Suzuki DT 25 (86-88) - Browns Point86-88).pdf · PREFACE b. MODIFICATION NOTI@ A parts bulletin will be sent to you on all occasions when changes in parts occur, including interchangeable

DT 25 (1986-1988)

PREFACE b. MODIFICATION NOTI@ A parts bul le t in will be sent t o you on a l l occasions when changes i n par t s

occur, including interchangeable modifications between new par t s and old ones. When it becomes necessary t o replace par ts on SUZWI OUTBOARD HDTWS, always

u s e SUZUKI GENUIM PARTS which have passed a strict Inspection which guarantees 4 . NO_rZ quali ty and performance.

VGIVHJVY. other models.

5-1. There a r e sane different par ts fram those of production models among spare par ts for the a h i n i s t r a t i v e reasons and c m n use of them ui th Yhis parts catalogue covezs the list of a l l service parts f a r SUZUI 0725

INSTRUCTIONS MR PWYINE THE CATiLOwE

1. masrw D h n s i o n s OF the par ts i n t h i s catalogue are indicated i n u n i t millimeters.

2. --‘IAYIONs Abbreviations used in t h i s catalogue a re a s follows:

PR : As required NY : Number of tee th A S 9 : Assembly OPT : Optional €.No. : Engine nunbe= 05 : Over slre F.Na. : Frame nlnnber STD : Standard d : Diamter of material T : Thickness I D : Inslde diameter us : Under size 00 : Outside diameter w : Width L : Length S,L,UL,U : Transom type LH : Left hand side RH : Right hand t i d e -123456 : Up t o F.Na.02503-lZM56 123456- : From F.NO.02503-123456

x 2 Y 5.6 ....-*.. Figures Ln the description column show the d h n s i o n s o f parts. I i - i -

I D OD T(or W,L)

3. IMER PARTS OF ASSEMBLY

on a text page are separately serviced parts of t h e assembly. Parts number that have a period (.) mark i n front o f the p a r t description

CT25 VJ E3 - 1 -

5-2. In respect of rubber hoses and vinyl tubes, please be s u r e t o use them by cutting off according to the length mentioned on p a r t s catalogue o r what Is actually requW on the vehicle.

5-5. ’

Note that the drawings on the i l lus t ra t ion paae are f a r ready reference o f spare par ts nunber. not t e be used as an assembly manual. When assembling, use *SUZuCI SERVICE WW*.

D Y 2 5 VG : 02503430947- DYZ M : o ~ i u 3 - 7 i m i - 7 2 0 ~ 7 DY25 VY : 02503-82021&.

7. MLOR

: Color No. : Color descriPtion : om : Rrctic-Silver : OlY : Francois White-? :

1

FIG. 1

@

- 0725 VJ E3

REF. NO. 1 2 3-L 3-2 4 5 6 7 8 9

10 . 11 12 13 14 15 16 17 18 19 20 21-1 u - 2 22 23 24 25 26

FIG.1 ( B- 2 ) CYLIWR

PART NO. bESCRIPTION 11161-96302-02!4 COVER, cylinder head 11162-36302 GASKET L1111-96511-02H CYLINDER HEAD Lllll-%312-02H CYLINDER WAD iii41-96302 w w r

08321-21682 LOCK W A S t E R 68322-LpO82 WnYrR 01107-06252 BOLT 00321-21062 LOCK W R 08322-21062 WnWER 1130L-96306-02M CYLINDEC( m y

01107-08658 BOLT

04211-09109 .PIN 01107-08552 .BOLT 01107-08452 .BOLT 0110748602 .B6LT 08321-21082 .uyXwny(ER

08322-11otu .wsbER 01Lo7-06252 .BDLY 08321-21062 .LOCKwAMR 08322-2lI362 .nAstER

17670-93962 -YAY (M’C) 09343-03051 HCtSfI (3.l,~6.2~,33t!) 09Wlld6403 CUP 09404-06204 C W (L:65) 16710-96300 WEW VALVE 11400-96847 GASKET SEY

m m - w 3 0 1 THER#ISTAT (M-c)

Q’YY REMCiRKS

1

1 -614831 1 616052- L 1D 10 10 2 2 2

2 4 2 2 0 8 4 4 0

1 modervG 1 madel W,VY 2 4 2 1 1 OPT

8T25 VJ E3

L

- I -

@

FIG.2

12

14

17

- 18 (.g.g$j 22 -if 22

FIG.2 ( B- 3) tX#K%t~m P'TY

REF.NO. PART NO. DESCRIPTION REUtRKS 1-2 1-2 1-3 2-1 2-2 2-3 3 4 5 6 7-1 7-2 8 9

10 11 12 13 14 15 16 17-1 17-2 28 19 20 21 22

12110-96303 PISTON, STO 12110-96353-025 PISTON, 05:0.25 12110-%353-050 PISYON, E:C.% 12340-96501 RING SET, piston, STO

12140-%3S1-025 RING S Y , PlStM. 0 S : O . Z

12240-%551-OM RING SET, piston, 05:O.M

OT25 VJ 55

12151-92501 09381-18002 09263-la16 09269-18001 12200-%3c)6 12200-96307 12161-96300 09263-26018 09181-24001 32211-%311 122u-%ull 12221-96305 32232-%504 1223l-%~ 09160-502

12260-96310 09262-30055 09289-58013 09283-3W11 09283-30042

l2240-%M5

~ z a 2 - ~ s o o 4

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

.?T apr

OPT OPT

-717993 717996-

-717393 Y 17996-

b

-__ I__

DT25 VJ E3

FIG.3

1 17

R E E N O . PART NO. DESCRXPTION REHARKS 01317-06252 =T 8 1

2 3 6 5 b 7 8 9

LO 11 12 13 14 15 16-1 16-2 17 18 19 2rl

I 19

0725 VJ E3

08316-L60&2 HUT 12681-%3034a( CnSE, inlet 13125-93006 0161L-06202 01621-06202 D150-9630i3 13152-96300 13153-%uW oZL12-Om2 08321-2l032 02122-06362 08316-16082 16151-96500 14231-36361

CAS(E1, carburetor STUO BOLT STUI BOLT REED VALVE ASSY .STOfFfR, reed valve .VALVE, reed .swEw .lax WAUER SCREW NUT W T , exhaust cover PLATE, exhaust

2 1 1 2 2 1 6 6

12 12 1 2 2 1 1 412700 1 6UM1- 12 1 3 3

F1G.4 1 I

5

0725 VJ E3

FICA ( B- 5 ) CARBLJREYOR P'TY

REF.NO. PART NO. DESCRIPTION REMRKS 1 2 3 4 5 6 7 8 9

10 11 12 u 14 Is 16 17 1s 19-1 19-2 19-3 19-4 20 21

13200-96323 09492-4wlo2 13271-93311 13269-93313 l3%-96300 13237-94400 13250-93032 l.3251-933la 33254-93610 13370-?8310 13268-%llO 135M-96300 09491-28012 13392-58600 13be1-96m ~%!-%300 02112-05202 08321-2l052 09691-29006 09491-28610 09491-26009 139493-251324 13651-93500 OQMS-C14005

c.hR%mEYW ASSY . X T , a h (90) .SPRING, alr screw .SmEw, pirot a i r .No= .NozuE .FLOAT .GIIlKET, f loat chamber .PIN, Il-t .VALVE ASSY. needle .SPRING, thrott le stop .5iXW, thrott le stop .XI, main Clb2.5) .GWET9 valve seat .LEVER, choke . W T

.w wny*R

XY, Wain (145) 33, nain 1140) SET, main (UO) Z Y . mein il1U) WO& starter Buy(

-- I

1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1

WT WY WY WT

REEND. 1 2 3 4 5 6 7

PART NO. DESCRIfTION 11411-96361 IUIUSIffi, upper oil seal 11413-96300 W X E T 02122-06202 SCREW 31911-96U12-OM E#ncKEY, starter 01107-08252 BOLT 08321-2L082 UXK UASm 08522-11082 WAyER

Q'TY REUARK!j

L 1 4 1 ELECTRICSTARYEI? 4 ELECTRICSTARTER 4 ELECTRYCSTJWZTER 4 ELECTRIC SIJWZTER

UY25 VJ E3 B6

6

F K . 6 ( 8- 7) FOEL W FIG.6 18 '17

A

P'TY DESCRXPTIM RENARKS REENO. PART NO.

w PSSY. fuel 1 1 2 3 4 5 6 7 8

9 10 11 12 13 14

15 16 17

19

21

ie

m

0725 VJ E3 _ _ _ DY25 VJ ES

15LM-913oY. 15170-943U 15183-94301 15186-94500 l5851-903Do 0 1 1 0 7 ~ 2 08321-21062 15321-99700 0954345147 09343-05147 b040149402 15410-934W L541s-934M W32-93400 mu-93600 15616-93600 08322-21082 08510-22082 0954345149 09404-06204 U331-94300

1 2 2 3 2 2 1 1 L:195 1 L:195 6 1 1 1 1 1 1 1

1 2

I L:3m

FIG. 7

16

L 2-1 2-2 3 4 5 6 7-1 7-2 8 9

10 11 12 13 14 15 16 1v 18 19 20 23 22 23

FIG.7 ( 5 8 ) WATER Pup

a*w R&F.NO. PART Na DESCRIPTION RMhRKS

1

1 5 T W E 1 LTYPE 2 1 1 1 1 STYPE 1 L W 1 1 1 1 6

4 4

1 1 1 1 1 2 2 1 1 WY

DTZ5 VJ ES B8

@

DT25 VJ E3 I

t"n

STARTER A S Y , recoil 1 REKNO. PARY NO. DESCRIPTION REUARKS 1 2 3 4 5 6 7 8

9

10 11 12 u 14 u 16 17

- 1 18 19 20 P n 23 26 25 26 27 28

0125 VJ E3

1811M-%W 18120-%301 18131-96301 18US-%S& 18351-%301 18142-%wyl 18191-95202 38192-95204 18195-9520[3 18355-96360 18162-96Joo 18U5"%Ml 18124-96W 18144-%3iM

013321-31068 181%-95ooo 18200-95203 18210-9Wl 38281-96306 18282-36300 19294-96m 18348-96300 18131-96502 18255-'9&Mo 18291-06Sw) 18342-96JOo 18156-96500

18332-96300

.REEL . R n Y M T .SPRING .RATE .SPRING .PLATE .m, protector .RING

.wisHm

.wisHm

.SPRING

.mJsn

.PLAK

.WILT

.uyx WnYER

.SPRING, prctector

.QW A!%Y

. .WIP

.LEM1. stoppar

.AI#, stopper

.SPRING

.PIN

.w, starter

.SNAP CLIP

.-, cable

.scww

.SPACER

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 1

FIG. 8

31 I

REENO. 29

3u 31 32 33 36 35 x 37

PART NO. bESCRIPTION 18290-96301 CABLE, MI 18YU-%M3-02F( BRncE, recall starter STBD 01517-I#202 BOLT

0152746252 BOLT 01517-08252 BOLY 18m-p63I1342H ERncE, recoil starter, WRY 01107-08252 BOLT 083u-21m2 uyx uA!jlU?

oa322-13082 WIwOs:

1

\

Q”YY

1 1 2 2 1 1 p(LwnLsTlu?m

2 2

2

REn4RKs

0725 VJ E3 0725 YJ E3

@

DT25 VJ E3

/

i-9 I

10 FIC.9 ( C- 2) CLUTCH

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

1 2 3 4 5 6 7 8

9-1 9-2 LO 11 12 13 14 15 16 17 18 19 20 u 22 23 24 25 26 27 28 29 30 31

21230-%300 SHAFT, clutch 09i603-0soia WASHER (5.5~10~0.8) 09204-0100l. COTYER PIN 09200-05006 PIN 21311-96300 HDLDER. clutch shaft aisi7-~b207 eolr (ma)

wi4a-wo4 ' 1 NUT 231ll-%W ROD. clutch

25111-%310 ROD, sh i f t 25111-96300 i ROD, sh i f t 25222-96300 BOOT, shift rod G9260-a8005 0 RING 25211-%501 WIDE. sh i f t rod 09280-uo115 ,' 0 RING 0920565621 SPRING PIN 252lS-%ulr SnmXFt, shift md guide

scsw 09205-02004 SPRING PIN 25311-96303 CAW, sh i f t 233ll-94500 T l J W U X U , clutch rod 23131-w4500 BOOT, crutch rad 22Lll-%3oz-azw LEVER, crutch wia3-06033 BOLT cm) 09260-1OW5 STEEL Bnu 5904047022 SPRING 09305-10Mll Buyl

2ll20-%30l. PLATE, clutch notch 09204-01002 COTTER PIN 21241-96305 ROD, crutch e n 25231-%301 SPACER, mewet z232-%3oi w r 21121-93300 PLATE

1. 1 1 1 1 4 1 1 1 S T r n 1 LprpE 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1

OT25 VJ E3

FIG. 10 26

DESCRIPTION REHARKS REENO. PART NO. 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 2 1 1 2 1 3 1 1 1 1 1 1 2

2

1 19l21-%301 LEVER, throttle control 2 19131-95502 COMECYOR. thrcttk lever 3 19131-%306 RETAINER. rod connector 4

5 19US-96301 Roo 6 7 8

9 19720-96502 SHAFl, remo-cm throttle

19U2-95500 c(p$*CTOR

19141-96301 W, throttle 1%54-%u10 m 3%56-%300 m

10 39761-96300 SYAY. throttle cable 11 19811-9630L-02M L3MITYER. throttle 12 19851-96301 LEVER, &I 13 10861-%301 SYAY, NSI cable

09100-06131 &IT Cbxl2) 14 09100-061)83 BOLT (6x30) l.5 a 9 1 0 ( 1 ~ 3 e o l Y ( 6 x x l ) 16 09103-&X!49 B a T (6XrZ) 17 w119-05010 BOLT

19 031t;O-o6046 WXR (6.5~20~1.5) 20 0918O-IX105 SPAER (6 .Lrlbt14}

0920594002 SPRINGPIN 21 093%-16001 BWH 22 083111-11052 MJT 23

21 19151-%3[wd2w EETAINER, stator 25 26. 39172-%302 STOPPER, stator

0 - 2 2 3 27 28 29 30 0934347140 CUSHION 31 D9329-oc;oO2 CUSHION 32 33

la

19161-WSOl SPACER, stator

a 9 i ~ 9 - 3 ~ ~ 0 mu oP139-ot;OU SCREW 099140-06000 NUT

01107-05102 K L Y 08322-21052 WASHER

I

3

0125 VJ E3 YL -

0725 VJ €3

FIG. 1 1

7

9 6 5

1 DTZ5 VJ E3

~ ~~

1 31100-96323 2 3U20-96300 3 31320-%300 4 31312-96300 5 31360-96300 6 31273-%301 7 31132-96300 8 31132-96300 9 3113E%300 10 31281-93340 11 bllD7-08252 12 68321-21062 u 08322-11082 14 31800-94400 15 31805-96350 16 0110746202 17 m3u-23062 18 38422-94510

12

FI'C.11 ( C- 4) STARTING MoTIyc

P'TY

REF.NO. PART NO. DESCRIPTION REMARKS 1 WTW ASSY, starter

DT2.5 VJ EY

1 1 1 1 1 1 1

2 2 2 2 2 3 1 1 1 1

t FIG. 1 2 1 !

11

u FIG.12 ( C- 5 ) M Y 0

L 2-1 2-2 3 6 5 6 7 a 9

LO 11 12 u 14 u

32101-%340 32120-%3M 32120-%310 02112-05252 GZ..L-;?1052 32l40-96m 02112-05206 D8321-2lD52 32150-36310 0211244122 08321-21042 321M-%MO 021rp-OSi22 08341-3lM9 09160-18011 08310-22182

D E S C R I P T I O N REMARKS STATOR ASSY 1 '

REKNO. PART NO.

1 ELECTRIC STARTER 1 ~ S T I \ R T E R 2 2 1 2 2

1 2

2 1 3 1 1 1

U725 VJ E3

FIG. 1 3

DT25 VJ E3

FIG.13 ( C- 6) IGNITION P'TY

32900-96540 CDI UNIT / IGNITIW COIL ASSY 1 REENO. PART NO. DESCRIPTION REUARKS 1 2 092Bo-62001 3 33510-95510 4 0948260269 5 32890-%M1 6 3665Q-%rn 7 01107-06122 8 09160-06054 9 092600-l2O20 10 09320-Lzoll 11 32800-95720

12 OZl.33245252 l3 CIBJLU-11052 14 08321-21052

DT25 VJ ES

0 RING CAP, Spark Plug S P N PLUG (8%) HOUIER, electric parts COVER. junction box BM;T

WAsla

Wnyuz C12.5r26wl.6) CUSHION RECTIFIER A5sY SUEU NUT Loa;(w\yoz

1 2 2 1. 1 3 3 3 3 1 1 1 1

FlG. 14 15

FIG.16 ( G- 7) ELECTRICAL

REF.NU. PART NO. 1 36610-96302 2 36619-96304 3 09103-06050

5 09481-2oc01 8 6 35810-96305

‘ 7 33811-96500 8 338U-94501

9 a 36760-95252

9 09103-(#009 10 33816-96300

’ 11 63242-06259 12 37600-93950 u xs99-96302 16 09103-06049 15-1 38423-95501 15-2 33833-951500

a’Ty

REWARKS 1 1 2 1 1 1 1 1 1 1 1 1

1

DT25 VJ E3 DTZ5 VJ ES c7

FIG. 1 5 I t

i d

8

1 2

3 4

5 6 7 8

9

PO

Ll

37160-%310 37142-94302 37721-96554 37725-95500 37726-96301

09100-05104 091*045001 58600-%301

o910045m

091m4Xl10

09162415662

16 FIG.15 ( C- 8) ElECTRlCnL (ELECTRIC STARTER)

P'TY REENO. PART NO. DESCRIPTION RDURKS

SWITCH. start 1 OPT WASHER, ipnition switch SWITM. neutraL ACTUATOR, neutral switch BRIUXEY. neutral switch

NUT SOLENOID, chuke

BOLY (5x12)

WAWER (5.5wloW0.8)

UyxwnsHUz

2

I I 1 1 L 1

2

2

2

OPT

DT25 VJ E3 _- -. - .______

DTZS VJ E3

FIG. 1 6

? 1 3'

29 I

I f FIG.16 ( 0- 2) CLACP W E T

P'TY

1 2 3 I,

5 6-1 6-2 6-3 7-1 7-2 8 9 10 11 12 13 16 15 16-1 16-2 17 181

. 19

RELNO. PART NO. DESCRIPTION REUARKS

DT25 VJ E3 DT25 VJ E3

0920546012 09503-11662 41211-93920 41211-33910 61211-9390il 41222-96310 41222-%311 41215-98100 41221-%300 09140480U D9162-08007

~140-08082 09100-08239 W18O-QSti16 091UObBL% 4UlO-%u16 41310-96501 0936268007 Wl40-08016 wu9-2Mo3

1 1 2 2 1 2 20pt

201r1 1 -717568 1 717549- 2 1 2

2 4 2 2 1 1 nadeP VG,W 1 rnodelVJ 1 1 1

FEC, 1 6

31 I

1 24 i

18 PIC.16 ( 0- 5 ) C W

awn REF.NO. PART NO. DESCRIPTION REHARKS

WFT, clamp bracket (L:282) 1 20 21 22 23 24 25 26 27 28 29 M 31 32 53 w 35

41130-96330 41151-94500 41153-%MO 09580-12005 45700-96301 15720-96301 45725-9*rroo 65730-96301 09Wtl-17Ml w 3 - 6 8 0 0 5 55320-95310 368911-95200 09125-05050 031614M14 (15420-96510 09443-17ol31

0725 VJ €3

2 CAP, shaft 2 CAP, bolt L SPRING

SHntLOw m1VE nssY 1 laodcl VC.W .sHnFT, shallow water drive 1

.w 1

.PLATE. shellow uater drive 1

L .SPRING 1 .SPRING 1 ZINC SET, protection

LEAD 1 ! X S W 2

2 WnSHER

PIN. tilt 1adc 1 modelVJ .spRINc 1 modelVJ

FIG. 1 7 19

FIG.17 ( D- 4) SWIVEL W E T a 'TY

RENARKS REF.NO. PART NO. DESCRIPTION 1-1 1-2 2

3 4 5 6 7

8

9

10 11 12 33 14 u 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

431lZ-96311-02H W U E T , swivel 45111-96320-02U WACXEY, swivel

43711-96301 Buy(, steering upper 437U-WMl Buy(, steering under 43T21-96301 PLATE. upper bush

43751-96303-02w B W X Y , steering

0 9 3 0 6 - m Buyl

091D3-08123 BbLT 434ll-%%l ADJUSTER, steering 434U-%301 BUSH 03119-DBoM BOLT 09460-UM5 SPRING 45231-96303 AM, revera Lock 45246-96302 SPACER 45241-96503 LIW, reverse lock am 95252-96302 LIW. release lever 45255-96300 KNo8, release laver 415257-96300 BUSH, %lease lever 45260-%300 LEYER, release 45311-9&30262M BRPSXET, release lever 09100450Ll BOLT (5w12) D91604MlO WnYlER 09111-10034 BOLT 09145-10032 NUT 0916tlo-t)4012 WAYlER (4.2xlDxl) 09~dS011 PIN 09M4dlOX MlYYER PIN 09319-04001 WSH

22511-99001 NIPPlE, clutch body

43741-%302-02H SHAFT. pilot

09ia0-40005 W~SHER (40u5ex2)

OY25 VJ E3

1 model VG.W

1 mode1VJ 4 1 1 1 1 1 1 2 4 1 1 1 1 1 1 3 1 1 1 1 1 2 2 2 2 1 1 1 1

FIG. 1 7 FIG.17 ( 0-

REENO. PART NO. 31 09440-04021 32 034L3-oU)u 33 ~3-09016 34 45706-%3ll 35 45255-95500

45731-96310 36

37 091L1-10032 38 09160-ob113

09162dboU1 39 40 09443-08031 41 67100-%wM 62 43?55-%Ml 43 091M-06224 44 09162-08w17 45 09340-08016

O W VJ ES

5 ) SWIVEL BRACKET Q'TY

DESCRIPYION SPRING 1 SPRING 1 SPRING 1 yu\uow WATER WIVE SET .MOB, shallow drive .RATE, shallow drive 1 .BOLT 2 .BOLT L .w WnSwER

.sNzING 1 AYTna)lENT SET 1

L 1

1

.ATrACHZNT, steering bracket 1

2 .NU (8x35)

2 .LIxx WAsKR

.NUT 2

REHARKS

model VY

OPT

OPT

OPT OPT OPT

21

FIG. 1 8

REENO. 1 2

3 4-1 4-2 5 6

FIC.16 ( D- 6 ) UOWLST TUBE P'TY

11433-%302 G4SKET. lower oll seal housing L 1 11431-96310 HOUSING. under oil seal

52113-%304 GASKEY. drlve shaft housing 1

PART NO, DESCRIPTION REHARKS

14211-96350 TUBE, exhaust 1 L n P E 14231-96540 TueE, exhaust L s m

osl62-060M WCK wA!%ER 5 5

t9100-06117 BOLT (6x35)

DT25 VJ E3 DTES VJ E3

FIG. 1 9

31

#

_I__---. - - DT25 VJ E3

22 FIG.19 ( 0- 7) WIVEWFT HOUSING

Q'TY

1 2 3 4 5 6-1

6-2

6-3 6-4

6-5 6-6 Y

6

9 10 11 12-1 32-2 13 16 u 16 17 16 19 20

DESCRIPTION REUARM. RELNO. PART NO. 2 09202-060Y5 PIN

09160980U WAYrR 09162-08007 LOCK WAYLEFl 09100-06203 BOLT (8x85)

52111-9632162H HOUSING, drive shaft ( 5 ) 09100-08204 BOLT (8x50)

52111-%322-02H HOUSING, drive shaft (5) 52111-%525-0zW HOUSING, drive shaft IS) 52111-%350-02U HOUSING, drive shaft (L)

52l11-%33142M HOUSING. drive shaft (L) 52ll1-96332-02M HousIffiJG, drive shaft (L) 54lZl-96300 WNYING, upper thrust reverse w100-06102 6 a . Y 0926256OiX LOW WASHER 54U7-%30162U WVER, upper mounting 54130-96310 MUNYXNG, upper

09100-m BOLT t)9160-10062 WASHER (10.5X1W) 09159-10050 NUT

w~oo-iom BDLT (iws)

54160-96310 W I N G , lover 54165-96310 M R , reverse stopper 561666-96301 &oLY, Lower mounting 09140-30032 NUT 09160-10083 WASHER (10.5X30~3.2) 54221-%301-02M COVER. lower mounting

8

8 4 4 1

1 1 1

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

414534 52111-%322-Oa( W/52117-%400 614535.720217 lnodel VJ 414549 5u-96331-02w W / 5 U l Y - ~ 614550-720217 madel VJ

MdeL VG madel VH.VJ

0725 VJ E3

Lh

CAT- 2 CAT- C

f z 2 T T 2

T T T z z t rl

pf

S f 4c f C Z f T f OI: 52

82 LZ 92 n Qt n zz TZ

24

FIG. 20 3 C

REF.NO. 1 2 5 4 5 6 Y 0

9

10 11 12 U-1 l3-2 u-3 l3-4 u-5 u-6 U-7 14 15-1 15-2 u-3 u-4 u-5 15-6 15-7 u-8 16 17-1 17-2 18

___.

1 1 1 1 1 1 1 3 3 6 6

2 1 1 1 1 1 1 1 1

1 1 f 1 1 1 1 1 1 1 1 1 1

RWRKS

PW1 Plml P l l O l Plzbl p1301

PlirDl P l M l PSL3M).Stalrtless Steel

far Ref.No.u for Ref.No.U

DT2S VJ E3 D9

FIG. 20 ..r

25 FIC.20 ( D-30) GZPR CnJE

P'M

1 1 1 2 2

REENO. PART NO. DESCRIFRON REMARKS 09160-14MB WGHf3 (14.5WX2.5) 09159-14031 NUT

19 20

21 22 23

25

092[)4-03004 COTTERPIN 17631-%310 FILTER. water 03142-04259 TAPPING

24 55360-95500 ZXNC ASSY, protectrM 1 B T 1 55181-95200 A'lYI\CMWT, flush how

- 5

DY25 VJ U

FIG.21

1 b 0 I

16 3

REENO. PART NO. DESCRIPTION REHARKS 1-1 1-2 2

3-1 3-2 3-3 3 4 3-5 3-6 3-7 5-8 41 5 6 7 8

9 10 U-1 11-2 u-3 u.4 51-5 ll-6 12 u 14 u 16 17 18 19 20 21 22

M, drive M. drive 1)(Rusl kaER XASIER (T:O.S) WAYLR (T:0.9) WAYul (1:1.0) WASHER (Y:l.l) WASHUZ (TA.2) wl\yw (Y:1.3) WlSlER (1:1.4) WAYur (1:l.S) CIRCUP SPRING WAYlER wsn3 SPACER, preload spring m m PINIOlJ WAStEK (T:1.7) WSlER (T:r.a) WmER (T:l.9) WmER (7:2.0) WISER (T:2.1) MwER (T:2.2) NUT 0 RPWG m, P d YWDl [1:1.5) m. PU* PIN WIRER. clutch tJo~ PIN . SPRTNG SPRING y(AR, propeller

1 S T W E 1 LTYPE 1 1 1

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

0-1 0-1 0-1 bl a-1 0-1 1 1 1 1 1 1 1 1 1 1 1

I I FIG. 21 27

FIG-21 ( D12) TRIWSC(ISSI0H

P’TY

23-1 23-2 23-3 25-4 23-5 234 24 25-1 25-2 3 - 3 25-4 26 27 28 29 50 31

DESCRIPTION REMARKS R E N O . PART NO. 08221-20256 wny(ER [Y:o.8)

16 3

DTZS VJ U

FIG. 22

' 5

v5 e3, 8 - 4 ? 'P

I E l

6

28 FIG.22 E- 2) W R COVER

P'TY REENO. PART NO. DESCRIPTION RHARKS 1 2 3 4 5 6 7-1 7-2 8

9 30 11 12 u 14

IS 16

61110-%304-OW COVER, engine under 6llL3-96300 SEAL. under cover 0932O-lCnJ31 CUSHION, under cover 09180-06112 SPACER (6.8X10~11.5) 09105-D6094 BOLT (6x25) 092xJ-t)81J07 w , c u s h i o n 61631-96301 W, under cover 6U31-94410 Hww(, uwks cover 09r64-uo05 WjIm 09306-13Do2 Buyl

61633-960U2-02M LEVER. hook 0110746102 BOLT 08322-21062 Ksm m25-94300 cnp 225U-99001 N I W . dutch notch CILu&%ML COVER,*eter wl25-06069 SCRRJ

1 1 4 4 4 2 1 model. VC,W 1 nadeLV3 L 1 1 1 1 1 ' L 1 2

FIG. 23

29

FIG.23 ( E- 3) ENGIM COVER

OT25 VJ E3 P . . . __. . __

Q'TY - . .

REllARKS REF.NO. PART NO. DESCRIPTION

1-1 61401-96850-0~~ COW SET, engine 1 model V6.W -. .. ~_._

1 m 0 d e l V Y 1-2 2

61401-96831-02H COVER SET , engine 61431-%301-02~4 .HIwoLE, tilt w 1

3 4 5 6 7 0

9 10-1 10-2 11 12 u 14 15 14 17

3 1 1 1 1 1 2

0324246169 .SCREW 61422-93930-706 .MIX, emblem. Prunt 61443-96380-2G .LEU, side STm 61653-%380-2G .DEW, side PORT 61435-%380-7OC .EM3LEu, r w 21131-96003 .MAW, clutch shift 61441-96310 .DB1M. side

61610-96502 .FASYEt&3 1 -1 VG,W

01107-0b122 .BOLT 083U-2l062 .uxXwnyER

08322-21062 .WASHER

61610-96310 . FASTEN3 1 hadeLVY 1 1 1 L 61132-96302 RUBBER. wder cover

61622-96301 SEAL, tubber, recoil starter 1

0980041800 T M L S E T 68110-95210 'COMR, weather 1 OPr

1

DY25 VJ E3

-- _ _ .

FIG. 24

1 2 3 4 5 6 7 8

9 10 11 12 l3 14

- u 16 17 18 19 20 21

30 FIG.24 ( E- 4) HANolE

P'TY REENO. PART NO. DESCRIPTION REHARKS

1 63121-96302-0a4 MWER, t i l l er handle

1 2 2 2 1

63114-94500 SPI\IxR, handle cover 09108-08147 STUD B a T

Q9162-08oO7 LOCK wc\sHER 09140-08016 NUT 63lLL-%311-024 HnNocE, t i l l er 63115-%M1 63625-%300 63610-%301 63W-952aO 63240-96300 09440-12027 63227-93200 63223-93202 0916346001 09J.26-06oO6 63220-93901 63220-96300 632115-93400 63U7-96300 63300-93900

1 1 2 1 1 1 1 L:14 1 1 1 1 1 1 l. 1 m

E4

FiG. 25 25

I 1 2 3 4 5 6 7 8 9 LO L1 12 13 14 Ls l 6 17 18 19

u 22 23 24 25

m

65000-95201 65510-98507 65S61-98502 65871-93010 OZlS2-06162 02112-06402 09168-0&lO2 65850-95506 65740-95500 65855-93001 65853-9-1 0w2-04208 65864-95200 65830-95500 09168-12c01 65700-95206 65750-38505 65750-9W 65781-98500 65770-99703 6572o-985m 083U-ZU02 0 8 Y 1O-p102 657cO-9527L 65720-98590

31 FLG.25 ( E- 5 ) NEL TAN( <ti?33EL VG,W)

P‘TY REMARKS REENO. PART’ NO. DESCRIPTION

TAN( SET. fuel (23L) 1 6 a.m./ 5 W.W. .CAP nssY .GI\sKET .GQSKET. fuel gauge .SCREW .SCR€W .wAyIER

.w my, fuel

..CONNECTOR, male fuel

..GASKET, strainer

..SCREW . . m y

..FILTER, outlet

..GASKET (lZ.Sx20rl) I@€, fuel .coHsCToR, female fuel .coHJEFIw, femele fuel .CLIP .w, squeeze CONJECIOR, male fuel UKxwAYul WT HOSE, fuel jafnt W C I O R , mle fuel

. .sTRnrm

1 1 1 3 1 4 1

1 1 2 1 1 1 1 i ID:U 1 I0:13 4 1

1 Wl2,OO:U

i m:u 2 . 1 L O P T 1 OPT”LU2-21

DY25 VJ €3

Refer t o FPG.26 (€4) for FUEL (MOEL VJ)

I F6G. 26 f 6

32 FIG.26 ( E- 6) RlEL TAW (WWL VJ)

P'TY REUARKS DESCRIPTION REENO. PART NO,

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 K 17 18 19 20 ZL 22 23

65800-92820 65510-92Mo 6556L-92WO W2-06162 091688-06002 65720-94410 0916a-12001 65850-92000 65855-92000 L585ii-92010 65853-= 65854-9ZlXto 03221-06086 65860-32WO 6s-921110 65871-92000 655co-87015 657,750-94403 65770-95503 65781-98500 65720-p4600 68320-22102 08321-21102

TAW SET. fuel (24L) .CAP ASSY, separate tank . .GEXET, tank cap

.SCREW

.WAYER

.CChWECTCR, fuel

.CASKET. connector

.muGE A S Y , rue1

..covER'!3awe

..GASKET

..LENS

..cnsKEY. lens . .s€R€n . . r u l A T ""NUT, push ..u\sKET, PW1 Hoy. fuel .-OR, fuel .PUP, squeeze .CUP CotwCYoR, fuel hlllT umC.MsH€R

1 1 1 4 4 1

1 1 1 1 1 1 2 1 1 1 1 2

1 4 1 1 1

6.3 U.S W 5 . 3 Twp W

DY25 VJ E3 0725 VJ E3

33 ~1c.27 ( F- 21 w r I m : ELECTRICAL (FOR MANUAL STARTER)

P'TY

1 1 L L 1 1 1 L

REENO. PART NO. DESCRIPTION REHARKS 1 31101-9630 MCTCft SET, starter 2 33800-%303 SWITCH, starterlcable set 3 32102-%380 FLWEEL 4 32801-%Mo RECTIFIER SET 5 3679l.-952OO .W.JER 6 36898-93300 .LEN), w i r e 7 33815-94500 PROIECTW, cable 8 09103-Ddo49 BOLT (6x12)

FIG. 27

4 3

1 I

Dl25 VJ E3 F2

34

- FIG. 28 FIG.28 ( F- 3) OPTIONAL : ELECTRICAL (FOR ELECTRIC STARTER) Q'TY

REHARKS REENO. PART NO. DESCRIPTION 1 2 3 4 5 6 7 8 9 I0 11 12 u 14 15-1 15-2 15-3 Ls-4 15-5 l5-6 16 17 18 19

32500-95722 01107-06128 08322-UO67 36620-87020 36630-96330 36631-94300 36639-94300 36632-95501 37100-95210 37820-95355 37139-93251 371M-933M 37101-93310 37330-95210 37243-93W 3714195310 37141-93320 37141-93330 37141-93340 37141-933% OJU2-06120 366l2-94301 36633-94306 37820-94620

0725 VJ U

REGUUTOR, voltage BOLT WAStER WIRING tiWESS, extension WIRING HnwIIEsS, r m - c b n .W, temo-con harness GRou&T Claw, connector grannet PAEL S Y , switch SWITCH B Y . emergency .PANEL, switch .HouER .WI Panel .SWITCH. wprgency .*KEY, Spare (8511) ..KEY, spare (8512) ..KEY, spare (8553) ""KEY, spare (8611) ..KEY, spare (a612)

..KEY, rpsre (a6W SCBW C;W)*(ET, 1 GRUWT. 2 W T W A S Y , emergency

1 2 2 1 1 1 1 1 1 i 1 1 HZ7.1 2 1 1 I 1 L 1 1 b

1 1 1

FIG. 29

1 2 3 4 5-1 5-2 6 7 8

3

10 ll 12 13 14 15

35

FIC.29 ( F- I ) OPTIONAL : ELECTRICAL

Q'TY

1 REF.NO. PART NO. DESCRIPTION REMARKS

' TACMMYERASSY

.BULB (lZv,3.4W) SPEEW#TER ASSY

.BULB CWJ.4W) MYW ASSY, hour KYER S S Y , hour MYER ASSY, voltage .BULB (lZv,3.4W) SWITCH. heat SOPWRTW, unit CLACP (L:52) W ~ . uarnlng W, warning buzzer ScIEw SWITCH ASS, meter LEnD, meter extensim

1 1 1 II. 1 PWRYZ 1 1 1 1. 1 1 1 2 1 1.

DT25 VJ E3 DT25 VJ E3 w

36 FIG.N) c F- 5 ) WYIW : ~ u c m r w [m HI\MIAL STARTER)

4 ' TY

REF.NO. PART NO. DESCRIPTION REMARKS 1 2 2 1 1 1 L 1

3290-95722 REouLI\YoR, voltage 0110746L28 BOLT 08322-23067 WnsHER

1 2 3 4

5 6

7 8

39600-93900 CONSENT sEr 36632-9Sxll . C W 39601-93902 .CONSENT ASSY, lenp 39602-93900 .PUG ASSY, lam@ cord 39603-939od .GR(WIET

FIG. 30

I 4 7

2

8 5

DT25 V3 U

FIG031

1

I

1 2 3 4 5 6 7 0 9

10 11 12 l3-1 13-2 l3-3 u-4 u-5 u-6 u - 7 13-8 u - 9 U-M u-11 u-12 l3-u 13-14 l E l 5 U-16 11 15

37 FXG.31 ( F- 6 ) BTIOIJAL : REMITE C M R M PARTS

Q'TY

REENO. PART NO. DESCRIPTION REUARKS 67UO-963DZ-O% REMOTE CMRDL PARTS ASSY

67341-94M1 . W R . remo-con cable 67440-93701 .UJXoE. clutch cable oP205-02006 ..SPRING PIN ~ - 0 9 0 1 2 ..SPRING 00160-D6015 .wnMR (6.5xUxl) 002M)-06115 .BOLT (6xU) 67466-95200 .CONNECTOR, remo-con cabla

091W3-061u 09360-06515 09119-06047 67320-95500 67320-95510 67320-95520 6732093530 67320-95540 67320-95550 67320-95560 67320-95570 67320-95580 67320-95590 67520-95600 6?320-35610 67320-95620 67320-9!5,630 67520-956hU G7320-95650 67200-95203 67200-95213

16 672M-95871

[IT25 VJ E3 . __ -.

1 2 1 1 1 2 2 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1

BDX ASSY, t w i n remaeon &

I

I FIG. 32 1 I

18 14

’? I

38 FIG.32 ( F- 7) OPTIoNnL : REMITE CONTROL

P’TY REENO.

1-1 -

1-2

1-3 2 5 4 3 6 7 8 9

10 11 Lz-1

12-2 13 14 15 16 17 18 19 20 21 22 23 24

PART NO. DESCRIPTION 672CU-WLO-OBi RE!WTE CQIClRa 8ox S S Y 1

67200-93960 67232-95600 67232-95620 67296-95600 67294-95600 67288-94510 t)914O-W&34

67232-95610 0253-9- 67252-956kM o9im-oeiiz 67296-94300

Dl25 VJ E3

6723&94300 67241-95650 09326-O5&l3 67243-95600 67220-956m 67273-95600 67223-95600 67292-94500 67267-95610 6.7296-95610 6725745610 67256-95600 67251-95650

.sCfEw -LEVER’ f t ~ t h b t .soREw .Buy(

.PLATE ASSY

.END, eeble

.KNOB, brake AW

.E RINS

.CWER, uire .SCREW .W. lever .HOLLER, neut lock .LEVER, handle

1 1 1 3 3 3 3 2 1 2 1 3

2 1 2 1 1 2 1 3 1 7 1 1 1

* 67200-93960 includes ReP.No.2-U)

REHARKS model vG,w W i t h ELECTRIC START PARTS

mdel VJ With ELECTRIC START PARTS Y(m r\lg T m m W Y

PIG. 32 I ! ~

I

I

1 . .KEY (101) 1 ..KEY (102) 1 1 ..KEY (104) 1 . .KEY (105) 1 ..KEY (106)

.Buzzl? 1

.m

..KEY (103)

39 FIG.52 ( F- 8 ) W T I W : RWOTE UnJTRM.

Q'TY

lmdel VG.W

18 DESCRIPTION REUARKS REF.NO. PART NO.

2 25 67297-95600 .W 26 27 20 29 30 31

32 33 344 34-2 34-3 34-4 34-5 3t-6 35-1 35-2 36 37 38

67273-95600 37820-WO2 37823-94400 67255-95600 67261-95650 672144-915600

37721-94600 37110-94600 37143-94400 37141-94410 37141-94420 3714 1-944M 37141-94440 37142-94450 3am-87m 3850047010 %20-94610 677140-956C~l 67282-95610

0725 VJ E3

60 FI6.35 ( F- 9 ) O P T I W : WnG LYM

P'TY

REF.NO. PART NO. DESCRIPTION REMARKS 1 67701-%XtO DRI\C LYW asSV 1

t 1 FIG. 33

43755-%301 67721-90300 6776-90500 67726-94500 091W-08U4 091.40-08016 67728-90501) 09162-08007

1. 1 . 1 2 2 2 3 2

0725 VJ €3

FIG. 34

tIv2.5 VJ ES

9

1

~

0125 VJ E3