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General| Max Power | 140 HP |
|---|---|
| Gear Ratio | 2.59:1 |
| Starting System | Electric |
| Steering | Remote |
| Number of Cylinders | 4 |
| Alternator Output | 12V 40A |
| Trim Method | Power Trim and Tilt |
| Exhaust | Through propeller |
| Displacement | 2, 044 cc |
| Shaft Length | 20 in |
| Oil Capacity | 5.0 L |
| Engine Type Detail | 4-Stroke |
| Engine Type | 4-Stroke DOHC 16-Valve |
| Fuel System | Multi-point sequential electronic fuel injection |
Detailed specifications for DF90T, DF115T/115WT, DF140T, DF140Z/140WZ models.
Key service data for Powerhead, including recommended operating range and compression.
Torque specifications for important fasteners, including general bolts.
List and illustrations of special tools required for servicing.
List of required materials such as oils, greases, and sealants.
Recommendations for fuel type, octane rating, and engine oil specifications.
Procedure and recommendations for breaking in new or rebuilt outboard motors.
Information on recommended propeller specifications and selection.
Recommended intervals for periodic service work based on hours or months.
Detailed servicing procedures for periodic maintenance requirements.
Procedure for changing engine oil and replacing the oil filter.
Procedure for changing gear oil, including recommended oil type and capacity.
Points requiring lubrication and recommended grease.
Inspection and replacement procedures for spark plugs, including gap and carbon deposit checks.
Procedure for checking and adjusting tappet clearance for intake and exhaust valves.
Procedure for checking and adjusting engine idle speed using the IAC valve.
Procedure for inspecting ignition timing at specified engine speeds.
Procedure for measuring cylinder compression and identifying potential issues.
Overview of the integrated control system and its components.
Description of major control components like ECM, sensors, and actuators.
Details on CKP, CMP, MAP, IAT, and CTP sensors and switches.
Explanation of how the ECM controls ignition timing based on sensor inputs.
Overview of the speed-density, multi-point, sequential fuel injection system.
Description of caution systems for over-revolution, low oil pressure, overheat, and low battery voltage.
Explanation of diagnostic codes, flashing patterns, and fail-safe system activation.
Diagnostic flowcharts for common system faults and malfunctions.
Circuit illustration and explanation of the battery charging system.
Circuit diagram and explanation of the starting system components.
Procedures for starter motor removal, installation, disassembly, and inspection.
Inspection procedure for the ignition switch continuity at key positions.
Inspection procedure for neutral switch continuity in remote control box and on cylinder block.
General safety precautions when working with gasoline and the fuel system.
Procedure to relieve fuel pressure before disconnecting or removing fuel system components.
Procedures for removing and installing fuel hoses, including cautions.
Procedure to check for fuel leakage after performing fuel system service.
Removal, disassembly, inspection, and assembly procedures for these components.
Procedures for inspection, removal, and installation of fuel injectors.
Procedures for removal, installation, disassembly, and inspection of the low pressure fuel pump.
Procedure for removal and installation of the intake manifold assembly.
Step-by-step instructions for removing the power unit.
Procedures for removal, installation, disassembly, inspection, and reassembly.
Procedures for disassembly, inspection, servicing, and reassembly.
Inspection of cam face, cam wear, and camshaft identification.
Specifications and procedures for valve diameter, clearance, and guide inspection.
Measurement of piston ring end gap, free end gap, groove width, and thickness.
Inspection and assembly of connecting rod components.
Measurement of crankshaft runout, thrust play, and bearing thickness.
Procedures for oil pump removal, inspection, and installation.
Procedures for timing chain and tensioner removal, inspection, and installation.
Procedure for thermostat removal, inspection, and installation.
Diagram and explanation of the engine oil lubrication system.
Procedure for removing the engine side covers.
Procedure for removing the driveshaft housing and oil pan.
Procedure for removing swivel, steering, and clamp brackets.
Procedure for water pressure valve removal, inspection, and installation.
Procedures for checking oil level and air bleeding the PTT system.
Step-by-step instructions for removing the power trim and tilt unit.
Information on PTT motor installation, air bleeding, and removal.
Methods for testing PTT motor relays, including resistance and operation checks.
Procedure for testing continuity of PTT switch at different positions.
Explanation of how the power trim and tilt system operates.
Detailed explanation of the TRIM / TILT "UP" and "DOWN" circuits.
Procedures for removing and disassembling the lower unit.
Procedure for pinion bearing removal and installation, including required tools.
Inspection of propeller for damage, wear, and slipping.
Inspection of gearcase for cracks and pinion bearing for wear.
Inspection of horizontal slider, connector pin, clutch dog shifter, and dog pin.
Inspection of shift rod guide housing, shifter yoke, oil seal, O-ring, and detent ball.
Inspection of impeller vanes, pump case, and under panel for damage.
Inspection of housing, oil seals, and O-ring; procedure for replacing oil seals.
Inspection of driveshaft splines and bearing for wear or damage.
Procedures for assembling and installing the lower unit components.
Procedure for adjusting the trim tab to counteract steering pull.
Procedure for shimming gears to ensure correct contact and backlash.
Procedure to measure and adjust propeller shaft thrust play.
Complete wiring diagram for DF90T/DF115T models.
Illustrations showing proper routing of wires and cables.
Illustrations showing proper routing of fuel and water hoses, with cautions.
Detailed specifications for DF90T, DF115T/115WT models.
Key service data for Powerhead, including recommended operating range and compression.
Torque specifications for important fasteners for DF90/115 models.
List and illustrations of special tools required for servicing DF140 models.
List of required materials such as oils, greases, and sealants.
Information on ECM, wiring harness, and digital gauge system for DF140.
Details on engine oil cooler, camshaft, cylinder block, and crankshaft components.
Information on camshaft height and identification for DF140 models.
Specifications and procedures for valve diameter, clearance, and guide inspection.
Specifications for cylinder bore, piston skirt, and piston ring dimensions.
Specifications for conrod and crankshaft bearing dimensions and clearances.
Service procedures for oil level, air bleeding, and unit removal/installation.
Procedures for PTT motor removal, disassembly, inspection, and assembly.
Procedures for lower unit removal, disassembly, and assembly for normal rotation models.
Procedure for shimming gears to ensure correct contact and backlash.
Detailed specifications for DF90T, DF115T/115WT models.
Key service data for Powerhead, including recommended operating range and idle speed.
Torque specifications for important fasteners, including specific values for DF90 and DF115.
List of required materials such as oils, greases, and sealants.
Illustrations showing proper routing of fuel and water hoses, with cautions.
Specifications for ignition and fuel injection systems, including changes from previous models.
Information on changes to camshaft and cylinder block for DF140 models.
Specifications for camshaft height and identification for DF90 and DF115 models.
Specifications for valve diameter, clearance, and guide protrusion.
Specifications for cylinder bore, piston skirt, and piston ring dimensions.
Specifications for conrod and crankshaft bearing dimensions and clearances.
Specifications for ignition, starter motor, and electrical system components.
Specifications for starter motor output, brush length, and commutator dimensions.
Specifications for PTT motor brush length and commutator diameter.
Troubleshooting guide for diagnostic codes, lamp flashing patterns, and fail-safe systems.
Detailed specifications for DF90T, DF115T/115WT models.
Key service data for Powerhead, including recommended operation range and idle speed.
Specifications for cylinder head distortion and camshaft dimensions.
Specifications for valve diameter, clearance, and guide dimensions.
Specifications for cylinder bore, piston skirt, and piston ring dimensions.
Specifications for conrod and crankshaft bearing dimensions and clearances.
Specifications for ignition timing, starter motor, and electrical system components.
Specifications for starter motor output, brush length, and commutator dimensions.
Specifications for PTT motor brush length and commutator diameter.
Information on changes to the cylinder temperature sensor.
Information on changes to the cylinder block due to temperature sensor modification.
Information on changes to the rectifier & regulator due to temperature sensor modification.
Information on changes to P.T.T. relays, relay plate, and ground cable.
Description of the added tilt limit switch system and adjustment procedure.
Procedure for adjusting lower unit gears, shimming, and backlash.
Detailed specifications for DF90T, DF115T/115WT models.
Key service data for Powerhead, including recommended operation range and idle speed.
Torque specifications for important fasteners, including model-specific changes.
List of required materials such as oils, greases, and sealants.
Specifications for ignition and fuel injection systems on DF100 models.
Information on intake camshaft changes for DF100 models.
Details on intake camshaft design and identification marks for DF100.
Illustrations showing proper routing of wires and hoses for DF90/115/140 models.
Complete wiring diagram for DF90/115/140 models.
Specifications for PTT motor brush length and commutator diameter.
Troubleshooting guide for diagnostic codes and fail-safe system activation.
Specifications for cylinder head distortion and camshaft dimensions.
Specifications for valve diameter, clearance, and guide dimensions.
Specifications for cylinder bore, piston skirt, and piston ring dimensions.
Specifications for conrod and crankshaft bearing dimensions and clearances.
Specifications for ignition timing, starter motor, and electrical system components.
Specifications for starter motor output, brush length, and commutator dimensions.
Information on changes to engine wiring harness connectors.
Details on the added tilt limit switch cover and related bolt changes.
Information on changes to the exhaust plug, gasket, and circlip.
Details on changes to transom bolt thread pitch and washer thickness.
Detailed specifications for DF90T, DF115T/115WT models.
Key service data for Powerhead, including recommended operation range and idle speed.
Torque specifications for important fasteners, including changes from 2006 model year.
Recommended intervals for periodic service work.
Information on ECM program changes.
Information on the redesigned neutral switch feature.
Information on the new style fuel filter with a drain feature.
Information on changes to the delivery pipe shape.
Information on the addition of an O-ring to the oil cooler.
Information on changes to cooling water passages and related components.
Details on changes to the clutch link and related parts.
Information on redesigned swivel brackets with fewer grease nipples.
Information on redesign of the upper mount system and steering bracket modification.
Information on changes to upper mount, related parts, and tightening torque.
Information on changes to the water pump and related parts.
Details on changes to shift rod guide housing shape, materials, and bolts.
Information on changes to the shape of shift rod, shifter yoke, and horizontal slider.
Illustrations showing proper routing of wires and hoses.
Complete wiring diagram for DF90/115/140 models.
Detailed specifications for DF90T, DF115T/115WT models.
Key service data for Powerhead, including recommended operation range and idle speed.
Specifications for cylinder head distortion and camshaft dimensions.
Specifications for valve diameter, clearance, and guide dimensions.
Specifications for cylinder bore, piston skirt, and piston ring dimensions.
Specifications for conrod and crankshaft bearing dimensions and clearances.
Specifications for ignition timing, starter motor, and electrical system components.
Specifications for starter motor output, brush length, and commutator dimensions.
Specifications for PTT motor brush length and commutator diameter.
Troubleshooting guide for diagnostic codes, lamp flashing patterns, and fail-safe systems.
Recommended intervals for periodic service work.
Information on the warning memory condition program on ECM.
Information on changes to fuel hose, cable grommet, and front panel.
Details on the added tilt limit switch cover and related bolt changes.
Information on changes to gear tooth numbers and gear ratios for DF140.
Detailed specifications for DF90T, DF115T/115WT models.
Key service data for Powerhead, including recommended operation range and idle speed.
Torque specifications for important fasteners, including model-specific changes.
Recommended intervals for periodic service work.
Procedure for adjusting engine idle speed using IAC valve duty.
Information on ECM program changes and wiring harness modifications.
Details on ECM program changes and accommodation of digital gauges.
Information on changes to SDS communication connector and digital gauge connections.
Information on available digital gauge components and installation.
Procedure for setting up the tachometer according to engine specifications.
Explanation of caution system and self-diagnostic system indications.
Information on the elimination of exhaust plug and gasket.
Complete wiring diagram for DF90/115/140 models.
Illustrations showing proper routing of wires for the engine.
Detailed specifications for DF100T/100WT models.
Key service data for Powerhead, including recommended operation range and idle speed.
Torque specifications for important fasteners, including model-specific changes.
List and illustrations of special tools required for servicing DF100 models.
List of required materials such as oils, greases, and sealants.
Specifications for ignition and fuel injection systems on DF100 models.
Information on intake camshaft design and identification marks for DF100.
Details on intake camshaft design and identification marks for DF100 models.
Illustrations showing proper routing of wires and hoses for DF90/115/140 models.
Complete wiring diagram for DF90/115/140 models.
Illustrations showing proper routing of fuel and water hoses, with cautions.
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