FOREWORD CONTENTS Page

The primary purpose of this manual is to provide Honda
dealers with the established Labor Operation Numbers and
Flat Rate Times for work done in connection with the
applicable warranty offered by American Honda
Motor Co., Inc.
For more detailed information on warranty claim
preparation, please refer to the Warranty Operations chapter
of the Service Operations Guide (TM045).
Portable Outboard Motors……………………………. 1
BF2, BF5, BF8, BFP8, BF9.9, BFP9.9, BF15, BFP15,
BF20, BFP20
Marine Engines……………………………………………
15
BF25, BF30, BF35, BF40, BF45, BF50, BF60, BF75, BF90,
BF115, BF130, BF135, BF150, BF200, BF225

Each model section contains Flat Rate Time and Labor

Operation Numbers for all the major components on
Honda Marine Engines and Portable Outboard Motors.
At the sole discretion of the dealer, these times may also
be used as a guide for computing retail labor charges.

The flat rate time allowances published in this manual

are subject to revision by American Honda Motor Co.,
Inc. at anytime without notice, depending upon new time
studies, design changes or improved methods, techniques,
equipment, or other advances in the industry.

The most up-to-date flat rate information is available on the

Interactive Network (iN). Select SERVICE>
Online Flat Rate Manual to use the Online Flat Rate system.

Portable Outboard Motors and Marine Engines

i Foreword and Table of Contents
ii Portable Outboard Motors and Marine Engines
Foreword and Table of Contents
Model VIN Plate Repair Page
BF2A BAEB, BAEL, BAES Engine Lower………………………………………… 2
BF2D BZBF, BZBJ, BZBK, BZBL Engine Upper, Recoil Starter…………………………3
BF5A BADL, BADS Oil Pump, Water Pump, Oil Pan…………………… 4
BF8A BACL, BACS, BACU, BZBC Gear Case, Centrifugal Clutch………………………5
BF8D BAAJ Vertical Shaft/Propeller, Fuel Tank/Pump………… 6
BFP8D BAAJ Carburetor, Breather, Exhaust………………………7
BF9.9A BABL, BABS, BABU Frame, Body……………………………………………8
BF9.9D BABJ Battery Cable, Wire Harness, Starter Motor……… 9
BFP9.9D BABJ Charging System, Ignition System………………… 10
BF15A BAAL, BAAS, BAAU Switches, Lights……………………………………… 11
BF15D BALJ Control Panel………………………………………… 12
BFP15D BALJ Meters, Steering………………………………………13
BF20A BAHL Cables………………………………………………… 14
BF20D BAMJ
BFP20D BAMJ

Portable Outboard Motors

1 Table of Repair Contents
 2 Portable Outboard Motors
Engine Lower
Engine Lower
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
110101 Outboard motor (remove and reinstall not included) N/A N/A N/A N/A N/A N/A 0.4 N/A
110105 * Cylinder/Crankcase Assembly 2.3 1.6 2.2 3.5 5.0 4.2 6.5 5.0
110125 * Crankshaft 1.9 1.3 1.9 2.6 4.3 3.3 6.5 4.3
110126 Crankshaft Bearing - Output Shaft Side 1.4 N/A N/A 2.1 N/A 2.8 5.5 N/A
110127 Crankshaft Bearing - Flywheel Side 1.5 1.4 2.0 2.1 N/A 2.8 N/A 1.1
110128 Crankshaft Bearing - Both Sides 1.9 N/A N/A 2.2 N/A 2.9 N/A N/A
110130 Crankshaft Oil Seal - Output Shaft Side 1.4 0.6 0.9 2.0 2.0 2.6 N/A 2.0
Crankshaft Oil Seal - Flywheel Side
110131 1.5 0.6 0.5 2.0 1.1 *1.0 2.7 1.1
*Does not require engine removal.
110132 Crankshaft Oil Seal - Both Sides 1.7 1.2 1.4 2.1 3.1 2.6 3.0 3.1
110135 Balancer Weights or Bearing A or B N/A N/A N/A N/A N/A 1.1 N/A N/A
110145 * Connecting Rod 1.9 1.4 2.0 2.2 4.8 4.9 6.5 4.8
110155 Crankshaft Timing Pulley N/A N/A N/A 0.5 0.7 0.6 0.6 0.7

* Warranty replacement requires prior authorization from your District Service Manager or Techline.
Engine Upper
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
111103 * Piston, Rings, or Pin 2.0 1.4 2.0 2.7 4.8 3.9 7.0 6.5
Cylinder Head
111106 * *Does not require engine removal.
N/A 1.2 1.2 *1.2 3.1 *1.2 3.5 3.5

111109 Valve, Guide, Springs, or Seal N/A 1.5 1.7 2.1 2.7 2.1 3.7 2.7
Cylinder Head Gasket
111115 N/A 0.8 1.2 *0.9 1.8 *0.9 2.5 1.8
*Intake manifold removal not required.
111118 Camshaft or Lifters 1.2 1.2 1.2 1.2 2.4 1.2 3.0 3.0
111124 Camshaft or Driven Pulley N/A N/A N/A 0.2 0.6 0.2 0.3 0.5
111127 Camshaft Oil Seal N/A N/A N/A 0.3 1.0 0.3 0.3 1.0
111157 Timing Belt N/A N/A N/A 0.3 0.6 0.3 0.5 0.5
111160 Rocker Arm or Shaft, Pivot Bolt, or Push Rod ) 1.0 N/A 0.4 1.1 2.4 1.1 2.7 2.7
111172 Valve Cover, Gasket, or Tappet Adjusting 0.8 0.4 0.4 0.4 0.3 0.4 0.4 0.3
* Warranty replacement requires prior authorization from your District Service Manager or Techline.

Recoil Starter
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
112115 Recoil Starter Assembly 0.5 0.5 0.5 0.5 0.4 0.5 0.5 0.6
112120 Starter Case or Gasket N/A N/A N/A 0.5 1.0 N/A N/A N/A
112215 Recoil Starter Rebuild 0.5 0.6 0.6 0.6 0.5 0.5 0.6 0.5

Portable Outboard Motors

3 Engine Upper, Recoil Starter
 4 Portable Outboard Motors
Oil Pump, Water Pump, Oil Pan
Oil Pump
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
113145 Oil Pan or Pan Gasket 1.3 0.6 1.1 1.1 2.4 1.8 1.4 2.4
113150 Oil Slinger or Shaft 1.1 0.6 N/A N/A N/A N/A N/A N/A
113200 Oil Pump Rebuild or Inspection N/A N/A 1.4 1.1 1.8 1.1 2.7 1.8

Water Pump
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
114105 Water Pump Impeller, Liner, or Housing N/A 0.7 0.7 0.6 0.7 0.7 0.7 0.7
114115 Thermostat Cover or Gasket N/A N/A 0.4 0.4 0.3 0.4 0.2 0.2
114125 Water By-Pass Hose N/A N/A N/A 0.2 0.2 0.2 N/A N/A

Oil Pan
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
117100 Oil Case N/A 0.7 1.3 2.0 3.4 N/A N/A N/A
Gear Case
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
210120 Shift Shaft N/A N/A 2.2 2.5 2.5 2.5 1.4 2.5
210165 Shift Rod (one piece) N/A N/A N/A 0.5 N/A N/A N/A N/A
210168 Shift Rod A and/or B N/A N/A 2.4 N/A 1.4 1.0 2.4 1.4
210170 Shift Rod Joint or Upper Grommet N/A N/A 0.3 0.6 0.6 0.3 1.0 0.6
210200 Gear Case Rebuild 1.0 1.0 2.7 2.7 2.7 2.7 3.5 2.7
2102D3 * Gear Case Assembly 0.3 0.3 0.5 0.8 0.8 0.8 0.8 0.8
* Warranty replacement requires prior authorization from your District Service Manager or Techline.

Centrifugal Clutch
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
212200 Clutch Rebuild 1.5 N/A N/A N/A N/A N/A N/A N/A

5 Portable Outboard Motors

Gear Case, Centrifugal Clutch
 6 Portable Outboard Motors
Vertical Shaft/Propeller, Fuel Tank/Pump
Vertical Shaft/Propeller
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
219100 * Extension Case 0.5 0.4 2.1 1.0 0.9 1.0 1.5 0.9
219105 Water Tube N/A 0.4 1.0 1.0 1.0 1.0 0.6 1.0
219115 Vertical/Pinion Shaft 0.5 0.4 0.7 1.2 1.2 1.2 2.0 1.5
219125 Propeller Shaft 0.4 0.4 0.6 1.0 1.0 1.0 1.0 1.0
219130 Propeller Shaft Gasket or O-Ring 0.2 0.2 0.3 0.3 0.3 0.2 0.4 0.3
219135 Propeller 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
219140 Propeller Shaft Bearing, Holder, or Seal 0.5 0.5 0.6 0.6 0.6 0.5 1.0 0.6

Fuel Tank/Pump
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
310100 Fuel Tank Assembly 0.4 0.4 0.4 0.4 0.2 0.4 0.4 0.2
310115 Fuel Filter 0.4 0.2 0.2 0.2 0.2 0.2 0.2 0.2
310120 Fuel Pump Assembly N/A N/A 0.2 0.2 0.2 0.2 0.3 0.2
310130 Fuel Tank Cap 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
310220 Fuel Pump Rebuild N/A N/A 0.4 0.3 0.3 0.3 N/A N/A
Carburetor
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
311005 * Carburetor Rebuild (labor only) (one or all) 1.0 1.0 1.0 1.0 1.0 1.0 1.6 1.0
311105 * Carburetor Assembly (one or all) 0.6 0.6 0.6 0.6 0.6 0.6 0.9 0.6
311110 Carburetor Insulator or Gasket 1.0 1.0 1.0 1.0 0.5 1.0 1.6 0.5
311115 Carburetor Manifold or Gasket 0.6 0.6 0.4 0.4 0.5 0.6 1.7 0.5
311116 Intake Manifold Gasket N/A N/A 0.2 N/A N/A N/A 1.0 N/A
311165 Throttle Diaphragm N/A N/A 0.2 N/A N/A N/A 0.3 N/A
311205 * Carburetor Rebuild (with parts) (one or all) 1.0 1.0 1.0 1.0 1.0 1.0 1.6 1.0
* Warranty replacement requires prior authorization from your District Service Manager or Techline.

Breather
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
312110 Crankcase Breather (any part) 0.4 0.5 0.6 0.5 0.5 0.5 0.5 0.5

Exhaust
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
313110 Exhaust Header Pipe, Manifold, or Gasket 1.1 0.2 1.3 1.0 0.4 1.0 1.7 1.7
313115 Exhaust Pipe Seal N/A N/A N/A 0.7 0.7 0.7 N/A N/A
313125 Exhaust Heat Shield or Protector 0.4 0.2 N/A N/A N/A N/A N/A N/A

Portable Outboard Motors

7 Carburetor, Breather, Exhaust
 8 Portable Outboard Motors
Frame, Body
Frame
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
410100 Frame N/A N/A 0.7 1.0 2.8 1.5 3.5 2.8
410105 Carry Handle 0.2 0.2 0.2 0.2 0.2 0.4 N/A 0.2
410106 Rubber Mount/Brushing(s) N/A N/A 0.2 1.0 0.8 0.4 N/A 0.8
410115 Tilt Arm or Shaft (tilt tube or steering tube) 0.2 0.2 0.3 0.4 0.5 0.4 0.6 0.5
410125 Tilt Lever 0.3 0.3 0.3 0.3 0.5 0.3 0.5 0.5
410135 Reverse Lock Arm or Hook N/A N/A 0.3 0.3 0.5 0.3 0.5 0.5

Body
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
413122 * Engine Cover - Upper 0.4 0.4 0.4 0.5 0.5 0.2 0.4 0.6
413123 Engine Cover - Lower 1.5 N/A 1.2 N/A 0.4 N/A 4.0 0.4
413124 Swivel Case 0.4 0.5 0.9 1.3 3.0 1.0 4.0 3.0
413126 Swivel Shaft N/A N/A N/A 1.0 1.5 1.5 3.9 NA
413128 Stern Bracket(s) 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
413132 Clamp Screw(s) N/A 0.2 0.2 0.2 0.2 0.2 0.2 0.2
413133 Gas Assist Assembly N/A N/A N/A N/A 0.8 N/A 2.5 2.5
413135 * Power Tilt Assembly N/A N/A N/A N/A 0.8 N/A 3.0 0.8
413140 Power Tilt Motor (repair or replace) N/A N/A N/A N/A 1.1 N/A N/A 1.1

* Warranty replacement requires prior authorization from your District Service Manager or Techline.
Battery Cable
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
610115 Starting Cable(s) (electric start models only) N/A N/A N/A N/A 0.2 0.5 0.8 0.2

Wire Harness
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
611110 Wire Harness N/A N/A N/A N/A 0.8 0.6 0.6 0.8

Starter Motor
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
612005 Starter Motor Rebuild (labor only) (electric start models only) N/A N/A N/A N/A 0.8 0.8 0.8 0.8
612105 Starter Motor Assembly (electric start models only) N/A N/A N/A N/A 0.4 0.4 0.4 0.4
612205 Starter Motor Rebuild (with parts) (electric start models only) N/A N/A N/A N/A 0.8 0.8 0.8 0.8

Portable Outboard Motors

9 Battery Cable, Wire Harness, Starter Motor
 10 Portable Outboard Motors
Charging System, Ignition System
Charging System
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
613100 Charging Coil N/A N/A 0.5 0.4 0.5 0.5 0.5 0.5
613105 Flywheel or Key 0.5 0.5 0.4 0.3 0.3 0.3 0.3 0.3
613110 Rectifier/Regulator N/A N/A 0.2 0.2 0.4 0.2 0.2 0.4
613115 Cooling Fan or Housing Cover 0.5 0.5 N/A N/A N/A N/A N/A N/A

Ignition System
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
614100 CDI Unit N/A N/A N/A 0.5 0.3 0.3 0.4 0.3
614105 Ignition Coil(s) 0.4 0.5 0.5 0.5 0.3 0.5 0.5 0.3
614110 Exciter Coil N/A N/A N/A 0.4 0.4 0.4 0.4 N/A
614120 Pulser Coil N/A N/A N/A 0.2 0.2 0.2 0.5 0.2
614130 Spark Plug(s) 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
Switches
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
615120 Engine Stop Switch 0.2 0.2 0.5 0.5 0.5 0.5 0.2 0.3
615150 Neutral Switch N/A N/A N/A 0.3 0.3 N/A 0.2 0.3
615160 Oil Pressure Switch N/A N/A 0.2 0.2 0.2 0.2 0.2 0.3
615165 Starter Switch (electric start models only) N/A N/A N/A N/A 0.4 0.4 0.2 0.3

Lights
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
616142 Indicator Bulb N/A N/A 0.2 0.2 0.2 0.2 0.2 0.2
616146 Power Tilt Switch N/A N/A N/A N/A N/A 0.2 0.2 0.2
616149 Tilt/Trim Relay N/A N/A N/A N/A N/A 0.4 0.4 0.4

Portable Outboard Motors

11 Switches, Lights
 12 Portable Outboard Motors
Control Panel
Control Panel
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
6221H3 Case, Electronic Parts (D-models only) 0.5 N/A N/A N/A 0.5 N/A N/A 0.5
622100 Control Panel Assemble (D-models only) 1.0 N/A N/A N/A 1.0 N/A N/A 1.0
622105 Housing "A" (D-models only) 1.2 N/A N/A N/A 1.2 N/A N/A 1.2
622110 Control Wheel on Shift Link Arm (D-models only) 0.5 N/A N/A N/A 0.5 N/A N/A 0.5
622115 Friction Adjusting Bolt or Block (D-models only) 0.7 N/A N/A N/A 0.7 N/A N/A 0.7
Link Joint Arm, Bracket, or Sliding Plate/Collar
622120 0.7 N/A N/A N/A 0.7 N/A N/A 0.7
(D-models only)
622125 Acceleration Wheel or Spring (D-models only) 0.3 N/A N/A N/A 0.3 N/A N/A 0.3
622130 Shift Detent (Click), Spring, or Roller (D-models only) 0.4 N/A N/A N/A 0.4 N/A N/A 0.4
622135 Fast Idle Detect (Click), Spring, or Roller (D-models only) 0.2 N/A N/A N/A 0.2 N/A N/A 0.2
622140 Remote Control Handle Grip (D-models only) 0.4 N/A N/A N/A 0.4 N/A N/A 0.4
622145 Remote Control Handle Assembly (D-models only) 0.6 N/A N/A N/A 0.6 N/A N/A 0.6
622150 Control Box Cover "B" (D-models only) 0.2 N/A N/A N/A 0.2 N/A N/A 0.2
Remote Control Cable Assembly, Electric
622155 0.7 N/A N/A N/A 0.7 N/A N/A 0.7
(D-models only)
Meters
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
732100 Tachometer (D-models only) 0.5 N/A N/A N/A 0.5 N/A N/A 0.5
732105 Hour Meter (D-models only) 0.5 N/A N/A N/A 0.5 N/A N/A 0.5
732115 Volt Meter (D-models only) 0.5 N/A N/A N/A 0.5 N/A N/A 0.5
732120 Speedometer (D-models only) 0.5 N/A N/A N/A 0.5 N/A N/A 0.5
732125 Water Pressure Gauge (D-models only) 0.5 N/A N/A N/A 0.5 N/A N/A 0.5

Steering
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
810100 Steering Handle 0.2 0.2 0.7 0.5 1.3 1.0 1.0 1.3
810140 Choke Lever or Knob 0.2 0.2 0.2 0.2 0.5 0.5 0.2 N/A
810150 Throttle Grip, Pipe Reel, or Lever 0.2 0.2 0.7 0.5 0.2 0.2 0.8 0.8
810175 Shift Lever N/A N/A 0.7 0.4 0.3 0.9 0.2 0.3

Portable Outboard Motors

13 Meters, Steering
 14 Portable Outboard Motors
Cables
Cables
BF8D BF15D
BFP8D BFP15D
Operation BF9.9D BF9.9A BF20D
Number Job Description BF2D BF2A BF5A BF8A BFP9.9D BF15A BF20A BFP20D
811100 Throttle Cable 0.3 0.8 0.8 0.8 1.0 0.8 0.8 1.0
811120 Choke Cable or Rod 0.2 0.2 0.2 0.2 0.3 0.2 0.2 0.3
811145 Neutral Lockout Cable N/A N/A N/A N/A 0.3 0.2 N/A 0.3
Model VIN Plate Repair Page
BF25A BAJL, BAJS, BAJU Engine Lower……………………………………………16
BF25D BATJ Engine Upper……………………………………………17
BF30A BAWL, BAWS Recoil Starter, Oil Pan, Water Pump…………………18
BF30D BAUJ Oil Case, Gear Case, Vertical Shaft/Propeller………19
BF35A BLAG, BSAG, BAPU Vertical Shaft/Propeller, Fuel Tank/Pump……………20
BF40A BAYL, BAYS, BAYU Carburetor/Fuel Injection ………………………………21
BF40D BBDJ Throttle Body……………………………………………22
BF45A BLAF, BSAF, BANU Exhaust, Frame…………………………………………23
BF50A BAZJ, BAZL, BAZS, BAZU Body, Battery Cables……………………………………24
BF50D BBEJ Wire Harness, Starter Motor, Charging System……… 25
BF60A BBFJ Ignition System………………………………………… 26
BF75A BBAL, BBAU Switches/Lights…………………………………………27
BF75D BBAJ Remote Control Unit, Gauges…………………………28
BF90A BBBJ, BBBL, BBBU Controls, Cables…………………………………………29
BF90D BBCJ
BF115A BZBD, BZBG
BF115D BBHJ
BF130A BZBE, BZBH
BF135A BARJ, BASJ
BF150A BANJ, BAPJ
BF200A BAEJ, BAFJ
BF225A BAGJ, BAHJ

Marine Engines
15 Table of Repair Contents
 16 Marine Engines
Engine Lower
Engine Lower
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
110101 Outboard motor remove and reinstall 0.7 1.0 1.4 1.4 1.5 1.4 1.4 1.4
110900 * Power Head (remove and reinstall) 5.0 5.0 6.5 7.5 7.5 7.5 7.5 8.5
Cylinder-Crankcase Assembly/Short Block
110105 * Power head remove and reinstall included.
7.5 7.5 7.9 10.0 11.0 10.5 11.8 13.5
Crankshaft
110125 * Power head remove and reinstall included.
7.9 7.9 7.9 10.2 10.7 10.9 11.0 14.0
Crankshaft Bearing
110126 7.9 7.9 7.9 10.2 10.7 10.9 11.0 14.0
Power head remove and reinstall included.
Crankshaft Oil Seal - Lower Side
110130 7.4 N/A N/A 8.0 8.0 8.0 8.0 8.5
Power head remove and reinstall included.
Crankshaft Oil Seal - Upper Side
110131 2.7 2.0 2.0 2.7 2.2 2.7 0.4 2.7
Engine removal not required.
Crankshaft Oil Seal - Both (upper and lower side)
110132 N/A N/A N/A 8.5 8.5 8.5 8.5 10.0
Power head remove and reinstall included.
1101J1 Rear Balancer Shaft N/A N/A N/A N/A N/A 7.2 7.2 N/A
1101J2 Front Balancer Shaft N/A N/A N/A N/A N/A 7.2 7.2 N/A
110136 Balancer Shaft Bearing (all) N/A N/A N/A N/A N/A 9.0 7.5 N/A
Crankshaft Timing Pulley(s) or Sprocket(s)
110155 0.8 0.8 1.1 1.0 2.3 2.0 3.3 2.0
Engine removal not required.
1101B7 Crankcase Cover N/A N/A N/A N/A N/A N/A 7.7 7.7
1101B9 Packing Extention Oil Filter N/A N/A N/A N/A N/A N/A N/A 0.3

* Warranty replacement requires prior authorization from your District Service Manager or Techline.
Engine Upper
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
Piston and/or Ring Set and/or Bearing and/or Rod
1111R1 * (one cylinder)
7.8 7.8 7.8 10.8 11.6 10.8 11.8 14.5
Piston and/or Ring Set and/or Bearing and/or Rod
1111R1A * (two cylinders)
8.1 8.1 8.1 11.2 12.0 11.2 12.2 14.9
Piston and/or Ring Set and/or Bearing and/or Rod
1111R1B * (three cylinders)
8.4 8.4 8.4 11.6 12.4 11.6 12.6 15.3
Piston and/or Ring Set and/or Bearing and/or Rod
1111R1C * (four cylinders)
N/A N/A N/A 12.0 12.8 12.0 13.0 15.7
Piston and/or Ring Set and/or Bearing and/or Rod
1111R1D * (five cylinders)
N/A N/A N/A N/A N/A N/A N/A 16.1
Piston and/or Ring Set and/or Bearing and/or Rod
1111R1E * (six cylinders)
N/A N/A N/A N/A N/A N/A N/A 16.5

1111M4 * Cylinder Head Assembly - Left Bank N/A N/A N/A N/A N/A N/A N/A 3.6
1111M5 * Cylinder Head Assembly - Right Bank N/A N/A N/A N/A N/A N/A N/A 3.4
1111M6 * Cylinder Head Assembly - All 2.5 2.5 2.5 3.0 4.2 3.6 4.6 4.8
1111F2 Cylinder Head Rebuild - Left Bank N/A N/A N/A N/A N/A N/A N/A 7.8
1111F3 Cylinder Head Rebuild - Right Bank N/A N/A N/A N/A N/A N/A N/A 7.6
1111L4 Cylinder Head Rebuild - Both Banks N/A N/A N/A N/A N/A N/A N/A 12.8
1111D4 Cover, Cylinder Head and/or Gasket (one) 0.4 0.4 0.4 0.4 0.8 0.5 0.8 1.5
1111L5 Cover, Cylinder Head and/or Gasket (both) N/A N/A N/A N/A N/A N/A N/A 1.9
111109 Valve, Guide, Spring, or Seal 3.7 3.7 3.7 5.5 7.1 6.0 7.6 N/A
111118 Camshaft 3.0 3.0 3.0 4.0 4.5 4.0 4.8 N/A
1111T7 Camshaft - Left Bank N/A N/A N/A N/A N/A N/A N/A 4.8
1111T8 Camshaft - Right Bank N/A N/A N/A N/A N/A N/A N/A 4.6
111124 Camshaft Driven Pulley 0.5 0.5 0.5 0.5 2.3 0.6 2.7 N/A
1111S7 Camshaft Pulley - Left Bank N/A N/A N/A N/A N/A N/A N/A 1.2
1111S8 Camshaft Pulley - Right Bank N/A N/A N/A N/A N/A N/A N/A 1.2
111127 Camshaft Oil Seal 0.3 0.6 0.6 0.6 N/A 0.8 N/A 1.4
1111N6 Timing Belt/Chain 0.5 0.5 0.5 0.8 2.1 1.0 2.2 2.0
111160 Rocker Arm or Rocker Arm Shaft 2.7 2.7 2.7 4.0 4.3 2.9 4.3 4.1
1111E6 Spool Valve, Spool Valve Filter N/A N/A N/A N/A 0.3 N/A 0.5 0.5

* Warranty replacement requires prior authorization from your District Service Manager or Techline. Marine Engines
Engine Upper
17
 18 Marine Engines
Recoil Starter, Oil Pan, Water Pump
Recoil Starter
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
112115 Recoil Starter Assembly 0.5 N/A N/A N/A N/A N/A N/A N/A
112215 Recoil Starter Rebuild 0.6 N/A N/A N/A N/A N/A N/A N/A

Oil Pan
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
113145 Oil Pan or Oil Pan Gasket 1.6 1.6 1.6 2.0 2.1 2.0 2.5 2.5
Oil Pump Rebuild 3.3 3.3 3.3 3.6 3.6 9.0 8.5 10.5
113200
Power head remove and reinstall included for BF115A~BF225A.
113205 Oil Pump Assembly Replacement 2.7 2.7 2.7 3.2 3.5 5.6 5.6 7.5
Power head remove and reinstall included for BF115A~BF225A.
1131B5 Strainer, Oil Pickup N/A N/A 1.4 N/A 2.2 N/A 2.5 2.5

Water Pump
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
114105 Water Pump Impeller, Liner, or Housing 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.1
Thermostat Cover or Gasket
114115 0.2 0.2 0.2 0.2 N/A 0.4 0.3 0.8
(one or all for BF200A/225A)
1141M1 Head (thermostat) N/A N/A N/A N/A 0.2 N/A N/A N/A
1141M3 Block (thermostat) N/A N/A N/A N/A 0.2 N/A N/A N/A
114125 Water By-Pass Hose N/A N/A N/A N/A N/A 0.5 N/A N/A
114130 Water Pressure Relief Valve N/A N/A N/A 0.5 0.6 0.5 0.6 0.6
114135 Fresh Water Flush Valve N/A N/A N/A 0.5 0.5 0.5 0.5 0.5
114138 Water Return Hose (both) N/A N/A N/A N/A N/A N/A N/A 0.7
114140 Water Relief Hose (both) N/A N/A N/A N/A N/A N/A 0.4 0.6
1141J1 Lower Water Tube (left) N/A N/A N/A N/A N/A N/A N/A 0.5
1141J2 Lower Water Tube (right) N/A N/A N/A N/A N/A N/A N/A 0.7
Oil Case
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
117105 Primary Gear(s) or Gasket Upper 5.9 5.9 5.9 N/A N/A N/A N/A N/A
117110 Primary Gear Case 6.5 6.5 6.5 N/A N/A N/A N/A N/A
117115 Primary Gear Case Bearing or Seal(s) 5.9 5.9 5.9 N/A N/A N/A N/A N/A
117120 Engine Under Case 6.4 6.4 6.4 7.7 N/A 7.7 N/A N/A
117125 * Mount Case 6.2 6.2 6.2 7.5 6.5 7.5 7.2 9.0
* Warranty replacement requires prior authorization from your District Service Manager or Techline.

Gear Case
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
Shift Shaft
210120 1.4 1.4 1.4 6.0 6.0 6.0 6.0 7.0
Includes Power Head removal for BF75~BF225A.
210168 Shift Rod A and/or B 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9
210170 Shift Rod Joint or Upper Grommet 1.0 1.0 1.0 N/A N/A N/A N/A N/A
2101A5 Arm Shaft Shift N/A N/A N/A N/A 0.6 N/A 0.3 0.7
210200 Gear Case Rebuild 3.5 3.5 3.5 3.8 3.8 3.8 3.8 3.8
2102D3 * Gear Case Assembly 0.8 0.8 0.8 0.8 0.8 0.8 0.9 0.9
* Warranty replacement requires prior authorization from your District Service Manager or Techline.

Vertical Shaft/Propeller (continued on page 20)

BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
219100 * Extension Case 1.5 1.5 1.5 1.8 1.9 1.8 1.9 2.0
219105 Water Tube 0.6 0.6 0.7 0.6 1.9 0.6 1.9 2.1
219115 Vertical Shaft 2.2 2.2 2.2 2.5 2.5 2.5 2.5 2.5
219125 Propeller Shaft 1.3 1.3 1.3 1.5 1.5 1.5 1.5 1.5
* Warranty replacement requires prior authorization from your District Service Manager or Techline. Marine Engines
19 Oil Case, Gear Case, Vertical Shaft/Propeller
 20 Marine Engines
Vertical Shaft/Propeller, Fuel Tank/Pump
Vertical Shaft/Propeller (continued)
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
2191B1 Water Seal, Vertical Shaft (both sides) 1.3 1.3 1.3 1.3 1.3 1.3 1.1 1.3
219130 Propeller Shaft Gasket or O-Ring 0.4 0.4 0.4 0.4 1.1 0.4 0.5 1.1
219135 Propeller 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
219140 Propeller Shaft Bearing, Holder, or Seal 1.2 1.2 1.2 1.8 1.8 1.8 1.8 1.8
219145 Gear Case Reseal 1.5 1.5 1.5 1.9 1.9 1.9 1.9 1.9

Fuel Tank/Pump
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
310100 Fuel Tank 0.2 0.2 N/A N/A N/A N/A N/A N/A
310115 Fuel Filter/Water Separator 0.2 0.2 0.2 0.2 0.2 0.2 0.4 0.3
310120 Fuel Pump Assembly - Low Pressure 0.3 0.3 0.3 0.3 0.3 0.4 0.4 0.4
310125 High Pressure Fuel Pump N/A N/A 1.0 N/A 1.3 0.8 0.8 1.9
310130 Fuel Tank Cap 0.2 0.2 N/A N/A N/A N/A N/A N/A
310140 High Pressure Fuel Filter N/A N/A 0.8 N/A 0.3 0.8 0.4 1.3
310145 Low Pressure Fuel Line N/A N/A 0.5 N/A 0.8 0.4 0.4 1.2
310150 High Pressure Fuel Lines N/A N/A 0.5 N/A 0.8 0.3 0.6 1.2
310155 Fuel Vent Tubes N/A N/A 0.5 N/A 1.8 0.2 0.5 1.5
310160 Fuel Cut Solenoid N/A N/A N/A N/A N/A 0.4 N/A 0.4
310170 Vapor Separator N/A N/A 0.7 N/A 1.1 0.7 0.7 1.6
310200 Air Cleaner Case N/A N/A N/A 0.3 N/A N/A N/A N/A
Carburetor/Fuel Injection
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
311006 Synchronize Carburetors (all) 0.5 0.5 N/A 0.6 N/A N/A N/A N/A
Cannot be used with any other carburetor labor operation number.
311105 * Carburetor Replace 2.0 2.0 N/A 2.8 N/A N/A N/A N/A
includes synchronizing all carburetors
311110 Carburetor Insulator or Gasket 1.6 1.6 N/A 2.0 N/A N/A N/A N/A
311115 Carburetor Manifold or Gasket 1.7 1.7 N/A 2.0 N/A N/A N/A N/A
311165 Throttle Diaphragm 0.3 0.3 N/A 0.3 N/A N/A N/A N/A
311175 Throttle Dashpot Check Valve 0.2 0.2 N/A 0.2 N/A N/A N/A N/A
3111A2 Auto Bystarter Assembly 0.2 0.2 N/A N/A N/A N/A N/A N/A
3111A3 Float Chamber 1.2 1.2 N/A N/A N/A N/A N/A N/A
Intake Manifold Cover and/or Packing,
3111A6 N/A N/A N/A N/A N/A N/A N/A 1.1
Intake Manifold Upcover
3111B6 Intake Manifold Gasket 1.0 1.0 1.0 1.4 0.8 1.5 0.7 1.2
3111C4 Intake Manifold N/A N/A 0.8 N/A 0.8 1.7 0.7 1.4
3111K0 Fuel Injectors Left Bank N/A N/A N/A N/A N/A N/A N/A 1.8
3111K1 Fuel Injectors Right Bank N/A N/A N/A N/A N/A N/A N/A 1.7
3111K2 Fuel Injectors (all) N/A N/A 0.5 N/A 0.6 1.0 0.6 2.0
311204 Muffler Case (Silencer) 1.2 1.2 N/A 1.5 N/A N/A N/A N/A
311205 * Carburetor Rebuild (with parts) 2.4 2.4 N/A 3.2 N/A N/A N/A N/A
includes synchronizing all carburetors
* Warranty replacement requires prior authorization from your District Service Manager or Techline.

Marine Engines
21 Carburetor/Fuel Injection
 22 Marine Engines
Throttle Body
Throttle Body
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
312110 Electronic Air Control Valve Assembly or Gasket N/A N/A 0.3 N/A 0.6 0.3 0.3 0.3
312112 Pressure Regulator Assembly, O-Ring, or Hose N/A N/A 0.6 N/A 1.1 0.5 0.6 1.6
312114 Air Temp Sensor or O-Ring N/A N/A 0.3 N/A 0.4 0.5 0.3 0.3
312116 PCV Valve N/A N/A N/A N/A N/A 0.5 N/A N/A
312118 Throttle Body Assembly or Gasket N/A N/A 0.4 N/A 0.5 0.8 0.8 0.8
312120 Silencer Case or Grommet N/A N/A 0.3 N/A 0.3 0.5 0.3 0.5
312122 Breather Element or Body N/A N/A 0.3 N/A 0.3 0.5 0.3 0.5
312124 Breather Joint or Hoses N/A N/A 0.3 N/A 0.5 0.5 0.6 1.0
312126 Vacuum Tube Joint, Hoses, or Vacuum Tank N/A N/A N/A N/A N/A 0.5 NA 1.6
312130 Injector Base N/A N/A N/A N/A N/A N/A 0.8 4.9
312135 Injector Rail N/A N/A 0.4 N/A 0.5 0.4 0.6 1.9
312145 Map Sensor N/A N/A 0.3 N/A 0.2 N/A 0.3 0.3
312150 Block Temperature Sensor N/A N/A 0.2 N/A 0.5 0.4 0.4 2.9
312152 Water Temperature Sensor N/A N/A 0.2 N/A 0.2 0.5 0.4 0.5
312155 Knock Sensor N/A N/A N/A N/A 0.7 N/A 0.7 3.6
312160 High Oil Pressure Sensor N/A N/A N/A N/A 0.4 N/A 0.4 2.9
312165 Low Oil Pressure Sensor N/A N/A 0.2 N/A 0.2 N/A 0.4 2.9
312170 Exhaust Manifold Water Temperature Sensor N/A N/A N/A N/A 0.2 N/A 0.2 0.2
312175 O2 Sensor N/A N/A 0.2 N/A 0.2 N/A 0.3 0.7
312180 Crank/Angle Sensor N/A N/A 0.9 N/A 0.2 N/A 0.5 0.7
312185 Sensor Comp TDCI - TDC2 N/A N/A N/A N/A 0.5 N/A 0.8 1.4
Exhaust
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
Exhaust Header Pipe or Gasket
313110 1.7 1.7 1.7 1.9 N/A 1.9 NA 2.2
BF200A/BF225A includes 2 pipes
313126 Exhaust Water Jacket Cover, Gasket, or Anode 0.9 0.9 0.5 1.0 0.7 1.0 0.2 N/A
3131C0 Manifold - Exhaust Left N/A N/A N/A N/A N/A N/A NA 1.2
3131C1 Manifold - Exhaust Right N/A N/A N/A N/A N/A N/A NA 1.1
3131K4 Metal- Exhaust Anode Left N/A N/A N/A N/A N/A N/A NA 1.0
3131K5 Metal- Exhaust Anode Right N/A N/A N/A N/A N/A N/A NA 1.0
313130 Manifold N/A N/A N/A N/A N/A N/A 1.3 N/A

Frame
BF60A BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
410100 Frame 3.5 3.5 3.5 3.9 N/A 4.1 N/A N/A
Remove engine with oil case and extension gear
case as sub-assembly.
410110 Upper Mount(s) or Holder(s) 3.0 3.0 3.6 7.0 4.6 7.0 5.5 8.0
BF75/90/115/130 includes power head remove and reinstall.
410111 Lower Mount Rubber or Bolt (each) 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
410112 Lower Mount Center Housing 1.0 1.0 1.6 1.6 2.7 1.6 1.6 1.6
410115 Tilt Arm or Shaft (Tilt Tube or Steering Tube) 1.0 1.5 1.5 1.5 1.5 1.5 1.5 1.6
Cover, Lower Mounting Left
4101E1 N/A N/A N/A N/A N/A N/A N/A 0.1
(BF200/225A LA Type Only)
Cover, Lower Mounting Right
4101E2 N/A N/A N/A N/A N/A N/A N/A 0.1
(BF200/225A LA Type Only)
4101H7 Frame, Mounting N/A N/A 4.1 N/A 5.6 N/A 3.0 8.1

Marine Engines
23 Exhaust, Frame
 24 Marine Engines
Body Body, Battery Cables
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
Engine Cover Upper
413122 * Includes Decal Replacement
0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6

413123 Riveted Top Cover N/A N/A N/A N/A N/A N/A N/A 0.3
413124 Swivel Case 4.0 4.0 4.2 4.0 6.0 4.0 3.0 5.2
413125 Swivel Case Liner - Upper 4.0 4.0 4.2 4.0 5.6 4.0 3.0 4.0
413126 Swivel Shaft 3.9 3.9 5.6 5.6 5.6 3.9 3.0 8.1
Stern Bracket - Left
413128 1.3 1.3 1.3 1.4 1.4 1.4 1.4 1.4
May require engine remove and reinstall.
Stern Bracket - Right
413129 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3
May require engine remove and reinstall.
Stern Bracket - Both
413130 1.5 1.7 1.7 1.7 1.7 1.7 1.7 1.7
May require engine remove and reinstall.
413131 Engine Under Cover 0.2 0.2 0.2 0.2 N/A 0.2 N/A N/A
4131C5 Engine Under Cover - Left N/A N/A N/A N/A 0.3 N/A 0.3 0.4
4131C6 Engine Under Cover - Right N/A N/A N/A N/A 0.4 N/A 0.6 0.6
413133 Gas Assist Assembly 1.3 1.3 1.3 N/A N/A N/A N/A N/A
413135 * Power Tilt Assembly 2.5 2.5 2.5 2.8 2.8 2.8 2.8 2.8
413140 Power Tilt Motor (repair or replace) 3.0 3.0 3.0 3.5 3.5 3.5 3.5 3.5
413150 Engine Cover Brackets (BF200/225A only) N/A N/A N/A N/A N/A N/A NA 1.0
* Warranty replacement requires prior authorization from your District Service Manager or Techline.

Battery Cables
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
610115 Starting Cable(s) (electric start models only) 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8
Wire Harness
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
611110 Wire Harness 1.0 1.0 2.1 1.0 2.3 1.8 1.9 3.2
6111B5 Cord, Switch/Harness N/A N/A N/A N/A N/A N/A N/A 3.5

Starter Motor
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
Starter Motor Rebuild (labor only)
612005 0.8 0.6 0.8 0.6 1.0 0.8 0.8 0.8
(electric start models only)
612105 Starter Motor Assembly (electric start models only) 0.4 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Starter Motor Rebuild (with parts)
612205 0.8 0.8 1.0 0.8 1.2 0.8 0.5 0.8
(electric start models only)

Charging System
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
613100 Charging Coil/AC Generator 0.5 0.8 0.8 1.1 1.2 0.5 0.5 0.5
613105 Flywheel, Key, or Rotor 0.3 0.3 0.4 5.0 5.2 5.8 5.8 7.4
613110 Rectifier/Regulator 0.2 0.2 0.4 0.4 0.2 0.8 0.8 0.9
613120 AC Generator Rebuild N/A N/A N/A N/A N/A 1.1 1.4 1.4

Marine Engines
25 Wire Harness, Starter Motor, Charging System
 26 Marine Engines
Ignition System

Ignition System
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
614100 * CDI Unit/ECM 0.7 0.7 0.5 0.3 0.5 0.3 0.5 0.5
614103 Main Power Relay N/A N/A N/A N/A 0.5 0.5 0.5 0.7
614105 Ignition Coil (one) 0.5 0.5 0.3 0.5 0.2 0.5 0.2 N/A
Ignition Coil (each additional)
614105G 0.5 0.5 0.3 0.5 0.2 0.5 0.5 N/A
Use as secondary code to 614105
614110 Exciter Coil 0.4 0.7 N/A N/A N/A N/A N/A N/A
614120 Pulser Coil 0.5 0.5 0.6 1.0 N/A 1.0 N/A N/A
614130 Spark Plug (one) 0.2 0.2 0.2 0.2 0.2 0.2 0.2 N/A
Spark Plug (each additional)
614130G 0.1 0.1 0.1 0.1 0.1 0.1 0.1 N/A
Use as secondary code to 614130
Ignition Coil Hole Plug, Left Bank, BF200A/225A
6141E0 only, under engine left cover remove/reinstall N/A N/A N/A N/A N/A N/A N/A 0.6
included
Ignition Coil Hole Plug, Right Bank, BF200A/225A
6141E1 N/A N/A N/A N/A N/A N/A N/A 0.4
only
Ignition Coil Hole Plug, Both Banks,
6141E2 N/A N/A N/A N/A N/A N/A N/A 1.0
BF200A/225A only
Spark Plug, Left Bank (cylinders 4,5,6),
6141E4 BF200A/225A only, under engine left cover N/A N/A N/A N/A N/A N/A N/A 0.7
remove/reinstall included
Spark Plug, Right Bank (cylinders 1,2,3),
6141E5 N/A N/A N/A N/A N/A N/A N/A 0.5
BF200A/225A only
6141E6 Spark Plug, Both Banks, BF200A/225A only N/A N/A N/A N/A N/A N/A N/A 1.2
* Warranty replacement requires prior authorization from your District Service Manager or Techline.
Switches/Lights
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
615120 Engine Stop Switch 0.5 N/A N/A N/A 0.6 N/A N/A N/A
615150 Neutral Switch 0.2 0.2 0.3 0.2 0.6 0.2 0.6 0.7
615160 Oil Pressure Switch 0.2 0.2 N/A 0.2 N/A 0.3 N/A N/A
615165 Starter Switch Contactor (electric start models only) 0.2 0.2 0.4 0.3 N/A 0.3 0.6 0.6
616143 Indicator Lamp Assembly 1.0 1.0 1.0 1.0 0.7 1.0 1.0 1.6
616144 Ignition/Combination Switch 1.0 1.0 1.0 1.0 0.6 1.0 1.0 1.0
616145 Warning Buzzer 1.0 1.0 1.0 1.0 0.5 1.0 1.0 1.0
616146 Power Tilt Switch or Bracket (engine) N/A 0.2 0.2 0.2 0.4 0.2 0.3 0.7
616147 Thermo Switch 0.2 0.2 N/A 0.2 N/A 0.2 N/A N/A
616148 Trim Control Unit or Bracket N/A 0.4 N/A N/A N/A N/A N/A N/A
616149 Tilt/Trim Relay N/A 0.4 0.4 0.4 1.3 0.4 0.5 0.5
616150 Power Tilt Switch (remote mounted) N/A 0.6 0.6 0.6 0.7 0.6 0.6 0.7
616151 Trim Angle Sensor N/A 0.6 0.8 0.6 0.6 0.6 0.6 0.7
616152 Choke Solenoid 0.4 0.4 N/A 0.4 N/A N/A N/A N/A
616153 Choke Solenoid Switch (remote control only) 0.6 0.6 N/A 0.4 N/A N/A N/A N/A

Marine Engines
27 Switches/Lights
 28 Marine Engines
Remote Control Unit, Gauges
Remote Control Unit
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
622100 Control Panel Assembly 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
6221H3 Case, Electronic Parts N/A N/A 0.9 N/A N/A N/A 0.5 N/A
622105 Housing "A" 1.2 1.2 1.2 1.2 0.8 1.2 1.2 1.2
622110 Control Wheel on Shift Link Arm 0.5 0.5 0.5 0.5 0.4 0.5 0.5 0.5
622115 Friction Adjusting Bolt or Block 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7
622120 Link Joint Arm, Bracket, or Sliding Plate/Collar 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7
622125 Acceleration Wheel or Spring 0.3 0.3 0.3 0.3 0.4 0.5 0.5 0.7
622130 Shift Detent (click), Spring, or Roller 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
622135 Fast Idle Detent (click), Spring, or Roller 0.2 0.2 N/A 0.2 0.2 N/A N/A N/A
622140 Remote Control Handle or Grip 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
622145 Remote Control Handle, Spring on Lock Lever 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
622150 Control Box Cover "B" 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
622155 Remote Control Cable Assembly, Electric 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7

Gauges
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
732100 Tachometer 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
732105 Hour Meter 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
732110 Trim Meter 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
732115 Voltmeter 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
732120 Speedometer 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
732125 Water Pressure Gauge 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Controls
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
810100 Steering Handle 1.0 1.0 1.0 1.0 1.0 N/A N/A N/A
810140 Choke Lever or Knob 0.2 0.2 N/A 0.2 N/A N/A N/A N/A
810150 Throttle Grip, Pipe, or Reel 0.8 0.8 0.8 0.8 0.2 N/A N/A N/A
810175 Shift Lever 0.2 0.2 0.2 0.2 0.2 N/A N/A N/A

Cables
BF60A BF115D BF200A
Operation BF25/30A BF35/40A BF40D BF75A BF75D BF115A BF135A BF225A
Number Job Description BF25/30D BF45/50A BF50D BF90A BF90D BF130A BF150A BF225K1
811100 Throttle Cable/Rod 0.4 0.4 0.5 0.6 0.5 0.6 0.5 0.6
811120 Choke Cable or Rod 0.2 0.2 N/A 0.2 N/A N/A N/A N/A

Marine Engines
29 Controls, Cables