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Periodic maintenance
Periodic maintenance schedule
Maintenance and tune-up procedures
Oil pressure
Cylinder compression
Engine control system
Engine control system structure
Components for system control
Ignition system
Electronic fuel injection system
Caution system
Self-diagnostic system
Fail-safe system
Operating hour indication system
Oil change reminder system
Start-in-gear protection system
Feedback system
Inspection
Troubleshooting
Removal / installation
Electrical
Battery charging system
Electric starter system
Monitor-tachometer
Electric parts holder
Wire / hose routing
Wiring diagram
Wire routing
Fuel / water hose routing
Fuel system
Precaution on fuel system service
Fuel line
Fuel vapor separator / high pressure fuel pump
Fuel injector
Low pressure fuel pump
Tank
Power unit
Intake manifold assembly
Power unit
Oil pump
Timing chain / tensioner
Cylinder head assembly
Cylinder / crankshaft / piston
Thermostat
Operation
Mid unit
Engine side cover
Driveshaft housing and oil pan
Swivel bracket, steering bracket and clamp bracket
Water pressure valve
Power trim and tilt
System wiring diagram
Service procedure
Power trim and tilt unit
PTT motor relay
PTT switch
Operation
Lower unit
Removal and disassembly
Pinion bearing
Inspection
Assembly and installation
Trim tab
Lower unit gears-shimming and adjustment
DF140 “K2” (’02) model
General information
Engine control system
Power unit
Mid unit
Power trim and tilt
Lower unit (normal rotation model)
Counter rotation lower unit (DF140Z)
Wiring diagra
Hose routing
DF90 / 115 “K2” (’02) model
Specifications
Service data
Tightening torque
Materials required
Fuel/water hose routing
Over-revolution caution system
Crank pin and conrod bearing
Conrod assy and bearing
Crankshaft and flywheel
Camshaft and tappet shim
Engine holder gasket
Engine holder bolt
Upper mount front nut
Clutch linkage
DF90 / 115 / 140 “K3” (2003) model
Specifications
Service data
Tightening torque
ECM
ECM main relay and starter motor relay
Battery charge coil
Rectifier and regulator
Exhaust cam shaft (for DF115 only)
Remote control cable holder
Cylinder head instllation
Crankcase to cylinder instllation
Upper mount
Drive shaft
Propeller shaft bearing housing
Wiring diagra
Water hose routing
DF90 / 115 / 140 “k4” (’04) model
Specifications (DF90T / 115T / 115WT)
Specifications (DF140T / 140WT / 140Z)
Service data (DF90 / 115)
Service data (DF140)
Temperature sensor
Cylinder block
Rectifier and regulator
Power trim and tilt (P.T.T.) relay
Electric parts holder
P.T.T. Motor
Tilt limit switch system
Swivel bracket
Clamp bracket shaft
Port clamp bracket
Driveshaft
Pinion gear back up shim
Lower unit gears-shimming and adjustment
Wiring diagram
DF90 / 115 / 140 “k5” (2005) model
Specifications (DF90T / 115T / 115WT)
Specifications (DF140T / 140WT / 140Z / 140WZ)
Service data (DF90T / 115T / 115WT)
Service data (DF140T / 140WT / 140Z / 140WZ)
Engine wiring harness
Safety relay system
ECM
Sub-battery cable
Remote control box and remote control wire
Tilt limit switch cover
Piston oil ring
Tensioner adjuster
Engin holder
Upper and lower mount
Transom bolt
Wire / hose routing
Wiring diagram
DF90/115/140 “K6” (2006) model
Specifications (DF90T / 115T / 115WT)
Specifications (DF140T / 140WT / 140Z / 140WZ)
Service data (DF90T / 115T / 115WT)
Service data (DF140T / 140WT / 140Z / 140WZ)
Tightening torque
Periodic maintenance schedule
ECM
Neutral switch
Fuel filter
Delivery pipe
Oil strainer
Oil cooler (for DF140)
Engine holder and cylinder block
Cltuch link
Swivel bracket bushing grease path
Clamp bracket (for DF90 AND DF115)
Swivel bracket
Steering bracket
Upper mount
Water pump
Water pump tube
Exhaust seal rubber
Shift rod guide housing
Shift rod, shifter yoke and horizontal slider
Drive shaft
Propeller shaft and connector pin
Forward gear and clutch dog
Wiring / hose routing
Wiring diagram
DF90 / 115 / 140 “K7” (2007) model
Specifications (DF90T / 115T / 115WT)
Specifications (DF140T / 140WT / 140Z / 140WZ)
Service data (DF90T / 115T / 115WT)
Service data (DF140T / 140WT / 140Z / 140WZ)
Periodic maintenance schedule
ECM
Fuel hose, cable grommet and front panel
Pinion / gear set
DF90 / 115 / 140 “K8” (2008) model
Specifications (DF90T / 115T / 115WT)
Specifications (DF140T / 140WT / 140Z / 140WZ)
Service data (DF90T / 115T / 115WT)
Service data (DF140T / 140WT / 140Z / 140WZ)
Periodic maintenance
Engine control system
Digital gauge system
Engine holder
Wiring diagram
Wire routing
DF100 “K9” (2009) model
General information
Engine control
Power unit
Wire / hose routing |
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