Suzuki DT 2 (80-82) - Browns Point Marine Service

DT 2 (1980-1982)

I 1

PREFACE t 4. MODIFICATION NOTICE A par ts bu l le t in wi l l b e sent to you on all accasions when changes

in par ts occur, including interchangeable modifications between rrew par ts and old ones.

5. NOTE

When it becomes necessary to replace parts on SUZUKI OUTBOARD MOTORS, always use SUZUKI GENUINE PARTS which have passed a s t r i c t inspection which guarantees qual i ty and performance.

c

This par ts catalogue covers t h e l i s t of a l l service par ts for 5 - n h e r e are some d i f fe ren t par ts from those o f product ion models among spare par ts . f o r the administrat ive reasons and common use o f them wi th other models.

In respect o f rubber hoses and vinyl tubes, please b e sure to use them by cu t t ing o f f according to the length mentioned on par ts catalogue or what is actual ly requi red on the vehicle.

Note t h a t the drawings on the i l lustrat ion page are f o r ready reference of spare par ts number, pot t o be used as a n assembly manual. When assembling, use "SUZUKI SERVICE MANUAL".

SUZUKI DT2G, DT2J, DT2VZ.

A. INSTRUCTIONS FOR QUOTING THE CATALOGUE 5-2.

1. DIMENSIONS Dimensions of the par ts in th is catalogue are indicated in

5-3 - Number o f teeth

- unit mi I1 imeters . 2. ABBREVIATIONS

Abbreviat ions used in th is catalogue are as. follows:

AR : As requi red N T ASSY : Assembly OPT E.No. : Engine Number 0s F.No. : Frame Number STD d : Diameter o f material T ID : Inside diameter us OD : Outside diameter W

L : Length LHD LH : Left hand-side RHD RH : Right hand side S,L,UL,LL : *123456 : Up to E.N0.0201-123456 1234561. : From E - No. 0201 -1 23456

Optional Over Size

6. SPECIFICATION CODE This catalogue contains the par ts f o r the model designed f o r

Standard the following spec. ;

Thickness Under size i 7. SERIAL ENGINE NUMBER

W i d t h i. + model y V Z model

spec. code: G ( E l , E3), J ( E l , E3, E13), VZ (E l , €13)

L DT2VZ : 0201 -2XXXXX %

Lef t handle d r i v e 1 DT2G : 0201-001001~

Right handle d r i v e DT2J : 0201-1XxXXX~ Transom t y p e

LJ model

12 x 34 x 5.6 ..------ Figures in t h e descript ion column show the dimensions o f parts. 7 1 1

ID OD T ( o r W,L)

The number of le t ter shown below Q l t y indicate t h e MODEL NAME as shown below-

Q'ty . I

ALL G/J VZ - - - DT2VZ DT2J DT2G

3 . INNER PARTS OF ASSEMBLY Parts number tha t have a per iod ( . ) mark in f r o n t of the

p a r t descript ion on a t e x t page are separately serviced par ts o f the assembly.

., - 2 - -

. . ! . . . , . , . ' . I.. . .. . . A

DT2 - 1 - D T2

1 FIG.1 CYLINDER

a'tv ALL Remar(<S

i

Ref. No. Part No. ' Description '

1-1 11171-98401-OIJ CYLINDER HEAD 1 model G 1-2 17111-98462-01J CYLINDER HEAD 1 model J,VZ

2-1 11 141 -98400 GASKET, cylinder head 1 model G,J 2-2 11 141 -98401 GASKET, cylinder head 1 model' VZ

from 111 11 -98401 -01 J I

from 1 1 141 -98400 4 model G,J BOLT

BOLT 4 model VZ to ,01107-06308

LOCK 'WASHER 4 .i 4 08321 -21 068 5 08322-21 068 WASHER 4

6 09403-10309 CLAMP 1

11 300-98842-01 J CY L I N D ER / ANKCASE ASSY 1 to 11300-98400-01J L 11300-98400-01J CYLINDER/CRANKCASE ASSY 1 , model G 7-3 11301-98400-01J CYLINDER/CRANKCASE ASSY 1 from 113

'\$ c: 7-4 11301-98401-01J CYLINDER/CRANKCASE ASSY 1

{ to 1 1301 -98402-01 J ) 7-5 11 301 -98!i02-01 J LINDER/CRANKCASE ASSY 1 7-6 -11301~984C3-01J CYLINDER/CRANKCASE ASSY 1 model VZ

9-1 01 107-06358 -BOLT 2 model G,J 8 0421 1-031 09 -DOWEL PIN 2

2 model VZ -BOLT L - to 01 107-06358

9-2 01907-06358 .',

0 - -BOLT (6x70) 4 10 09100-06062 -LOCK WASHER 6

13 52113-98400 GASKET, drive shaft housing 1 1 14 13153-19012 VALVE, reed

15 13152-19010 16; 08321 -21 038 17 ' 021 12"03088

I

. 0 RING, cylinder

-. STOPPER, reed valve 1

LOCK WASHER 2 SCREW . 2

14

/. ' .

_ _ _ . DT2 DT2

3 FIG.3 CARBURETOR

Q'W - Ref.No. Part No. Description ALL Remarks

FIG.3

1 13200-98411 , CARBURETOR ASSY 1 stamp:98411 2 13433-9841 0 -SCREW 1

3 13426-9841 0 *LOCK WASHER 1

4 361 5-9841 2 *WASHER 1

5 3432-331 10 .RING, f r ic t ion 1

1 6 13564-98411 .LEVER ASSY , throt t le 1 7 04111-12108 -COTTER PIN 1 8 13557-9841 0 ' -PLATE 2 model G,J 9 13557-9841 0 -PLATE -

17--modei vz 10 13557-98420 -PLATE 1

11 -1 13567-9841 1 -NUT 1 to 13567-9841 2, modei G

11 -2 13567-9841 2 .NUT 1

1 2 13589- 9841 1 .WASHER 1

13 13265-98411- .TOP, carburetor 1

14-1 13573-98410 -SPR I NG 1 to 13573-9841 1, model G

14-2 13573-98411 -SPRING 1 mode! J,VZ

c 15 13552-9841 1 -PIPE 1 16 13533-9841 0 -E RING 1 17 13545-98410 (1 -SEAT, spr ing 1

' 18 13552-98410 ' -ROD, th ro t t le 1

I- 20 13394-12110 *CLIP 1 21 13383-9841 0 -NEEDLE, je t 1

23 13267-01 01 0 -SCREW, stop 1 24 13268-01 01 0 -SPRING . - 1 25 13295-9841 0 -0 RING 1 26 13376-98400 .FILTER 1 27 13392-01 01 0 -GASKET, valve seat 1 28 13370-2301 0 -VALVE ASSY, needle 1 29 09494-001 79 -NOZZLE, needle 1 30 13252-9841 0 -FLOAT 1 31 13253-9841 0 -ARM, float 1

1

,- 19 13563-98410 -PIN, seat

22 13551 -9841 1 -VALVE, throt t le (CA:1.5) 1

I

r

, -

- __ - _- -- DT2 DT2

5 FIG.4 STARTER

Q'tY

STARTER, recoil 1 2 181 11 -98400 .CASE, starter 1

-SPRING, recoil 1 4 18127-98400 -DRUM, sheave 1 5 18131-98400 *PAWL, drive 1

- ALL Remarks Rd.No. Part No. Descriptbt \'i

I

1 181 00-98401

3 18142-98400

model G

from 181 45-98400 1

from 181 53-98400

_- '_ L

6- 1 181 45-98400 -SPRING, pilot shaft

6-2 181 53-9841 0 *SPRING, pilot shaft

7 18151-98400 -PLATE

8-1 18153-98400 .BOLT, pivot

8-2 18332-98400 -BOLT, pivot

9 181 81 -98400 -GUIDE, rope

10 181 83-98400 * E RING

11 -1 18170-98401 -GRIP ASSY, starter 11 -2 18200-98401 -GRIP ASSY, starter 12 1821 0-98400 - -GRIP t

-1 13-1 01107-06108 BOLT 2 model G,J

2 model VZ 4 to 01107-06

13-2 01907-06108 BOLT -* --.' 14 0832'1 -21 068 LOCK WASHER 2

SCREW 3

CUP, star ter 1

17 32725-98400 I NSULATOR , magneto 1

15 02122-06128 16 18411-98401

1 '

-\ c.2

16

,-

~. - - - ._ _-__ __ . D T2 D T2

6 FIG.5

( model G,J ) @- 19

e 1 321 00-98431 MAGNETO ASSY 1

2- 1 321 01 -9843 -STATOR ASSY 1 model G

2-2 321 01 -98434 -STATOR ASSY 1 from 32101-98433

3 32140-98431 - -COIL , ignition 1

4 08321-27058 - -LOCK WASHER 2

5 021 12-05258 --SCREW 2

6 32240-98034 - - PO I N T ASSY, contact 1

7 08322-21048 --WASHER 1

8 08321-21048 --LOCK WASHER 1

9 0231 1 -041 08 --SCREW 1

10 32341 -98430 --CONDENSER 1 1 1 021 12-041 08 --SCREW 1 12 08321 -21 048 - -LOCK WASHER 1 13 321 02-98431 -ROTOR ASSY 1 14 021 12-051 28 SCREW 2 15 08322-21 058 WASHER 2

17 -B)

16-1 09482-00143 SPARK PLUG (BRSHS,NGK) 1 model G 16-2 09482-00142 SPARK PLUG (B4H,NGK) 1 model J,..0201-114150

16-3 09482-001 43 SPARK PLUG (BR5HS,NGK) 1 model J,0201-114151~

1 7 08341 -31 039 KEY 1

18 08321 -31 128 1

19 0831 0-221 28 NUT 1 Q

20 37800-93350 SWITCH ASSY, engine stop 1 21 09404-0641 3 CLAMP, stop switch lead cord 1 22 3351 0-92~~2? CAP, spark plug 1 model G

23 33510-22010 24 33541 -93310

model J 0201-114151* CAP, spark plug model J,..0201-114150

SEAL, spark plug

25 33542-98000 SEAL, high tension cord 24

FIG.6 (6-9) : model VZ

DT2 DT2

1-

15

I 1 12 FIG.10 WATER PUMP

Ref. No. Part No. Description A L L Remarks

1 17410-98400-01J CASE, water pump 1 2 17411-98400-01J -CASE, water pump 1 to 1741 0-98400-01 J

model G 3 09289-1 0003 , -011 SEAL, water pump case 1 10x26~8

FIG.11 TRANSMISSION / PROPELLER FIG. 1 1

2-1 08221-10165 SHIM, pinion (T:0.5) AR(01.2) 2-2 08221-10164 SHIM, pinion (T:0.2) AR(01.2) 2-3 08221 -1 01 63 AR(01.2)

3 5731 1-98400 4 08332- 1 1068 5- 1 08221 -1 01 65 AR(01.2)

5-2 08221-10164 5-3 08221 - 101 63 SHIM, gear (T:0.1)

1 E RING 1

6 5761 0-98407 SHAFT, propeller (NT:23) 1 7 09202-04002 SHEAR PIN 7

1 8 09180-10044 SPACER (10x14~17)

9-1 581 11 -98401 -01T PROPELLER (A510)( 3 ~ 1 8 8 ~ 1 3 5 ) 1 to 581 11 -98402-01T model G

9-2 58111-98402-01T PROPELLER (A510)(3x1S8x135) 1 mbdel J ,VZ 10-1 58111-984 -01 T PROPELLER (A5001 (3x1 XI221 1 to 58111-98452-01-r

10-2 581 11 -98452-01 T PROPELLER (A500)( 3 ~ 1 8 8 ~ 1 2 2 ) ! 1 11 -1 581 11 -98462-01T + PROPELLER (A400)

11-2 58111-98

11 -3 12 09204-02001 COTTER PIN 13 091 81 -20004 SHIM, bearing stopper . 1 20x26x0.5,model J

581 1 1 -98464-01 T (A400)( 3x188~115) model J , VZ, 0201 -1 120861. 1

_- 14 FIG.12 ENGINE COVER

Q'tv FIGo 1 2

Description ALL Remarks Ref. No. Part No.

1 61420-98400 EMBLEM, engine cover f ront 1 2 61422-98402 MARK, f ront emblem 1

3 09126-04003 SCREW (4x35) 2 4-1 61460-98840-01T COVER SET, engine RH 1 model G

4-2 61460-98847-01T COVER SET, engine RH 1 model J,VZ

5-1 61441-98401 .EMBLEM, "SUZUKI" 1 model G 5-2 61 441 -9841 0 - EM B L EM, 'IS U Z U K I 'I 1 model J,VZ

from 67460-98840-05-

from 61 441 -98401 6 61445-98410 .STRIPE, side RH 1

7-1 61470-98830-01T COVER SET, engine LH 1 model G

7-2 61470-98831-017- COVER SET, engine LH 1 model J,VZ

8-1 61441 -98401 - EM B L EM, " SU Z U K I I' 1 model G 8-2 61441 -98410 EM6 L EM , I' SU ZU K I 'I 1 model J,VZ

from 61470-98830-01 T

from 61441-98401

9 61455-98410 -STRIPE, side LH 1 10 09125-06025 SC R EW (6x20) 4 1 1 - 1 091 25-05028 SCREW (5x1 2) 4 model G I 1 -2 09125-05028 SCREW (5x12) I 1 -3 09125-05029 SCREW (5x16) 11 -4 09125-05035 SCREW (5x25) model VZ-I 12-1 09160-05010 WASHER (5 .5~10~018) model G,J 72-2 09160-05010 WASHER ( 5 . 5 ~ 1 Ox0 - 8) 3 model VZ 12-3 08322-21058 WASHER 1 model VZ 13-1 61465-98402 PLATE, engine cover

13-2 61 490-98400 PLATE, engine cover

14 09148-05011 NUT 8 model G

15 091 48-0501 1 NUT 4 -

r : I m o d e l

4 model G 4 1 from 61465-98402

Q- 19 16 61 481 -98401 HINGE, engine cover 1

17 61485-98401 SPRING, engine cover hinge 1 I

18 091 26-05003 SCREW (5x1 2) 6, 19 61 521 -98400 HOLDER, shear pin 1

4 ' , i

j i

J - i

DT2 D T2

16 FIG.14 OPTIONAL i

Q'W Remarks ALL Ref.No. part No. Description

FIG. 1 4

1 99000-31 120 SUZUKI SILICONE SEAL 1 for gear case,50g

2 99000-31050 GASKET, liquid 1 fo r gear case,100g

GREASE , water resistant 4 99000-25170 GR €ASE, water resistant 5 99000-22540 GEAR OIL, outboard moter 1 400cc 6 99000-2507 0 SUZUKI SUPER GREASE A 1 450g,for crank oil seal

1 509 7 99000-32050 THREAD LOCK "1342" 8 99000-32020 THREAD LOCK SUPER 19333B11 1 509

1 9-1 99000-21 145 CCI OIL (l2x24,SHELL) 9-2 99000-21 460 CCI OIL (l2x24,MITSUBISHI) 1

1 9-3 99000-21 021 CCI OIL (42x6)

9-4 99000-21 150 9-5 99000-21250 CCI SUPER OIL (12x24)

1 2509 1 509

CCI OIL (2002) 1 1 1

99000-32040 CEMENT, thread lock (2009) 1 10 09914-39911 HANGER, engine

12-1 99000-10109-0111 PAINT (Francois White-2) 1 NET:90g

12-2 99000-10209-01J PAINT (Andes Blue Metallic) 1 NET:90g 1 NET:500g 13-1 99000-10105-017- PAINT (Francois White-2)

13-2 99000-10205-01J PAINT (Andes Blue Metallic) 1 NET:500g

3

DT2 DT2