x15 COVER STUD BOLT 6x12 NUT LOCK WASHER 6 1Xf2 2X1 5 GASKET lOX17X1 5 PLUG DRAIN 10X7 5 PIN 11x12 1 1 1 2 2 1 1 2 1 8 1 1 1 1 1 1 1 1 1 1 4 1 1 2 2 2 3 3 2 61 DT1151140 E3 DT115 709842 DTl40 709964 55100 945304ED 25141 94510 25142 94510 521 21 945104E0 091 03 061 18 0928448003 DT115 709843 DT140 709965 USED WITH DT115S DT115 1401140EFI DT115S DT1151140 140EFI DT115S G 5 _ _ I ___ _ _ _ _ _ _ _ E
46. 7 09443 06040 091 25 06067 091 40 06020 09160 06055 6 1642 95500 09441 12001 09385 06003 09307 06005 61481 94504 OED 6 1 482 945 1 0 6 1485 945OO 6 1544 94500 6 1486 94600 6 1487 94602 03242 051 63 71 DT1151140 E3 HOOK COVER RELEASE 1 HOLDER HOOK SPRING 1 HOOK RELEASE 1 PACKING HOOK SPRING HOLDER 1 GROMMET LATCH RELEASE ROD 1 SHAFT RELEASE HOOK 1 ROD LATCH RELEASE 1 KNOB HOOK 1 LEVER LOWER COVER LATCH 1 E RING 1 SCREW TILT HANDLE 4 WASHER 2 HANDLE TILT UP 1 NUT 1 CONNECTOR LATCH RELEASE ROD 1 PIN LINKAGE SPRING SCREW 6x16 NUT WASHER 7X12X1 PIN SPRING PIN BUSHING LID OIL TANK FILLER HINGE SPRING PAD CAP ENGINE COVER COVER FRONT EMBLEM INNER SCREW 1 1 2 2 2 2 1 4 4 1 1 1 1 1 1 4 _ _ _I CARBURETOR B 09 6 02 LOWER COVER H 02 PT WIRING HARNEW 5 04 SWIVEL BRACKET F 05 CLAHP BRACKET F 02 B 07 LUBRICATION HOSE C 02 PTIONAL 5 07 TH ROTTLE BODY C 04 CLUTCH D 05 C 10 MAGNETO E 04 OWER UNIT F 08 TH ROTTLE LINK D 04 CRANKCASE B 02 C 05 O I L PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 CRANKSHAFT B 05 TANK 1 02 S E NSOR amp METER
47. 92E00 OPT OPT BLACK 83 Dill511 40 E3 __ _ _ _ _ _ I _ ll l_ l_ l __ _I_ _ CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 bPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 CLUTCH D 05 FUEL INJECTOR C 10 HAGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK D 04 RANKCASE 8 02 FUEL PUMP C 05 OIL PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 RANKSHAFT 8 05 FUEL TANK 1 03 O I L TANK 1 02 SE NSOR amp HETER E 13 TR ANSMISSION 6 08 RIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 OPT GASKET SET 5 06 SILENCER CASE B 14 TR In CYLINDER F 12 LECTRICAL E 09 GEAR CASE 6 05 OPT METER J 02 SILENCER 8 13 WATER PUMP D 02 NGINE CONTROL UNIT E 14 IGNITION E 07 OPT PANEL SWITCH J 03 SOLENOID E 15 F I 1 ENGINE COVER H 05 IINTAKE MANIFOLD B 08 bPT T I E ROD J 05 IbTARTIN6 HOTOR E 02 I I 1 FIG 56 1 I 16 1 s I 1 20 PRBURETOR B Q9 CLAMP BRACKET F 02 CLUTCH D 05 CRANKCASE 8 02 CRA
48. BRACKET F 02 EXHAUST COVER 8 07 LUBRICATION HOSE C 02 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 IT CRANKCASE B 02 YEL PUMP C 05 OIL PUMP C 11 OtdTROL BOX DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 OPT GASKET SET 5 06 CASE ELECTRICAL E 09 GE AR CASE 05 OPT METER 5 02 ENGINE CONTROL UNIT E 14 IGNITION E 07 OPT PANEL SWITCH 5 03 ENGINE COVER H 05 INTAKE flANIFOLD B 08 OPT T I E ROD 5 05 CRANKSHAFT B 05 FUEL TANK 1 03 OIL TANK 1 02 flETER FIG 28 b FIG 28 E 8 IGNITION DT115S1140EFI QTY REF NO PART NO DESCRIPTION REMARKS 13 I 1 2 3 4 5 6 14 t 16 1 I 15 7 8 9 10 11 12 13 14 15 16 17 32890 94640 0 1 500 08307 091 60 081 24 091 80 081 93 09320 12028 32895 94630 0321 2 05203 0321 2 05303 3341 0 94630 0930406007 032 245203 3351 0 87D20 09482 00370 33810 94601 09404 08205 09407 14403 01550 08167 HOLDER ELECTRIC PARTS BOLT WASHER 8 5xxJX1 6 SPACER 8 5X12X17 CUSHION ID 12 OD 20 L 17 5 COVER HOLDER PARTS SCREW SCREW COIL ASSY IGNITION GROMMET 01 6 8 SCREW CAP SPARK PLUG SPARK PLUG BR
49. BRACKET CLAMP PORT 41 130 95540 SHAFT CLAMP BRACKET 41151 94500 CAP CLAMP BRACKET SHAfT 41 152 94500 55320 953 10 091 16460 BOLT 6Xi6 PLUG CLAMP BRACKET SHAFT ZINC SET PROTECTION AGNETO E 04 I L PUMP C 11 GASKET SET 5 06 METER J 02 PANEL SWITCH J 03 COLOR 01T WHITE 02M SILVER OED GRAY REFER TO FIG 34 F 4 FOR MODEL 96 01 46 DT1151140 E3 1 1 1 1 1 1 1 1 1 1 1 1 1 DT115 608865 DT140 609069 4 4 1 091 60 22046 1 11 95602 OED USED WITH DT115 608866 DT140 609070 DT115 608865 DT140 609069 41111 95602 0ED USED WITH 091 60 22046 DT115 608865 DT140 609069 41121 95610 0ED USED WITH 091 60 22046 4113O 95520 DTl15 608866 609018 D f 1 40 609070 609260 41121 9561O OED USED WITH 41 130 95520 DT115 608865 DT140 609069 41121 95610 OED USED WITH 091 60 22046 4l130 95520 DT115 608866 609018 DT140 609070 609260 41121 95610 0ED USED WITH 41 130 95520 MODEL 87 95 _ _ _ _I I __ OPT WIRING HARNEW 5 06 OPTIONAL J 07 POWER UNIT a F 08 REMOTE CONTROL BOX 1 05 SENSOR 8 flETER E 13 SILENCER CASE B 14 SILENCER B 13 SOLENOID E 15 __ WIVEL BRACKET F 05 ROTTLE BODY C 04 ROTTLE LINK D 04 I L T CYLINDER F 07 RANSMISSION 6 08 I N CYLINDER F 12 t ATER PUMP
50. COVER H 02 bPT WIRING HARNEW 5 04 SWIVEL BRACKET F 05 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 MAGNETO E 04 POWER UNIT F 08 M ROTTLE LINK D 04 OIL PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 I L TANK 1 02 SENSOR amp METER Ea13 TR ANSMISSION 6 08 GASKET SET J 06 SILENCER CASE B 14 TR In CYLINDER F 12 METER J 02 SILENCER B 13 dATER PUMP D 02 PT PANEL SWITCH 5 03 SOLENOID E 15 9 I FIG 10 2 I 1 FIG 10 C 4 THROTTLE BODY DT115S 140EFI QTY REF NO PART NO DESCRIPTION REMARKS DT115S MODEL 96 01 DT140EFI MODEL 97 01 _ _ll ll 1_ I __ I 1 I I RBURETOR B 09 LAMP BRACKET F 02 LUTCH D 05 IT RANKCASE 8 02 ONTROL BOX RANKSHAFT B 05 RIVESHAFT HOUSING G 03 NGINE CONTROL UNIT E 14 NGINE COVER H 05 LECTRICAL E 09 1 2 1 2 2 3 4 5 6 7 8 9 131 25 W9OO 13300 94900 13300 94910 378 10 94900 13381 94 900 13391 94900 091 4O O5O05 091 60 0503 01 550 0855 09404 08205 16 DTll5 140 E3 GASKET THROTTLE BODY BODY ASSY THROTTLE BODY ASSY THROTTLE SENSOR THROllLE VALVE SCREW THROTTLE SENSOR SCREW ADJUST NUT WASHER BOLT CLAM
51. E 07 E PT PANEL SWITCH FIG1 4 12 11 I FIG 14 C 9 FUELVAPOR SEPARATOR DT115SI140EFl QTY REMARKS REF NO PART NO DESCRIPTION 1 2 1 2 2 3 4 5 6 7 8 9 10 I f 12 13 14 15 16 17 18 2 15412 E00 156OO NWO OED 156OO 949Ol OED 13370 92E00 13392 1 6600 09246 05006 15620 94900 0ED 15626 92E12 15650 87DOO 15654 92E00 021 12 061 67 15633 94901 091 69 06067 09320 09039 01500 08207 09160 08054 01 550 06257 09355 35755 600 09401 06405 FILTER SUCTION SEPARATOR ASSY FUEL VAPOR SEPARATOR ASSY FUEL VAPOR VALVE ASSY NEEDLE GASKET NEEDLE VALVE PLUG COVER FUEL VAPOR SEPARATOR GASKET COVER FLOAT PIN FLOAT SCREW EBACKET VAPORSEPARATOR WASHER CUSHION BOLT WASHER BOLT HOSE CLIP COLOR OED GRAY MODELS 01 1 1 1 1 1 4 1 4 2 2 2 2 1 L 600 380 2 i 21 DT115 14O E3 c 9 _ __ l ll_l __ I _I_ CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 bPT WIRXNG HARNEW J 04 SWIWEL BRACKET F 05 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 OPTIONAL 5 07 TH ROTTLE BODY C 04 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 TH RO
52. GASKET SET 5 06 PT PANEL SWITCH 3 03 PT METER J 02 63 DT1151140 E3 OPT WIRING HARNEW J 04 OPTIONAL 5 07 POWER UNIT F 08 REMOTE CONTROL BOX 1 05 SENSOR amp HETER E 13 SILENCER CASE B 14 SILENCER B 13 SOLENOID E 15 OPT OPT OPT OPT OPT OPT OPT OPT TYPE V OPT TYPE U OPT NOT SHOWN G 7 IVEL BRACKET F 05 ROTTLE BODY C 04 HROTTLE LINK D 04 I L T CYLINDER F 07 ANSMISSION 6 08 I H CYLINDER F 12 ATER PUMP D 02 f FIG 46 8 7 9 7 1 J I 2 4 i I b I 21 23 I bl i CARBURETOR B 09 CLAMP BRACKET F 02 CLUTCH D 05 CRANKCASE 8 02 CRANKSHAFT 8 05 DRIVESHAFT HOUSING 6 03 FNGINE CONTROL UNIT E 14 ELECTRICAL E 09 ENGINE HOLDER 6 02 XHAUST COVER B Of UEL INJECTOR C 10 UEL PUMP C 05 UEL TANK 1 03 UEL VAPOR SEPARATO C 09 AR CASE 6 05 a IGNITION E 07 FIG 46 G 8 TRANSMISSION QW REFSO PART NO DESCRIPTION REIMARKS 1 1 1 2 1 3 1 4 2 1 2 2 3 4 5 6 7 8 1 8 2 8 3 8 4 8 5 8 6 8 7 8 8 9 10 11 12 13 571 00 94520 57100 94540 57 100 94530 57 100 94550 09440 31 003 09440 36002 09205 0401 9 571 33 94502
53. LEVER BLACK 1 25 67256 95600 HOLDER NEUT LOCK 1 26 67251 95680 LEVER HANDLE GRAY 1 27 371 10 92E01 IGNITION SWITCH 1 28 1 371 41 92E00 KEY 11 1 28 2 37 1 4 1 92E 1 0 KEY 12 1 28 3 37141 92E20 KEY 13 1 28 4 371 41 92E30 KEY 14 1 28 5 371 41 92E40 KEY 15 1 7 28 6 37141 92E50 KEY 16 1 84 DT115 140 E3 17 bPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 OPTIONAL 5 07 TH ROTTLE BODY C 04 POWER UNIT F 08 TH ROTTLE LINK D 04 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 SENSOR L METER E 13 TR ANSMISSION 6 08 ILENCER CASE B 14 TR IH CYLINDER F 12 ILENCER 8 13 rlATER PUMP D 02 OLENOID E 15 REMOTE CONTROL BOX hrlODEL93 01 FIG 56 I 8 FIG56 1 QTY REF NO PART NO DFSCRIPTION REMARKS I I I 28 7 16 28 8 20 44 I PRBURETOR B O 9 CLAMP BRACKET F 02 CLUTCH D 05 CRANK CASE B 02 CRANKSHAFT B 05 DRIVESHAFT HOUSING G 03 ELECTRICAL E 09 ENGINE CONTROL UNIT E 14 I _ I NGINE HOLDER 6 02 XHAUST COVER B 07 UEL VAPOR SEPARATO C 09 AR CASE 6 05 6 IGNITION E 07 UEL INJECTOR C 10 UEL PUMP C 05 UEL TANK 1 03 _ LOWER COVER H 02 LUBRICATION HOSE C 02 MA
54. POWER UNIT F 08 TH ROTTLE LINK D 04 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 SENSOR amp METER E 13 TR ANSMISSION 6 08 SILENCER CASE 8 14 TR I H CYLINDER F 12 SILENCER B 13 WATER PUHP D 02 FTARTING HOTOR E 02 SOLENOID E 15 FIG 44 G 4 DRIVESHAFT HOUSING QTY REF NO PART NO DESCRIPTION R E M A R U FIG44 26 27 28 09387 45001 04221 05109 521 22 94500 RING PIN SPACER COVER 1 2 1 1 3 1 1 1 2 1 2 2 1 1 1 1 1 2 1 1 30 DT115 709842 DT14O 709964 DT115 709843 DTl40 709965 37 29 09103 06118 BOLT 6x60 30 31 32 33 34 35 36 37 38 52181 94500 521 90 94500 52194 94510 521 95 94500 091 1746038 36894 95201 091 25 05050 09161 05114 551 27 87wO TUBE OVER FLOW TUBE WATER OUTLET GROMMET WATER OUTLET TUBE BOLT 6x16 LEAD L 165 SCREW 5x8 WASHER 52x1 1x1 UNION SPEEDOMETER HOSE GASKET WATER ounn TUBE DT115 709843 DT140 709965 DT115 709843 DT140 709965 L 600 70 DT140 709965 L 600 210 DTl15 709843 DTl15 709843 DTl40 709965 L 2000 900 MODEL 01 DT1151709843 DTi 7B965 39 0936249008 NIPPLE 12 I P 40 1 09355 40805 600 HOSE L 4X8X600 40 2 09355 40805 600 HOSE X 4X8X600 HOSE L X 4X8X2000 40 3 09355 408
55. PREFACE When it becomes necessary t o replace parts on SUZUKI OUTBOARD MOTORS always use SUZUKI GENUINE PARTS which have passed a s t r i c t inspection which guarantees quality and performance This partscataloguecovers the l i s t o f a l l service parts for SUZUKI DT115 140 86 01 MODEL INSTRUCTIONS FOR QUOTING THE CATALOGUE 1 DIMENSIONS Dimensions o f the parts i n t h i s catalogue are indicated i n u n i t millimeters 2 ABBREVIATIONS Abbreviations used i n t h i s catalogue are as follows AR As required NT Number of teeth ASSY Assembly OPT Optional E No Engine number os Over size F No Frame number STD Standard d Diameter o f material T Thickness ID Inside diameter us Under size OD Outside diameter W Widt L Length w With LH P0RT Left hand side S L UL LL Transom type RH STBD Right hand side sus Stainless steel 123456 Up t o F No 11502 123456 PTT Power trim and tilt 123456 From F No 11502 123456 00 MODEL 2000 01 MODEL 2001 12 x 34 x 5 6 Figures i n the description column 1 7 r show the dimensions o f parts ID OD T or W L 12345 56781 Parts No indicates that the parts number was changed t o 12345 56781 and the new Darts are interchangeable with the former ones but the former ones are not interchangeable with new ones e 12345 56781 Parts No indicates that the former and new parts are interch
56. Qm REF NO PART NO DESCRIPTION REMARKS 25 26 27 28 29 30 31 32 33 34 1 34 2 35 36 37 38 65700 87D17 65750 95500 65750 98505 65770 95540 65781 98500 6570047032 65750 95500 657 i395504 65781 98500 09407 1 4403 09407 25402 65700 87021 65770 95504 65781 98500 0 3401 1a409 81 DT115 14O E3 HOSE FUEL SOCKET FUEL HOSE IN SOCKET FUEL HOSE OUT PUMP SQUEEZE CLIP HOSE FUEL SOCKET FUEL PUMP SQUEEZE CLIP CLAMP FUEL HOSE CLAMP HOSE FUEL PUMP SQUEEZE CLIP CLIP 1 1 1 1 4 1 1 1 3 1 1 1 1 2 2 DTI15 231153 DT140 231137 DTl15 231153 DT140 231137 DT115 231153 DT140 231137 DT140 231137 DT115m 153 DTl15 231153 DT140 231137 MODEL193 96 MODELz93 96 ivlODEL 93 96 MODELz93 96 MODEL 95 96 NlFUEL TANK MODEL 97 01 MODEL 97 01 MODEL 97 01 MODEL197 01 NlFUEL TANK 14 RBURETOR B 09 ENGINE HOLDER G 02 LOWER COVER H 02 bPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 LAMP BRACKET F 02 EXHAUST COVER 8 07 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 LUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK D 04 ANKCASE 8 02 FUEL PUMP C 05 3IL PUMP C 11 RE
57. SCREW BOLT BOLT LOCK WASHER CLAMP L 80 1 4 3 2 2 4 1 1 1 1 1 1 DT115 D T W MODEL MODEL 86 89 MODEL 93 MODEL 97 MOOEL186 93 E 15 SWIVEL BRACKET F 05 THROTTLE BODY C 04 THROTTLE LINK D 04 T I L T CYLINDER F 07 TRANSMISSION 6 68 TRIM CYLINDER F 12 WATER PUMP D 02 1 I FNGINE COVER H 05 IINTAKE MANIFOLD B 08 bPT TIE ROD J 05 IbTARTING MOTOR E 02 I FIG 33 4 21 22 1 I I I 20 _ I _ _ _ CARBURETOR B 09 ENGINE HOLDER 6 02 CLAMP BRACKET F 02 EXHAUST COVER B 07 CLUTCH D 05 FUEL INJECTOR C 10 CRANKCASE 8 02 FUEL PUMP e C 05 CRANKSHAFT B 05 FUEL TANK 1 03 ELECTRICAL E 09 GEAR CASE 6 05 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 ENGINE CONTROL UNIT E 14 IGNITION E 07 FIG 33 F 2 CLAMP BRACKET MODEL 95 QTY REMARKS REF NO PART NO DESCRIPTION 1 1 1 2 1 3 2 1 41 1 11 9451 1 02M BRACKET CLAMP STBD 411 11 95602 OED BRACKET CLAMP STBD 41111 94511 01T BRACKET CLAMPSTBD 41121 94531 02M BRACKET CLAMP PORT 2 2 2 3 2 4 2 5 3 4 5 6 7 41121 94532 02M BRACKET CLAMP PORT 41121 94531 01T BRACKET CLAMP PORT 41121 94532 011 BRACKET CLAMP PORT 41121 95610 OED
58. TANK 1 02 LECTRICAL o E 09 GEAR CASE 6 05 OPT METER 5 02 FIG 47 H 3 LOWER COVER QTY REMARKS REF NO PART NO DESCRIPTION 24 25 1 25 2 26 1 26 2 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 1 44 2 45 1 45 2 45 3 46 36895 95300 LEAD 091 1748056 BOLT 8x40 091 18 081 27 BOLT 8x40 091 60 08081 WASHER 8 5X23X1 5 091 60 08082 WASHER 8 5X16X1 2 091 62 08007 LOCK WASHER 61 142 94502 GROMMET 09250 09001 CAP STEERING JOINT 09250 1 001 2 09308 0801 3 GROMMET REMOCON CABLE 36656 94900 GROMMET PTT CABLE 67271 94500 HOLDER REMOCON CABLE 67276 94502 PLATE REMOCON CABLE HOLDER 01421 06127 STUD BOLT 0 1421 06307 STUD BOLT 08316 10067 NUT 36656 9461 2 GROMMET CABLE 36661 95210 CAP PlT CABLE CUSHION 13851 9521 0 CUSHION CAP CARBURETOR ADJUST 13851 95210 61240 94610 70G DECAL SET LOWER COVER 61231 94600 26G DECAL LOWER COVER PORT 61 116 94601 BRACKET ENGINE COVER HOOK 1 116 94601 SRACKET ENGINE COVER HOOK 091 17 06046 BOLT 6x20 BOLT 6x20 091 17 06046 091 1646106 BOLT 6x20 61 61 0 9551 4 FASTENER COLOR 019 BLACK 26M BURGUNDY 70G 7641019 764 GOLD 8EH 26Ml764 26G BLACK 68 DT115 140 E3 1 4 4 4 4 4 1 1 1 2 1 1 2 2 2 4 1 1 1 2
59. WIRE TRIM GAUGE EXTENTION 1 MODEL 93 00 CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COWER H 02 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 CLUTCH D 05 FUEL INJECTOR fie10 MAGNET3 E 04 CRANKCASE B 02 FUEL PUMP 2 05 O I L PUMP C 11 CRANKSHAFT B 05 FUEL TANK 1 03 TANK 1 02 GASKET SET J 06 ELECTRICAL E 09 GEAR CASE 6 05 METER J 02 DRIVESHAFT HOUSING 6 03 FUEL WAPOR SEPARATO C 09 ENGINE CONTROL UNIT E 14 IGNITIOM E 07 PANEL SWITCH J 03 PT WIRING HARNEW 5 04 SWIVEL BRACKET F 05 PTIONAL 5 07 TH ROTTLE BODY C 04 OWER UNIT F 08 TH ROTTLE LINK D 04 EMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 SENSOR amp METER E 13 TRANSMISSION 6 08 SILENCER CASE B 14 TR In CYLINDER F 12 SILENCER 8 13 WATER PUMP D 02 SOLENOID E 15 FIG 29A 14 FIG 29A E 12 ELECTRICAL MODELOI QTY REF NO PART NO DESCRIPTION REMARKS 1 2 3 4 5 6 1 6 2 7 8 9 10 11 12 13 14 15 16 17 32800 94620 09404 08205 09407 1 4403 01 5 06207 36610 94680 09404 08205 09404 08206 36630 92E00 33831 94630 33832 94601 37801 98300 3681 0 94610 36740 94620
60. 0 091 25 06069 34876 92E00 03212 Ei 63 185W 94600 18590 53A01 091 60 06052 091 60 06084 091 69 06062 09404 06432 021 62 N257 09403 1 7304 021 62 061 27 34881 94600 34881 92E00 43 DT115 140 E3 LOWER COVER H 02 PT WIRING HARNEW 5 04 LUBRICATION HOSE C 02 PTIONAL J 07 AGNETO E 04 I L PUMP C 11 TANK 1 02 PT GASKET SET 5 06 PT METER 5 02 PT PANEL SWITCH 5 03 OWER UNIT F 08 EMOTE CONTROL BOX 1 05 NSOR amp METER E 13 CASE B 14 ILENCER B 13 OLENOID E 15 TACHOMETER ASSY GAUGE ASSY MONITORING SENSOR CYLINDER TEMP SUPPORTER CYLINDER TEMP SCREW CYLINDER TEMP SENSOR AIR TEMP SUPPORTER TEMP SENSOR SCREW 6x12 PLUG WATER SNSR HOLE SCREW WATER SNSR HOLE LUG SENSOR AIR PRESSURE SENSOR AIR PRESSURE WASHER AIR PRESSURE WASHER AIR PRESSURE SPACER AIR PRESSURE CLAMP AIR PRESSURE BOLT AIR PRESSURE CLAMP PlT MOTOR CABLE BOLT P l l MOTOR CABLE BMCKET AIR PRESSURE SENSOR BRACKET AIR PRESSURE SENSOR 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 6x1 2 MODEL MODEL MODEL OPT MODEL 96 6 5X16X1 20 OPT 6 5X18X1 60 6 3X17X1 60 OPT E 13 __ ___ __ ____ I ___ __ SWIVEL BRACKET F 05 THROTTLE BODY C 04 THRO
61. 0 07033 SPRING CAM NOTCH 1 PLATE DETENT SPRING 1 33 21 121 9333oO 21 4 34 09440 1 2025 SPRING SHIFT ROD 1 C I RCLl P 1 35 36 25230 94300 MAGNET SET GEAR CASE 1 37 25232 94300 MAGNET 1 I 0833 1 4 1 309 31 DT115 140 E3 33 D6 _ _ _ I _ _ I__ I_ _ CARBURETOR 9 09 ENGINE HOLDER 6 02 CLAMP BRACKET F 02 EXHAUST COVER 9 07 ROTTLE BODY C 04 CLUTCH 11 05 FUEL INJECTOR C 10 ROTTLE LINK D 04 CRANKCASE 9 02 FUEL PUMP C 05 LT CYLINDER F 07 ANSMISSION 6 08 In CYLINDER F 12 CRANKSHAFT 9 05 FUEL TANK 1 03 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 OPT GASKET SET 5 06 ELECTRICAL E 09 GEAR CASE 6 05 OPT HETER J 02 ENGINE CONTROL UNIT E 14 IGNITION E 07 3PT PANEL SWITCH J 03 OPT T I E ROD 5 05 ENGINE COVER H 05 INTAKE MANIFOLD 9 08 e FIG 23 E 2 STARTING MOTOR MODEL 99 REF NO PART NO DESCRIPTION REMARKS LOCK WASHER 2 MODEL 89 2 MODEL 89 2 MODEL 90 92 2 MODEL 93 99 2 FOR 01 500 08353 2 FOR 071 30 08407 WASHER 8 7X22X2 WASHER 8 5X20X1 6 SPACER 8 1X1218 8 MOTOR ASSY STARTING HOLDER ASSY MOTOR BRUSH MODEL 94 99 31100 94610 31 173 95310 7 I SPRING BRUSH THROUGH BOLT STOPPER SET PINION DAMPER UPPE
62. 0 08407 31911 946204ED 01 580 08257 31912 94600 31 91 8 94600 01 550 081 67 3382a 94600 MOTOR ASSY STARTING BRUSH SPRING HOLDER ASSY BRUSH BOLT HOUSING ARMATURE PINION STOP SET PINION WASHER SET DAMPER UPPER DAMPER MIDDLE WASiiEii SPACER BOLT BRACKET STARTING MOTOR BOLT BAND STARTING MOTOR DAMPER LOWER BOLT CABLE PLUS TERM RELAY 33 DT115 140 E3 1 1 4 1 2 1 1 1 1 2 1 3 2 2 1 4 1 1 2 1 E3 l__ l _ _I __ __ _I __ OPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 OPTIONAL J 07 M ROTTLE BODY C 04 POWER UNIT F 08 M ROTTLE LINK D 04 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 SENSOR L METER E 13 TR ANSNISSION 6 08 SILENCER CASE B 14 TR I M CYLINDER F 12 SILENCER B 13 WATER PUHP D 02 SOLENOID E 15 FIG 24 17 27 20 FIG 24 E 4 MAGNETO MODEL 88 QTY REF NO PART NO DESCRIPTION REMARKS 1 321 02 94600 FLYWHEEL 1 2 321 40 94600 COIL PRIMARY NO l 1 COIL PRIMARY N0 2 1 3 4 021 12 06207 SCREW 4 LOCK WASHER 4 5 6 321 20 94600 COIL BAlTERY CHARGING NO l 1 7 321 20 9461 0 COIL BATTERY CHARGING N0 2 1 8 021 12 06257 SCREW 4 9 08321 01 067 LOCK WASHER 4 10 321 60 946
63. 0 2 11 12 14 15 16 1 16 2 17 18 20 21 22 23 61 1 10 94X53 OED 6 1 1 55 94500 61 131 94502 OED 61 141 94503 OED 61139 94511 61 139 94901 13979 37400 61 1 12 94502 61 1 13 94503 61631 94602 61631 94602 091 17 06040 01 55O 06167 091 60 06082 091 28 06052 61 138 94601 091 22 86003 091 25 06069 021 42 061 27 338 16 94600 0 1 421 061 27 08316 10067 366 16 94600 091 2546069 0 1 550 06 127 COVER LOWER TUBE WATER COVER ENGINE HOLDER STBD COVER ENGINE HOLDER PORT TUBE DRAIN TUBE DRAIN RETAINER DRAIN TUBE SEAL LOWER COVER UPPER SEAL LOWER COVER LOWER HOOK LOCATING HOLDER HOOK LOCATING HOLDER BOLT 6x151 BOLT 6x16 WASHER 6 5X13Xl BOLT 6x26 COVER WATER BOLT 6x16 SCREW 6x1 2 SCREW CLAMP STUD BOLT NUT HOLDER HARNESS CONNECTOR SCREW 6x12 BOLT COLOR OED GRAY 1 1 1 1 1 1 1 1 1 2 1 4 2 2 4 1 1 2 2 1 2 2 1 1 1 MODEL 01 MODEL194 MODEL 86 87 MODEL 86 87 MODEL 88 95 MODEL 88 95 MODEL 88 95 MODEL 01 MODEL186 92 MODEL 93 01 67 DT1151140 E3 __ _ _I _ I I _ _ _ I I _ CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 OPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 E
64. 0 764 MARK OIL INJECTION 61442 94600 019 MARK OIL INJECTION 03242451 23 SCREW FRONT EMBLEM 61443 94620 700 DECAL STBD 61443 94620 8EH DECAL STBD 61443 94630 70G DECAL STBD 61453 94620 70G DECAL PORT 61453 94620 8EH DECAL PORT 61453 94630 700 DECAL PORT 6 1 641 9450 1 61641 94600 HOOK FRONT 09100 061 31 BOLT 6x25 091 18 06095 BOLT 6x25 091 62 06006 LOCK WASHER 6 1X12 2X1 5 091 60 06036 WASHER 6 5X18X1 5 091 64 1 3005 WASHER 13 2X24X0 6 61 652 94501 6 1653 94502 ROD LATCH RELEASE HOOK COVER RELEASE 61645 94600 OED LEVER FRONT HOOK GROMMET LATCH RELEASE ROD 1 1 1 1 1 1 1 1 1 2 2 2 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 COLOR OED GRAY 8EH 26Mn64 019 BLACK 01T WHITE 764 GOLD 70G 764 019 2TN 764 OED 74 DT115 140 E3 DT115 61420 946d2 0ED DT115 61420 94682 0ED DT140 61420 94682 0ED DT14U 61420 94682 0ED DT115 FOR OED D i l l 5 FOR OED DT115 FOR OED DT115 FOR 01T DT140 FOR OED FUR OED FOR 01T FOR OED FOR 01T MODEL DTl15 FOR OED DT115 FOR 01T DT140 FOR OED DT115 FOR OED DT115 FOR 01T DT140 FOR OED MODEL 89 93 MODEL MODEL 89 93 MODEL 89 93 H 9 PT WIRING HARNEW J 04 sw IVEL BRACKET F 05 PTIONAL J 07 TH ROTTLE BODY C 04 O
65. 02 CRANKSHAFT B 05 DRIVESHAFT HOUSING 6 03 ELECTRICAL E 09 ENGINE CONTROL UNIT E 14 _____I __ __I ___ ENGINE HOLDER 6 02 EXHAUST COVER 8 07 FUEL INJECTOR C 10 FUEL PUMP C 05 FUEL TANK 1 03 FUEL VAPOR SEPARATO C 09 GEAR CASE 6 05 IGNITION E 07 FIG 9B C 3 LUBRICATION HOSE DT1 lSS l40EFI MODEL97 01 QTY REF NO PART NO DESCRIPTION REMARKS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 14 2 15 16 09355 30705 600 09355 30705 600 09355 35755 600 09355 35755 600 09355 35755 600 09355 35755 600 09355 35755 600 09355 35755 600 09355 35755 600 1691 1 92E20 09367 040 10 09401 071 01 1671 0 9521 1 09404 08207 09404 08205 09401 06405 09408 00024 PROTECTOR 3 WAY CLIP VALVE CHECK CLAMP L 97 CLAMP L 62 CLIP CLIP HOSE LUBRICATION NO l HOSE LUBRICATION N0 2 HOSE LUBRICATION N0 3 HOSE LUBRICATION N0 4 HOSE LUBRICATION NOS HOSE LUBRICATION N0 6 HOSE LUBRICATION N0 7 HOSE LUBRICATION N0 8 HOSE LUBRICATION N0 9 15 DT1151140 E3 1 1 4 4 4 1 1 1 1 1 4 32 5 2 1 4 1 L 600 120 L 60O UlO L 600 30 L 600 50 L 600 90 L 600 380 L 600 440 L 600 520 L 600 560 L 54045 c 3 __ _I l l _ l l _ l l l l LOWER
66. 04 POWER UNIT F 08 THROTTLE LINK D 04 CRANKSHAFT B 05 FUEL TANK 1 03 O I L TANK 1 02 SENSOR amp METER E 13 TR ANSMISSION 6 08 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 OPT GASKET SET 5 06 SXLENCER CASE B 14 TR I M CYLINDER F 12 ELECTRICAL E 09 GEAR CASE 6 05 OPT METER J 02 SILENCER B 13 WATER PUMP D 02 ENGINE CONTROL UNIT E 14 IGNITION E 07 lOPT PANEL SWITCH 5 03 SOLENOID E 14 CRANKCASE B 02 FUEL PUMP C 05 OIL PUMP C 11 QEHOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 31 1 2 3 29 28 29 18 1 I 3 t FIG 7 8 12 CARBURETOR DT140 MODEL QTY REF NO PART NO DESCRIPTION REMARKS 19 20 21 1 21 2 21 3 21 4 22 1 22 2 23 24 25 26 27 28 29 30 1 30 2 30 3 30 4 30 5 31 32 021 12 04163 SCREW LOCK WASHER 08321 4 1 043 JET MAIN 157 5 09491 31007 09491 31014 JET MAIN 1 55 09491 32008 JET MAIN 162 5 09491 31 01 4 JET MAIN 155 JET MAIN 150 09491 30010 09491 3201 3 13534 95000 1 3268 96 1 1 1 13245 9521 0 01 41 1 08207 08316 10087 09352 50903 600 09401 0841 1 09491 29006 09491 29010 09491 30009 09491 3201 3 09491 33007 13510 94600 139 10 94
67. 05 008 41 09407 14403 09404 06432 CLAMP L 125 CLAMP BOLT 42 43 091 00 06131 60 DTll5 140 E3 G 4 ENGINE HOLDER 6 02 LOWER COVER H 02 bPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 EXHAUST COVER B 07 LUBRICATION HOSE C 02 OPTIONAL J 07 M ROTTLE BODY C 04 FUEL INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK D 04 UEL PUMP C 05 O I L PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 UEL TANK 1 03 I L TANK 1 02 SENSOR amp METER E 13 TR ANSMISSION 6 08 UEL VAPOR SEPARATO C 09 PT GASKET SET J 06 SILENCER CASE E 14 TR I M CYLINDER F 12 AR CASE 6 05 PT METER J 02 SILENCER B 13 dATER PUHP D 02 f IGNITION E 07 PT PANEL SWITCH J 03 SOLENOID E 15 RBURETOR B 09 LAMP BRACKET F 02 LUTCH D 05 RANKCASE 8 02 RANKSHAFT B 05 RIVESHAFT HOUSING 6 03 LECTRICAL E 09 CONTROL UNIT E 14 FIG 45 G 5 GEAR CASE FIG 45 21 A QTY REF NO PART NO DESCRIPTION REMARKS 45 1 1 1 2 2 3 4 5 1 5 2 6 7 8 9 10 11 12 13 1 13 2 14 1 14 2 15 16 17 18 19 20 21 22 23 24 25 55100 9451042M
68. 09 050 17 09443 06040 031 25 06 091 40 06020 091 60 06055 61 642 5OO 0938546003 G9301 06005 61481 94504 0ED 6 1 482 945 1 0 61485 94500 61 544 94500 61 486 94600 61487 94602 0324245 163 ROD LATCH RELEASE LEVER LOWER COVER LATCH E RING SCREW TILT HANDLE WASHER HANDLE TILT UP CONNECTOR LATCH RELEASE ROD PIN LINKAGE SPRING SCRW 6x16 NUT WASHER 7XlW1 PIN PIN BUSHING 6x8 LID OIL TANK FILLER PINGE SPRING PAD CAP ENGINE COVER COVER FRONT EMBLEM INNER SCREW COLOR OED GRAY 73 DT115 140 E3 1 1 1 4 2 1 1 1 1 2 2 2 1 2 2 H 8 CARBURETOR 8 09 ENGXNE HOLDER 6 02 LOWER COVER H 02 b P T WIRING HARNEW J 0 4 SWIVEL BRACKET F 05 CLAHP BRACKET F 02 EXHAUST COVER B 07 LUBRICATIOH HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK D 04 AWSHISSION 6 0 8 AR CASE 6 05 OPT HETER J 02 SILENCER B 13 ATER PUMP D 02 ELECTRICAL E 09 GE ENGINE CONTROL UNIT E 14 IGNITION E 07 P P T 8 PANEL SWITCH J 03 SOLENOID E 15 CRANKCASE 8 02 FUEL PUMP C 05 O I L PUMP C 11 REHOTE CONTROL ROX 1 0
69. 1 15 FlG 55 I 6 REMOTE Cc NTROL BOX Qn REFNO PART NO DESCRIPTION REMARKS 24 1 24 2 24 3 25 26 1 26 2 26 3 27 28 1 28 2 28 3 284 28 5 28 6 29 30 31 32 33 34 55 36 37 38 39 40 41 42 43 44 45 67257 95600 67257 9561 0 67257 95620 67256 95600 67251 95600 67251 95650 67251 95680 371 10 9461 1 37141 94400 371 41 9441 0 371 41 34420 371 4 1 94430 371 4 1 94440 37141 94450 67297 95600 67273 95600 38500 92x50 36620 92E00 37820 92E00 37823 94400 67255 95600 67261 95600 37860 9461 0 37869 95590 091 39 02003 67263 95600 67245 95600 67258 87D00 67259 87DOO 671 40 95600 67282 95610 CAP LEVER 1 CAP LEVER 1 CAP LEVER 1 HOLDER NEUTRAL LOCK 1 LEVER HANDLE 1 LEVER HANDLE 1 LEVER HANDLE 1 SWITCH ASSY IGNITION 1 KEY 101 1 KEY 102 1 KEY io31 1 KEY 104 1 KEY 105 1 KEY 106 1 WASHER 2 s PP x 1 BUZZER 1 WIRING HARNESS L5000 1 SWITCH ASSY EMERGENCY 1 CAP 8 ROPE 1 ARM NEUTRAL LOCK 1 GRIP 1 SWITCH TRIM 1 CAP TRIM SWITCH 1 SCREW 2 CAP GRIP 1 DRUM FREE THROTLE BRACKET NELiTRAL ARM 1 SPRING NEUTRAL ARM 1 ATTACHMENT TWIN REMOCON KIT 1 DECAL REMOCON BOX PORT 1 4 BLUE BLACK RED WHITE SILVER GRAY 37110
70. 10 COIL PULSER NO l 1 COIL PULSER N0 2 1 11 321 40 9461 0 08321 01067 321 70 9510 12 32180 94610 COIL PULSER N0 3 1 13 32190 94610 COIL PULSER N0 4 1 14 321 50 94600 COIL GEAR COUNTER 1 8 SCREW 15 021 12 75107 16 021 12 35127 SCREW 2 17 09140 18007 NUT 1 18 09160 18011 WASHER 18 5X35X4 1 19 08341 31059 KEY 1 20 1 151 1 94603 COVER RING GEAR 1 21 09404 06432 CLAMP L 80 4 SCREW 23 38423 955 10 TUBE L 150 1 24 11521 94602 OED CASE RING GEAR GRAY 1 25 1 1523 9461 0 GASKET RING GEAR CASE 1 26 021 12 06167 SCREW 4 e SCREW 27 02142 05167 28 04221 04089 PIN 1 4 22 021 42 05087 L 150 100 REFER TO FIG 25 E 5 FOR MODEL 89 97 REFER TO FIG 26 E 6 FOR DT115S1140EFI 34 DT115 140 E3 E4 _ _ _ _ I _ _ RBURETOR B 09 ENGINE HOLDER G 02 LOWER COVER H 02 PT WIRING HARNEW 5 04 SWIVEL BRACKET F 05 LAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 PTIONAL J 07 TH ROTTLE BODY C 04 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 OWER UNIT F 08 TH ROTTLE LINK D 04 CRANKSHAFT 8 05 FUEL TANK 1 03 O I L TANK 1 02 SENSOR 8 METER E 13 TR ANSMISSION 6 08 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 OPT GASKET SET J
71. 1130 94600 ZINC CYLINDER 49 09404 06432 CLAMP 3 DT115 140 E3 bPT WIRING HARNEW J 04 OPTIONAL J 07 DOWER UNIT F 08 REMOTE CONTROL BOX 1 05 SENSOR amp HETER E 13 ILENCER CASE B 14 I f ENCER B 13 LZNOID E 15 SWIVEL BRACKET F 05 THROTTLE BODY C 04 THROTTLE LINK D 04 TILT CYLINDER F 07 TRIM CYLINDER F 12 JlATER PUMP D 02 TRANSMISSION 6 08 DT115 011278 DT140 011168 DT115 011279 DT140 011169 L 600 180 FOR 34870 94630 34820 946 10 B4 FIG2 FIG 2 8 5 CRANKSHAFT QTY REF NO PART NO DESCRIPTION REMARKS 8 __I _ _ _lll CARBURETOR B 09 CLAMP BRACKET F 02 CRANKCASE B 02 CRANKSHAFT B 05 DRIVEWAFT HOUSING G 03 ELECTRICAL E 09 ENGINE CONTROL UNIT E 14 CLUTCH D 05 k L 4 1 1 1 2 1 3 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 PISTON 121 10 9461 1 12100 94611 025 PISTON SET 05k0 25 12100 9461 1 050 PISTON SET OS 0 50 1 21 40 87DO2 121 51 94601 09381 22004 09263 22063 09181 22251 09283 35030 1 ZCO 94605 1 21 6 1 94900 1 221 1 9461 0 12221 94603 12231 94602 12232 94601 12240 94601 12322 94600
72. 14 TR IM CYLINDER F 12 CRANKCASE B 02 FUEL PUMP C 05 OIL PUMP C 11 EMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 RANKSHAFT B 05 FUEL TANK 1 03 I L TANK 1 02 AR CASE 6 05 PT METER J 02 WATER PUMP D 02 ENGINE CONTROL UNIT E 14 IGNITION E 07 PT PANEL SWITCH J 03 ELECTRICAL E 09 GE I gNGXNE COVER H 05 INTAKE MANIFOLD B 08 PT T I E ROD J 05 FIG 39 F 10 POWER UNIT MODEL 90 95 QTY I REF NO PART NO DESCRIPTION REMARKS FIG 39 1 1 3 2 i I I 26 27 I 16 11 17 23 22 23 24 25 26 27 1 1 1 2 2 3 4 5 6 7 8 9 IO 11 12 13 14 15 16 17 18 19 19A 20 21 48500 94620 OED 48500 94690 OED 09280 09005 4851 1 95500 48502 94530 48550 94600 48581 94500 48583 94520 48585 94520 48593 94500 48586 94500 09280 70005 3 1281 946 10 3 1 170 946 1 0 OED 3 1 173 94620 31133 94610 31 1 10 94610 0ED 3131 1 94610 48570 9461 0 OED 33799 9461 0 33899 94600 091 08 081 30 091 40 0801 6 091 6248007 091 17 08074 481 31 95200 091 08 081 37 091 40 0801 6 091 62 08007 COLOR OED GRAY REFER TO FIGAO F 1 POWER UNIT ASSY POWER TRIM POWER UNIT ASSY POWER TRIM PLUG PUMPNALVE BOD
73. 140 811649 DT115 812175 DT140 811650 OPT DT115 812174 DT140 811649 17400 94602 u5e3 WITH 09420 05006 DT115 812175 DT140 811650 OPT 27 DT115 140 E3 D 2 LOWER COVER H 02 OPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 MAGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK D 04 O I L PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 O I L TANK 1 02 SENSOR 8 METER E 13 TRANSMISSION 6 08 bPT GASKET SET J 06 SILENCER CASE B 14 TR Ill CYLINDER F 12 PT METER J 02 SILENCER B 13 WATER PUMP D 02 OPT PANEL SWITCH J 03 BOLENOID E 15 FIG 20 1 23 4 20 I 24 CARBURETOR B 09 CLAMP BRACKET F 02 CLUTCH D 05 CRANKCASE B 02 CRANKSHAFT B 05 DRIVESHAFT HOUSING 6 03 LECTRICAL E 09 NGINE CONTROL UNIT E 14 I I I_I I __ ENGINE HOLDER 6 02 LOWER COVER H 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 FUEL INJECTOR C 10 MAGNETO E 04 UEL VAPOR SEPARATO C 09 OPT GASKET SET J 06 t IGNITION E 07 OPT PANEL SWITCH J 03 UEL PUMP C 05 OIL PUMP C 11 UEL TANK 1 03 O I L TANK
74. 189 92 MODEL93 97 MODEL 8S 97 608721 13204 94670 USED WITH 37810 9461 1 08321 21052 08322 21052 09125 05046 608722 MODELz86 88 MODEL189 97 651 200 MODEL186 88 MODEL 89 97 4HTIMODEL 86 88 4HT MODEL 89 97 B9 bPT WIRING HARNEW J 04 SWIVEL BRWKET F 05 OPTIONAL J 07 THROTTLE BODY C 04 POWER UNIT F 08 TH ROTTLE LINK D 04 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 SENSOR L METER E 13 TR ANSMISSIQN 6 08 SILENCER CASE B 14 TI I M CYLINDER F 12 TER PUMP D 02 D WITH 21 052 05046 FIG 6 I 31 FIG 6 B lo CARBURETOR DT115 QTY REF NO PART NO DESCRIPTION REMARKS 22 22A 23 28 29 28 27 9 13 14 15 _ I I 1 CARBURETOR 8 09 ENGINE HOLDER 6 02 CLUTCH D 05 FUEL INJECTOR C 10 CRANKSHAFT B 05 FUEL TANK 1 03 ELECTRICAL E 09 GE AR CASE 6 05 ENGINE CONTROL UNIT Em14 IGNITION E 07 CLAMP BRACKET F 02 EXHAUST COVER B 07 CRANKCASE B 02 FUEL PUHP C 05 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 5 24 25 1 25 2 26 27 28 1 28 2 29 30 1 30 2 30 3 31 32 13268 961 11 1 8395210 13240 94600 13240 94620 09492 82002 09492 65002
75. 2 13 14 15 i 6 17 18 19 20 21 22 23 1 23 2 24 32800 94601 03212 05303 08322 01057 32800 87EOO 32800 94610 32800 94620 32805 94600 01 550 06257 01 550 06207 32800 95001 03212 05253 08322 01 057 37875 9461 1 37875 94630 37875 9464 1 03212 05163 08322 01057 3792087D00 37920 94621 37922 9461 1 021 12 04087 0321 2 051 23 091 60 05024 37940 94701 09404 06432 03242 05103 32900 94602 32900 94640 03242 05253 39 DT115 140 E3 RECT amp REGULATOR ASSY 1 SCREW 1 WASHER 1 RECT amp REGULATOR ASSY 1 RECT amp REGULATOR ASSY 1 RECT amp REGULATOR ASSY 1 PLATE ASSY RECT amp REGULATOR 1 BOLT 2 BOLT 2 RECTIFIER ASSY 1 SCREW 1 WASHER 1 UNIT LOW OIL RESET 1 UNIT LOW OIL RESET 1 UNIT LOW OIL RESET 1 SCREW 1 WASHER 1 SWITCH ASSY IGNITION TIMING 1 SWITCH ASSY IGNITION TlMfNG 1 KNOB SCREW SCREW WASHER RESISTOR IGN TIMING CLAMP L 80 SCREW CDI UNIT CDI UNIT SCREW I 1 1 1 1 1 1 1 1 2 MODEL 86 88 MODEL 89 90 DTll5 461656 DT140 461585 MODEL 90 91 MODEL 91 94 MODEL 89 90 MODEL 91 00 MODEL 86 88 DTI 15 608698 DT140 608910 DTI 15 608699 711082 DT140 6089I 1 710784 DT115 811083 DT140 810785 MODEL 86 88 MODEL 89 90 MODEL 91 94 MODEL 91 94 MODEL 91 9
76. 2 43 44 45 46 47 48 38410 94540 38410 94551 36740 94720 09481 20001 0321 2 051 23 G9404 08205 09404 08206 36740 94771 09481 25001 36740 94620 09481 10001 36791 87E00 09408 00043 09407 08401 09408 00021 36610 94600 366 10 9463 1 3661 0 94640 36610 94670 3661 0 94680 37930 94706 33831 94630 021 12 36207 083 10 00067 021 12 36207 08310 00067 34820 94600 34853 94600 RELAY ASSY TRIM UP amp DN RELAY ASSY TRIM UP amp DN CASE ASSY FUSE BATTERY FUSE 20A SCREW CLAMP L 62 CLAMP L 82 CASE ASSY FUSE FUSE 25A CASE ASSY FUSE FUSE 10A HOLDER FUSE CASE HOLDER FUSE CASE CLAMP FUSE LEAD CLIP HARNESS ASSY WIRING HARNESS ASSY WIRING 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 HARNESS ASSY WIRING 1 HARNESS ASSY WIRING 1 HARNESS ASSY WIRING 1 SWITCH ASSY OIL WARNING RESET 1 CABLE ASSY TRIM RELAY 1 SCRFvV 1 NUT 1 SCREW 1 NUT 1 SENSOR ErJGlNE TEMP 1 SUPPORT ENGINE TEMP SENSOR 1 MODEL186 89 MODEL N OO MODEL 86 88 MODEL 86 88 MODELz89 92 DTl15 608590 DTl40 608910 DT115 608591 DT140 608911 MODEL 89 92 MODEL 93 96 DT115S 140EFI MODEL 86 88 MODEL 89 MODEL 89 E 10 __I I_ I _ _ I I I I_ _ I _ _ _ CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER
77. 251 1 9901 0 36894 94401 36894 95201 43111 94901 0ED 4321 1 95510 43740 94505 OED 09140 33002 09125 05050 091 60 33002 091 60 36004 09161 05114 091 66 33002 091 81 36005 09306 36002 05421 05006 41 220 95E 12 41221 95E40 41224 95E01 41 225 94400 41 228 95E00 41 230 95E00 091 60 06082 4 1 233 95E 1 C 091 25 06063 09140 10032 09204 01006 09440 19028 09160 12067 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21A 22 23 24 25 26 27 COLOR OED GRAY NIPPLE GREASE LEAD LEAD BRACKET SWIVEL BUSH SHAFT PILOT NUT SCREW 5x8 WASHER 33X60X3 0 WASHER 36 5X6OX2 0 WASHER 52x1 lXl O WASHER SHIM 36 3X60X0 3 BUSH KEY LEVER TILT LOCK LEVER TILT LOCK PORT BUSH TILT STOPPER ROD RUBBER TILT LOCK SPRING TILT LOCK LEVER LINK TILT LOCK LEVER WASHER 6 5X13Xl O BRACKET TILT LOCK SPRING SCREW 6x10 NUT PIN COITER SPRING WASHER 12 5X23Xl O 5 1 1 1 2 1 1 3 1 1 3 1 4 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 J 14 I 2 U 50 DTl15 140 E3 __ PRBURETOR B 09 HOLDER 6 02 HAUST COVER 8 07 CLUTCH D 05 CRANKCASE B 02 CRANKSHAFT B 05 DRIVESHAFT HOUSING 6 03 ELECTRICAL E 09 CLAM
78. 30 PUMP ASSY OIL 161 00 94620 PUMP ASSY OIL 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 4 3 2 1 DT115 DT140 MODELS 1A 1B 16091 94900 16092 92640 161 98 87000 16331 94601 16340 94610 16411 94611 1641 1 94601 19 31 95502 083 1 0 OOO57 16731 95520 0920W5017 071 3046307 16250 9471 0 16710 94641 1691 1 92E20 1691 1 92E20 16911 92E20 16911 92E20 09351 50803 OOA 09352 50903 600 09352 50903 600 09352 50903 600 09352 50903 600 09355 25705 600 BOLT GASKET O RING GEAR OIL PUMP DRIVEN RETAINER OIL PUMP ROD OIL PUMP CONTROL ROD OIL PUMP CONTROL CONNECTOR OIL PUMP COWT NUT GASKET OIL PUMP CONNECTOR OIL PUMP CONT BOLT SENSOR OIL CHECK VALVE PROTECTOR OIL HOSE PROTECTOR OIL HOSE PROTECTOR OIL HOSE PROTECTOR OIL HOSE HOSE OIL VALVE TO 3 WAY HOSE OIL SENSOR TO PUMP HOSE OIL SENSOR TO PUMP HOSE OIL TANK TO SENSOR HOSE OIL TANK TO SENSOR HOSE OIL PUMP TO VALVE 23 I 24 1c 2 3 4 1 4 2 5 DT115 DT140 Y 11 P 20 8 4 6 7 8 9 10 11 12 1 12 2 18 TYPE DOUBLE L 540 240 L 540 145 MODEL 97 L 540 145 L 540 4O MODEL 96 L lOo0 160 L 600 45 L 600 11O MODEL 97 L 600 270 L 600 180 MODEL 97 L 600 60 L 600 4O M
79. 31 31 356 09263 400 10 09283 40024 09390 80002 04221 04089 1 1431 94600 09280 70005 09282 24003 121 00 9461 1 025 121 40 95320 025 121 00 946 1 1 050 121 40 95320 050 PISTON RING SET PISTON PIN CI RCLl P BEARING 22X28X29 9 WASHER OIL SEAL UNDER 35X58X8 CRANKSHAFT ASSY CONNECTING FlOD PIN CRANK CRANKSHAFT UPPER WHEEL MlDDLE UNDER WHEEL MIDDLE UPPER CRANKSHAFT UNDER SEAL RING GEAR OIL PUMP DRIVE WASHER 30X50X1 BEARING CRANKSHAFT UNDER BEARING CRANK PIN BEARING CRANKSHAFT MIDDLE KEY OIL PUMP DRIVE GEAR WASHER OIL PUMP DRIVE UNDER WASHER OIL PUMP DRIVE UPPER CIRCLIP DRIVE GEAR BEARING UPPER SEAL CRANKSHAFl UPPER OIL C RING KNOCK PIN CRANKSHAFT BEARING HOUSING OIL SEAL 0 RING OIL SEAL UPPER 24X36X6 PlSTONlRlNG SET OS 0 25 RING SET PISTON OS 0 25 PISTON RING SET OS 0 50 RING SET PISTON 0S OSO 4 4 4 8 4 8 1 1 4 4 1 3 3 1 6 1 e 1 4 3 1 1 1 1 1 1 1 4 40X80X18 30X40X22 40X65X37 40X62X8 1 1 2 4 OPT 4 OPT 4 OPT 4 OPT 5 DT115 140E3 8 6 I ___ __ ll_ll_ _I_ LECTRICAL E 09 AR CASE 6 05 _ _I_ _ __ _l ROTTLE BODY C 04 ROTTLE LINK D 04 ANSHISSION 6 08 IH CYLINDER F 12 NGINE CONTROL UNIT E 14 IGN
80. 4 DT115608993 8 12886 DT140 609254 812249 DTll5 912900 DT140 912231 E9 _I i_ _ _ I I _I I_ __ _ _ _ _ I l____l_ ___ _ ___ CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 bPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 OPTIONAL J 07 ROTTLE BODY C 04 CLUTCH D 05 FUEL INJECTOR C lll YAGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK D 04 CRANKCASE B 02 FUEL PUMP C 05 OIL PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F O f RANKSHAFT B 05 FUEL TANK 1 03 I L TANK 1 02 SENSOR L HETER E 13 TR ANSMISSION 6 08 RIVESHAFT HOUSING G 03 amp PT GASKET SET 5 06 TR I H CYLINDER F 12 FUEL VAPOR SEPARATO C 09 SILENCER CASE B 14 I METER J 02 ILENCER B 13 PUHP 0 02 ENGINE CONTROL UNIT E 14 FGNITION E 07 i PANEL SWITCH 5 03 OLENOID E 15 LECTRICAL E 09 EAR CASE 6 05 FIG 29 FIG 29 E 10 ELECTRICAL M0DEL OO QTY REF NO PART NO DESCRIPTION REMARKS 40 DTl15H40 E3 25 26 28 29 30 31 1 31 2 32 33 34 35 36 37 38 39 40 1 40 2 40 3 404 40 5 41 4
81. 400 JET MAIN 160 SCREW SPRING CHAMBER ASSY FLOAT STUD BOLT NUT HOSE FUEL CLIP FUEL HOSE JET MAIN 145 JET MAIN 147 5 JET MAIN 152 5 JET MAIN 160 JET MAIN 167 5 ROD THROTLE CONTROL REPAIR KIT CARBURETOR 11 DT1151140 E3 2 2 1 1 1 1 4 4 1 1 4 8 8 2 4 1 1 1 1 1 2 1 TOPIMODEL 86 88 2NDIMODEL 86 88 3RDIMODEL 86 88 4MNODEL 86 88 TOP12N 013 RD14TH MODEL 89 96 651314 651 31 5 L 600 135 UPPER L 500 270 LOWER OPT OPT OPT OPT OPT OPT NOT SHOWN Is 12 I j ENGINE COVER H 05 IINTAKE MANIFOLD B 08 bPT T I E ROD J 05 I k T k T I N G MOTOR E 02 I FIG 8 11 11 I I 15 I 1 i 15 194 18 15 CARBURETOR B 09 CLAMP BRACKET F 02 CLUTCH D 05 CRANKCASE B 02 CRANKSHAFT B 05 DRIVESHAFT HOUSING 6 03 FNGINE CONTROL UNIT E 14 ELECTRICAL E 09 ENGINE HOLDER 6 02 EXHAUST COVER B 07 FUEL INJECTOR C 10 FUEL PUMP C 05 FUEL TANK 1 03 GEAR CASE 6 05 IGNITION E 07 FUEL VAPOR SEPARATO C 09 _ _ll_l LOWER COVER H 02 LUBRICATION HOSE C 02 MAGNETO E 04 OIL PUMP C 11 OPT GASKET SET J 06 OPT PANEL SWITCH J 03 O
82. 40TCN DT140TCP DT14OTCR DT14OTCS DT14OTCT DT14OTCV DT140TCW DT140TCX DT140TCY DT140TCl 89 90 91 92 93 94 95 96 97 96 97 98 99 00 01 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 ENGINE CONTROL UNIT E 14 IIGNITION E 07 bPT PANEL SWITCH J 03 IBOLENOID E 15 I 1 1502 L x 1 1502 L X 1 1 502 L X 1 1502 L X 1 1502 L I X L X 1 1 502 11502 L X 11502 L X 1 1502 L X 1 1 502 L X 1 1 503 L 1 1503 L 1 1503 L 1 1503 L 1 1503 L 1 1503 L 14002 L X 14002 L X 14002 L X 14002 L X 14002 L X 14002 L X 14002 L X 14002 L X 14002 L X 14002 L X 14002 L X 14003 L X 14003 L X 14003 L X 14003 L X 14003 L X 1 1502 81 1083 1 1 502 91 2900 1 1 502 01 1001 11502 131001 1 1 502 231 001 1 1 502 351001 1 1 502 461 001 11502 581001 1 1 502 651001 1 1 502 75 1001 1503 651001 1503 751001 1 503 861 001 1503 971 001 1503 030001 1503 1 51 001 4002 608049 4002 709261 4002 81 0785 4002 91 2231 4002 01 1001 14002 1 31001 14002 231001 14002 351001 14002 461 001 14002 581 001 14002 651001 14003 751 001 14003 861 001 14003 971 001 14003 030001 14003 1 51 001 A 1 r l___l_l_ _ _
83. 5 T I L T CYLINDER F 07 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 OPT GASKET SET J 06 SILENCER CASE B 14 TRIM CYLINDER F 12 CRANKSHAFT 8 05 FUEL TANK 1 03 O I L TANK 1 02 SENSOR amp flETER E 13 F FlG 50 3 F I G S H 9 ENGINE COVER MODELz89 94 QTY REF NO PART NO DESCRIPTION REMARKS CARBURETOR B 09 CLAMP BRACKET F 02 CLUTCH D 05 CRANKCASE B 02 DRIVESHAFT HOUSING G 03 ELECTRICAL E 09 ENGINE CONTROL UNIT E 14 CRANKSHAFT B 05 XHAUST COVER 8 07 UEL INJECTOR C 10 UEL PUMP C 05 UEL VAPOR SEPARATO C 09 EAR CASE 6 05 UEL TANK I 03 AGNETO E 04 I L PUMP C 11 PT GASKET ET J 06 PT PANEL SWITCH J 03 PT METER J 02 1 1 1 2 2 1 2 2 3 4 5 1 5 2 6 7 4 7 2 8 1 8 2 9 10 1 10 2 11 12 1 12 2 13 14 15 16 17 17A 18 19 20 21 22 61406 94865 OED COVER SET ENGINE 61406 94872 01T COVER SET ENGINE 61406 94896 OED COVER SET ENGINE 61407 94810 01T COVER SET ENGINE 61421 94601 2TN EMBLEM FRONT 61422 94640 019 MARK FRONT 61435 94620 706 MARK REAR 61435 94620 8EH MARK REAR 61435 94630 706 MARK REAR 61441 600 764 MARK SUZUKI 68181 17000 019 MARK SUZUKI 61442 9460
84. 50 06307 0831 0 COO87 08322 01087 65793 94600 091 00 0821 5 091 60 08082 PUMP ASSY FUEL DIAPHRAGM SET O RING INSULATOR FUEL PUMP FILTER ASSY FUEL ELEMENT SET CUP PROTECTOR 0 RING D 2 4 ID l 1 8 HOSE PUMP TO SEPARATOR HOSE FILTER TO PUMP HOSE CONN TO FILTER CLIP CLIP BOLT NUT WASHER HOLDER FUEL HOSE BOLT 8x16 WASHER 8 5X16X1 2 1 1 1 1 1 1 1 1 1 1 4 6 1 2 1 1 1 1 1 L 540 350 L 600400 L 600 200 L 6007230 MODELS 01 MODEL 01 MODEL 01 u 20 DTll51140 E3 C 8 _ __ _ _ ENGINE KOLDER 6 02 LOWER COVER H 02 PT WIRING HARNEW J 04 IVEL BRACKET F 05 IE XHAUST COVER B 07 LUBRICATION HOSE C 02 PTIONAL J 07 ROTTLE BODY C 0 4 __ ROTTLE LINK D 04 UEL PUMP C 05 I L PUMP EMOTE CONTROL BOX 1 05 CYLINDER F 07 In CYLINDER F 12 AR CASE 6 05 PT METER ILENCER B 13 PUHP D 02 UEL INJECTOR C 10 AGNETO OWER UNIT F 08 UEL TANK 1 03 I L TANK ENSOR L METER E 13 C 09 PT GASKET SET ILENCER CASE B 14 OLENOID E 15 ANSMISSION 6 08
85. 6 41 2 34870 94630 PIN 11 OX8 4X12 2 BOLT 6 BOLT 4 BOLT 18 STOPPER DRIVE GEAR 1 PLUG CRANKCASE NO l 1 PLUG CRANKCASE N0 2 3 PLUG OIL GEAR 1 STUD BOLT 2 WASHER 2 LOCK W 4SHER lO Wl8 4X2 5 2 NUT 2 SENSOR COOLING WATER 1 SENSOR COOLING WATER amp TEMP 1 41 3 34820 9461 0 SENSOR ASSY CYLINDER 1 NOTE FOR 97 99 E F I MODELS SEE FIGURE 30 COLOR OED GRAY 2 DTl151140 E3 REMARKS DT1151140 MODEL 96 11301 94640 OED USED WITH 17666 94600 1766594600 09128 06021 DT115 MODEL 97 DT115S MODEL 96 USED WITH 17666 94600 1766594600 091 28 06021 DTi i5S MODEL 97 DT14OEFI DTI 15S1140EFI MODEL 9801 11301 94910 0ED DT115 011278 DT140 01 1168 44870 94630 USED WITH 0321 2 05163 4 DT115 011279 DT140 011169 MODEL 92 96 SEE NOTE B 3 CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 PT WIRING HARNEW J 04 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 PTIONAL J 07 TH ROTTLE BODY C 04 CLUTCH D 05 FUEt INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 THROTTLE LINK D 04 CRANKCASE B 02 FUEL PUMP C 05 O I L PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 CRANKSHAFT B 05 FUEL TANK 1 03 O I L TANK 1 02 SENSOR L PETER E 13
86. 7 i PT PANEL SWITCH J 03 SO LENOID E 15 EXHAUST COVER 8 07 LUBRICATION HOSE C 02 OPTIONAL 5 07 TH ROTTLE BODY C 04 FUEL INJECTOR C 10 AGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK D 04 FUEL PUMP C 05 I L PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 CUEL TANK 1 03 I L TANK 1 02 SE NSOR L METER E 13 TR ANSMISSION 6 08 FUEL VAPOR SEPARATO C 09 PT GASKET SET J 06 SILENCER CASE B 14 TR In CYLINDER F 12 1 I _ _ ENGINE COVER H 05 IINTAKE MANIFOLD B 08 bPT t T I E ROD 5 05 IbTARTING MOTOR E 02 I FlG 3 8 6 CRANKSHAFT MODEL 01 FIG 3 Qn DESGRlPTION REMARKS REFJO PART NO 8 11 12 i i 34 13 12 I 10 DT115ii 30 E03 003 CRANKSHAFT 96 01 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 30 31 32 33 34 35 121 10 94611 121 40 87002 121 51 94601 09381 22004 09263 22063 091 81 22251 09283 35030 12200 94900 1 21 61 94900 1221 1 94610 1222 1 94900 12232 94900 12231 94900 12240 94900 12323 94600 16321 94600 091 60 30034 092624003 09263 3001 9 09269 40003 09421 10002 091 8 1 35 1 67 091 81 35240 083
87. 7DOo 0 RING 1 5 16331 94601 GEAR OIL PUMP DRIVEN 1 6 16340 94610 RETAINER OIL PUMP 1 7 16420 94900 CABLE OIL PUMP 1 8 1 643 1 WOO BRACKET OIL PUMP CASLE 1 9 16731 95520 GASKET OIL PUMP 1 10 071 30 06307 BOLT 2 11 16250 9471 0 SENSOR OIL 1 12 1 1671 0 94641 VALVE CHECK OIL 12 2 13 1691 1 92E20 PROTECTOR 1 DOUBLE SINGLE 16710 92E01 VALVE CHECK OIL 1 MODEL 00 01 1 L 540 90 PROTECTOR 1 L 540 110 PROTECTOR 1 L 540 145 14 1691 1 92E20 15 1691 1 92E20 16 09351 50803 00A HOSE OIL VALVE TO SEPARATOR 1 L 1000 290 17 09352 50903 600 HOSE OIL SENSOR TO PUMP 1 L600 110 18 09352 50903 600 HOSE OIL TANK TO SENSOR 1 L 600 180 20 09401 06405 CLIP 2 21 09401 07403 CLIP 2 22 09401 0841 1 CLIP 4 23 09404 08205 CLAMP 2 19 09355 25705 600 HOSE OIL PUMP TO VALVE 1 L 600 150 26 DT115 140 E3 C 14 ECTOR P K OR SEPARATO E FIG 19 19 18 23 CARBURETOR B 09 ENGINE HOLDER 6 02 CLAMP BRACKET F 02 EXHAUST COVER B 07 CLUTCH D 05 FUEL INJECTOR C 10 CRANKCASE 8 02 FUEL PUMP C 05 CRANKSHAFT B 05 FUEL TANK 1 03 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 ELECTRICAL
88. 8HS CABLE ASSY STARTER CLAMP L 50 CLAMP L 125 BOLT 1 4 4 4 4 1 4 1 4 4 4 4 4 1 1 4 1 38 DT115 40 E3 _ I lll_ CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 RANKCASE 8 02 FUEL PUMP C 05 OIL PUMP C 11 RANKSHAFT B 05 FUEL TANK 1 03 TANK 1 02 RIVEWAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 GASKET SET J 06 LECTRICAL E 09 GEAR CASE 6 05 METER 5 02 NGINE CONTROL UNIT E 14 IGNITION E 07 PANEL SWITCH J 03 bPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 OPTIONAL J 07 TH ROTTLE BODY C 04 ROTTLE LINK D 04 POWER UNIT F 08 TH SENSOR amp METER E 13 TR ANSHISSION 6 08 SILENCER CASE B 14 TR In CYLINDER F 12 SILENCER B 13 WATER PUMP D 02 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 SOLENOID E 15 FIG 29 I 51 26 FIG 29 E 9 ELECTRICAL M0DELL OO QW REF NC PART NO DESCRIPTIO amp REIMAMS 1 2 3 4 5 1 5 2 6 7 1 7 2 8 9 10 11 1 11 2 11 3 1
89. 9 NOT SHOWN MODEL 90 MODEL 91 MODEL 92 MODEL93 MODEL 94 MODEL 95 MODEL 96 DTI 15 MODEL97 DT115S DT115S MODEL 97 DT 140EFI DT115S1140EFI MODEL 98 MODEL99 DT115S 140EFI M0DEL OO DT115S1140EFI M0DEL Ol D i i 15SiiJOEFI J7 RBURETOR B 09 6 02 ILOWER COVER PT WIRING HARNEW 9 04 SWIVEL BRACKET F 05 LAMP BRACKET F 02 B 07 LUBRICATIOH HOSE PTIONAL J 07 ROTTLE BODY C 04 C 10 In AGNETO OWER UNIT F 08 TH ROTTLE LINK D 04 EUTCH D 05 RANKCASE B 02 UEL PUMP C 05 P I L PUHP C 11 CONTROL BOX 1 05 CYLINDER F 07 RIVESHAFT HOUSING 6 03 UEL VAPOR SEPARATO C 09 EPT GASKET SET J 06 CASE B 14 ANSHISSION 6 08 I M CYLINDER F 12 NSOR amp METER E 13 RANKSHAFT B 05 UEL TANK 1 03 I L TANK 1 02 E I I METER J 02 ILENCER B 13 PUHP D 02 PANEL SWITCH J 03 It OLENOID E 15
90. 9140 06020 09164 13005 03242 041 03 03542 061 63 08322 0 1067 61440 94900 68111 42031 1RR 61463 94900 6 1581 9861 0 61421 94601 2TN 61422 94640 01 9 61487 94602 03242 051 23 33242 051 23 69711 93E10 09800 01001 77 DT115 i40 E3 _ _ _ ___ LOWER COVER H 02 PT WIRING HARNEW J 04 LUBRICATION HOSE C 02 PTIONAL J O f AGNETO E 04 OWER UNIT F 08 I L PUMP C 11 EMOTE CONTROL BOX 1 05 I C TANK 1 02 SENSOR amp WETER E 13 PT GASKET SET J 06 SILENCER CASE B 14 PT METER J 02 SILENCER B 13 PT PANEL SWITCH 5 03 SO LENOID E 15 COVER SET ENGINE GRAY HOLDER HOOK RIVET WASHER HANDLE TILT UP GRAY LID OIL TANK FILLER GRAY HINGE OIL FILLER LID SPRING OIL FILLER LID CAP ENGINE COVER PAD OIL FILLER LID HOOK FRONT HOOK REAR LEVER HOOK GRAY STRIKER OIL FILLER LID BOLT SCREW NUT WASHER WAVE SCREW SCREW WASHER DECAL SET ENGINE COVER MARK SUZUKI GOLD DECAL EMGINE COVER REAR MAR amp CkFETY WARNING COVER INTAKE GOLDIGMY MARK EMBLEM FR BLACK COVER INTAKE INNER SCREW FRONT EMBLEM SCREW INNER COVER LABEL CAUTION TOOL ASSY 1 2 10 10 1 1 1 1 1 1 1 1 2 1 2 2 2 2 2 4 4 1
91. AY BRUSH 31 133 94521 31 110 94520 0ED YOKE ASSY GRAY 53 DTl15 14O E3 31 31 1 94600 09407 14403 48583 94520 09282 08003 33861 95600 09708 08130 091 00 0821 9 09140 08016 091 62 08007 38423 9551 0 48131 95200 09108 081 37 09140 08016 091 62 08007 ARMATURE CLAMP DRIVE JOINT OIL SEAL 8X22X7 CABLE PlT STUD BOLT 820 BOLT 8x22 NUT LOCK WASHER TUBE P l l MOTOR CABLE SPACER STUD BOLT 8x35 NUT LOCK WASHER 8 2X15 4X2 _ I ___ __I _I _ __ ____I I_ _ 2 1 1 2 1 1 2 1 1 1 2 1 2 3 1 1 3 3 3 MODEL 87 89 L 1000 0PT PORT SIDE 0PT PORT SIDE 0PT PORT SIDE 0PT PORT SIDE F 9 CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 PT WIRING HARNEW J 04 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 PTIONAL J 07 TH ROTTLE BODY C 04 SLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 OWER UNIT F 08 TH ROTTLE LINK D 04 NSOR amp flETER E 13 TR ANSMISSION 6 08 RIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 gPT GASKET SET J 06 I ILENCER CASE B
92. DE HOUSING PIN BOLT 8x35 ROD SHIFT L ROD SHIFT L ROD SHIFT X ROD SHIFT X 1 2 2 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 1 1 1 DTll5S 971 072 DTl40EFI L 971110 DT140EFI X 971202 NPE L NPE X TYPE X TYPE X M0DEL Ol MODEL MODEL 95 00 DT115 709842 DT140 709964 DT115 709843 DT1 709965 DTI 15 708842 DT140 709964 DT115709843 DT140 709965 4251 1 1 94503 USED WITH 09160 081 19 2 DT115S 971072 DT140EFI 971 110 25111 94511 USED WITH 09160 081 19 2 DT115S 971 072 DTIrtOEFI 971202 D 5 _ _ _ _ _ _ I _ _ _ IVEL BRACKET F 05 ROTTLE BODY C 04 ROTTLE LINK D 04 1LT CYLINDER F 07 ANSMISSION 6 08 In CYLINDER F 12 PUMP D 02 081 19 2 081 19 2 FIG 22 0 6 CLUTCH FIG 22 QTY REF NO PART NO DESCRIPTION REMARKS 20 09280 08008 0 RING INNER D 3 5 ID 7 8 2 21 09280 1 5003 0 RING OUTER D 1 9 ID 14 5 1 22 25211 94501 GUIDE SHIFT ROD 1 23 091 604901 5 WASHER 9X19X1 1 24 25205 94501 COLLAR SHIFT ROD SPRING 1 25 25311 94510 CAM CLUTCH 1 26 091 60 090 1 0 WASHER 9X30X1 6 1 27 09205 02004 PIN L l2 1 28 09205 02006 SPRING PIN 1 29 09205 03021 SPRING PIN 1 30 09260 1 0005 BALL CAM NOTCH 1 31 09284 08003 DUST SEAL 8X19X4 5 1 20 4 32 0944
93. EEDOMETER SENDER SPEEDOMETER SCREW GAUGE ASSY FUEL GAUGE FUEL LEAD FUEL GAUGE ADAPTER FUEL GAUGE BULB METER ASSY HOUR BULB METER ASSY VOLTAGE BULB GAUGE ASSY WATER PRESSURE TUBE BAND UNION GROMMET BULB CUSHION TERMINAL amp SLEEVE SET 1 STD 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 MAX 80MM MAX 50MIH MAX 45KNOTS NOT FOR U S MARKET NOT FOR U S MARKET NOT FOR U S MARKET NOT FOR US MARKET 30p51 86 DTll5l140 E3 12 1 LOWER COVER H 02 PT WIRING HARNEW J 04 SWIVEL BRACKET F 05 UBRICATION HOSE C 02 PTIONAL J 07 TH ROTTLE BODY C 04 AGNETO E 04 OWER UNIT F 08 TH ROTTLE LINK D 04 I L PUMP c 11 EMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 I L TANK 1 02 ENSOR amp flETER E 13 TR ANSHISSION 6 08 PT GASKET SET J 06 SILENCER CASE B 14 TR I N CYLINDER F 12 PT METER J 02 SILENCER B 13 WATER PUMP D 02 OPT PANEL SWITCH 5 03 SOLENOID e E 15 PT T I E ROD 5 05 6TARTING flOTOR E 02 a F16 59 FIG 59 J 4 OPT WIRING HARNESS QTY REF NO PART ti0 DESCRIPTION REMARKS I 34109 94500 LEAD METER EXTENSION 1 2 36640 95500 WIRING HARNESS CONTROL 1 L 5000 3 3661596300
94. ER 3 WAY L 6 0 0 4 MODEL L 600 4d 3 WAY PU M P L 600 200 MODEL L 600 280 PUMP CARB L 600 390 PUMP CARB L 600 230 CONNECTOR FILTER 15410 95540 DT115 581617 dt140 581 497 MODEL C6 I I I _ I _ I _ _ _ l l_ll l CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 bPT WIRING HARNEW 5 04 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK D 04 RANKSHAFT B 05 FUEL TANK 1 03 O I L TANK 1 02 NSOR amp METER E 33 TR ANSMISSION 6 08 RIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 GASKET SET J 06 LENCER CASE B 14 TR In CYLINDER F 12 RANKCASE B 02 FUEL PUMP C 05 O I L PUMP C 11 MOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 LECTRICAL E 09 GEAR CASE 6 05 i METER J 02 LENCER B 13 WATER PUMP D 02 1 kNGIME CONTROL UNIT E 14 IGNITION E 07 PT PANEL SWITCH J 03 OLENOID E 15 I _ ENGINE COVER H 05 INTAKE MANIFOLD 8 08 PT T I E ROD 5 05 TARTING MOTOR E 02 FIG 12A
95. GE OIL FILLER LID SPRING OIL FILLER LID CAP ENGINE COVER PAD OIL FILLER LID HOOK FRONT HOOK REAR LEVER HOOK GRAY STRIKER OIL FILLER LlG BOLT SCREW NUT WASHER WAVE SCREW SCREW WASHER DECAL ENGINE COVER STBD DECAL ENGINE COVER PORT MARK SUZUKl GOLD DECAL ENGINE COVER REAR COVER INTAKE GRAYIGOLD MARK EMBLEM FRONT BLACK COVER INTAKE INNER SCREW FRONT EMBLEM SCREW INNER COVER LABEL CAUTION MARK SAFETY WARNING LABEL ENGINE COVER TOOL ASSY 1 2 10 10 1 1 1 1 1 1 1 1 2 1 2 2 2 2 2 4 4 1 1 2 1 1 1 1 4 4 1 1 1 1 M0DEL Ol H 03 __ I __I _ _ _ _ _ CASE ELECTRICAL E 09 GE AR CASE 6 05 3PT METER J 02 ENGINE CONTROL UNIT E 14 IGNITION E 07 OPT PANEL SWITCH J 03 i 9 4 h 1 FIGS3 c I 2 15 1 F I G S I 2 OIL TANK QTY DESCRIPTION REMARKS REF NO PART NO 1 2 3 4 5 6 7 8 9 10 1 10 2 11 1 11 2 11 3 114 691 10 94602 69200 94510 69241 94500 6931 1 94610 0 1550 08 1 67 6931 2 94600 09329 1 2004 69361 94602 TANK OIL CAP ASSY OIL TANK FILLER GASKET SUPPORT OIL TANK BOLT SUPPORT CUSHION U
96. GEAR CASE 6 05 OPT METER J 02 1 1 1 20 2 5 2 1 1 1 1 4 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 MODEL 97 01 MODELz97 01 MODEL 97 01 DT115 140 DT140 131262 DT140 131263 DT140EFI DT115S DTllm40 DT140 131 262 DT140 i31263 DTI40EFI DT115S DT115S1140EFI DT115S 140EFI B2 bPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 OPTIONAL J 07 TH ROTTLE BODY C 04 POWER UNIT F 08 TH ROTTLE LINK D 04 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 SENSOR 8 METER E 13 TR ANSMISSION 6 08 SILENCER CASE B 14 TR Ill CYLINDER F 12 SILENCER B 13 WATER PUHP D 02 FIG l FIG 1 8 3 CRANKCASE Qn DESCRIPTION REF NO PART NO 23 11231 94602 OED COVER CYLINDER WATER JACKET 1 24 1 1232 9461 0 GASKET WATER JACKET 1 25 01 570 06207 BOLT 2 26 1 11301 94625 OED CYLINDEWCRANKCASE ASSY 1 26 2 11301 94640 OED CYLINDEWCRANKCASE ASSY 1 26 3 11301 94900 OED CYLINDERICRANKCASE ASSY 1 26 4 11307 949iO OED CYLINGEWCMNKCASE A S S 1 26 5 11301 9492O OED CYLINDERICRANKCASE ASSY 1 27 0421 1 1 1129 30 01 560 10557 31 01560 10757 32 01 550 08407 33 1635 1 9461 0 34 1 131 5 94600 35 1 131 6 94600 1636 1 94600 37 091 08 10026 38 08322 01107 39 09162 1r3005 40 09140 10031 41 1 34870 94614 3
97. GNETO E 04 O I L PUMP C 11 3PT GASKET SET J 06 OPT METER J 02 DPT PANEL SWITCH J 03 OIL TANK 1 02 28 9 28 1 0 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 37141 92E60 37141 92E70 37141 92E80 37141 92E90 67297 95600 67273 95600 38500 92x50 36620 92E00 37820 92E00 37823 92E00 67255 95600 67261 956CO 37860 9361 0 37869 95590 091 39 02003 67263 95600 67245 95600 67258 87wO 67259 87wO 671 40 95600 67282 9561 0 85 DT115 140 E3 I _I I bPT WIRING HARNEW J 04 PTIONAL J 07 OWER UNIT F 08 REMOTE CONTROL BOX 1 05 SENSOR amp METER E 13 SILENCER CASE B 14 SILENCER 8 13 SOLENOID E 15 1 KEY 17 1 KEY 18 1 KEY 19 1 KEY 20 1 WASHER 2 SPACER 1 BUZZER 1 WIRING HARNESS 1 SWITCH ASSY EMERGENCY 1 PLATE 1 ARM NEUTRAL LOCK 1 GRIP 1 SWITCH TRIM 1 CAP TRIM SWITCH 1 SCREW 2x6 2 CAP GRIP 1 DRUM FREE THROTTLE 1 BRACKET NEUTRAL ARM 1 SPRING NEUTRAL ARM 1 ATTACHMENT TWIN REMOCON KIT 1 DECAL REMOCON BOX PORT 1 0 PT B LACK 18 SWIVEL BRACKET F 05 THROTTLE BODY C 04 THROTTLE LINK D 04 T I L T CYLINDER F Of TRANSMISSION 6 08 TRIM CYLINDER
98. I L TANK 1 02 OPT METER J 02 FIG 8 B 13 SILENCER QTY REF NO PART NO QESCRUPTION REMARKS 1 2 3 1 3 2 4 5 6 7 1 7 2 8 1 8 2 9 10 11 12 13 14 15 16 17 18 19 1 3855 933 1 0 13855 9521 0 1381 1 9461 1 13811 94601 0832241 067 08321 01067 01 107 06657 08321 01067 08321 01 067 0 1 550 06 1 67 01550 06167 13853 94510 138 12 94504 021 42 05207 02142 05357 09250 1 50 10 0 1550 05457 09401 06405 09355 30705 600 09355 30705 600 0940448420 16710 9521 1 GASKET SILENCER GASKET SILENCER CASE SILENCER CASE SILENCER WASHER LOCK WASHER BOLT LOCK WASHER LOCK WASHER BOLT BOLT GASKET SILENCER COVER COVER SILENCER SCREW SCREW PLUG D1 15 D2 19 BOLT CLIP HOSE 3 1X6 8X600 HOSE 3 1X6 8X600 CLAMP L 137 CHECK VALVE DT115 231514 DT140 231403 REFER TO FIG 9 8 14 FOR DT115 231515 DT1401231404 12 DT415 140 E3 4 4 1 1 1 1 1 11 8 11 8 1 1 4 6 4 4 4 1 1 1 1 DT115 DT140 DT115 DT140 DT115 DT140 DT115 DT140 L 600400 L 600 120 B 13 OPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 OPTIONAL J 07 TH ROTTLE BODY C 04 POWER UNIT F 08 TH ROTTLE LINK D 04 REMOTE CONTROL BOX 1 05 T I L T CYLINDER
99. ID SPRING PAD CAP ENGINE COVER COVER FRONT EMBLEM INNER SCREW HOLDER FRONT HOOD RIVET WASHER BRACKET COVER LOCATING RIVET STRIKER ASSY OIL FILLER LID CAP STRIKER SCREW STRIKER TOOL SET 1 1 2 2 2 1 2 2 1 1 1 1 1 1 4 1 5 5 1 H 10 __ I _ I I _ _I _ I _I__ __I_ _I CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 OPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 ZLAMP BRACKET F 02 EXHAUST COVER 8 07 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 LUTCH D 05 FUEL INJECTOR C 10 AGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK D 04 RIVESHAFT HOUSING G 03 UEL VAPOR SEPARATO C 09 EPT GASKET SET J 06 ZLENCER CASE 8 14 TR In CYLINDER F 12 RANKCASE B 02 FUEL PUMP C 05 I L PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 RANKSHAFT B 05 UEL TANK 1 03 b TANK 1 02 NSOR amp METER E 13 TRANSMISSION 6 08 FIGS1 FIGS1 H 1 1 ENGINE COVER MODEL95 97 QTY 5 I REF NO PART NO DESCRIPTlON REMARKS 1 2 3 4 5 6 7 8 9 10 11 11A 12 13 14 15 16 17 18 19 20 21 22 23 24 25
100. ITION E 07 PT PANEL SWITCH J 03 NGINE COVER H 05 INTAKE MANIFOLD 8 08 PT TIE ROD 5 05 I FIG 4 9 7 1 FIG 4 B 7 EXHAUST COVER QTY REF NO PART NO DESCRIPTION REMARKS 2 18 P 17 1 1 1 2 2 3 4 1 4 2 4 3 4 4 5 6 7 8 9 11 12 13 14 15 16 17 18 P 15 16 13125 93010 13125 95210 08316 10087 01421 08357 1 31 1 0 9461 1 131 10 946VO 131 10 94601 13110 946V1 1 31 21 945 1 0 13150 94502 131 52 9450 1 131S MOO 021 12 33083 13156 9451 1 141 51 945 10 14131 94503 14141 94500 OED 01550 06357 36895 94400 09404 08205 09404 08206 GASKET CARBURETOR GASKET CARBURETOR NUT STUD BOLT CASE INLET CASE INLET CASE INLET CASE INLET GASKET INLET CASE VALVE ASSY REED STOPPER ALE REED SCREW GASKET REED VALVE GASKET EXHAUST COVER PLATE EXHAUST COVER EXHAUST BOLT LEAD ENGINE GROUND CLAMP L 62 CLAMP L 82 COLOR OED GRAY REFER TO FIGS B 8 FOR DTl1 5S 140EFI 4 4 16 16 1 1 1 1 4 4 16 16 32 4 2 1 1 23 1 1 1 DT115 1D 34 DT1 40 ID 41 DT115 DTl15 MODEL95 97 dt140 DT140 MODEL 95 96 6 DT1151140 E3 B7 I I__ I ____ _ _ _ I __ _ __ ___ ___ _ __ _ _ I CARBURET
101. KET 5 8X13X1 2 UNION OUTLET CHECK VALVE CHECK VALVE HOSE 5XSXlOOO PROTECTOR HOSE 2 5X7X600 HOSE 2 5xIX600 PROTECTOR HOSE 5X8X1000 REFER TO FIG 17 2 13 FOR MODEL 95 97 REFER TO FIG 18 C 14 FOR DT115S 140EFI 1 1 1 1 8 12 8 4 2 2 2 1 1 1 1 1 1 1 1 4 8 4 1 3 1 1 1 1 1 3 dt115 DTI 40 011729 DT115 DT140 TYPE SINGLE TYPE DOUBLE L 1 0004 1 00 L 540 30 L 600 350 MODEL 86 90 L 600 350 MODEL 91 94 L 540 340 L 100045 23 DT1151140 E3 c 11 _I_ __ _ _ _ _ CARBURETOR 8 09 ENGINE HOLDER 6 02 LOWER COVER H 02 bPT s WIRING HARNEW J 0 4 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 EXHAUST COVER 8 07 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 THROTTLE LINK D 04 RANKCASE B 02 FUEL PUMP C 05 OIL PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 RANKSHAFT B 05 FUEL TANK 1 03 OIL TANK 1 02 SENSOR amp METER E 13 TR ANSHISSION 6 08 RIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 OPT GASKET SET J 06 SILENCER CASE 8 14 TR IM CYLINDER F 12 NGIHE C
102. L PUMP C 05 O I L PUMP C 11 CRANKSHAFT B 05 FUEL TANK 1 03 TANK 1 02 DRIVESHAFT HOUSING G 03 FUEL VAPOR SEPARATO C 09 GASKET SET J 06 AR CASE 6 05 METER J 02 ENGINE CONTROL UNIT E 14 IGNITION E 07 PANEL SWITCH J 03 ELECTRICAL E 09 GE 13 DT115 140 E3 B 14 PTIONAL OWER UNIT EMOTE CONTROL BOX ENSOR amp METER ILENCER CASE ILENCER OLENOID J 04 J 07 F 08 1 05 E 13 8 14 B 13 E 15 kWIVEL BRACKET F 05 THROTTLE BODY C 04 THROTTLE LINK D 04 T I L T CYLINDER F 07 TRANSMISSION 6 08 TRIM CYLINDER F 12 WATER PUMP 0 02 U 14 DT 09355 35755 600 09355 35755 600 09355 35755 600 09355 35755 600 09355 35755 600 09367 04002 09401 07101 1 671 0 9521 1 09403 1 2308 HOSE LUBRICATION HOSE LUBRICATION HOSE LUBRICATION HOSE LUBRICATION HOSE LUBRICATION 3 WAY CLIP VALVE CHECK CLAMP 12 1 1 1 1 4 32 4 2 REFER TO FIG 9B C 3 FOR DT115S1140EFI MODEL 97 01 151140 E3 L 600 50 L600 320 L 6 0 0 4 0 L 60040 L 6 0 0 4 6 0 c 2 _ __ I FIG 9B _ _ __ CARBURETOR B 09 CLAMP BRACKET F 02 CLUTCH D 05 CRANKCASE B
103. MOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 ANKSHAFT B 05 FUEL TANK 1 03 I L TANK 1 02 SE NSOR amp flETER E 13 TR ANSMISSION 6 08 RIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 PT GASKET SET J 06 SILENCER CASE B 14 TR Ifl CYLINDER F 12 T LECTRICAL E 09 GEAR CASE 6 05 E PT METER J 02 SILENCER 8 13 rJATER PUMP D 02 ENGINE CONTROL UNIT 1 4 IIGNITION E 07 P T PANEL SWITCH J 03 I LENOID E 15 I I I F I G S 1 I 1 I 16 15 I 20 I 17 i A 44 _ LAMP BRACKET F 02 LUTCH D 05 RANKCASE B 02 RANKSHAFT B 05 RIVESHAFT HOUSING 6 03 LECTRICAL E 09 NGINE CONTROL UNIT E 14 kNGINE HOLDER 6 02 EXHAUST COVER 8 07 FUEL INJECTOR C LO FUEL PUMP C 05 FUEL TANK 1 03 FUEL VAPOR SEPARATO C 09 GEAR CASE 6 05 IGNITION E 07 32 FIGS5 I 5 REMOTE CONTROL BOX QTY REF NO PART NO DESCRIPTIOK REMARKS 1 1 1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 15 2 1G 17 18 19 20 21 22 1 22 2 23 672OO 87D12 02M REMOTE CONTROL BOX ASSY 1 67200 87020 OED REMOTE CONTROL BOX ASSY 1 67232 95600 67232 95620 67296 95600 67294 95600 091 60 06104 091 40 06020
104. NETO E 04 LAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 CRANKCASE B 02 FUEL PUMP C 05 OIL PUMP C 11 CRANKSHAFT FUEL TANK 1 03 O I L TANK e 1 02 B 05 PRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 OPT USKET SET 5 06 1 3201 946370 13201 946A4 13202 94682 13202 946A3 13203 WA3 1 3204 946 1 1 13204 94670 13204 946A3 13269 9331 1 13271 9331 1 0949f 26013 09491 27014 13235 94350 13236 96300 13237 94400 13392 58600 13370 281 10 13254 98300 13250 93012 13251 93320 09162 05202 021 12 05207 1361 6 94500 13271 9331 1 378 10 9461 1 3781 0 95606 021 12 041 63 13606 18E00 13267 93900 CAREURETOR TOP CARBURETOR TOP CARBURETOR 2ND CARBURETOR 2ND CARBURETOR 3RD CARBURETOR 4TH CARBURETOR 4TH REFER TO FIG 7 8 11 FOR UTI40 8 DT115 140 E3 CARBURETOR 4TH ADJUSTOR SPRING MAIN JET 1 32 5 MAIN JET 1 37 5 NOZZLE NOZZLE MAIN NOZZLE GASKET VALVE EAT VALVE NEEDLE PIN FLOAT GASKET LOCK WASHER SCREW SCREW DRAIN SPRING SENSOR ASSY THROTTLE LEVER SENSOR ASSY THROTLE LEVER SCREW LOCK WASHER SCREW 1 1 1 1 1 1 1 1 4 4 4 4 4 4 4 4 4 4 4 4 16 16 4 4 1 1 2 2 1 MODEL 86 138 MODEL189 97 MODEL
105. NK 1 02 DRIVESHAFT HOUSING G 03 C 09 JPT F C SET J 06 6 05 OPT I R o J 0 2 ENGINE CONTROL UNIT E 14 E 07 OPT 8 EL SWITCH J 0 3 ENGINE COVER H 05 B 08 OPT z I l E ROD J 05 ELECTRICAL E 09 PTIONAL OWER UNIT EMOTE CONTROL BOX ENSOR amp METER 1 4 4 4 4 4 4 4 4 4 4 4 4 4 16 16 4 4 1 1 MODEL 86 88 MODEL39 96 MODEL 88 MODEL 89 96 MODEL186 88 MODEL39 96 608910 13204 94660 USED WITH 37810 94601 08321 21052 08322 21052 09125 05046 MODELz86 88 60891 1 812886 MODEL 89 96 MODEL 86 88 MODEL39 92 MODEL 93 96 MODELz86 88 MODEL 89 96 4HT MODEL 86 88 4HT MODEL 89 96 J 04 SWIVEL BRACKET F 05 J 07 TH ROTTLE BODY C 04 F 08 TH ROTTLE LINK D 04 1 05 T I L T CYLINDER F 07 E 13 TR ANSMISSION 6 08 ILENCER CASE B 14 TR I H CYLINDER F 12 ILENCER B 13 WATER PUMP D 02 E OLENOID E 15 FIG7 31 __ CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 OPT WIRING HARNEW 5 04 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 CLUTCH D 05 FUEL INJECTOR C 10 HAGNETO E
106. NKSHAFT B 05 DRIVESHAFT HOUSING 6 03 ELECTRICAL E 09 ENGINE CONTROL UNIT E 14 _ I l_ NGINE HOLDER 6 02 LOWER COVER H 02 UEL INJECTOR C 10 MAGNETO E 04 UEL VAPOR SEPARATO C 09 OPT GASKET SET J 06 i IGNITION E 07 OPT PANEL SWITCH J 03 XHAUST COVER 8 07 LUBRICATION HOSE C 02 UEL PUMP C 05 OIL PUMP C 11 UEL TANK 1 03 31L TANK 1 02 AR CASE 6 05 OPT METER J 02 FIG 56 I 7 REMOTE CONTROL BOX MODEL93 01 QTY REF NO PART NO DFSCRIPTION REMARKS 1 67200 87D30 OED REMOTE CONTROL ASSY 1 2 67232 95600 BUSH 1 3 67232 95620 BUSH 1 4 67296 95600 SCREW 3 3 SPACER 5 67294 95600 6 09160 06104 WASiER 3 7 09140 06020 NUT 3 8 67232 956 10 BUSH 1 9 67253 95600 WASHER 1 10 11 12 13 14 15 16 17 18 67252 95600 09 1 00 08232 67214 95600 67296 94300 37721 94600 67241 95680 091 26 05003 67243 95600 67220 95620 BUSH 1 BOLT 1 ACTUATOR 1 3 SCREW SWITCH NEUTRAL 1 LEVER FREE THROllLE GRAY 1 SCREW 2 BUSH 1 PLATE ASSY 1 19 67275 95600 END CABLE 2 20 67223 95600 KNOB BRAKE ADJUST 1 21 67292 94300 E RING 3 22 67267 95610 COVER WIRE BLACK 1 SCREW 23 67296 956 10 24 67257 95610 CAP
107. ODEL 97 MODELS 7 I 2 16 2 17 1 17 2 18 1 3 18 2 19 20 21 22 23 24 25 09355 25705 600 09367 08005 09401 06405 09401 08409 09401 08411 09404 08205 09408 00024 1691 1 92E20 HOSE OIL PUMP TO VALVE 3 WAY CLIP CLIP CLIP CLAMP CLIP PROTECTOR SENSOR TO PUMP MODEL95 L 540 90 MODEL 97 25 DT115 140 E3 C 13 lt CARBURETOR 9 09 ENGINE HOLDER 6 02 LOWER COVER H 02 OPT WIRING HARNEW 5 04 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 EXHAUST COVER 8 07 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 CLUTCH 0 05 FUEL INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK D 04 CRANKSHAFT 9 05 FUEL TANK 1 03 O I L TANK 1 02 SENSOR L CIETER E 13 TR ANSHISSION 6 08 PRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 OPT GASKET SET 5 06 SILENCER CASE 0 B 14 TR I M CYLINDER F 12 CRANKCASE 9 02 FUEL PUMP C 05 O I L PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 e ATER PUMP D 02 FIG 18 C 14 OIL PUMP DT115S1140EFI FIG1 8 QTY REF NO PART NO DESCRIPTION REMARKS 1 16100 94900 PUMP ASSY OIL 1 2 16191 94900 SCREW 1 3 16092 92440 GASKET 1 4 161 98 8
108. ONTROL UNIT E 14 IGNITION E 07 OPT PANEL SWITCH J 03 SOLENOID E 15 LECTRICAL E 09 GE AR CASE 6 05 OPT METER 5 02 SILENCER B 13 WATER PUHP 0 02 NGINE COVER H 05 INTAKE ANIFOLD B 08 OPT T I E ROD J 05 STARTING HOTOR E 02 FIG 16 kARBURETOR e B 09 ENGINE HOLDER 6 02 CLAMP BRACKET F 02 EXHAUST COVER B 07 CLUTCH D 05 FUEL INJECTOR C 10 CRANKCASE B 02 FUEL PUMP C 05 CRANKSHAFT 8 0 5 FUEL TANK 1 03 DRIVESHAFT HOUSING G 03 FUEL VAPOR SEPARATO C 09 ELECTRICAL E 09 GEAR CASE 6 05 c ENGINE CONTROL UNIT E 14 FIG 16 C 12 OIL PUMP MODELM IGNITION E 07 QTY I O P T LUBRICATION HOSE C 02 MAGNETO E 04 OIL PUMP C 11 TANK 1 02 PT GASKET SET J 06 PT METER J 02 PT PANEL SWITCH J 03 J REMARKS REF NO PART NO DFSCRIPl ION WIRING HARNEW J 04 SWIVEL BRACKET F 05 OPTIONAL J 07 TH ROTTLE BODY C 04 POWER UNIT F OS THROTTLE LINK D 04 REMOTE CONTROL BOX 1 05 TILT CYLINDER F 07 SENSOR amp METER E 13 TR ANSMISSION 6 08 SILENCER CASE B 14 TR I H CYLINDER F 12 SILENCER B 13 dATER PUMP D 02 SOLENOID
109. OR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 PPT WIRING HARNEW 5 04 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 EXHAUST COVER 8 07 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 CLUTCH 0 05 FUEL INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK D 04 CRANKCASE B 02 FUEL PUMP C 05 O I L PUMP C 11 QEMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 CRANKSHAFT B 05 WEL TANK 1 03 I L TANK 1 02 SE NSOR L METER E 13 TRANSMISSION 6 08 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 PT GASKET SET J 06 SILENCER CASE B 14 TR I M CYLINDER F 12 AR CASE G 05 PT METER J 02 SILENCER B 13 WATER PUMP D 02 ENGINE CONTROL UNIT E 14 IGNITION E 07 PT PANEL SWITCH J 03 SOLENOID E 15 ELECTRICAL E 09 GE 2 CARBURETOR B 09 CLAMP BRACKET F 02 CLUTCH D 05 CRANKCASE B 02 CRANKSHAFT B 05 DRIVESHAFT HOUSING 6 03 ENGINE CONTROL UNIT E 14 ELECTRICAL E 19 ENGINE HOLDER 6 02 EXHAUST COWER B 07 FUEL INJECTOR C 10 FUEL PUHP C 05 FUEL TANK 1 03 GEAR CASE 6 05 IGNITION E 07 FUEL VAPOR SEPARATO C 09 L
110. OWER COVER H 02 lOPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 MAGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK D 06 O I L PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 FIGS B 8 INTAKE MANIFOLD DT115Sll40EFI QTY REF NO PART NO DESCRIPTION REMARKS 1 131 11 949OO OED MANIFOLD INTAKE GRAY 1 2 13121 94510 GASKET INLET CASE 4 3 01421 08357 BOLT STUD 16 4 08316 10087 NUT 16 5 OS404 08206 CLAMP 2 TANK 1 02 GASKET SET J 06 METER 5 02 PANEL SWITCH 5 03 7 DT115 140 E3 SENSOR L METER E 13 TR ANSHISSION 6 08 SILENCER CASE B 14 TR IN CYLINDER F 12 SILENCER B 13 d amp TER PUHP D 02 SOLENOID E 15 FNGIME COVER H 05 IINTAKE HANIFP amp U 8 08 foPT T I E ROD J 05 STARTING MOTOR E 02 I 1 I FIG 6 31 13 14 15 FIGS B 9 CARBURETOR DT115 QTY REF NO PART NO DESCRIPTION REMARKS 28 4 1 1 1 2 2 1 2 2 3 4 1 4 2 4 3 5 6 7 1 7 2 8 1 8 2 8A 9 10 11 12 13 14 15 16 17 18 1 18 2 19 20 21 RBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 CLUTCH D 05 FUEL INJECTOR C 10 MAG
111. P 1 1 1 1 3 1 1 3 4 1 FCG 1 I 11 6 I FIG 11 C 5 FUEL PUMP MODEL86 94 QTY REF NO PART NO DESCRIPTION REMARKS 1 151 00 94603 PUMP ASSY FUEL 1 2 15100 72812 DIAPHRAGM SET 1 3 1 5 1 65 930 1 0 O RING 1 4 01421 06307 STUD BOLT 2 MODEL90 I a SA lo 13 14 5 5A 6 7 8 9 10 11 1 11 2 12 13 14 15 1 15 2 16 1 16 2 17 18 083 16 1 0067 01550 06307 15322 93000 09280 12012 09355 70125 600 09355 701 25600 09355 701 25 600 09401 1 1 403 09401 11407 09355 701 25 600 0831 0 00087 08322 01 087 1541 0 95530 1541 0 95531 15430 9341 0 15430 9341 1 1541 5 93400 1541 3 93400 NUT BOLT INSULATOR 0 RING ID1 1 8 DD 2 40 HOSE HOSE HOSE CLIP CLIP ID ll 6 HOSE NUT WASHER FILTER FUEL FILTER FUEL STRAINER SET STRAINER SET O RING CUP REFER TO FIG 12 C 6 FOR MODEL 95 96 REFER TO FIG 13 C 8 FOR DT115S1140EFI REFER TO FIG 12A C 7 FOR DT115 MODELz97 MODEL 90 MODEL191 94 9280 12005 L 600 390 PUMP4ARB L 600 280 PUMP CARB L KIQ X Q FILTTER PUMP MODEL 91 94 L 600 230 CONNECTORjFILTER FOR 1541 0 95530 FOR 15410 95531 17 DTll5 14O E3 c 5 _ _ _ _ _ __ bPT WIRING HARNEW J 04 W IVEL BRACKET F 05 OPTIONAL J 07 TH ROTTLE BODY C 04 EC
112. P BRACKET F 02 ENGINE CONTROL UNIT E 14 LOWER UPPER F6 LOWER COVER H 02 OPT WIRING HARNEW J 04 LUBRICATION HOSE C 02 OPTIONAL J 07 HAGNETO E 04 POWER UNIT F 08 31L PUMP C 11 REMOTE CONTROL BOX 1 05 TANK 1 02 SENSOR L METER E 13 GASKET SET 5 06 SILENCER CASE B 14 METER 5 02 SILENCER B 13 PANEL SWITCH J 03 SO LENOID E 15 ROTTLE LINK D 04 ANSMISSION 6 08 Ill CYLINDER F 12 FIG 37 FIG 37 F 7 TILT CYLINDER MODEL 95 QTY REF NO PART NO DFSCRIPTION REMARKS 9 10 11 12 13 14 15 1 16 17 18 COLOR OED GRAY 48400 9451 14ED 48401 94501 48427 94500 48433 94500 48441 9451 0 2251 1 9901 0 46720 94521 48730 94521 48740 94521 48750 94521 48321 945 10 09306 1 6003 09380 1 6003 09407 14403 48720 94580 48730 94580 48740 94580 48750 94580 TILT CYLINDER ASSY PISTON 8 PISTON ROD SUB ASSY O RING PISTON O RING TUBE CYLINDER GREASE NIPPLE PIPE TILT INLET PIPE TILT OUTLET PIPE TRIM INLET PIPE TRIM OUTLET SHAFT TILT CYLINDER UPPER BUSHING SNAP RING CLAMP PlT PIPE TUBE TILT INLET TUBE TILT OUTLET TUBE TRIM INLET TUBE TRIM OUTLET 1 1 1 1 1 2 1 1 1 1 1 2 2 6 1 0PT PORT SIDE 1 0PT PORT SIDE 1 0PT PORT SIDE 1 0PT PO
113. PPER CUSHION OIL TANK NO l CUSHION LOWER N0 2 34860 94621 SENSOR OIL LEVEL 34701 92x50 34700 92E11 GAUGE ASSY MONITORING 36660 946 10 WIRING INDICATOR EXT WIRING INDICATOR EXT WIRING INDICATOR EXT INDICATOR OIL amp WATER WARNING 36660 94690 36660 95610 36660 92E90 WIRING MONITOR GAUGE EXT 79 DT115l140 E3 MODEL 93 01 L 6500 L 2000 MODEL 93 01 OPT MODEL 93 01 I 2 CARBURETOR B 09 6 02 LOWER COVER H 02 PT WIRING HARNEW J 04 sWIVEL BRACKET F 05 CLAMP BRACKET F 02 B 07 LUBRICATION HOSE C 02 PTIONAL J 07 M ROTTLE BCDY C 04 CLUTCH D 05 C 10 AGNETO E 04 OWER UNIT F 08 M ROTTLE LINK D 04 ANSMISSION G O 8 I M CYLINDER F 12 6 05 PT METER J 02 ILENCER B 13 JATER PUMP D 02 CRANKCASE B 02 C 05 I L PUMP C 11 QEMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 CRANKSHAFT B 05 1 03 1L TANK 1 02 SENSOR amp METEL E 13 TR DRIVESHAFT HOUSING 6 03 C 09 PT GASKET SET J 06 SILENCER CASE B 14 TR r LECTRICAL E 09 ENGINE CONTROL UNIT E 14 E 07 PT PANEL SWITCH J 03 EOLENOID E 15 FIG 54 A CARBURETOR B 09 CLAMP BRACKET F 02 CRANKCASE B 02 CRANKSHAFT B 05 DRIVE
114. R E 13 TR ANSHISSION 6 08 SILENCER CASE B 14 TR I M CYLINDER F 12 SILENCER B 13 WATER PUMP D 02 SOLENOID E 15 I _I _ _ ENGINE COWER H 05 INTAKE MANIFOLD B 08 b P T T I E ROD 5 05 IbTARTfNG HOTOR E 02 I FIG 45 G 7 GEAR CASE QTY REF NO PART NO DESCRIPTION REMARKS FIG 45 45 42 41 55300 95500 ZINC PROTECTION 1 42 17500 94520 SEAL ASSY EXHAUST 1 PLUG SUB AND WATER TUBE 1 43 17636 94500 ATCH FLUSH HOSE 1 44 55182 95200 TUBE SET COOLING 1 45 1 1 0 7500 945 PLUG KIT SUB WATER TUBE 1 46 17600 94500 47 5 5 1 1 16 9451 PLUG GEAR CASE 1 48 1 57630 94500 NUT KIT PROPELLER 1 48 2 57630 95500 NUT KIT PROPELLER 49 25700 94500 RE SEALING KIT GEAR CASE I 23 24 J6 37 v 36 38 I I _ _ _ I I CARBURETOR B 09 CLAMP BRACKET F 02 CLUTCH D 05 CRANKCASE B 02 CRANKSHAFT 8 05 DRIVESHAFT HOUSING 6 03 ELECTRICAL E 09 ENGINE CONTROL UNIT E 14 ENGINE HOLDER 6 02 XHAUST COVER 8 07 UEL INJECTOR C 10 UEL PUMP C 05 UEL TANK 1 03 UEL VAPOR SEPARATO C 09 i IGNITION E 07 AR CASE 6 05 LOWER COVER H 02 LUBRICATION HOSE C 02 AGNETO E 04 I L PUMP TANK C 11 1 02 PT
115. R DAMPER MIDDLE DAMPER LOWER 4 31 91 1 94620 OED BRACKET STARTING MOTOR BAND STARTER CABLE ASSY PLUS TERM TO RELAY 1 COLOR OED GRAY REFER TO FIG 23A E 3 FOR MODEL 00 01 32 DT115 140 E3 _ _ FIG 23A E 3 STARTING MOTOR MODEL 00 01 F1G 23A 1 4 f QTY REF NO PART NO DESCRIPTION REMARKS 1 R I 19 v 20 1 2 4 13 0 10 Q 16 I 7 A 6 5 11 1 B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 LAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 LUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 RANKCASE 8 02 FUEL PUMP C 05 O I L PUMP C 11 CRANKSHAFT B 05 FUEL TANK 1 03 OIL TANK 1 02 DRIVESHAFT HOUSING G 03 CUEL VAPOR SEPARATO C 09 3PT GASKET SET J 06 NGINE CONTROL UNIT E 14 IGNITION E 07 3PT PANEL SWITCH J 03 NGINE COVER H 05 INTAKE MANIFOLD B 08 OPT T I E ROD J 05 ELECTRICAL E 09 GEAR CASE 6 05 OPT METER J 02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 31100 94610 31131 WE00 31 1 E00 31 173 WE00 31281 94510 3131 amp WE00 31312 87JOO 31320 94600 3 1360 E10 31 91 6 94500 31 91 7 94500 091 60 031 24 091 80 08097 071 3
116. ROD ROD CABLE LINKAGE TURNBUCKLE CONhECTOR CAM LEVER NUT ROD THROTTLE ROD THROllLE PIVOT 1 1 1 2 2 2 2 2 1 1 1 29 DT1151140 E3 I_ ___ _I I COVER H 02 OPT WIRING HARNEW J 04 UEL PUMP C 05 O I L PUMP C 11 REMOTE CONTROL BOX 1 05 XHAUST COVER B 07 LUBRICATION HOSE C 02 OPTIONAL J 07 UEL INJECTOR C LO MAGNETO E 06 POWER UNIT F 08 UEL TANK 1 03 O I L TANK 1 02 SE NSOR L METER E 13 UEL VAPOR SEPARATO C 09 GASKET SET J 06 SILENCER CASE B 14 METER J 02 SILENCER B 13 IGNITION E 07 PANEL SWITCH J 03 SOLENOID E 15 ROTTLE BODY C 04 ROTTLE LINK D 04 ANSMISSION 6 08 In CYLINDER F 12 DTl15S 971342 DT140EFI 971433 DTl15S 140EFI DTi 155 971342 DT140EFI 971 433 D 4 FIG 22 RBURETOR LAMP BRACKET RANK CASE CRANKSHAFT RIVESHAFT HOUSING LECTRICAL B NGINE CONTROL UNIT LUTCH B 09 F 02 D 05 B 02 B 05 G 03 E 09 E 14 FIG 22 D 5 CLUTCH QTY REF NO PART NO DESCRIPTION REMARKS 1 9 2 3 4 6 7 8 1 8 2 8 3 8 4 9 1 9 2 10 1 10 2 11 1 11 2 12 13 14 15 16 Pelo I 7 17 18
117. RT SIDE 51 DT115 140 E3 F 7 FIG 38 F 8 POWER UNIT MODEL86 89 FIG 38 QTY REF NO PART NO DFSCRIPTION REMARKS 1 1 48500 94611 02M POWER UNIT ASSY POWERTRIM 1 MODELz86 88 348500 94620 0ED USED WITH 38410 94550 33832 94601 1 2 48500 94600 01T POWER UNIT ASSY POWER TRIM 1 MQDEL 86 Z48500 9462O OED USED WITH 38410 94550 33832 94601 1 3 48500 94611 C1T POWER UNIT ASSY POWERTRIM 1 MODEL 87 89 48500 94620 0ED USED 33832 94601 WITH 38410 94550 1 4 48500 946114ED POWER UNIT ASSY POWER TRIM 1 MODEL 89 48500 94620 0ED 33832 94601 48500 94690 0ED USED WITH 38410 94550 1 5 48500 9468142M POWER UNIT ASSY POWER TRIM 1 OPTPORT SIDE MODEL 86 88 USED WITH 38410 94550 33832 95601 1 6 48500 9468141T POWEFl UNIT ASSY POWER TRIM 1 OPTPORT SIDE MODEL 86 88 48500 94690 0ED USED WITH 38410 94550 33832 95601 1 7 48500 94681 OED POWER UNIT ASSY POWER TRIM 1 0PT PORT SIDE MODELB9 i48500 94690 OED USED WITH 38410 94550 33832 94601 2 091 68 10022 GASKET lD 9 3 0D 17 0 1 3 09248 1 0008 PLUG 10X7 5 2 4 48502 94530 VALVE BODY 1 5 48550 94600 VALVE MANUAL 1 4 SCREW 6 48593 94500 7 48592 945N WASHER 4 8 48585 94520 O RING 1 9 09280 70005 O RING D 3 1 10 69 4 2 10 48570 94600 OED RESERVOIR ASSY 1 48570 94600 02M I I 1 G I COLOR 02M SILVER 01T WHITE OED GRAY E 6 i 1 5
118. SCREW LOCK WASHER COIL IGN TIMING NO l COIL IGN TIMING NO2 COIL IGN TIMING N0 3 COIL IGN TIMING N0 4 COIL GEAR COUNTING SCREW SCREW NUT WASHER 18 5X35X4 KEY COVER RING GEAR CLAMP L 80 SCREW TUBE CABLE L 150 CASE RING GEAR GRAY GASKET RING GEAR CASE SCREW SCREW KNOCK PIN 1 1 1 4 4 1 1 4 4 1 1 1 1 1 8 2 1 1 1 1 4 4 1 L 1504 00 1 1 4 8 1 r DT115 MODEL 97 DT140 MODEL196 35 DT115 14O E3 E 5 CARBURETOR B 09 CLAMP BRACKET F 02 CLUTCH D 05 CRANKCASE B 02 CRANKSHAFT B 05 RIVESHAFT HOUSING 6 03 LECTRICAL E 09 NGINE CONTROL UNIT E 14 _I _ I_ _ __ _ _ _____ _ ___ _ I _ _ _l __ ll ENGINE HOLDER 6 02 LOWER COVER H 02 bPS WIRING HARNEW J 04 SWIVEL BRACKET F 05 FUEL INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 THROTTLE LINK D 04 FUEL PUMP C 05 O I L PUPp C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 FUEL TANK 1 03 TItJK 1 02 SENSOR amp METER E 13 TR ANSMISSION 6 08 FUEL VAPOR SEPARATO C 09 b CKfT SET 5 06 I H CYLINDER F 12 GEAR CASE 6 05 METER 5 02 PUMP D 02 IGNITION E 07 PANEL
119. SHAFT HOUSING 6 03 ELECTRICAL E 09 ENGINE CONTROL UNIT E 14 CLUTCH D 05 NGINE HOLDER 6 02 XHAUST COVER B 07 FUEL IMJECTOR C 10 FUEL PUMP C 05 FUEL TANK 1 03 FUEL VAPOR SEPARATO C 09 GEAR CASE 6 05 IGNITION E 07 FIGS4 I 3 FUEL TANK QTY REF NO PART NO DESCRIPTION REMARKS 1 2 3 4 5 1 5 2 6 1 6 2 7 1 7 2 8 9 1 9 2 10 1 10 2 11 12 1 12 2 13 14 15 16 17 18 19 20 21 22 23 1 23 2 24 65800 92823 65510 92wO 65561 92W0 021 12 16167 091 68 06004 091 68 06026 55720 9441 1 65740 95500 09 1 68 1 2001 091 68 1201 5 65850 92W 1 65855 92WO 65855 9201 0 65854 92D10 65854 92D20 65853 92W0 65854 92W0 65854 92D30 03222 04083 65864 92W0 65866 92WO 6587 1 92WO 65700 8701 6 65750 94404 55770 95504 6578 1 98500 65720 9441 1 091 61 1 2004 65720 9551 1 65721 87D00 09 161 1 2004 80 DT1151140 E3 TANK SET FUEL 24L CAP ASSY SEPARATE TANK GASKET TANK CAP SCREW GASKET 6x1 1 8X1 5 GASKET 6 4X11 5X0 8 CONNECTOR FUEL CONNECTOR FUEL GASKET 1 2 5X20Xl GAUGE ASSY FUEl COVER GAUGE COVER GAUGE GASKET GASKET LENS GASKET LENS GASKET LENS SCREW FLOAT NUT PUSH GASKET 12 2x2ixo a GASKET
120. STON BOLT RESERVOIR RESERVOIR CAP 0 RING SHAFT TILT CYLINDER LOWER PAD TRIM CYLINDER RAM SHAFT TILT CYLINDER UPPER BUSH TILT CYLINDER NUT WASHER BUSH CIRCLIP ciacLip 57 DT115I140 E3 1 1 3 2 2 2 2 1 1 1 3 1 1 5 1 1 1 2 2 2 2 2 2 F 13 __ LOWER COVER H 02 ROTTLE BODY C 04 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE LINK D 04 MAGNETO E 04 POWER UNIT F 08 TH OIL PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 TANK 1 02 SENSOR L METER E 13 ANSMISSION 6 08 TR PT GASKET SET J 06 SILENCER CASE B 14 TR I M CYLINDER F 12 PT PANEL SWITCH J 03 SOLENOID E 15 PT z METER J 02 SILENCER 8 13 WATER PUHP D 02 F1G 43 G 2 ENGINE HOLDER Qn FlG 43 1 REF NO PART NO DESCRIPTION REMARKS 1 51 11 I 94510 OED HOLDER ENGINE GRAY 1 2 09206 11016 DOWEL PIN 11x12 2 3 51 21 1 94530 GASKET ENGINE HOLDER 1 4 09206 1 301 7 PIN 13X10 4X20 2 5 1 54130 94501 MOUNT UPPER 5 2 541 30 9451 1 MOUNT UPPER 2 DT115S 5 3 54130 94511 MOUNT UPPER 6 091 08 1 2002 STUD BOLT 2 7 09140 12029 NUT 2 8 09 162 1 2005 LOCK WASHER 12 2X21 SX3 2 9 541 36 94503 STOPPER UPPER MOUNT 1 1 DT115 140 140EFI 10 1
121. SWITCH 5 03 EXHAUST COVER B 07 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 FIG 26 12 10 ll 18 2 14 4 kl 1 17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 321 01 94620 321 02 94620 02112 35127 021 12 36257 321 60 94620 321 56 94610 321 50 94630 32156 94600 09140 18007 091 60 1 80 1 1 08341 31059 1151 1 94603 09404 06432 38423 95510 11521 949004ED 1 1523 946 10 021 62 061 67 02142 051 67 04221 04089 COIL STATOR FLYWHEEL SCREW SCREW COIL IGN TIMING BAND IGN TIMING COIL COIL GEAR COUNTING BAND GEAR COUNTING COIL NUT WASHER 1 8 5X35X4 KEY COVER RING GEAR CLAMP L 45 TUBE CABLE L 150 CASE RING GEAR GRAY GASKET RING GEAR CASE SCREW SCREW KNOCK PIN FIG 26 E 6 MAGNETO DT115S 140EFl QTY REF NO PART NO DESCRIPTION REMARKS 1 1 4 3 1 1 1 1 1 1 1 1 1 1 1 1 4 8 1 L l50 100 ROTTLE LINK D 04 LT CYLINDER F 07 ANSKISSION 6 08 If4 CYLINDER F 12 TER PUMP D 02 36 DT115 140 E3 FIG 27 22 FIG 27 E 7 IGNITION QTY REF NO PART NO DESCRIPTION REMARKS 23 1 I I 26 27 24 I L 1 1A 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
122. T GASKET SET QTY REF NO PART NO D E S C m I O N REMARKS 1 2 7 8 9 i 0 11 12 13 14 1 1E 17 18 19 20 21 VIEW E I VIEW F 11410 94812 1 1 141 94620 1 11 62 94630 17685 9461 0 11232 94610 131 25 9301 0 13125 95210 131 21 9451 0 131 56 945 1 1 141 51 945 10 13855 5331 0 13855 9521 0 13853 9451 0 16731 95520 1 1 523 946 1 0 17567 9451 0 17472 94510 25142 94560 251 42 94520 5121 1 94530 521 72 94541 521 94 9451 0 VIEW D 18 L L I I 1 1 90 DT1151140 E3 GASKET SET GASKET CYLINDER HEAD GASKET CYLINDER HEAD COVER GASKET THERMOSTAT COVER GASKET WATER JACKET GASKET CARBURETOR GASKET CARBURETOR GASKET INLET CASE GASKET REED VALVE GASKET EXHAUST COVER GASKET SILENCER GASKET SILENCER GASKET SILENCER COVER GASKET OIL PUMP GASKET RING GEAR CASE GASKET WATER TUBE GASKET PUMP CASE PANEL GASKET SHIFT GUIDE GASKET SHIFT GUIDE GASKET ENGINE HOLDER GASKET EXHAUST HOUSING GASKET WATER OUTLET TUBE 1 1 1 1 1 4 4 4 4 2 4 4 1 1 1 1 1 1 1 1 1 1 DT115 DT140 DT115 709842 DT140 769964 D i t 13709843 DT140 709965 RIVEWAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 3PT GASKET SET J 06 CASE LECTRICAL E 09 GE AR CASE 6 05 OPT HETER
123. TER PUMP REPAIR KIT 1 1 1 1 1 1 2 2 2 2 2 4 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 2 4 1 2 1 1 1 STD DT115S OPT DT140EFI DT115S DT140EFI DT115S DT14OEFI OPT D 3 _I _1 I __ _ I bPT WIRING HARNEW J 04 SWIVEL BRACKET F 05 OPTIONAL J 07 TH ROTTLE BODY C 04 POWER UNIT F 08 TH ROTTLE LINK D 04 SENSOR L METER E I3 TR ANSHISSION 6 08 SILENCER CASE B 14 TR Ill CYLINDER F 12 ILENCER B 13 WATER PUMP D 02 REHOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 I OLENOID E I 5 I _ ENGINE COVER H 05 IINTAKE MANIFOLD B 08 bPT T I E ROD 5 05 IbTARTING MOTOR E 02 I FIG 21 D 4 THROTTLE LINK F16 21 QV DESCRIPTION REMARKS REFNO PART NO DT115 140 E03 021 THROTTLE LINK _ _ LAMP BRACKET F 02 LUTCH D 05 RANKCASE B 02 RANKSHAFT B 05 RIVESHAFT HOUSING 6 03 LECTRICAL E 09 NGINE CONTROL UNIT E 14 1 1 1 2 2 3 4 5 6 7 8 1 8 2 9 191 11 94601 1911i 94602 091 16 06127 1 91 31 94503 191 37 94500 09159 0501 1 191 31 95502 091 40 05005 191 36 94600 191 36 94900 091 19 05010 LEVER MROllLE CONTROL LEVER THROTTLE CONTROL BOLT 6x1 2 RETAINER
124. TIONAL J 07 ILENCER B 13 I OLENOID E 15 POWER UNIT F 08 REMOTE CONTROL BOX 1 05 SENSOR 8 HETER E 13 SILENCER CASE B 14 _ II__I__I_ __I_ __I__ SWIVEL BRACKET F 05 THROTTLE BODY C 04 THROTTLE LINK D 04 T I L T CYLINDER F 07 TRANSMISSION 6 08 TRIM CYLINDER F 12 WATER PUMP D 02 FIG 16 C 11 OIL PUMP MODEL M QTY REF NO PART NO DESCRIPTION REMARKS Df 1 1517 LO 03 0 i 6 OIL PUPvlP 9 1 1 1 2 2 3 4 5 1 5 2 6 7 8 9 10 11 12 13 14 15 1 15 2 16 17 18 19 20 21 22 23 24 1 24 2 25 26 16100 94615 161 00 94605 16191 94600 16192 94600 09401 06405 09401 08409 09401 08409 094014841 1 083 10 00067 091 62 06006 01421 06257 16340 94610 16731 95520 1 633 1 9460 1 0920945017 19131 95502 1641 1 946 1 1 1641 1 94601 091 40 05005 0936046012 091 6846023 09363 02002 16710 92E91 16710 9464 i 09351 50803 00A 1691 1 92E20 09351 25703 600 09355 25705 600 16911 92E20 09351 50803 00A PUMP ASSY OIL PUMP ASSY OIL BOLT AIR VENT WASHER AIR VENT CLIP CLIP CLIP CLIP NUT LOCK WASHER 6 1X12 2Xl S STUD BOLT RETAINER DRIVEN GEAR GASKET GEAR DRIVEN PIN CONNECTOR ROD CONTROL ROD CONTROL NUT BOLT 6x1 8 GAS
125. TOR POWER UNIT F OS TH ROTTLE LINK D 04 P EMOTE CONTROL BOX 1 05 T I L T CYLINDER F 09 K ENSOR amp HETER E 13 TR ANSHISSION 6 08 SILENCER CASE B 1 4 TR I H CYLINDER F 12 SILENCER B 13 dATER PUHP D 0 2 OR SEPARATO E SOLENOID E 15 STARTING HOTOR E 02 FIG 12 5 11 I 19 FIG 12 C 6 FUEL PUMP MODEt9596 QTY REF NO PART NO DESCWION REMARKS 1 2 3 4 5 6 7 1 7 2 8 1 8 2 9 10 11 12 13 14 15 16 16A 17 18 19 20 21 22 151 OO 94603 1 5 100 7281 2 151 65 9301 0 01 55O 06307 15322 93000 09280 1 201 2 09355 701 25 600 09355 701 25 600 PUMP ASSY FUEL DIAPHRAGM SET O RING BOLT INSULATOR 0 RING ID 11 8 OO 2 40 HOSE 7XlWSOO HOSE 09355 70125 600 HOSE 7XlW600 09355 70125 600 HOSE 09355 70125 600 HOSE 7XlW600 09355 70125 600 HOSE 7XlW600 09401 1 1407 CLIP lD 11 6 09355 70125 600 HOSE 18 DT115 140 E3 0831 O OOO87 08322 01 087 1541 0 95531 15430 9341 1 1541 5 93400 1541 3 93400 09367 08005 1541 0 95540 15430 87D10 1 541 3 87D 10 09408 00024 1 1 10 1 NUT 1 WASHER 1 FILTER FUEL 1 STRAINER SET 1 O RING 1 CUP 1 3 WAY 1 FILTER FUEL 1 ELEMENT SET 1 cu P 1 CLIP 1 L 600 200 FlLT
126. TR ANSflISSION 6 08 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 OPT GASKET SET 5 06 SILENCER CASE B 14 TR I f 4 CYLINDER F 12 ENGINE CONTROL UNIT E 14 IGNITION E 07 OPT PANEL SWITCH J 03 SOLENOID E 15 ELECTRICAL E 09 GEAR CASE 6 05 OPT METER J 02 SILENCER B 13 WATER PUMP D 02 ENGINE COVER H 05 INTAKE MANIFOLD B 08 OPT T I E ROD 5 05 ETARTING MOTOR E 02 FIG l CARBURETOR B 09 CLAMP BRACKET F 02 CLUTCH D 05 CRANKCASE B 02 CRANKSHAFT B 05 DRIVESHAFT HOUSING 6 03 ELECTRICAL E 09 ENGINE CONTROL UNIT E 14 ENGINE HOLDER 6 02 EXHAUST COVER B 07 FUEL INJECTOR C 10 FUEL PUMP C 05 FUEL TANK 1 03 FUEL VAPOR SEPARATO C 09 GEAR CASE 6 05 IGNITION E 07 LUBRICATION HOSE AGNETO I L PUMP PT GASKET SET PT PANEL SWITCH PT HETER H 02 c 02 E 04 c 11 1 02 J 06 5 02 5 03 FIG l 8 4 CRANKCASE QTY REF NO PART NO DESCRIPTION REMARKS 42 34875 94660 GASKET COOLING WATER SENSOR 1 43 1 032 1 2 05 1 23 SCREW 5x12 2 43 2 0321 2 051 63 SCREW 2 44 09404 10204 CLAMP 45 09352 50903 600 HOSE 5X9X600 46 09401 0841 1 CLIP ID 8 6 47 0 9 4 0 4 w 2 CLAMP L 80 48 1
127. TTLE LINK D 04 TRANSMISSION 6 08 In CYLINDER F 12 TER PUMP D 02 T I L T CYLINDER F 07 FIG 31 5 1 29 FIG 31 E 14 ENGINE CONTROL UNIT DTI 15S1140EFI QTY REF NO PART KO DESCRJJ TION REMARKS 1 1 33920 94601 UNIT ENGINE CONTROL 1 DT115S 1 2 33920 94630 UNIT ENGINE CONTROL 1 DTl15S MODEL 00 01 1 3 33920 9461 0 UNIT ENGINE CONTROL 1 DT140EFI DT140EFI 1 4 33920 93640 UNIT ENGINE CONTROL 1 MODEL 00 01 2 36615 96300 TERMINAL RESIN 4 3 01 550 06403 BOLT ENGINE CONTROL UNIT 4 4 08310 00063 NUT ENGINE CONTROL UNIT 4 5 09304 06432 CLAMP UNIT LEAD L 80 3 44 DT1151140 E3 _ E 14 CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 CLAMP BRACKET F 02 XHAUST COVER B 07 LUBRICATION HOSE C 02 ROTTLE BODY C 04 CLUTCH U 05 UEL INJECTOR C 10 AGNETO E 04 ROTTLE LINK D 04 CRANKSHAFT B 05 UEL TANK 1 03 I L TANK 1 02 ANSMISSION 6 08 RIVESHAFT HOUSING 6 03 UEL VAPOR SEPARATO C 09 PT GASKET SET J 06 I H CYLINDER F 12 LECTRICAL E 09 GEAR CASE 6 05 PT METER 5 02 TER PUMP D 02 CRANKCASE B 02 UEL PUMP C 05 I L PUMP C 11 MOTE CONTROL BOX 1 05 LT CYLINDER F 07 NGINE CONTROL UNIT E 14 IGNITION
128. TTLE LINK D 04 CRANKCASE B 02 FUEL PUMP C 05 3KL PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 CRANKSHAFT B 05 FUEL TANK 1 03 TANK 1 02 SE NSOR amp METER E 13 TR ANSMISSION 6 08 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 GASKET SET J 06 SILENCER CASE B 14 TR I H CYLINDER F 12 ELECTRICAL E 09 GEAR CASE 6 05 t METER J 02 SILENCER B 13 dATER PUMP D 02 ENGINE CONTROL UNIT E 14 IGNITION E 07 PANEL SWITCH 5 03 SOLENOID E 15 1 I _ I _ _ FNGINE COVER H 05 IINTAKE MANIFOLD B 08 bPT T I E ROD J 05 IbTARTING MOTOR E 02 I FIG 15 G10 FUEL INJECTOR DT115S 140EFI FIG 15 26 I 3 I 25 __ _ __ _ CARBURETOR B 09 ENGINE HOLDER 6 02 CLUTCH D 05 FUEL INJECTOR C 10 CRANKSHAFT B 05 CUEL TANK 1 03 ELECTRICAL E 09 GE AR CASE 6 05 ENGINE CONTROL UNIT E 14 IGNITION E 07 CLAMP BRACKET F 02 EXHAUST COVER B 07 CRANKCASE B 02 FUEL PUMP C 05 DRIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 LUBRICATION HOSE C 02 AGNETO E 04 I L PUMP
129. WER UNIT F 08 TH ROTTLE LINK D 04 EMOTE CONTROL BOX I 05 T I L T CYLINDER F 07 NSOR L METER E 13 TR ANSHISSION 6 08 ILENCER CASE B 14 TR Ill CYLINDER F 12 ILENCER B 13 rlATER PUMP D 02 Ib OLENOID E 15 ENGINE COVER H 05 IINTAKE MANIFOLD B 08 bPT TIE ROD J OS IkTARTING MOTOR E 02 1 I FIG 50 23 FIG 50 H 10 ENGINE COVER MODEL 89 94 QTY REMARKS DESCRIPTION REF NO PART NO 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 61661 94501 LEVER LOWER COVER LATCH 1 1 09383 03001 03542 061 63 SCREW TILT HANDLE 4 08322 01067 WASHER 2 61431 94503 OED HANDLE TILT UP 1 19131 95502 CONNECTOR LATCH RELEASE ROD 1 E RING 75 DT1 W140 E3 09209 050 1 7 09443 06040 0912546067 091 60 06055 091 40 06020 61 642 95500 09385 06003 09301 06005 61 481 94504 OED 61482 94510 61 485 94530 61544 94500 61 486 94600 61487 94602 03242 051 23 6 165 1 94602 09229 0427 08322 01057 6 1644 94502 09229 0401 4 6 1670 94600 09250 1 2012 03242441 03 09800 01 001 COLOR OED GRAY PIN LINKAGE SPRING SCREW 6x1 6 WASHER 7X12X1 NUT PIN PIN BUSHING LID OIL TANK FILLER HINGE OIL FILLER L
130. XHAUST COVER B 07 LUBRICATION HOSE C 02 OPTIONAL J 07 TH ROTTLE BODY C 04 CLUTCH D 05 FUEL INJECTOR C 10 MAGNETO E 04 POWER UNIT F 08 TH ROTTLE LINK D 04 CRANKCASE B 02 UEL PUMP C 05 O I L PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 CRANKSHAFT B 05 UEL TANK 1 03 TANK 1 02 SENSOR amp HETER E 13 TR ANSMISSION 6 08 DRIVESHAFT HOUSING 6 03 UEL VAPOR SEPARATO C 09 GASKET SET J 06 SILENCER CASE B 14 TR III CYLINDER F 12 METER J 02 SILENCER B 13 WATER PUIIP D 02 ENGINE CONTROL UNIT E 14 IIGNITION E 07 PANEL SWITCH J 03 SOLENOID E 15 ELECTRICAL E 09 F GEAR CASE 6 05 FIG 47 d 17 I L I I 3 Lad OIL WaRiiIMG RESET 4 ARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 RIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 OPT GASKET SET J 06 6 NGINE CONTROL UNIT E 14 IGNITION E t7 aPT PANEL SWITCH 5 03 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 LUTCH D 05 FUEL INJECTOR C 10 HAGNETO E 04 RANKCASE 8 02 FUEL PUMP e C 05 OIL PUMP C 11 ANKSHAFT 8 05 FUEL TANK 1 03 O I L
131. Y ASSY VALVE MANUAL FILTER P l l PUMP JOINT DRIVE SCREW VALVE BODY PLUG VALVE BODY O FIING 0 3 1 1D 69 4 O RING D 1 9 10 8 8 O RING VALVE BODY THROUGH BOLT COVER UPPER HOLDER BRUSH BRUSH YOKE ASSY ARMATURE RESERVOIR SEAL OIL SEAL SET PIT CABLE BOLT STUD NUT TRIM CYL LOCK WASHER 8 2 X 1 5 BOLT 8x22 SPACER STUD BOLT 8x35 NUT LOCK WASHER 8 2X15 4X2 1 1 2 2 1 1 1 1 1 4 4 2 1 1 1 2 1 1 1 1 1 2 4 2 1 1 3 3 3 FOR MODEL 96 01 0PT PORT SIDE 0PT PORT SIDE 0PT PORT SIDE 0PT PORT SIDE 0PT PORT SIDE I IW 10 54 DT115 140 E3 F 10 __ _ CARBURETOR B 09 ENGINE HOLDER 6 02 LOWER COVER H 02 CLAMP BRACKET F 02 EXHAUST COVER B 07 LUBRICATION HOSE C 02 CLUTCH D 05 FUEL INJECTOR C 10 WAGNETO E 04 CRANKCASE B 02 FUEL PUMP C 05 OIL PUMP C 11 CRANKSHAFT B 05 FUEL TANK 1 03 TANK 1 02 RIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 GASKET SET J 06 LECTRICAL E 09 GE AR CASE 6 05 METER J 02 1 b P T WIRING HARNEW J 0 4 BWIVEL BRACKET F 05
132. YLINDER F 07 B 05 FUEL TANK 1 03 I L TANK 1 02 SENSOR 8 METER E 13 TR ANSMISSION 6 08 RIVESHAFT HOUSING 6 03 FUEL VAPOR SEPARATO C 09 PT GASKET SET 5 06 SILENCER CASE 8 14 TR I H CYLINDER F 12 LECTRICAL E 09 GE AR CASE 6 05 PT METER J 02 SILENCER Be13 WATER PUMP D 02 NGINE CONTROL UNIT E 14 IGNITION E 07 PT PANEL SWITCH J 03 SOLENOID E 15 NGINE COVER H 05 INTAKE MANIFOLD B 08 PT T I E ROD J 05 ETARTING HOTOR E 02 I I FOG 44 30 RBURETOR B 09 ENGINE HOLDER 6 02 ILOWER COVER H 02 LAMP BRACKET F 02 XHAUST COVER B 07 LUBRICATION HOSE C 02 LUTCH D 05 UEL INJECTOR C 10 AGNETO E 04 RANKCASE B 02 UEL PUMP C 05 I L PUMP C 11 RANKSHAFT B 05 UEL TANK 0 1 03 OIL TANK 1 02 RIVESHAFT HOUSING G 03 UEL VAPOR SEPARATO C 09 OPT GASKET SET 5 06 LECTRICAL E 09 GEAR CASE 6 05 OPT METER J 02 GINE COVER H 05 t INTAKE RANIFOLD B 08 OPT T I E ROD 5 05 b NGINE CRWTROL UNIT E 14 IGNITION E 07 3PT PANEL SWITCH 5 03 FIG 44 G 3 DRIVESHAFT HOUSING REF NO PART NO DESCRIPTION 1 521 11 9451 1 OED HOUSING DRIVE SHAFT 2 091
133. angeable with each other and both are usable 3 INNER PARTS OF ASSEMBLY Part name with a dot 1 i n front as shown i n the descriPtion column indicates the component o f the assembl y a1 so avai 1 ab1 e i ndi v i dual 1 y 4 MODIFICATION NOTICE A parts b u l l e t i n w i l l be sent t o you on a l l occasions when changes i n parts occur including interchangeable modifications between new parts and old ones Q 2001 American Suzuki Motor Corporation 5 NOTE 5 1 7 There are some different parts from those o f production models among spare parts for the administrative reasons and common use of them with other model s 5 2 In r e s p x t o f rubber hoses and vinyl tubes please be sure t o use them by cutting o f f according t o the length mentioned on parts catalogue or what i s actually required on the vehicle 5 3 Note that the drawings on the iTlustration page are for ready reference of spare parts number not t o be used as an assembly manual When assembl i ng use SUZUKI SERVICE MANUAL 6 MODEL NAME AND ENGINE NUMBER MODEL YEAR S TYPE TRANSOM ENGINE No I 11502 DT11 5TCVG L X 1 1 502 607706 h DT115TCVH 87 11502 L X 1 1 502 70901 9 DTll 5TCVJ 88 DTll5TCK DT11 5TCL DTl 15TCM DTll 5TCN DT115TCP DT115TCR DTll5TCS DTll5TCT DT115TCV DTll5STCLT DTll5STCLV DT115STCLW DTll5STCLX DTll 5STCLY DT115STCLl DT140TCVG DTl40TCVH DT140TCVJ DT140TCK DT140TCL DT140TCM DT1
134. e e b DRIVESHAFT HOUSING G 03 FUEL VAPOR SEPARATO C 09 OPT GASKET SET J 06 NGINE CONTROL UNIT E 14 IGNITION E 07 3PT PANEL SWITCH J 03 NGINE COVER H 05 INTAKE MANIFOLD Be08 OPT T I E ROD 5 05 F I G 3 F 4 CLAMP BRACKET MODEL 96 01 QTY REMARKS REF NO PART NO DESCRIPTION FIG 34 1 1 1 2 2 1 41 11 1 95E03 0ED BRACKET CLAMP STBD 1 1 1 1 1 4 1 2 4 1 4 1 4 4 4 1 1 1 2 2 2 1 1 2 1 1 2 DT115I140 MODEL196 DT115S MODEL 96 01 DTl40EFl MODEL 97 01 DT115 140 MODEL 96 41121 95E20 OED USED WITH 33834 93E00 DT115S MODEL 96 01 DT140EFI MODEL97 01 DTll5 MODEL 97 DTl15 MODEL 97 41 11 1 94901 OED BRACKET CLAMP STBD 21 I 25 I 41 12 41 12 22 I 95E05 OED BRACKET CLAMP PORT 2 2 94901 OED BRACKET CLAMP PORT 17 SHAFT CLAMP BRKT CAP TRANSOM BOLT ANODESET CLAMP BRACKET BOLT 6x25 BOLT SCRFJV 6x10 NUT NUT WASHER WASHER WASHER LOCK CLAMP CLAMP PIN TILT LOCK BOLT 1 0x20 NUT WASHER SEAL STEERING CABLE 3 4 41 130 95540 41 153 94500 55320 94900 091 1646121 09100 12039 091 25 06063 09140 12028 091 59 22003 091 60 1 2044 091 60 1 2066 09162 12005 09404 4 3 09408 001 13 45421 87wO 091 06 1 0065 091 59 14020 091 60 lOO82 I 10 1 6 23
135. n l 1 REFER TO FIG 39 F IO FOR MODEL 95 REFER TO FIG 40 F 11 FOR MODELz96 01 DTi 1511 40 E03 038 POWER UNIT 86 89 52 DTl151140 E3 IF8 _ _ I____ I __ _I __ _ __ __ I I_ __I CARBURETOR B 09 6 02 LOWER COVER H 02 3PT WIRING HARNEW J 04 SWIVEL BRACKET F 05 CLAMP BRACKET F 02 B 07 LUBRICATION HOSE C 02 3PTIONAL J 07 TH ROTTLE BODY C 04 CLUTCH D 05 C 10 MAGNETO E 04 BOWER UNIT F 08 TH ROTTLE LINK D 04 CRANKCASE B 02 C 05 O I L PUMP C 11 REMOTE CONTROL BOX 1 05 T I L T CYLINDER F 07 CRANKSHAFT B 05 TANK 1 02 SENSOR amp METER E 13 TR ANSHISSION 6 08 DRIVESHAFT HOUSING 6 03 GASKET SET J 06 SILENCER CASE B 14 TR IH CYLINDER F 12 ELECTRICAL E 09 METER 5 02 SILENCER B 13 WATER PUMP D 02 ENGINE CONTROL UNIT E 14 PANEL SWITCH 5 03 SOLENOID E 15 FlG 38 FIG 38 F 9 POWER UNIT MODEL 86 89 QTY REMARKS REF NO PART PiO DESCRIPTION 29 1 25 1 i J DT7 1511 40 E03 038 POW E R UN lT 86 89 11 12 13 14 15 6 18 19 20 21 22 23 24 25 26 27 28 29 30 31 281 94520 SCREW 31 173 94521 BRUSHHOLDERASSY 31 170 94520 OED COVER UPPER GR

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