Honda BF 200A, BF 225A Outboard motor Owner's Manual

BF200A/BF225A

Owner’s Manual

31ZY2604

00X31-ZY2-6040

N

2eY1800.2004.04

Printed in Japan ©2004 Honda Motor Co., Ltd. -All Rights Reserved

PANTONE 288 CVC DIC F101 BLACK

2005

31ZY2604 00X31-ZY2-6040

04/03/29 10:28:24 31ZY2600_001

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Keep this owner’s manual handy, so you can refer to it at any time. This owner’s manual is considered a permanent part of the outboard motor and should remain with the outboard motor if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission.

04/03/29 10:28:31 31ZY2600_002

Congratulations on your selection of a Honda outboard motor. We are certain you will be pleased with your purchase of one of the finest outboard motors on the market.

We want to help you get the best results from your new outboard motor and to operate it safely. This manual contains information on how to do that; please read it carefully.

As you read this manual you will find information preceded by a symbol. That information is intended to help you avoid damage to your outboard motor, other property, or the environment.

We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership.

When your outboard motor needs scheduled maintenance, keep in mind that your Honda marine dealer is specially trained in servicing Honda outboard motors. Your Honda marine dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns.

2004 Honda Motor Co., Ltd. All

Rights Reserved

INTRODUCTION

1

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INTRODUCTION

A FEW WORDS ABOUT

SAFETY

Your safety and the safety of others are very important. And using this outboard motor safely is an important responsibility.

To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.

Of course, it is not practical or possible to warn you about all the hazards associated with operating or maintaining an outboard motor. You must use your own good judgment.

You will find important safety information in a variety of forms, including:

Safety Labels

− on the outboard motor.

Safety Messages

− preceded by a safety alert symbol three signal words, DANGER, WARNING, or CAUTION.

and one of

These signal words mean:

You WILL be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

Safety Headings

− such as

IMPORTANT SAFETY INFORMATION.

Safety Section

− such as

OUTBOARD MOTOR SAFETY.

Instructions

− how to use this outboard motor correctly and safely.

This entire book is filled with important safety information

− please read it carefully.

2

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OUTBOARD MOTOR SAFETY ...................................

. 7

IMPORTANT SAFETY INFORMATION ................

. 7

SAFETY LABEL LOCATION ..................................

. 9

CONTROLS AND FEATURES

..................................

. 10

CONTROL AND FEATURE IDENTIFICATION

CODES ..................................................................

. 10

COMPONENT AND CONTROL LOCATIONS ....

. 11

CONTROLS ..............................................................

. 15

Side-Mount Type

Ignition Switch ......................................................

. 15

Switch Clip and Emergency Stop Switch .............

. 16

Gearshift/Throttle Control Lever ..........................

. 16

Fast Idle Lever .......................................................

. 18

Panel-Mount Type

Ignition Switch ......................................................

. 18


. 19

Fast Idle Button .....................................................

. 20


. 20

CONTENTS

Top-Mount Type

Ignition Switch ......................................................

. 22


. 22

Fast Idle Button .....................................................

. 23


. 23

Common Controls

Power Trim/Tilt Switch ........................................

. 25

Power Tilt Switch ..................................................

. 26

Manual Relief Valve

Tilt Lock Lever

.............................................

.....................................................

. 26

. 26

Engine Cover Latch ..............................................

. 27

Trim Tab ................................................................

. 27

INSTRUMENTS .......................................................

Trim Meter (optional equipment) .........................

. 27

. 27

Tachometer (optional equipment) .........................

. 28

Digital Tachometer (optional equipment) .............

. 28

Digital Speedometer (optional equipment) ...........

. 28

3

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CONTENTS

INDICATORS ...........................................................

. 29

Alternator (ACG) Indicator ...................................

. 29

Oil Pressure Indicator ............................................

. 30

Overheat Indicator .................................................

. 30

Cooling System Indicator

OTHER FEATURES

.....................................

................................................

. 31

. 31

Water Separator Buzzer ........................................

. 31

Overrev Limiter .....................................................

. 32

Anodes ...................................................................

. 32

Fuel Priming Bulb .................................................

. 32

BEFORE OPERATION ................................................

. 33

ARE YOU READY TO GET UNDER WAY?

........

. 33

IS YOUR OUTBOARD MOTOR

READY TO GO?

..................................................

. 33

OPERATION ................................................................

SAFE OPERATING PRECAUTIONS ....................

. 35

. 35

BREAK-IN PROCEDURE .......................................

. 35

FUEL PRIMING .......................................................

STARTING THE ENGINE ......................................

. 36

. 37

Side-Mount Type ..................................................

. 37

Panel-Mount Type .................................................

. 40

Top-Mount Type ...................................................

. 42

STOPPING THE ENGINE .......................................

. 44

Emergency Engine Stopping ................................

. 44

Normal Engine Stopping .......................................

. 45

GEARSHIFT AND

THROTTLE OPERATION ..............................

. 46

Side-Mount Type ..................................................

. 46

Panel-Mount Type .................................................

. 47

Top-Mount Type ...................................................

. 47

STEERING

CRUISING

...............................................................

. 48

................................................................

. 49

SHALLOW WATER OPERATION ........................

. 51

MOORING, BEACHING, LAUNCHING ...............

. 51

4

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CONTENTS

SERVICING YOUR OUTBOARD MOTOR ..............

THE IMPORTANCE OF MAINTENANCE ...........

. 53

. 53

MAINTENANCE SAFETY .....................................

TOOL KIT and OWNER’S MANUAL ...................

. 54

. 55

MAINTENANCE SCHEDULE ...............................

. 56

TRIM TAB ADJUSTMENT ....................................

. 58

MANUAL RELIEF VALVE ....................................

. 59

ENGINE COVER REMOVAL AND

INSTALLATION ..................................................

. 59

Engine Oil Level Check

Engine Oil Change

............................................

....................................................

. 60

. 60

Oil Filter Change .......................................................

Engine Oil Recommendations ..................................

. 61

. 63

Lubrication Points .....................................................

. 64

Spark Plug Service ....................................................

. 65

REFUELING .............................................................

. 68

FUEL RECOMMENDATIONS ...............................

. 69

Fuel Filter Inspection and Replacement

Water Separator Inspection and Service

...................

...................

. 70

. 72

Anode Replacement ..................................................

Propeller Replacement ..............................................

. 74

. 75

STORAGE

....................................................................

STORAGE PREPARATION ...................................

. 76

. 76

Cleaning and Flushing ..........................................

. 76

Fuel ........................................................................

. 78

Engine Oil .............................................................

HOISTING THE OUTBOARD MOTOR ................

. 79

. 79

STORAGE PRECAUTIONS ...................................

. 80

REMOVAL FROM STORAGE ...............................

. 81

5

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CONTENTS

TRANSPORTING

........................................................

WITH OUTBOARD MOTOR

. 82

INSTALLED ON BOAT ......................................

. 82

WITH OUTBOARD MOTOR

REMOVED FROM BOAT ..................................

. 82

TAKING CARE OF UNEXPECTED PROBLEMS ....

. 83

BATTERY WILL NOT CHARGE AND

ELECTRIC STARTER WILL NOT

OPERATE .........................................................

. 88

Fuse Replacement .................................................

. 88

OIL PRESSURE INDICATOR LIGHT GOES OFF

AND ENGINE SPEED IS LIMITED ...................

. 90

OVERHEAT INDICATOR COMES ON AND

ENGINE SPEED IS LIMITED ............................

. 91

WATER SEPARATOR BUZZER SOUNDS ..........

. 92

WATER SEPARATOR INDICATOR .....................

. 92

SUBMERGED MOTOR ..........................................

. 93

Star Label ............................................................

. 100

Specifications ......................................................

. 102

CONSUMER INFORMATION .............................

. 105

INDEX .........................................................................

. 110

WIRING DIAGRAMS ........................

. Inside Back Cover

TECHNICAL INFORMATION ...............................

. 95

Serial Number Locations ......................................

. 95

Oxygenated Fuels ..................................................

. 96

Battery ...................................................................

Emission Control System Information .................

. 97

. 97

6

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IMPORTANT SAFETY

INFORMATION

Honda BF200A/BF225A outboard motors are designed for use with boats that have a suitable manufacturer’s power recommendation. Other uses can result in injury to the operator or damage to the outboard motor and other property.

Most accidents can be prevented if you follow all instructions in this manual and on the outboard motor.

The most common hazards are discussed below, along with the best way to protect yourself and others.

OUTBOARD MOTOR SAFETY

Operator Responsibility

It is the operator’s responsibility to provide the necessary safeguards to protect people and property.

Know how to stop the engine quickly in case of emergency.

Understand the use of all controls.

Stop the engine immediately if anyone falls overboard, and do not run the engine while the boat is near anyone in the water.

Always stop the engine if you must leave the controls for any reason.

Attach the emergency stop switch lanyard securely to the operator.

Always wear a PFD (Personal

Flotation Device) while on the boat.

Familiarize yourself with all laws and regulations relating to boating and the use of outboard motors.

Be sure that anyone who operates the outboard motor receives proper instruction.

Be sure the outboard motor is properly mounted on the boat.

Do not remove the engine cover while the engine is running.

7

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Refuel With Care

Gasoline is extremely flammable, and gasoline vapor can explode.

Refuel outdoors, in a wellventilated area, with the engine stopped. Never smoke near gasoline, and keep other flames and sparks away.

Refuel carefully to avoid spilling fuel. Avoid overfilling the fuel tank.

After refueling, tighten the filler cap securely. If any fuel is spilled, make sure the area is dry before starting the engine.

Carbon Monoxide Hazard

Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gas. Never run the engine in a closed garage or confined area.

8

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SAFETY LABEL LOCATION


The label shown here contains important safety information. Please read it carefully. These label is considered a permanent part of your outboard motor. If the label comes off or becomes hard to read, contact an authorized Honda marine dealer for a replacement.

9

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CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

Model BF200A BF225A

Type LA XA XCA XXA XXCA LA XA XCA XXA XXCA

Transom Height

20.0 in (508 mm)

25.0 in (635 mm)

30.0 in (762 mm)

Standard Rotating Propeller Shaft

Counterrotating Propeller Shaft

Power Trim/Tilt

10

Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications.

TYPE CODE (example)

X C A

Destination

A: America

Rotating direction of propeller shaft

C: Counterrotating propeller shaft

None: Standard rotating propeller shaft

Transom Height

L: 20.0 in (508 mm), X: 25.0 in (635 mm), XX: 30.0 in (762 mm)

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COMPONENT AND CONTROL LOCATIONS

OIL FILLER CAP

(inside engine cover)

ENGINE COVER

SPARK PLUG

(under coil)

ENGINE COVER

LATCH

OIL LEVEL DIPSTICK

COOLING SYSTEM

INDICATOR

POWER TILT

SWITCH

TILT LOCK

LEVER

ENGINE OIL

DRAIN BOLT

(inside cover)

STERN

BRACKET

MANUAL

RELIEF

VALVE

ANODE

ANODE

ANODE

FRAME SERIAL

NUMBER

FLUSH PORT

CONNECTOR

GEAR OIL

LEVEL PLUG

GEAR OIL DRAIN/FILL PLUG

ANTIVENTILATION

PLATE

TRIM TAB

EXHAUST PORT/WATER

OUTLET PORT

PROPELLER

COOLING

WATER

INTAKE PORT

11

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Remote Controls (optional equipment)

(SIDE-MOUNT REMOTE CONTROL)

GEARSHIFT/THROTTLE

CONTROL LEVER

POWER TRIM/TILT

SWITCH

NEUTRAL

RELEASE

LEVER

OIL PRESSURE

INDICATOR

OVERHEAT

INDICATOR

FAST IDLE

LEVER

SPARE SWITCH CLIP

BUZZER

(inside)

IGNITION

SWITCH

CONTROL LEVER

FRICTION ADJUSTER

LANYARD

EMERGENCY

STOP SWITCH

SWITCH CLIP

12

(PANEL-MOUNT REMOTE CONTROL)


CONTROL LEVER

NEUTRAL

RELEASE

LEVER

POWER TRIM/TILT

SWITCH

FAST IDLE

BUTTON

04/03/29 10:30:00 31ZY2600_014

(SINGLE TOP-MOUNT REMOTE CONTROL)


CONTROL LEVER


(DUAL TOP-MOUNT REMOTE CONTROL)


CONTROL LEVERS

POWER TRIM/TILT

SWITCH (RIGHT)

POWER

TRIM/TILT

SWITCH

POWER TRIM/TILT

SWITCH (LEFT)

FAST IDLE

BUTTON

CONTROL PANEL

(for PANEL/TOP-MOUNT type)

BUZZER

IGNITION

SWITCH

SWITCH CLIP

LANYARD

OIL PRESSURE

INDICATOR

OVERHEAT

INDICATOR

EMERGENCY

STOP SWITCH

FAST IDLE

BUTTON

(for TOP-MOUNT DUAL type)

13

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Trim Meter

(optional equipment)

Tachometer


Digital Speedometer


Digital Tachometer


14

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CONTROLS

Side-Mount Type

Ignition Switch

O F F

O N

START

IGNITION

SWITCH

Turning the ignition switch key to the

START position operates the starter motor. The key automatically returns to the ON position when released from the START position.

The ignition switch can be used to operate the starter motor only when

the control lever (p.

17 ) is in the N

(neutral) position, and the switch clip is in the emergency stop switch.

Turning the ignition switch to the

OFF position stops the engine.

The ignition switch controls the ignition system and starter motor.

15

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Switch Clip and Emergency Stop

Switch

EMERGENCY

STOP SWITCH

SWITCH CLIP

LANYARD

The switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The lanyard must be attached to the operator’s PFD (Personal Flotation

Device) or worn around the wrist as shown.

When used as described, the emergency stop switch and lanyard system stops the engine if the operator falls away from the controls.

A spare switch clip is stored in a slot in the control housing (optional equipment).

Gearshif t/Throttle Control

Lever

CONTROL LEVER

NEUTRAL RELEASE

LEVER

The gearshift/throttle control lever controls engine speed and selects F

(forward), N (neutral), or R (reverse) gears.

SWITCH CLIP

16

LANYARD


04/03/29 10:30:36 31ZY2600_018


Moving the control lever 30° from N

(neutral) selects the gear, and further movement increases engine speed.

The control lever automatically locks itself in the N (neutral) position. To move the lever out of the N (neutral) position, you must squeeze the neutral release lever on the underside of the lever handle.

A friction adjuster near the base of the control lever(s) adjusts the operating resistance of the control lever(s).

Less friction allows easier control lever movement. More friction helps to hold a steady throttle setting while cruising.

MAXIMUM

T H R O

F (FORWARD)

30°

N (NEUTRAL)

30°

SHIFT

SHIFT

T T L E O P E N

M

I

I

N

N

G

I M U M

R (REVERSE)

M I N I M U M

T H R O T T L E O P E N I N G

MAXIMUM


CONTROL LEVER

17

04/03/29 10:30:47 31ZY2600_019


Fast Idle Lever

N (neutral)

MAXIMUM FAST IDLE

Panel-Mount Type


ON

START

OFF

LOWEST POSITION

FAST IDLE LEVER

The fast idle lever is only needed for starting carbureted outboard models.

The BF200A and BF225A models use programmed fuel injection so, this lever will not be needed for starting.

After the engine starts and if the outside temperature is below 41°F

(5°C), the fast idle lever can be used to accelerate engine warm up.

The fast idle lever will not move unless the remote control lever is in the N (neutral) position. Conversely, the remote control lever will not move unless the fast idle lever is in the lowest position.

Lower the fast idle lever to the lowest position to decrease the fast idle.

IGNITION

SWITCH KEY


18

04/03/29 10:30:58 31ZY2600_020






21 ) is in the N





Switch

EMERGENCY

STOP SWITCH

SWITCH CLIP

LANYARD




A spare switch clip (optional equipment) can be stored in the tool bag.

SWITCH CLIP

LANYARD



19

04/03/29 10:31:07 31ZY2600_021


Fast Idle Button

F (forward)

N (neutral)

R (reverse)

It is necessary to position the control lever in N (neutral) to push in the fast idle button.


Lever

CONTROL LEVER

CONTROL

LEVER

Push

P u l l u p

NEUTRAL

RELEASE

LEVER

FAST IDLE BUTTON

By moving the control lever forward or reverse when the fast idle button is pushed in, the throttle opening will be increased without engaging the gears.

NEUTRAL RELEASE

LEVER



20

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The control lever automatically locks itself in the N (neutral) position. To move the lever out of the N (neutral) position, you must squeeze the neutral release lever on the underside of the lever handle.

A friction adjuster near the base of the control lever adjusts the operating resistance of the control lever. Refer

to p.

47 .


F (FORWARD)

35°

SHIFT

N (NEUTRAL)

35°

SHIFT


M I N I M U M

MAXIMUM

R (REVERSE)

M I N I M U M


MAXIMUM


CONTROL LEVER

21

04/03/29 10:31:26 31ZY2600_023


Top-Mount Type


START

ON

OFF

IGNITION

SWITCH

KEY





24 ) is in the N





Switch

EMERGENCY

STOP

SWITCH

SWITCH CLIP

LANYARD


SWITCH CLIP

LANYARD

22

04/03/29 10:31:38 31ZY2600_024





A spare switch clip (optional equipment) can be stored in the tool bag.



Fast Idle Button

F (forward)

N (neutral)

R (reverse)

CONTROL

LEVER

Push


By moving the control lever forward or reverse when the fast idle button is pushed in, the throttle opening will be increased without engaging the gears.

It is necessary to position the control lever in N (neutral) to push in the fast idle button.


Lever

SINGLE TYPE

DUAL TYPE

C O N T R O L

L E V E R

C O N T R O L

L E V E R S



23

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A friction adjuster inside the control box adjusts the operating resistance of the control lever(s).


F (FORWARD)

35°

SHIFT

N (NEUTRAL)

35°

SHIFT

R (REVERSE)

M I N I M U M


M I N I M U M


MAXIMUM

MAXIMUM

GEARSHIFT/THROTTLE CONTROL LEVER

24

04/03/29 10:31:58 31ZY2600_026

Common Controls

Power Trim/Tilt Switch

(side-mount type)

POWER

TRIM/TILT

SWITCH

CONTROL

LEVER

(top-mount type)

SINGLE TYPE

POWER TRIM/TILT SWITCH

CONTROL

LEVER

(panel-mount type)


CONTROL LEVER

DUAL TYPE


(LEFT) (RIGHT)


The power trim/tilt switch is located on the control lever. It is a rocker switch with UP and DN (down) positions for changing the angle of the outboard motor.

You can use the power trim/tilt switch anytime whether the boat is underway, stopped, or the ignition switch is in the OFF position. It is necessary for the ignition switch to be in the ON position for the trim meter to indicate the motor angle.

Trim the outboard motor to obtain the best performance and stability

(p.

49 ).

Tilt the outboard motor for shallow water operation, beaching, launching, or mooring.

For dual mount outboards, tilt them up at the same time.

C O N T R O L

L E V E R

25

04/03/29 10:32:11 31ZY2600_027


Power Tilt Switch

POWER TILT SWITCH

Manual Relief Valve

M A N U A L R E L I E F V A L V E

Tilt Lock Lever

F R E E

T I L T L O C K

L E V E R

L O C K

P O W E R

( T o f i x )

M A N U A L

( T o r e l e a s e )

The power tilt switch is located on the engine pan. It is a rocker switch with UP and DN (down) positions for changing the angle of the outboard motor.

The power tilt switch will operate without turning the ignition switch

ON.

This switch is used with the engine stopped to raise the outboard motor for mooring, trailering or maintenance.

26

The outboard motor can be tilted manually after opening the manual relief valve. This allows the outboard motor to be tilted when no battery is connected.

The tilt lock lever is used to support the outboard motor in the fully-raised position.

When the boat is to be moored for a long time, tilt the outboard motor as far as it will go. Then move the tilt lock lever to the LOCK position, and gently lower the outboard motor until the lever contacts the stern bracket.

04/03/29 10:32:22 31ZY2600_028

Engine Cover Latch

ENGINE COVER

LATCH

Trim Tab

U N L O C K


TIGHTENING

BOLT

INSTRUMENTS

Trim Meter


The engine cover latch fastens the engine cover to the outboard motor.

TRIM TAB

TRIM METER

The trim tab compensates for

‘‘torque steer,’’ which is a reaction of the outboard motor to propeller rotation.

If uncompensated, torque steer would make the outboard motor tend to turn to one side.

When the trim tab is correctly

adjusted (p.

58

), steering effort is

equal in either direction.

The trim meter has a range of

−

4° to

16° and indicates the trim angle of the outboard motor.

Refer to the trim meter when using the power trim/tilt switch to achieve the best performance from the boat.

27

04/03/29 10:32:46 31ZY2600_029


Tachometer






TACHOMETER

The tachometer shows engine speed in revolutions per minute.

Refer to the tachometer when using the throttle and power trim/tilt controls to achieve the best performance from the boat.

Digital Tachometer includes the following functions.

Tachometer

Hour Meter

Trim Meter

Oil pressure Indicator

Overheat Indicator

ACG Indicator

PGM-FI Indicator

Refer to the Operation Guide included with each Digital

Tachometer for operation information.

28

Digital Speedometer includes the following functions.

Speedometer

Fuel level Meter

Volt Meter

Tripmeter

Fuel Integration Meter

Fuel Economy Meter

Fuel Flow Meter

Water Separator Indicator

Refer to the Operation Guide included with each Digital

Speedometer for operation information.

04/03/29 10:32:56 31ZY2600_030

INDICATORS

Alternator (ACG) Indicator

ACG INDICATOR

Programmed Fuel Injection

(PGM-FI) Indicator

PGM-FI INDICATOR


The ACG indicator turns on and the buzzer sounds in one-second intervals when the charging system is faulty.

When the engine control system detects an PGM-FI malfunction, the

PGM-FI indicator turns on and the buzzer sounds at one-second intervals.

Under normal conditions when the ignition key is turned on the following will occur:

1.

Both the PGM-FI indicator and

ACG indicator will turn on.

2.

3.

4.

The buzzer will beep twice.

The PGM-FI indicator will turn off shortly after the second beep.

The ACG indicator will turn off after the engine starts.

29

04/03/29 10:33:06 31ZY2600_031


Oil Pressure Indicator


(GREEN)

(panel-mount/top-mount types)

(GREEN)

When the oil pressure indicator is lit, oil pressure is OK.

If oil pressure becomes low, the indicator will go off, and the engine protection system will limit engine speed. Refer to TAKING CARE OF

UNEXPECTED PROBLEMS, from

p.

90 .

All models are equipped with a buzzer that sounds when the oil pressure indicator goes off.

Low oil pressure indicates that the engine oil level is low, or that there is a problem with the engine lubrication system.

Overheat Indicator


(RED)

(panel-mount/top-mount types)

(RED)

30

04/03/29 10:33:17 31ZY2600_032

When the alert triggers, the overheat indicator comes on and the buzzer sounds a steady tone as the engine speed is reduced to 1,800 rpm. If the condition persists for another 20 seconds, the engine shuts off. Refer to TAKING CARE OF

UNEXPECTED PROBLEMS, from

p.

91 .

All models are equipped with a buzzer that sounds a steady tone when the overheat indicator comes on.

Engine overheating may be the result of clogged water intakes.

Cooling System Indicator

COOLING SYSTEM INDICATOR

Water should flow from the cooling system indicator while the engine is running. This shows that water is circulating through the cooling system.

If water stops flowing while the engine is running, it indicates a cooling system problem, such as clogged water intakes, which will cause engine overheating.


OTHER FEATURES

Water Separator Buzzer

The water separator buzzer sounds a rapid, repeating signal when water has accumulated in the water separator.

31

04/03/29 10:33:30 31ZY2600_033


Anodes Overrev Limiter

The engine is equipped with an overrev limiter to prevent the possibility of mechanical damage from excessive engine speed.

The overrev limiter may be activated during operation, limiting engine speed, if the outboard motor is trimmed or tilted excessively, or when propeller ventilation occurs during a sharp turn.

If the overrev limiter is activated, check the trim angle of the outboard motor.

Check to see if the correct propeller is installed.

ANODE

(each side)

ANODE

(stern bracket)

The anodes are made of a sacrificial material that helps to protect the outboard motor from corrosion.

There are two anodes on the gear case, one on the stern bracket, and two small anodes in the water passages of the engine block.

Fuel Priming Bulb

UP

OUTLET END

(motor)

PRIMING BULB

INLET END (tank)

A priming bulb is built into the fuel hose that connects the fuel tank to the outboard motor.

Before starting the engine, hold the priming bulb up in the direction of the arrow, then squeeze the priming bulb until it feels firm. This will ensure that fuel is supplied to the

engine (p.

36

).

32

04/03/29 10:33:43 31ZY2600_034

ARE YOU READY TO GET

UNDER WAY?

Your safety is your responsibility. A little time spent in preparation will significantly reduce your risk of injury.

Knowledge

Read and understand this manual.

Know what the controls do and how to operate them.

Familiarize yourself with the outboard motor and its operation before you get under way. Know what to do in case of emergencies.

Familiarize yourself with all laws and regulations relating to boating and the use of outboard motors.

BEFORE OPERATION

Safety

Always wear a PFD (Personal

Flotation Device) while on the boat.

Attach the emergency stop switch lanyard securely to your PFD or to your wrist.

IS YOUR OUTBOARD

MOTOR READY TO GO?

For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the outboard motor to check its condition.

Be sure to take care of any problem you find, or have your authorized

Honda marine dealer correct it, before you operate the outboard motor.

Improperly maintaining this outboard motor, or failing to correct a problem before operation, can cause a malfunction in which you could be seriously hurt or killed.

Always perform a preoperation inspection before each operation, and correct any problem.

Before beginning your preoperation checks, be sure the ignition switch is in the OFF position.

33

04/03/29 10:33:56 31ZY2600_035

BEFORE OPERATION

Safety Inspection

Look around the outboard motor for signs of oil or gasoline leaks.

Check that the fuel hose is undamaged and properly connected.

Wipe up any spills before starting the engine.

Check the stern bracket to be sure the outboard motor is securely installed.

Check that all controls are operating properly.

Replace any damaged parts.

Check that all fasteners are in place and securely tightened.

Maintenance Inspection

Check the engine oil level (p.

60 ).

Running the engine with a low oil level can cause engine damage.

Check to be sure the propeller is undamaged, and the castle nut is

secured with the cotter pin (p.

75 ).

Check that the anodes are securely

attached to the gear case (p.

74 )

and are not excessively worn. The anodes help to protect the outboard motor from corrosion.

Make sure the tool kit is onboard

(p.

55 ). Replace any missing items.

Check the fuel level in the fuel

tank (p.

68

).

Check that the battery fluid is between the upper and lower levels, and the battery leads are connected securely.

Check the water separator for

water contamination (p.

72

).

34

04/03/29 10:34:11 31ZY2600_036

OPERATION

SAFE OPERATING

PRECAUTIONS

To safely realize the full potential of this outboard motor, you need a complete understanding of its operation and a certain amount of practice with its controls.

Before operating the outboard motor for the first time, please review the

IMPORTANT SAFETY

INFORMATION

chapter titled

on page 7

and the

BEFORE OPERATION.

For your safety, avoid starting or operating the engine in an enclosed area. Your engine’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.

BREAK-IN PROCEDURE

Break-in period: 10 hours

Proper break-in operation allows the moving parts to wear in smoothly for best performance and long service life.

First 15 minutes:

Run the engine at trolling speed. Use the minimum throttle opening necessary to operate the boat at a safe trolling speed.

Next 45 minutes:

Run the engine up to a maximum of

2,000 to 3,000 rpm, which is about

10% to 30% of maximum throttle opening.

Next 60 minutes:

Run the engine up to a maximum of

4,000 to 5,000 rpm, which is about

50% to 80% of maximum throttle opening.

Short full-throttle bursts are OK, but do not operate the engine continuously at full throttle.

For boats that plane easily, bring the boat up on plane, and then reduce the throttle opening to the recommended rpm range.

Next 8 hours:

Do not run the engine at full throttle for more than 5 minutes at a time.

35

04/03/29 10:34:22 31ZY2600_037

OPERATION

FUEL PRIMING

UP

OUTLET END

(motor)

PRIMING BULB

INLET END

(tank)

Hold the priming bulb up in the direction of the arrow, then squeeze the priming bulb several times until it feels firm, indicating that fuel has reached the engine.

Check to be sure there are no fuel leaks before starting the engine.

Do not squeeze the priming bulb when the engine is running.

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

Stop the engine and keep heat, sparks, and flame away.

Handle fuel only outdoors.

Wipe up spills immediately.

36

04/03/29 10:34:32 31ZY2600_038

STARTING THE ENGINE

Side-Mount Type

EMERGENCY

STOP SWITCH

OPERATION

The engine will not start or run, unless the clip is in the switch.

The emergency stop switch clip and lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat.

Always attach the lanyard to your

PFD, or to your wrist, before starting the engine.

CONTROL

LEVER

N (neutral)

SWITCH CLIP

LANYARD

1.

Put the emergency stop switch clip in the emergency stop switch, and attach the lanyard to your PFD

(Personal Flotation Device) or to your wrist, as shown.

2.

Set the control lever in the N

(neutral) position.

The engine will not start if the F

(forward) or R (reverse) gears are engaged.

37

04/03/29 10:34:43 31ZY2600_039

OPERATION

LOWEST

POSITION

OFF

ON

START

IGNITION SWITCH KEY

FAST IDLE RANGE

3.

Leave the fast idle lever in the

OFF (fully lowered) position.

Fast idle lever cannot be raised unless the control lever is in the N

(neutral) position.

The control lever cannot be moved away from the N (neutral) position unless the fast idle lever is lowered.

4.

Turn the ignition switch key to the

START position and hold it there until the engine starts.

When the engine starts, release the key, allowing it to return to the ON position.

If the engine fails to start within 5 seconds, release the key and wait at least 10 seconds before operating the starter again.

38

Using the electric starter f or more than 5 seconds at a time will overheat the starter motor and can damage it.

Turning the ignition switch key to the START position while the engine is running can damage the starter motor and f lywheel.

04/03/29 10:34:53 31ZY2600_040

OPERATION

MAXIMUM FAST IDLE

FAST IDLE

RANGE

5.

Before getting under way, allow the engine to warm up sufficiently to ensure good performance.

Above 41°F (5°C), warm up the engine for 2 or 3 minutes.

Below 41°F (5°C), warm up the engine for at least 10 minutes at

2,000 rpm. Raise the fast idle lever to achieve approximately 2,000 rpm.

If the engine is not properly warmed-up bef ore raising the engine speed, the buzzer and overheat indicator may activate, and the engine speed will be automatically reduced.

During the warm-up period, check

the oil pressure indicator (p.

30 ), overheat indicator (p.

30 ), and

cooling system indicator (p.

31 ).

If the indicators show any abnormal condition, immediately stop the engine and determine the cause of the problem. Refer to

TAKING CARE OF

UNEXPECTED PROBLEMS

from p.

83 .

6.

If the fast idle lever was used to warm up the engine, gradually lower the lever as the engine warms up.

When the fast idle lever is fully lowered, the control lever can be moved away from the N (neutral) position.

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04/03/29 10:35:03 31ZY2600_041

OPERATION

Panel-Mount Type

EMERGENCY STOP

SWITCH

SWITCH CLIP

LANYARD

1.

Put the emergency stop switch clip in the emergency stop switch, and attach the lanyard to your PFD

(Personal Flotation Device) or to your wrist, as shown.





CONTROL

LEVER

N (neutral)

2.


(neutral) position.



40

04/03/29 10:35:15 31ZY2600_042

OPERATION

OFF

ON

START

IGNITION

SWITCH

KEY

3.





N (neutral)



CONTROL

LEVER


4.




2,000 rpm. Push the fast idle button then move the control lever forward or reverse to open the throttle and achieve approximately

2,000 rpm.

41

04/03/29 10:35:25 31ZY2600_043

OPERATION





30 ), and


31 ).


TAKING CARE OF


from p.

83 .

5.

If the fast idle control was used to warm up the engine, gradually return the control lever to the N

(neutral) position as the engine warms up.

Top-Mount Type

EMERGENCY STOP

SWITCH

SWITCH CLIP LANYARD

1.

Put the switch clip in the emergency stop switch, and attach the lanyard to your PFD (Personal

Flotation Device) or to your wrist, as shown.

42





04/03/29 10:35:35 31ZY2600_044

OPERATION

N (neutral)

ON

START

OFF

CONTROL

LEVER

2.


(neutral) position.



IGNITION

SWITCH

KEY

3.







43

04/03/29 10:35:50 31ZY2600_045

OPERATION

N (neutral)

CONTROL

LEVER


4.



44


2,000 rpm. Push the fast idle button then move the control lever forward or reverse to open the throttle and achieve approximately

2,000 rpm.





30 ), and


31 ).


TAKING CARE OF


from p.

83 .

5.

If the fast idle control was used to warm up the engine, gradually return the control lever to the N

(neutral) position as the engine warms up.

STOPPING THE ENGINE

Emergency Engine Stopping

Side-Mount Type

EMERGENCY

STOP SWITCH

LANYARD

PULL

SWITCH CLIP

Panel-Mount/Top-Mount Types

EMERGENCY

STOP SWITCH

CONTROL PANEL

PULL

LANYARD

SWITCH CLIP

04/03/29 10:35:58 31ZY2600_046

To stop the engine in an emergency, pull the clip out of the emergency stop switch by pulling the lanyard.

We suggest that you stop the engine this way occasionally to verify that the engine and emergency stop switch are operating properly.

Normal Engine Stopping


N (neutral)

CONTROL

LEVER

Panel-Mount Type

N (neutral)

OPERATION

Top-Mount Type

N (neutral)

CONTROL

LEVER

1.

Move the control lever(s) to the N

(neutral) position.

CONTROL

LEVER

45

04/03/29 10:36:08 31ZY2600_047

OPERATION


O F F

IGNITION KEY


OFF

3.

When the boat is not in use, remove and store the ignition key and the emergency stop switch clip and lanyard.

GEARSHIFT AND

THROTTLE OPERATION


CONTROL LEVER

NEUTRAL

RELEASE LEVER

N (neutral)

F (forward)

R (reverse)

IGNITION KEY

2.


OFF position.

46

04/03/29 10:36:20 31ZY2600_048

OPERATION


F (forward)

CONTROL

LEVER

N (neutral)

R (reverse)

To shift gears, move the control lever to select F (forward), N (neutral) and

R (reverse) gears.

The control lever cannot be moved from the N (neutral) position unless the neutral release lever is squeezed

(side-mount/panel-mount types).

Moving the control lever beyond the gear selection range increases engine speed.


THROTTLE

FRICTION

ADJUSTER

TO INCREASE

FRICTION

TO DECREASE

FRICTION


N (neutral)

F (forward)

R (reverse)


CONTROL LEVER


TO INCREASE

FRICTION

CONTROL

LEVER

TO DECREASE

FRICTION

47

04/03/29 10:36:27 31ZY2600_049

OPERATION


TO INCREASE

FRICTION

TO DECREASE

FRICTION

CONTROL LEVER


Adjust the throttle friction adjuster so the control lever will hold a constant throttle setting while cruising.

STEERING

Steer the boat in the same manner as an automobile.

48

04/03/29 10:36:42 31ZY2600_050

OPERATION

CRUISING

Engine Speed

For best fuel economy, limit the throttle opening to 80%. Use the

throttle friction control (p.

,

)

to help you hold a steady speed.

For rough water conditions or large waves, slow down to prevent the propeller from rising out of the water.

The engine is equipped with an overrev limiter to prevent the possibility of mechanical damage from excessive engine speed.

If, for example, the outboard motor is tilted excessively, or propeller ventilation occurs during a sharp turn, the engine may overrev, activating the overrev limiter.

If engine speed becomes unstable at high speed due to activation of the overrev limiter, reduce speed and check the trim angle of the outboard motor.

Trim

Use the power trim/tilt switch to trim the outboard motor for the best performance and stability.

You can use the power trim/tilt switch at any time, whether the boat is under way or stopped.

Press the UP or DN (down) side of the switch to adjust the angle of the outboard motor.

Refer to the trim meter (p.

27 ) for an

indication of whether the motor is trimmed high or low.

It is necessary to trim the angle of the outboard motor to compensate for changes in boat load, weight distribution, water conditions, or propeller selection.

Under normal conditions, the boat will perform best when the antiventilation plate is level with the water.

When cruising into a high wind, trim the outboard motor down slightly to level the boat and improve stability.

With a tail wind, trim the outboard motor up slightly.

Excessive trim/tilt angle during operation can cause propeller ventilation, overheating, and water pump damage.

49

04/03/29 10:36:53 31ZY2600_051

OPERATION




(single type)


MOTOR

TRIMMED TOO

LOW

MOTOR

TRIMMED TOO

HIGH

MOTOR TRIMMED

CORRECTLY



(dual type)


(LEFT) (RIGHT)

BOW TOO LOW DUE TO

1. LOAD IN THE FRONT

2. MOTOR TRIMMED TOO LOW

BOW TOO HIGH DUE TO

1. LOAD IN THE REAR

2. MOTOR TRIMMED TOO HIGH

50

04/03/29 10:37:05 31ZY2600_052

If steering effort is not equal in both directions, adjust the trim tab to compensate for ‘‘torque steer,’’ which is the reaction of the outboard motor to propeller rotation.

TIGHTENING BOLT

TRIM TAB

Adjust the trim tab with the engine stopped. Loosen the bolt above the trim tab, turn the trim tab, then tighten the bolt securely.

When the trim tab is correctly adjusted, steering effort will be equal in both directions.

OPERATION

SHALLOW WATER

OPERATION

When operating in shallow water, use

the power trim/tilt switch (p.

50 ) to

tilt the outboard motor, so the propeller and gear case won’t hit the bottom.

Proceed at low speed, and monitor water flow from the cooling system

indicator (p.

31 ) to be sure the

outboard motor is not tilted so high that the water intakes are out of the water.

An excessive trim/tilt angle during operation can cause propeller ventilation, overheating, and water pump damage. This type of damage is not covered by the Distributor’s

Limited Warranty.

MOORING, BEACHING,

LAUNCHING

To raise the outboard motor out of the water while the engine is stopped and the boat is moored, or for maximum clearance when beaching or launching, use the power tilt switch on the engine pan to tilt the outboard motor as far as it will go, move the tilt lock lever to the LOCK position, then gently lower the outboard motor until the lever contacts the stern bracket.

If more clearance is needed to swing the tilt lock lever into the LOCK position, rock the outboard motor forward slightly by pulling on the engine cover grip.

To lower the outboard motor, tilt up, move the tilt lock lever to the FREE position, then lower the outboard motor to the desired position.

51

04/03/29 10:37:15 31ZY2600_053

OPERATION

POWER TILT SWITCH

Do not attempt to use the power tilt switch to tilt the outboard motor down while the tilt lock lever is in the lock position. Damage to the power tilt system may occur.

MANUAL RELIEF VALVE

For manual tilting, use a screwdriver to turn the valve counterclockwise 1 or 2 turns. Close the valve firmly after positioning the engine.

Be sure the valve is closed before operating the outboard motor. If the valve is not closed, the outboard motor will tilt up when operated in reverse.

TILT LOCK LEVER

(Lock position)

FREE

L O C K

M A N U A L

( T o r e l e a s e )

P O W E R

( T o f i x )

The outboard motor can also be tilted manually after opening the manual relief valve. This feature enables the outboard motor to be tilted or lowered when no battery is connected.

52

04/03/29 10:37:24 31ZY2600_054

THE IMPORTANCE OF

MAINTENANCE

Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution.

Improperly maintaining this outboard motor, or failure to correct a problem before operation, can cause a malfunction in which you could be seriously hurt or killed.

Always follow the inspection and maintenance recommendations and schedules in this owner’s manual.

SERVICING YOUR OUTBOARD MOTOR

To help you properly care for your outboard motor, the following pages include a maintenance schedule, routine inspection procedures, and simple maintenance procedures using basic hand tools. Other service tasks that are more difficult, or require special tools, are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic.

The maintenance schedule applies to normal operating conditions. If you operate your outboard motor under unusual conditions, consult an authorized Honda marine dealer for recommendations applicable to your individual needs and use.

Remember that your authorized

Honda marine dealer knows your outboard motor best and is fully equipped to maintain and repair it.

To ensure the best quality and reliability, use only new, genuine

Honda parts or their equivalents for repair and replacement.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual, using parts that are ‘‘certified’’ to

EPA standards.

53

04/03/29 10:37:36 31ZY2600_055


MAINTENANCE SAFETY

Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.

Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed.

Always follow the procedures and precautions in the owner’s manual.

Safety Precautions

Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:

−

Carbon monoxide poisoning from engine exhaust.

Be sure there is adequate ventilation whenever you operate the engine.

−

Burns from hot parts.

Let the engine and exhaust system cool before touching.

−

Injury from moving parts.

Do not run the engine unless instructed to do so.

Read the instructions before you begin, and make sure you have the tools and skills required.

To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a nonflammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks, and flames away from all fuel-related parts.

Wear gloves when handling the propeller to protect your hands from sharp edges.

54

04/03/29 10:37:46 31ZY2600_056

TOOL KIT and OWNER’S MANUAL

14

×

17 mm WRENCH

SPARK PLUG WRENCH


SPARE EMERGENCY STOP

SWITCH CLIP


10

×

12 mm WRENCH

19 mm EYE WRENCH

TOOL BAG

8 mm WRENCH

16

×

17 mm BOX WRENCH

OWNER’S MANUAL

OIL CHECK

SCREWDRIVER

FLAT SCREWDRIVER

FUSE PULLER

PHILLIPS

SCREWDRIVER

SCREWDRIVER HANDLE

PLIERS

6 mm HEX. WRENCH

The tool kit can be used for simple maintenance procedures and emergency repairs. Keep these items on the boat, so they will always be available if you need them.

If your tool kit needs replacement, it is not available as a kit and each item must be ordered individually.

Always carry a spare emergency stop switch clip onboard. The spare clip may either be stored in the tool bag or in an easily accessible location on the boat.

55

04/03/29 10:37:58 31ZY2600_057


MAINTENANCE SCHEDULE

REGULAR SERVICE PERIOD (3)

ITEM

Engine oil

Gear case oil

Engine oil filter

ACG belt

Throttle linkage

Idle speed

Valve clearance

Spark plug

Perform at every indicated month or operating hour interval, whichever comes first.

Check level

Change

Change

Replace

Check-adjust

Check-adjust

Check-adjust

Check-adjust

Check

Clean

Replace

Check Propeller and Cotter pin

Anode

Lubrication

Water separator

Check

Grease

Check

Each use

○

○

○

After use

First month or

20 hrs.

○

○

(2)

○

○

(2)

(2)

○

○ (2)

○

(1)

Every 6 months or

100 hrs.

○

○

(2)

○

○

(2)

(2)

○

(1)

Every year or

200 hrs.

○

○

(2)

(2)

○

(2)

○

○ (2)

Every 2 years or

400 hrs.

○

○

(1)

(2)

(3)

(4)

Lubricate more frequently when used in salt water.

These items should be serviced by an authorized Honda marine dealer, unless you have the proper tools and are mechanically proficient.

Refer to the Honda shop manual for service procedures.

For professional/commercial use, log hours of operation to determine proper maintenance intervals.

When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.

56

04/03/29 10:38:11 31ZY2600_058


REGULAR SERVICE PERIOD (3)

ITEM

Fuel filter

Perform at every indicated month or operating hour interval, whichever comes first.

Check

Replace

Fuel filter

(High pressure type)

Thermostat

Fuel line

Replace

Check

Check

Replace

Check level-tightness Battery and cable connection

Bolts and Nuts

Crankcase breather tube

Cooling water passages

Water pump

Check-tightness

Check

Clean

Check

Each use

○

○

After use

○ (4)

First month or

20 hrs.

Every 6 months or

100 hrs.

○

Every 2 years (If necessary) (2)

○ (2) ○ (2)

Every year or

200 hrs.

○ (2)

○ (2)

○

(2)

Every 2 years or

400 hrs.

○

○

(2)

(1)

(2)

(3)

(4)

Lubricate more frequently when used in salt water.

These items should be serviced by an authorized Honda marine dealer, unless you have the proper tools and are mechanically proficient.

Refer to the Honda shop manual for service procedures.

For professional/commercial use, log hours of operation to determine proper maintenance intervals.

When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.

57

04/03/29 10:38:22 31ZY2600_059


TRIM TAB ADJUSTMENT

The trim tab compensates for

‘‘torque steer’’ which is a reaction of the outboard motor to propeller rotation.

If uncompensated, torque steer would make the outboard motor tend to turn to one side.

When the trim tab is correctly adjusted, steering effort is equal in either direction.

If steering effort is unequal, loosen the trim tab bolt and adjust the angle of the trim tab. Retighten the trim tab bolt securely.

LEFT

TIGHTENING BOLT

TRIM TAB

If less effort is required to make left turns, move the back of the trim tab left.

RIGHT

TIGHTENING BOLT

TRIM TAB

If less effort is required to make right turns, move the back of the trim tab right.

Adjust the trim tab in small increments, and retest steering effort with the boat evenly loaded and running at cruising speed.

58

04/03/29 10:38:34 31ZY2600_060




ENGINE COVER REMOVAL

AND INSTALLATION

ENGINE COVER

LATCH

To remove the engine cover, pull the engine cover latch to the unlocked position, then lift the engine cover straight up from the outboard motor.

To install the engine cover, place the cover on the outboard motor, and push down evenly.

Lubricate the engine cover rubber sealing ring with silicone spray to make installation easier.

P O W E R

( T o f i x )

M A N U A L

( T o r e l e a s e )

The outboard motor can be tilted manually after opening the manual relief valve. This feature enables the outboard motor to be tilted or lowered when no battery is connected.

For manual tilting, use a screwdriver to turn the valve counterclockwise 1 or 2 turns. Close the valve firmly after positioning the outboard motor.

Be sure the valve is closed before operating the outboard motor. If the valve is not closed, the outboard motor will tilt up when operated in reverse.

The engine cover latch fastens the engine cover to the outboard motor.

59

04/03/29 10:38:49 31ZY2600_061


Engine Oil Level Check

Check the engine oil level with the engine stopped and the outboard motor in the vertical position.

1.

Unlock and remove the engine

cover (p.

59 ).

2.

Remove the dipstick and wipe it clean.

UPPER

LIMIT

OIL FILLER CAP

4.

If the oil level is low, remove the oil filler cap, and add oil to reach the upper limit mark shown on the dipstick. Use the oil recommended

on p.

63 .

Engine Oil Change

An engine oil evacuation/filling device may be used to remove/add the engine oil.

Drain the used oil while the engine is warm. Warm oil drains quickly and completely.

1.


cover (p.

59 ).

DRAIN PLUG

SCREW

LOWER

LIMIT

OIL LEVEL DIPSTICK

3.

Insert the dipstick all the way in, then remove it and check the oil level shown on the dipstick.

Running the engine with a low oil level can cause engine damage.

5.

Install the oil filler cap and tighten it securely. Do not overtighten.

6.

Install and lock the engine cover.

DRAIN PLUG COVER

2.

Remove the screw from the oil drain plug cover, and remove the cover.

60

04/03/29 10:39:04 31ZY2600_062


GUIDE

SEALING WASHER

DRAIN PLUG COVER

DRAIN PLUG

3.

Set the drain plug cover under the guide.

4.

Place a suitable container below the oil drain guide to catch the used oil, then remove the oil filler cap and the drain plug.

5.

Allow the used oil to drain completely. Use a new sealing washer then reinstall the engine oil drain plug, and tighten it securely.

Improper disposal of engine oil can be harmf ul to the environment.

If you change your own oil, please dispose of the used oil properly.

Put it in a sealed container, and take it to a recycling center. Do not discard it in a trash bin or dump it on the ground.

6.

Install the oil drain plug cover and secure it with the screw.

7.

With the outboard motor in a vertical position, fill to the upper

limit mark on the dipstick (p.

60

)

with the recommended oil.

Engine oil refill capacity:

Without oil filter change:

8.0 US qt (7.6 )

With oil filter change:

8.2 US qt (7.8 )

8.

Install the oil filler cap and tighten it securely.

9.

Install and lock the engine cover.

Oil Filter Change

1.

Drain the engine oil, and reinstall the drain plug and oil drain cover

(see Engine Oil Change on p.

60 ).

2.

Tilt the outboard motor, and place a suitable container below the oil drain guide to catch the used oil.

3.

Use a suitable tool to remove the oil filter, and throughly drain the filter into the used oil container.

61

04/03/29 10:39:16 31ZY2600_063


OIL FILTER

USE A SUITABLE TOOL

4.

Clean the oil filter mounting base, and coat the gasket of the new oil filter with clean engine oil.

7.

Start the engine and check for leaks.

OIL DRAIN GUIDE

RUBBER SEAL

Use only a genuine Honda oil f ilter or a f ilter of equivalent quality specif ied f or your model.

Using the wrong f ilter, or a non-

Honda f ilter which is not of equivalent quality, may cause engine damage.

5.

Screw on the new filter by hand until it contacts the engine, then use a suitable tool to tighten the filter an additional 7/8 turn.

OIL FILTER TIGHTENING

TORQUE:

16 lbf·ft (22 N·m , 2.2 kgf·m)

6.

Return the outboard motor to the vertical position, and fill the crankcase with the specified

amount (p.

61 ) of the

recommended oil.

Running the engine without water can cause serious engine damage.

If you are changing the oil f ilter while the outboard motor is out of the water, use the water hose f lush port and a hose to supply water.

8.

Stop the engine, and check the oil

level as described on page 60 . If

necessary, add oil to bring the oil level to the upper limit mark on the dipstick.

62

04/03/29 10:39:23 31ZY2600_064

Engine Oil Recommendations

Oil is a major factor affecting performance and service life. Use

4-stroke automotive detergent oil.

SAE Viscosity Grades


The SAE oil viscosity and service classification are in the API label on the oil container. Honda recommends that you use API SERVICE category

SG, SH or SJ oil with the ‘‘starburst’’ certification mark displayed on the container.

AMBIENT TEMPERATURE

SAE 10W-30 is recommended for general use.

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04/03/29 10:39:32 31ZY2600_065


Lubrication Points

Apply marine anticorrosion grease to the following parts:

Lubrication interval:

After the first 20 hours or 1 month, then every 100 hours or 6 months. (Refer to the maintenance schedule page

56 ).

THROTTLE REEL

ENGINE COVER

LATCH

THROTTLE ARM/SHIFT

ARM SHAFT

Apply anticorrosion oil to pivot surf aces where grease cannot penetrate.

SHIFT ARM/

CLICK

ROLLER/

NEUTRAL

SWITCH

PTT THRUST RECEIVER

TILT SHAFT

PROPELLER SHAFT

SWIVEL

TILT LOCK LEVER/SHAFT CAM

Apply Honda Marine Corrosion Inhibitor (or equivalent) to all areas under the engine cover and any exposed metal surfaces except the belts.

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Spark Plug Service

RECOMMENDED SPARK PLUGS:

IZFR6F11 (NGK)

VKJ20RZ-M11 (DENSO)

Incorrect spark plugs can cause engine damage.

This outboard motor uses spark plugs that have an iridium coated center electrode. Be sure to observe the following when servicing the spark plugs.

Do not clean the spark plugs. If an electrode is contaminated with accumulated objects or dirt, replace the spark plug with a new one.

Use only a ‘‘wire-type feeler gauge’’ to check the spark plug gap if necessary. To prevent damaging the iridium coating of the center electrode, never use a

‘‘leaf-type feeler gauge.’’

Do not adjust the spark plug gap.

If the gap is out of specification, replace the spark plug with a new one.

1.

Disconnect the battery negative

(

−

) terminal.

2.


cover (p.

59 ).

SPECIAL

SCREWS

WIRE

CONNECTOR

IGNITION COIL

BOLT

R.ENGINE UNDER

COVER

L.ENGINE UNDER COVER

3.

Remove the twenty special bolts, and remove the R. and L. engine under covers.

4.

Disconnect the wire connector from the ignition coil by pushing on the lock tab and pulling on the connector. Pull on the plastic connector, not the wires.

5.

Use a 6 mm hex. wrench to remove the bolt holding the ignition coil. Remove the ignition coil by pulling it up slightly.

Do not strike or drop the ignition coil, or it may be damaged and require replacement.

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SPARK PLUG

WRENCH

19 mm EYE

WRENCH

6.

Remove the spark plugs with a spark plug wrench and 19 mm wrench.

0.039

(1.00

−

−

0.051 in

1.30 mm)

SEALING

WASHER

7.

Inspect the spark plugs. Replace them if the electrodes are worn, or if the insulators are cracked or chipped.

8.

Measure the spark plug electrode gap with a wire-type feeler gauge.

The gap should be 0.039

− 0.051

inches (1.00

− 1.30 mm). If the gap is out of the specification, replace the plug with a new one.

Never try to readjust the gap.

9.

Install the spark plugs carefully, by hand, to avoid cross-threading.

10.

After each spark plug seats, tighten with a spark plug wrench supplied in the tool kit to compress the sealing washer.

If reinstalling used spark plugs, tighten 1/8 - 1/4 turn after the spark plugs seat.

If installing new spark plugs, tighten 1/2 turn after the spark plugs seat.

Loose spark plugs can overheat and damage the engine.

Overtightening the spark plugs can damage the threads in the cylinder head.

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04/03/29 10:40:04 31ZY2600_068

11.

Install the ignition coil. Reinstall the bolt.

12.

Push the wire connector onto the ignition coil. Make sure it locks in place.

13.

Repeat this procedure for the other five spark plugs.

14.

Reinstall the covers. When reinstalling the covers, make sure not to jam the wire harnesses between the covers and engine case.


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REFUELING

Check the fuel level and refill if neccessary. Do not fill the fuel tank above the UPPER LIMIT. Refer to the boat manufacturer’s instructions.






Never refill the fuel tank inside a building where gasoline fumes may reach flames or sparks. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc.

Spilled fuel is not only a fire hazard, it causes environmental damage.


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FUEL RECOMMENDATIONS

Use unleaded gasoline with a pump octane rating of 86 or higher.

Your outboard motor is certified to operate on unleaded gasoline.

Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life.

Never use stale or contaminated gasoline or an oil/gasoline mixture.

Avoid getting dirt or water in the fuel tank.

Occasionally you may hear a light

‘‘spark knock’’ or ‘‘pinging’’

(metallic rapping noise) while operating under heavy loads. This is no cause for concern.

If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized Honda marine dealer.

Running the engine with persistent spark knock or pinging can cause engine damage.

Running the engine with persistent spark knock or pinging is misuse, and the

Distributor’s Limited

Warranty

does not cover parts damaged by misuse.

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Fuel Filter Inspection and

Replacement

The fuel filter (inside the strainer cup) is located below the engine oil filter.

Water or sediment accumulated in the filter can cause loss of power or hard starting. To prevent engine malfunction, inspect the filter and replace when necessary.






ENGINE COVER LATCH

1.

Remove the engine cover.

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04/03/29 10:40:41 31ZY2600_072

ENGINE OIL FILTER

FUEL FILTER (inside strainer cup)

2.

Looking through the translucent strainer cup, check the fuel filter for water accumulation or sediment.


SCREW (3)

FUEL HOSES

SUSPENSION STRAP

3.

Remove the suspension strap from the strainer bracket, then remove the strainer assembly from the strap.

Before removing the fuel filter, to prevent fuel leakage, place fuel hose clamps on the fuel hoses on each side of the fuel filter.

4.

Remove the three screws and separate the fuel strainer cup from the strainer body.

5.

Thoroughly clean the strainer cup, and replace with a new fuel filter.

6.

Reassemble the strainer body and the cup.

STRAINER TIGHTENING

TORQUE:

3.4 N·m (0.35 kgf·m , 2.5 lbf·ft)

7.

Reinstall the strainer in the original position.

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04/03/29 10:40:51 31ZY2600_073


8.

Prime the engine using the priming bulb (refer to page 36 ). Check for fuel leaks. Repair any fuel leaks if necessary.

If loss of power or hard starting are found to be caused by excessive water or sediment accumulation in the fuel filter, inspect the fuel tank.

Clean the fuel tank and tank filter if necessary. It may be necessary to drain the fuel tank completely and refill with fresh gasoline.

Water Separator Inspection and

Service

WATER SEPARATOR

The water separator is located beside the oil level dipstick. Water accumulation in the water separator can cause loss of power or hard starting. Check the water separator periodically. Clean it or consult with an authorized Honda marine dealer for cleaning.






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SUSPENSION STRAP

FUEL TUBES

SCREW (3)

1.

Remove the engine cover (see

page 59 ).

2.

Disconnect the water level sensor connector.

3.

Remove the suspension strap from the water separator bracket, then remove the separator assembly from the strap.

4.

Pinch the fuel tubes with tube clips to prevent fuel leakage.

5.

Remove the three screws and separate the water separator cup from the body.

6.

Thoroughly clean the water separator cup.

7.

Reassemble the water separator body and the cup.

TIGHTENING TORQUE:

3.4 N·m (0.35 kgf·m , 2.5 lbf·ft)

8.

Reinstall the strainer in the reverse order of removal.

9.

Squeeze and release the priming bulb to fill the vapor separator, and check for leaks.

If the buzzer sounds or water or sediment accumulation are found to be caused by excessive water or sediment accumulation in the fuel filter, inspect the fuel tank.

Clean the fuel tank and tank filter if necessary. It may be necessary to drain the fuel tank completely and refill with fresh gasoline.

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Anode Replacement

Painting or coating the anodes will def eat their purpose and will lead to rust and corrosion damage to the outboard motor. The anodes must be exposed to the water in order to protect the outboard motor.

ANODE

(stern bracket)

ANODE

(each side)

The anodes are located on each side of the gearcase. They are made of a sacrificial material that helps to protect the outboard motor from corrosion.

Replace the anodes when they have been reduced to about half their original size, or if they are crumbling.

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Propeller Replacement

Before replacing the propeller, remove the clip from the engine stop switch to prevent any possibility of the engine being started while you are working with the propeller.

The propeller blades may have sharp edges, so wear heavy gloves to protect your hands.

Operating the outboard motor at higher altitudes will reduce available power. This may require decreasing the propeller pitch to maintain correct engine RPM.

Removal

1.

Remove the cotter pin, unscrew the castle nut, remove the washer, then remove the propeller and thrust washer.

2.

Inspect the propeller shaft for any fishing line or debris.

Installation

Some propeller brands require specific mounting hardware. Refer to your specific propeller manufacturer’s instructions for proper installation.

1.

Apply marine grade grease to the propeller shaft and beveled surface of the thrust washer.

2.

Install the propeller in the reverse order of removal.

MARINE GREASE

THRUST WASHER

WASHER

Install the thrust washer with the grooved side toward the gear case.

Use a genuine Honda cotter pin and bend the pin ends as shown.

PROPELLER

COTTER PIN

CASTLE NUT

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04/03/29 10:41:34 31ZY2600_077

STORAGE

STORAGE PREPARATION

Proper storage preparation is essential for keeping your outboard motor troublefree and looking good.

The following steps will help to keep rust and corrosion from impairing your outboard motor’s function and appearance, and will make the engine easier to start when you use the outboard motor again.

Cleaning and Flushing

Thoroughly clean and flush the outboard motor with fresh water after operation in dirty water or salt water.

Touch up any damaged paint, and coat areas that may rust with Honda

Corrosion Inhibitor, or equivalent.

Lubricate controls with a silicone spray lubricant.

Cleaning

Wash the outside of the outboard motor with clean, fresh water, and flush the cooling system as follows.

Flushing With a Garden Hose

Do not run the motor when f lushing the motor with a garden hose or the motor may be damaged.

For safety, remove the emergency stop switch clip so the engine cannot be started while you are standing near the propeller.

FLUSH PORT

CONNECTOR

1.

Disconnect the flush port connector.

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04/03/29 10:41:41 31ZY2600_078

GARDEN HOSE

FLUSH PORT

CONNECTOR

2.

Connect the garden hose to the flush port connector.

EXHAUST PORT

3.

Turn on the fresh water supply and flush the outboard motor for at least 10 minutes.

4.

After flushing, disconnect the garden hose and reconnect the flush port connector.

STORAGE

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04/03/29 10:41:54 31ZY2600_079

STORAGE

Fuel

Gasoline will oxidize and deteriorate in storage. Old gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in your fuel tank and vapor separator deteriorates during storage, you may need to have the vapor separator and other fuel system components serviced or replaced.

The length of time that gasoline can be left in your fuel tank and vapor separator without causing functional problems will vary with such factors as gasoline blend, your storage temperatures, and whether the fuel tank is partially or completely filled.

The air in a partially filled fuel tank promotes fuel deterioration. Very warm storage temperatures accelerate fuel deterioration. Fuel deterioration problems may occur within a few months, or even less if the gasoline was not fresh when you filled the fuel tank.

The

Distributor’s Limited Warranty

does not cover fuel system damage or engine performance problems resulting from neglected storage preparation.

You can avoid fuel deterioration problems by draining the fuel tank and vapor separator.

Drain the fuel into an approved fuel container.

VAPOR SEPARATOR

DRAIN SCREW DRAIN HOSE

1.

Unhook the drain hose from the lower left of the head cover.

78

2.

Set the end of the hose toward the outside of the engine undercase and below the level of the vapor separator drain screw.

3.

Loosen the vapor separator drain screw.






04/03/29 10:42:08 31ZY2600_080

STORAGE

4.

With the outboard motor turned to the starboard side, tilt the motor up.

Keep the end of the drain hose below the level of the vapor separator drain screw and watch for the fuel to start flowing out the drain hose.

5.

After the fuel starts flowing out the drain hose, tilt the motor down and allow the siphon to finish draining the vapor separator.

6.

After draining thoroughly, tighten the drain screw securely.

7.

Clip the drain hose on the head cover.

8.

Drain the fuel tank into an approved gasoline container, or if you need to store fuel in the fuel tank, you can extend fuel storage life by filling the fuel tank with fresh gasoline and adding a fuel stabilizer that is formulated for that purpose.

Engine Oil

1.

Change the engine oil and the oil

filter (p.

60 − 62 ).

2.

Remove the spark plugs (p.

65 ),

and remove the clip from the emergency stop switch.

3.

Pour a tablespoon (5 − 10 cm ) of clean engine oil into each cylinder.

4.

Rotate the engine a few revolutions to distribute the oil in the cylinders.

5.

Reinstall the spark plugs (p.

66 ).

HOISTING THE OUTBOARD

MOTOR

ENGINE COVER

LATCH

1.

Unlock and remove the engine cover.

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04/03/29 10:42:17 31ZY2600_081

STORAGE

HOIST

HOOKS

2.

Attach the hoist hooks to the lifting eyes.

3.

Disconnect the outboard motor from the boat, hoist the outboard motor, and move it to the storage area.

4.

After the outboard motor is placed in storage and disconnected from the hoist, install the engine cover.

STORAGE PRECAUTIONS

Select a well-ventilated storage area.

If possible, avoid storage areas with high humidity.

If storing a container of gasoline, store it away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer. Also avoid any area with a spark producing electric motor, or where power tools are operated.

OUTBOARD

MOTOR STAND

If the outboard motor will be removed from the boat for storage, we recommend storing it vertically by mounting it on a stand.

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04/03/29 10:42:25 31ZY2600_082

PROTECTOR

If it is necessary to store the outboard motor horizontally, drain the vapor

separator (p.

78 ), and drain the

engine oil (p.

60 ), before removing

the outboard motor from the boat.

Rest the motor on a cushion of protective material.

STORAGE

Cover the outboard motor to keep out dust. Do not use sheet plastic as a dust cover. A nonporous cover will trap moisture, promoting rust and corrosion.

REMOVAL FROM STORAGE

Check your outboard motor as described in the

BEFORE

OPERATION

chapter of this manual.

If the cylinders were coated with oil during storage preparation, the engine may smoke briefly at startup.

This is normal.

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TRANSPORTING

WITH OUTBOARD MOTOR

INSTALLED ON BOAT

When trailering a boat with the outboard motor attached, leave the engine in the normal running position, if possible.

Use a motor support bar to prevent the outboard motor from moving while trailering the boat. Refer to the manufacturer’s instructions for using a motor support bar.

WITH OUTBOARD MOTOR

REMOVED FROM BOAT

Secure the outboard motor in either the vertical or horizontal position

shown on p.

80 −

81 .

MOTOR SUPPORT BAR

(commercially available)

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04/03/29 10:42:42 31ZY2600_084

ENGINE WILL NOT START

1.

Check emergency stop switch clip.

2.

Check control positions.

TAKING CARE OF UNEXPECTED PROBLEMS

Possible Cause

Clip not inserted in stop switch.

Control lever not in neutral position.

Fast idle lever raised (side-mount type).

Correction

Insert clip in stop switch.

Shift to neutral.

Leave fast idle lever OFF (p.

18 ).

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04/03/29 10:42:53 31ZY2600_085



(continued)

3.

Check fuel.

Possible Cause

Out of fuel.

Fuel hose not primed.

Fuel filter or fuel tank filter clogged.

Bad fuel; boat stored without treating or draining gasoline, or refueled with bad gasoline.

Correction

Refuel (p.

68 ).

Squeeze priming bulb (p.

32

).

Replace fuel filters (p.

70 ).

Drain fuel tank and vapor

separator (p.

78 ). Refill with fresh

gasoline (p.

68 ).

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(continued)

4.

Check battery.

Possible Cause

7.

Use starting procedure (p.

37 ),

if engine still will not start then take outboard motor to an authorized Honda marine dealer, or refer to the shop manual.

Battery connections loose or corroded.

5.

Check fuses.

Battery discharged.

Fuse(s) blown.

6.

Remove and inspect spark plugs.

Spark plugs faulty, fouled or improperly gapped.

Spark plugs wet with fuel (flooded engine).

Fuel system malfunction, fuel pump failure, ignition malfunction, stuck valves, starter malfunction, switch malfunction, or electrical problem in the starting circuit, etc.

Correction

Clean and tighten battery connections.

Recharge battery.

Replace fuse(s) (p.

88 ).

Replace spark plug (p.

65 ).

Dry and reinstall spark plugs. Start engine with the throttle open.

Replace or repair faulty components as necessary.

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HARD STARTING OR STALLS

AFTER STARTING

1.

Check control positions.

2.

Check fuel.

Possible Cause

Fast idle lever raised (side-mount type).

Fuel hose not primed.

Fuel filter or fuel tank clogged.

Bad fuel; boat stored without treating or draining gasoline, or refueled with bad fuel.

Correction

Leave fast idle lever OFF (p.

18 ).

Squeeze priming bulb (p.

32 ).

Replace fuel filters (p.

70 ).

Drain fuel tank and vapor

separator (p.

78 ). Refill with fresh

gasoline (p.

68 ).

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HARD STARTING OR STALLS

AFTER STARTING

(continued)

3.

Remove and inspect spark plugs.

4.

Take outboard motor to an authorized Honda marine dealer, or refer to the shop manual.

Possible Cause

Spark plugs faulty, fouled or improperly gapped.

Fuel system malfunction, fuel pump failure, ignition malfunction, etc.

Correction

Replace spark plug (p.

65 ).


ENGINE OVERHEATS

1.

Check water intake screens.

2.

Take outboard motor to an authorized Honda marine dealer, or refer to the shop manual.

Possible Cause

Water intake screens clogged.

Faulty thermostat or water pump.

Correction

Clean water intake screens.


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FUSES

Electric Starter Will Not

Operate

The 10A, 15A, and 30A main fuses protect the electric starter relay and related circuits.

The 10A main fuse protects the ignition switch and related circuits. If this fuse blows, the engine will not start or run, and the power trim/tilt switch will not activate the trim/tilt mechanism.

Battery Will Not Charge

A 150A ACG fuse protects the alternator circuit. If the ACG fuse blows, the engine will not charge the

battery. Refer to p.

89 .

Fuse Replacement

Main Fuse

1.

With the engine stopped, remove the engine cover.

2.

Remove the fuse cover.

FUSE HOLDER

FUSE COVER

3.

Use the fuse puller from the tool kit to remove the fuses. If a fuse is blown, install a replacement fuse of the same specified rating. The outboard motor is supplied with spare fuses in the fuse holder.

MAIN FUSE RATINGS:

10 A, 15 A, 30 A

FUSE PULLER

BLOWN

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04/03/29 10:44:03 31ZY2600_090


4.

Reinstall the fuse cover and the engine cover.

Never use a f use with a rating greater than specif ied. Serious damage to the electrical system could result.

If a blown fuse is found, try to determine and correct the electrical problem that caused the blown fuse.

An uncorrected electrical problem may cause the fuse to blow again.

If fuses continue to blow, take the outboard motor to an authorized

Honda marine dealer for inspection and service or refer to the shop manual.

ACG Fuse

FUSE CASE LID

FUSE (150A)

‘‘150A’’MARK

SPARE FUSE

Disconnect the battery cable at the battery negative (-) terminal bef ore replacing the f use.

Failure to do so may cause a short circuit.

Replacement

1.

Stop the engine.

2.

Remove the engine cover.

3.

Remove the fuse case lid.

4.

Remove the old fuse by removing two 5 mm screws.

5.

Install a new fuse with the ‘‘150

A’’ mark downward.

ACG FUSE: 150 A

6.

After finishing replacement, install the fuse case lid with its hook toward the engine side.

7.

Be sure to check the fuse case lid is securely locked.

A spare fuse is located on the reverse side of the fuse case lid and tightened with two 3 mm screws.

When the new fuse is set as a spare fuse on the reverse side of the fuse case lid, set the fuse so that you can see the ‘‘150 A’’ mark on it.

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OIL PRESSURE INDICATOR

LIGHT GOES OFF AND

ENGINE SPEED IS LIMITED



(GREEN)

(GREEN)


Normal

Abnormal

If oil pressure becomes low, the oil pressure indicator will go off, and the engine protection system limits engine speed. If you are at cruising speed, engine speed will decrease automatically.

The oil pressure indicator is also equipped with a buzzer that sounds when the oil pressure indicator goes off.

Low oil pressure may be the result of a low engine oil level, or there may be a problem with the engine lubrication system.

If the throttle is closed suddenly after full throttle operation, engine speed may drop below the specified idle rpm, and that could activate the engine protection system momentarily.

If low oil pressure activates the engine protection system, stop the engine, check the engine oil level

(p.

60 ), and add oil if needed.

With the engine oil at the recommended level, restart the engine. If the lubrication system is

OK, the oil pressure indicator should come on within 30 seconds, and the engine will respond normally to throttle control lever operation.

If the engine protection system remains activated after 30 seconds, return to the nearest boat landing, and have the outboard motor inspected by an authorized Honda marine dealer.

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04/03/29 10:44:29 31ZY2600_092

OVERHEAT INDICATOR

COMES ON AND ENGINE

SPEED IS LIMITED




If the engine is stopped after running at full throttle, and then restarted soon afterward, that could activate the engine protection system momentarily.

Normal

Abnormal

COOLING SYSTEM INDICATOR

(RED)

(RED)


If the engine overheats, the overheat indicator will come on, and the engine will stop in 20 seconds after the engine protection system limits engine speed. If you are at cruising speed, engine speed will decrease automatically.

All types are equipped with a buzzer that sounds when the overheat indicator comes on.

Engine overheating may be the result of restricted water intake screens, or there may be a problem with the cooling system thermostat or water pump.

If overheating activates the engine protection system, idle the engine in neutral, and check the cooling system indicator.

If water is flowing from the cooling system indicator, continue idling for

30 seconds. If the cooling system is

OK, the overheat indicator should go off within 30 seconds, and the engine will respond normally to throttle control lever operation.

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04/03/29 10:44:42 31ZY2600_093


If there is no water flowing from the cooling system indicator, stop the engine and check the discharge port first then tilt the outboard motor to inspect the water intake screens. If clogged, clean the water intake screens, return the outboard motor to the running position, restart the engine, and check the cooling system indicator again.

If there is still no water flowing from the cooling system indicator, or if the engine protection system remains activated after 30 seconds, return to the nearest boat landing, and have the outboard motor inspected by an authorized Honda marine dealer.

WATER SEPARATOR

BUZZER SOUNDS

WATER SEPARATOR

INDICATOR


Normal

Abnormal

WATER SEPARATOR

When the water separator buzzer sounds (a rapid, repeating signal):

1.

Check the water separator for water contamination. If water is accumulated, stop the engine, and clean the water separator following

the instructions on page 73

, or consult with an authorized Honda outboard motor dealer.

When the water separator indicator blinks.

Check the water separator for water contamination. If water is accumlated, stop the engine, and clean the water separator following the instructions

on page 72 , or consult with an

authorized Honda marine dealer.

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04/03/29 10:44:54 31ZY2600_094

SUBMERGED MOTOR

A submerged outboard motor must be serviced immediately after it is recovered from the water in order to minimize corrosion.

If there is a Honda marine dearship nearby, take the motor to the dealer immediately. If you are far from a dealership, proceed as follows:

1.

Remove the engine cover, and rinse the outboard motor with fresh water to remove salt water, sand, mud, etc.

2.

Drain the vapor separator as

described on p.

78 .


3.

Change the engine oil and oil filter

as described on p.

60

−

62 . If

there was water in the engine crankcase, or if the used engine oil showed signs of water contamination, then a second engine oil change should be performed after running the engine for half an hour.

4.

Remove the spark plugs (p.

65 ).

Operate the starter to expel water from the engine’s cylinder.

5.

Put a teaspoon of engine oil into each spark plug hole to lubricate the inside of the cylinders.

Reinstall the spark plugs.

If the engine was running when it submerged, there may be mechanical damage, such as bent connecting rods. If the engine binds when cranked, do not attempt to run the engine until it has been repaired.

6.

Attempt to start the engine (be sure the water level is at least 2 inches above the antiventilation plate).

Running the outboard motor without suf f icient cooling water will damage the water pump and overheat the engine.

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04/03/29 10:45:00 31ZY2600_095


If the engine fails to start, remove the spark plugs and dry them, then reinstall the spark plugs and attempt to start the engine again.

If the engine starts, and no mechanical damage is evident, continue to run the engine for a half hour or longer. Be sure the water level is at least two inches above the antiventilation plate to avoid overheating and water pump damage.

7.

As soon as possible, take the outboard motor to an authorized

Honda marine dealer for inspection and service.

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TECHNICAL AND CONSUMER INFORMATION

TECHNICAL INFORMATION

Serial Number Locations

Record the product identification number and engine serial number in the space provided on this page. You will need these numbers when ordering parts, and when making technical or warranty inquiries

(p.

105

).

PRODUCT

IDENTIFICATION

NUMBER

STERN BRACKET

The product identification number is stamped on a plate attached on the right stern bracket.

Product identification number:

ENGINE SERIAL NUMBER

The engine serial number is stamped on the upper right side of the motor.

Engine serial number:

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Oxygenated Fuels

Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and

Canada use oxygenated fuels to help reduce emissions.

If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.

Before using an oxygenated fuel, try to confirm the fuel’s contents. Some states/provinces require this information to be posted on the pump.

The following are the EPA-approved percentages of oxygenates:

ETHANOL:

ethyl or grain alcohol;

10% by volume.

You may use gasoline containing up to 10% ethanol by volume. Gasoline containing ethanol may be marketed under the name ‘‘Gasohol’’.

MTBE:

Methyl Tertiary Butyl Ether;

15% by volume.

You may use gasoline containing up to 15% MTBE by volume.

METHANOL:

methyl or wood alcohol; 5% by volume.

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04/03/29 10:45:29 31ZY2600_098


You may use gasoline containing up to 5% methanol by volume, as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system. Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of your fuel system.

If you notice any undesirable operating symptoms, try another service station, or switch to another brand of gasoline.

Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty.

Battery

For complete information, refer to the battery manufacturer’s instructions.

Minimum Requirements

12V − 110AH

(CCA800)

Emission Control System

Information

Source of Emissions

The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.

Honda utilizes various systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.

97

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PGM-FI System

The PGM-FI system uses sequential multiport fuel injection. It has three subsystems: Air Intake, Engine

Control, and Fuel Control. The

Engine Control Module (ECM) uses various sensors to determine how much air is going into the engine. It then controls how much fuel to inject under all operating conditions.

Ignition Timing Control System

The system constantly adjusts the ignition timing, reducing the amount of HC, CO and NOx produced.

The U.S. and Calif ornia Clean

Air Acts

EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems.

The following instructions and procedures must be followed in order to keep the emissions from your

Honda engine within the emission standards.

Tampering and Altering

Tampering with or altering the emission control system may increase emissions beyond the legal limit.

Among those acts that constitute tampering are:

Removal or alteration of any part of the intake, fuel, or exhaust systems.

Alterations that would cause the engine to operate outside its design parameters.

98

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Problems That May Af f ect

Emissions

If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer.

Hard starting or stalling after starting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuel consumption.

Replacement Parts

The emission control systems on your Honda engine were designed, built, and certified to conform with

EPA and California emission regulations. We recommend the use of genuine Honda parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system.

A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations.

Maintenance

Follow the maintenance schedule on

p.

56 . Remember that this schedule

is based on the assumption that your machine will be used for its designed purpose. Sustained high-load operation, or use in unusual conditions, will require more frequent service.

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Star Label

A Star label was applied to this outboard motor in accordance with the requirements of the California

Air Resources Board.

The Star Label means Cleaner Marine Engine

This engine has been certified as a:

The Symbol for Cleaner Marine Engines:

Cleaner Air and Water -

for healthier lifestyle and environment.

Better Fuel Economy -

burns up to 30 - 40 percent less gas and oil than conventional carbureted two-stroke engines, saving money and resources.

Longer Emission Warranty -

protects consumer for worry free operation.

100

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One Star

Low

Emission

Two Stars

Very Low

Emission

Three Stars

Ultra Low

Emission

Four Stars

Super Ultra

Low Emission


The one-star label identifies engines that meet the Air Resources Board’s

Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S.EPA’s 2006 standards for marine engines.

The two-star label identifies engines that meet the Air Resources Board’s

Personal Watercraft and Outboard marine engine 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than

One Star-Low Emission engines.

The three-star label identifies engines that meet the Air Resources Board’s

Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and inboard marine engine 2003-2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star-Low Emission engines.

The four-star label identifies engines that meet the Air Resources Board’s

Sterndrive and Inboard marine engine 2009 exhaust emission standards.

Personal Watercraft and Outboard marine engines may also comply with these standards. Engines meeting these standards have 90% lower emissions than One Star-Low Emission engines.

Cleaner Watercraft - Get the Facts

1-800-END-SMOG www.arb.ca.gov

101

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Specifications

MODEL

Description Code

Type

Overall length

Overall width

Overall height

Transom height

Weight

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

BAEJ BAEJ BAFJ BAEJ BAFJ

LA XA

BF200A

XCA XXA

36.2 in (920 mm)

XXCA

65.7 in

(1,670 mm)

20.0 in

(508

24.6 in (625 mm)

70.9 in

(1,800 mm)

75.8 in

(1,925 mm)

25.0 in (635 mm) 30.0 in (762 mm) mm)

589 lbs

(267 kg)

600 lbs (272 kg) 611 lbs (277 kg)

149.1 kW (200 HP)

5,000 − 6,000 rpm

4 stroke SOHC 6-cylinder (V6)

211.7 cu-in (3,471 cm )

0.039

− 0.051 in (1.00

− 1.30 mm)

Starter system

Ignition system

Lubrication system

Specified oil

Oil capacity

CARB star label

D.C. output

Cooling system

Exhaust system

Spark plugs

Fuel pump

Fuel

Gear change

Steering angle

Trim angle

(when transom angle is

12°)

Electric starter

Fully transistorized, battery ignition

Trochoid pump pressure lubrication

Engine: API standard (SG, SH, SJ)

SAE 10W-30

Gear case: API standard (GL-4/5) SAE

Engine:

90 outboard motor gear oil

8.0 US qt (7.6 ) without oil filter change

Gear case: 1.24 US qt (1.17 )

ULTRA · LOW EMISSION

12V − 60A

Water cooling with thermostat

Water exhaust

VKJ20RZ-M11 (DENSO)

IZFR6F11 (NGK)

Electric powered mechanical

Automotive unleaded gasoline (86 pump octane or higher)

Forward-Neutral-Reverse (dog type)

30° right and left

− 4° to 16°

Honda outboards are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.

102

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Specifications

MODEL

Description Code

Type

Overall length

Overall width

Overall height

Transom height

Weight

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

BAGJ BAGJ BAHJ BAGJ BAHJ

LA XA

BF225A

XCA XXA

36.2 in (920 mm)

XXCA

65.7 in

(1,670 mm)

20.0 in

(508

24.6 in (625 mm)

70.9 in

(1,800 mm)

75.8 in

(1,925 mm)

25.0 in (635 mm) 30.0 in (762 mm) mm)

589 lbs

(267 kg)

600 lbs (272 kg) 611 lbs (277 kg)

167.8 kW (225 HP)

5,000 − 6,000 rpm

4 stroke SOHC VTEC 6-cylinder (V6)

211.7 cu-in (3,471 cm )

0.039

− 0.051 in (1.00

− 1.30 mm)

Starter system

Ignition system

Lubrication system

Specified oil

Oil capacity

CARB star label

D.C. output

Cooling system

Exhaust system

Spark plugs

Fuel pump

Fuel

Gear change

Steering angle

Trim angle

(when transom angle is

12°)

Electric starter

Fully transistorized, battery ignition

Trochoid pump pressure lubrication

Engine: API standard (SG, SH, SJ)

SAE 10W-30

Gear case: API standard (GL-4/5) SAE

Engine:

90 outboard motor gear oil

8.0 US qt (7.6 ) without oil filter change

Gear case: 1.24 US qt (1.17 )

ULTRA · LOW EMISSION

12V − 60A

Water cooling with thermostat

Water exhaust

VKJ20RZ-M11 (DENSO)

IZFR6F11 (NGK)

Electric powered mechanical

Automotive unleaded gasoline (86 pump octane or higher)

Forward-Neutral-Reverse (dog type)

30° right and left

− 4° to 16°

Honda outboards are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.

103

04/03/29 10:47:39 31ZY2600_105


BF200A/BF225A Tune up

Spark plug gap

Idle speed

Valve clearance (cold)

Other specifications

0.039

− 0.051 in (1.00

− 1.30 mm)

650 ± 50 rpm

Intake:

Exhaust:

0.22

± 0.02 mm

0.30

± 0.02 mm

No other adjustments needed.

See page 66

See shop manual

See shop manual

104

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CONSUMER INFORMATION

Honda Publications

These publications will give you additional information for maintaining and repairing your outboard motor. You may purchase them from your Honda marine dealer.

Shop Manual

This manual covers complete maintenance and overhaul procedures.

It is intended to be used by a skilled technician.

Parts Catalog

This manual provides complete, illustrated parts lists.

Customer Service Information

Honda Marine dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership’s management. The Service Manager or General Manager can help. Almost all problems are solved in this way.

If you are dissatisfied with the decision made by the dealership’s management, contact the Honda

Marine Customer Relations Office.

You can write:

American Honda Motor Co., Inc.

Marine Division

Customer Relations Office

4900 Marconi Drive

Alpharetta, Georgia 30005-8847

Or telephone: (770) 497-6400

When you write or call, please give us this information:

Model and serial numbers (p.

95 )

Name of the dealer who sold the outboard motor to you

Name and address of the dealer who services your outboard motor

Date of purchase

Your name, address, and telephone number

A detailed description of the problem

105

04/03/29 10:48:09 31ZY2600_111

INDEX

Alternator (ACG) Indicator ...........................................

. 29

Anodes ...........................................................................

. 32

Replacement ..............................................................

. 74

ARE YOU READY TO GET UNDER WAY?

............

. 33

Battery ...........................................................................

BATTERY WILL NOT CHARGE AND

. 97

ELECTRIC STARTER WILL NOT OPERATE .....

. 88

BEFORE OPERATION ................................................

. 33

BREAK-IN PROCEDURE ...........................................

. 35

Common Controls .........................................................

COMPONENT AND CONTROL LOCATIONS ........

. 25

. 11

CONSUMER INFORMATION

Honda Publications

.................................

.....................................................

. 105

. 105

Customer Service Information ....................................

. 105

CONTROLS ..................................................................

. 15

CONTROL AND FEATURE IDENTIFICATION

CODES ......................................................................

. 10

CONTROLS AND FEATURES

CRUISING

..................................

Cooling System Indicator ..............................................

. 31

....................................................................

. 10

. 49

Digital Speedometer (optional equipment) ...................

. 28

Digital Tachometer (optional equipment) .....................

. 28

Emission Control System Information

Engine

.........................

. 97

Cover

Latch ......................................................................

. 27

REMOVAL AND INSTALLATION ...................

. 59

Oil

Change ...................................................................

. 60

Filter Change .........................................................

. 61

Level Check ..........................................................

Recommendations .................................................

. 60

. 63

110

04/03/29 10:48:13 31ZY2600_112

INDEX

Fast Idle Button

Panel-Mount Type .....................................................

. 20

Top-Mount Type .......................................................

. 23

Fast Idle Lever ...............................................................

. 18

Fuel

PRIMING ..................................................................

Priming Bulb .............................................................

. 36

. 32

RECOMMENDATIONS ..........................................

. 69

Filter Inspection and Replacement ............................

. 70

Fuse Replacement .........................................................

. 88

Gearshift/Trottle Control Lever

Panel-Mount Type .....................................................

. 20

Side-Mount Type

Top-Mount Type

......................................................

. 16

.......................................................

. 23

GEARSHIFT AND THROTTLE OPERATION .........

. 46

Panel-Mount Type .....................................................

. 47

Side-Mount Type

Top-Mount Type

......................................................

. 46

.......................................................

. 47

HOISTING THE OUTBOARD MOTOR ....................

. 79

Ignition Switch

Panel-Mount Type .....................................................

. 18

Side-Mount Type

Top-Mount Type

......................................................

. 15

.......................................................

. 22

IMPORTANT SAFETY INFORMATION ....................

. 7

INDICATORS ...............................................................

. 29

INSTRUMENTS ...........................................................

. 27

IS YOUR OUTBOARD MOTOR

READY TO GO?

......................................................

. 33

Lubrication Points .........................................................

. 64

MAINTENANCE SAFETY .........................................

MAINTENANCE SCHEDULE ...................................

. 54

. 56

MANUAL RELIEF VALVE ........................................

. 59

MOORING, BEACHING, LAUNCHING ...................

. 51

111

04/03/29 10:48:17 31ZY2600_113

INDEX

Oil Pressure Indicator ....................................................

. 30

OIL PRESSURE INDICATOR LIGHT GOES

OFF AND ENGINE SPEED IS LIMITED ..............

. 90

OPERATION ................................................................

OTHER FEATURES ....................................................

. 35

. 31

OUTBOARD MOTOR SAFETY ...................................

. 7

Overheat Indicator .........................................................

OVERHEAT INDICATOR COMES

. 30

ON AND ENGINE SPEED IS LIMITED ................

. 91

Overrev Limiter .............................................................

. 32

Oxygenated Fuels ..........................................................

. 96

Power Tilt Switch ..........................................................

. 26

Power Trim/Tilt Switch ................................................

. 25

Programmed Fuel Injection (PGM-FI) Indicator ..........

. 29

Propeller Replacement ..................................................

. 75

REFUELING .................................................................

. 68

REMOVAL FROM STORAGE ...................................

. 81

SAFE OPERATING PRECAUTIONS

SAFETY LABEL LOCATION

........................

. 35

......................................

. 9

Serial Number Locations ...............................................

. 95

SERVICING YOUR OUTBOARD MOTOR ..............

. 53

SHALLOW WATER OPERATION ............................

. 51

Spark Plug Service

Specifications

........................................................

..............................................................

. 65

. 102

Star Label ....................................................................

STARTING THE ENGINE

. 100

..........................................

. 37

Panel-Mount Type .....................................................

. 40

Side-Mount Type ......................................................

. 37

Top-Mount Type .......................................................

. 42

STEERING ....................................................................

. 48

STOPPING THE ENGINE ...........................................

. 44

Emergency Engine Stopping .....................................

. 44

Normal Engine Stopping ...........................................

. 45

STORAGE ....................................................................

. 76

STORAGE PRECAUTIONS ........................................

. 80

STORAGE PREPARATION ........................................

. 76

Cleaning and Flushing

Engine oil

..............................................

..................................................................

. 76

. 79

Fuel ............................................................................

. 78

SUBMERGED MOTOR ...............................................

. 93

Switch Clip and Emergency Stop Switch

Panel-Mount Type .....................................................

. 19

Side-Mount Type

Top-Mount Type

......................................................

. 16

.......................................................

. 22

112

04/03/29 10:48:21 31ZY2600_114

Tachometer (optional equipment) .................................

. 28

TAKING CARE OF UNEXPECTED PROBLEMS ....

. 83

TECHNICAL INFORMATION ...................................

. 95

THE IMPORTANCE OF MAINTENANCE ...............

. 53

Tilt Lock Lever ..............................................................

. 26

TOOL KIT and OWNER’S MANUAL ........................

. 55

TRANSPORTING ........................................................

WITH OUTBOARD MOTOR INSTALLED

. 82

ON BOAT .............................................................

WITH OUTBOARD MOTOR REMOVED

. 82

FROM BOAT .......................................................

Trim Meter (optional equipment) .................................

. 82

. 27

Trim Tab ........................................................................

. 27

TRIM TAB ADJUSTMENT ........................................

. 58

WATER SEPARATOR BUZZER SOUNDS

Water Separator Inspection and Service

..............

.......................

. 92

. 72

WIRING DIAGRAMS ........................

. Inside Back Cover

INDEX

113

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MEMO

114

04/03/29 10:48:25 31ZY2600_116

MEMO

115

04/03/29 10:48:26 31ZY2600_117

MEMO

116

BF200A/BF225A

Owner’s Manual

31ZY2604

00X31-ZY2-6040

N

2eY1800.2004.04

Printed in Japan ©2004 Honda Motor Co., Ltd. -All Rights Reserved

PANTONE 288 CVC DIC F101 BLACK

2005

31ZY2604 00X31-ZY2-6040

Honda BF 200A, BF 225A Outboard motor Owner's Manual 123 Pages

Honda BF 200A, BF 225A Outboard motor Owner's Manual

INTRODUCTION

1

A FEW WORDS ABOUT

SAFETY

2

CONTENTS

3

4

5

6

IMPORTANT SAFETY

INFORMATION

OUTBOARD MOTOR SAFETY

Operator Responsibility

7

Refuel With Care

Carbon Monoxide Hazard

8

SAFETY LABEL LOCATION

9

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

10

COMPONENT AND CONTROL LOCATIONS

11

Remote Controls (optional equipment)

12

13

Trim Meter

(optional equipment)

Tachometer

(optional equipment)

Digital Speedometer

(optional equipment)

Digital Tachometer

(optional equipment)

14

CONTROLS

Side-Mount Type

Ignition Switch

15

Switch Clip and Emergency Stop

Switch

Gearshif t/Throttle Control

Lever

16

17

Fast Idle Lever

Panel-Mount Type

Ignition Switch

18

Switch Clip and Emergency Stop

Switch

19

Fast Idle Button

Gearshif t/Throttle Control

Lever

20

21

Top-Mount Type

Ignition Switch

Switch Clip and Emergency Stop

Switch

22

Fast Idle Button

Gearshif t/Throttle Control

Lever

23

24

Common Controls

Power Trim/Tilt Switch

25

Power Tilt Switch

Manual Relief Valve

Tilt Lock Lever

26

Engine Cover Latch

Trim Tab