HONDA BF2D Outboard Motor Service Manual

HONDA
BE2D Paper book Part no. 66ZW600
PREFACE CONTENTS
This manual covers the construction, function and ser-
vicing procedures of the Honda BF2D outboard motor. SPECIFICATIONS
Careful observance of these instructions will result in
better, safe service work.
SERVICE INFORMATION
MAINTENANCE
ALL INFORMATION, ILLUSTRATIONS, DIREC-
TIONS AND SPECIFICATIONS INCLUDED IN
ENGINE COVER/FUEL TANK
THIS PUBLICATION ARE BASED ON THE LAT-
EST PRODUCT INFORMATION AVAILABLE AT
RECOIL STARTER/FAN COVER
THE TIME OF APPROVAL FOR PRINTING.
HONDA MOTOR CO., LTD. RESERVES THE
RIGHT TO MAKE CHANGES WITHOUT INCUR-
ENGINE REMOVAL/INSTALLATION
RING ANY OBLIGATION WHATEVER. NO PART
OF THIS PUBLICATION MAY BE REPRODUCED CARBURETOR
WITHOUT WRITTEN PERMISSION.
FLYWHEEL/IGNITION COIL
— HONDA MOTOR CO., LTD. CLUTCH
SERVICE PUBLICATION OFFICE
CAMSHAFT/ROCKER ARM
OIL CASE/CRANKSHAFT/
CYLINDER BLOCK/PISTON/VALVE
STEERING HANDLE
CLUTCH HOUSING ENGINE UNDER
CASE/EXHAUST PIPE
STERN BRACKET/EXTENSION CASE
GEAR CASE/VERTICAL SHAFT
00 154 | ©) ЕЛЕ | 60 | О | ES
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HONDA
BF2D
1. SPECIFICATIONS
1. SPECIFICATIONS
2. DIMENSIONAL DRAWINGS
3. WIRING DIAGRAM
1. SPECIFICATIONS
* DIMENSIONS AND WEIGHTS
Type s | u SH LH SC LC SCH LCH
Description code BZBK | BZBF
Overall length 410 mm (16.1 in)
Overall width 280 mm (11.0 in)
Overall height 945mm | 1,100 mm | 945 mM | 1,100 mm | 945 mm | 1,100 mm | 945 mm | 1,100 mm
(37.2 п) | (43.3 п) | (37.2 п) | (43.3 п) | (37.2 in) | (43.3 in) | (37.2 in) | (43.3 in)
Dry weight 12.1 kg 12.7 kg 12.4 kg 13.0 kg 12.4 kg 13.0 kg 12.7 kg 13.3 kg
(26.7 16) | (28.016) | (27.316) | (28.7 Ib) | (27.31b) | (28.7 Ib) | (28.0 Ib) | (29.3 Ib)
Operating weight 13.1 kg 13.7 kg 13.4 kg 14.0 kg 13.4 kg 14.0 kg 13.7 kg 14.3 kg
(29.9 ib) | (30.2 1b) | (29.5 1b) | (30.9 Ib) | (29.5 Ib) | (30.9 Ib) | (30.216) | (31.5 6)
Transom height 418 mm | 571mm | 418mm | 571 mm | 418mm | 571mm | 418 mm | 571 mM
(16.5 in) | (22.5in) | (16.5in) | (22.5in) | (16.5 in) | (22.5 п) | (16.5 п) | (22.5 in)
Transom angle
4-stage adjustment (5%, — 10°, —15°, —20°)
Tilt angle adjustment
1-stage adjustment
Tilt-up angle 75°
Swivel angle 360°
ENGINE
Type Vertical 4-stroke, overhead valve single cylinder
Displacement
57 ст? (3.48 си п)
Bore x stroke
45.0 x 36.0 mm (1.77 x 1.42 in)
Maximum horsepower
1.5 kW (2.0 PS) at 6,000 min-' (rpm)
Maximum torque
2.69 N-m (0.27 kgf-m, 1.95 Ibf-ft) at 4,500 min-' (rpm)
Compression ratio 8.0:1
Fuel consumption 420 g/kW-h (309 g/PS-h, 0.68 Ib/PS-h)
Cooling system Forced air
Ignition system
Transistorized magneto ignition
Ignition timing 27° B.T.D.C.
Spark plug NGK: CR5HSB, DENSO: U16FSR-UB
Carburetor Float type
Lubrication system
Forced splash
Oil capacity
0.25 2 (0.26 US at, 0.22 Imp qt)
Starting system
Recoil starter
Stopping system
Primary ground
Fuel used
Automotive unleaded gasoline 91 reach octane, 86 pump octane or higher
Fuel tank capacity
1.0 £ (0.26 US gal, 0.22 Imp gal)
Clutch
Centrifugal (SC, LC, SCH and LCH type only)
1-1
HONDA
BF2D
- LOWER UNIT
Type S, L, SH, LH, SC, LC, SCH, LCH
Reduction Spiral bevel gear
Gear ratio 0.41 (12/29) |
Gear case oil Hypoid gear oil (SAE #90)
Gear case oil capacity
0.05 £ (0.05 US gt, 0.04 Imp at)
Propeller Type
Aerofoil
No. of blades x Dia. x Pitch
3 x 184 x 120 mm
Rotating direction
Clockwise (Viewed from rear)
2. DIMENSIONAL DRAWINGS
S, L, SC, LC type:
-4-———— 510 (20.1)
“4— 410 (16.1) — >
S, SH, SC, SCH type: 945 (37.2)
L, LH, LC, LCH type: 1,100 (43.3)
L, LH, LC, LCH type:
418 (16.5)
571 (22.5)
Unit: mm (in)
SH, LH, SCH, LCH type:
4 280 (11.0) >
: Red
BI: Black
R
[5]
=
че
ый
E
5
COIL
[3] IGNITION
1INN
[2]
BF2D
3. WIRING DIAGRAM
EMERGENCY
STOP SWITCH
[1]
BI/R
Bi
magia to Sd po. ptit ci de
TEE sE as
HONDA
2. SERVIGE INFORMATION BF2D
1. THE IMPORTANCE OF PROPER SERVICING 6. TORQUE VALUES
2. IMPORTANT SAFETY PRECAUTIONS 7. SPECIAL TOOLS
3. SERVICE RULES 8. TROUBLESHOOTING
4. SERIAL NUMBER LOCATION 9. CABLE & HARNESS ROUTING
5. MAINTENANCE STANDARDS
1. THE IMPORTANCE OF PROPER SERVICING
Proper servicing is essential to the safety of the operator and the reliability of the engine. Any error or oversight made
by the technician while servicing can easily result in faulty operation, damage to the engine or injury to the operator.
Improper servicing can cause an unsafe condition that can lead to serious injury or death.
Follow the procedures and precautions in this shop manual carefully.
Some of the most important precautions are given below. However, we cannot warn you of every conceivable hazard that
can arise in performing maintenance or repairs. Only you can decide whether or not you should perform a given task.
Failure to follow maintenance instructions and precautions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this shop manual carefully.
2. IMPORTANT SAFETY PRECAUTIONS
Be sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing
and safety equipment. When performing maintenance or repairs, be especially careful of the following:
+ Read the instructions before you begin, and be sure you have the tools and skills required to perform the tasks safely.
Be sure that the engine is off before you begin any maintenance or repairs. This will reduce the possibility of several
hazards:
« Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you run the engine.
* Burns from hot parts.
Let the engine cool before you touch it.
* Injury from moving parts.
Do not run the engine unless the instruction tells you to do so. Even then, keep your hands, fingers, and clothing
away.
To reduce the possibility of a fire or explosion, be sure when working around gasoline. Use only a nonflammable sol-
vent, not gasoline, to clean parts. Keep all cigarettes, sparks, and flames away from all fuel-related parts.
2-1
BF2D
3. SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet
Honda's design specifications may damage the engine.
Use the special tools designed for the product.
Install new gaskets, O-rings, etc. when reassembling. |
When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diag-
onally, unless a particular sequence is specified. |
Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
After reassembly, check all parts for proper installation.and operation. |
Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws
will strip the threads and ruin the hole. | ВЕ
8. Use only metric tools when servicing this engine. Metric bolts, nuts and screws are not interchangeable with non-
metric fasteners. The use of incorrect tools and fasteners will damage the engine.
9. Be sure that the battery built in a tester is fully charged and check the meter before inspection using the tester.
10. Follow the instructions represented by these symbols when they are used.
м о e
Noo
fra: Apply recommended grease. - : Use special tool. | : Apply oil.
O x O (0): Indicates the diameter, length, and quantity of metric flange bolt used.
P.O-O :Indicates the reference page.
4. SERIAL NUMBER LOCATION —
The engine serial number is stamped on the clutch housing and frame serial number is located on the stern bracket.
Refer to this when ordering parts or making technical inquiries.
O
1
he
ENGINE SERIAL NUMBER FRAME SERIAL NUMBER
HONDA
BF2D
5. MAINTENANCE STANDARDS
ENGINE
Part item Standard Service limit
Engine Idle speed 2,000 + 100 min-' (rpm) —
Full throttle range 5,000 - 6,000 min-! (rpm) —
Cylinder compression 0.88 MPa (9.0 kgf/cm? 128 psi)/ I
| 1,000 min" (rpm)
Cylinder Sleeve I.D. 45.000 - 45.015 mm (1.7717 - 1.7722 in) | 45.100 mm (1.7756 in)
Piston Skirt O.D. 44.97 - 44.99 mm (1.770 — 1.771 in) 44.90 mm (1.768 in)
Piston-to-cylinder clearance 0.010 — 0.045 mm (0.0004 - 0.00187 in) | 0.120 mm (0.0047 in)
Pin bore I.D. 10.002 - 10.008 тит (0.3938 - 0.3940 in) | 10.050 mm (0.3957 in)
Piston pin O.D. 9.994 - 10.000 mm (0.3935 - 0.3937 in) | 9.950 mm (0.3917 in)
Pin-to-piston clearance 0.002 - 0.014 mm (0.0001 - 0.0006 in) 0.100 mm (0.0039 in)
Piston ring Ring width Top/second 0.97 — 0.99 mm (0.038 — 0.039 in) 0.920 mm (0.0362 in)
Ring side clearance Top/second 0.015 - 0.050 mm (0.0006 — 0.0020 in) 0.120 mm (0.0047 in)
Ring end gap Top | 0.100 - 0.250 mm (0.0039 - 0.0098 in) 0.600 mm (0.0236 in)
Second 0.250 — 0.400 mm (0.0098 - 0.0157 in) 0.6500 mm (0.0236 in)
Connecting rod | Small end 1.D. 10.006 — 10.017 mm (0.3939 — 0.3944 in) | 10.050 mm (0.3957 in)
Big end |.D. 15.000 - 15.011 mm (0.5906 — 0.5910 in) | 15.040 mm (0.5921 in)
Big end oil clearance 0.016 - 0.038 mm (0.0006 — 0.0015 in): | 0.100 mm (0.0039 in)
Big end side clearance 0.1 — 0.6 mm (0.004 — 0.024 in) 0.8 mm (0.031 in)
Crankshaft Crank pin O.D. 14.973 — 14.984 mm (0.5895 — 0.5899 in) | 14.940 mm (0.5882 in)
Valves Valve clearance IN 0.08 + 0.02 mm (0.0031 + 0.0008 in) —
EX | 0.11+0.02mm (0.0043 + 0.0008 in) —
Stem O.D. IN 3.970 - 3.985 mm (0.1563 — 0.1569 in) 3.900 mm (0.1535 in)
EX | 3.935 - 3.950 тит (0.1549 — 0.1555 in) 3.880 mm (0.1528 in)
Guide 1.0. - IN/EX | 4.000 - 4.018 mm (0.1575 - 0.1582 in) 4.060 mm (0.1598 in)
Stem-to-guide IN | 0.015 - 0.048 тит (0.0006 - 0.0019 п) | 0.098 mm (0.0039 in)
clearance ЕХ | 0.050 - 0.083 тит (0.0020 - 0.0033 п) | 0.120 mm (0.0047 in)
Valve spring Free length IN/EX 23.7 mm (0.93 in) 22.8 mm (0.90 in)
Camshaft Cam height 27.972 mm (1.1013 in) 27.672 mm (1.0894 in)
.D. (Bearing) 5.020 - 5.050 mm (0.1976 — 0.1988 in) | 5.100 mm (0.2008 in)
Camshaft roller | O.D. 4.990 —- 5.000 mm (0.1965 — 0.1969 in) 4,950 mm (0.1949 in)
Valve lifter 1.0. (Bearing) 5.005 - 5.025 mm (0.1970 - 0.1978 in) 5.060 mm (0.1988 in)
Valve lifter roller | O.D. 4.990 — 5.000 mm (0.1965 — 0.1969 in) | 4.950 mm (0.1949 in)
Crankcase cover | Camshaft Bearing 1.0. 5.005 — 5.023 mm (0.1970 — 0.1978 in) 5.050 mm (0.1988 in)
Valve lifter roller Bearing I.D. 5.005 - 5.023 mm (0.1970 - 0.1978 in) 5.050 mm (0.1988 in)
Cylinder block Camshaft roller Bearing |.D. 5.005 — 5.023 mm (0.1970 — 0.1978 in) 5.050 mm (0.1988 in)
Valve lifter roller Bearing !1.D. 5.005 - 5.023 mm (0.1970 - 0.1978 in) 5.050 mm (0.1988 in)
Rocker arm roller Bearing I.D. 4.000 — 4.018 mm (0.1575 — 0.1582 in) 4.050 mm (0.1594 in)
Rocker arm 1.D. (Bearing) 4.005 — 4.025 mm (0.1577 — 0.1585 in) 4.050 mm (0.1594 in)
Rocker arm roller | O.D. 3.990 - 4.000 mm (0.1571 - 0.1575 in) 3.950 mm (0.1555 in)
Clutch Lining thickness 2.0 mm (0.08 in) 1.0 mm (0.04 in)
Clutch outer D. 78.00 — 78.25 mm (3.071 — 3.081 in) 78.5 mm (30.09 in)
2-3
HONDA
BF2D
Part Item Standard Service limit
Spark plug Gap | 0.6 - 0.7 mm (0.024 - 0.028 in)
Ignition coil Resistance Primary side 0.98 — 1.20 2 ——
Secondary side 11 - 15 КО —
Air gap 0.3 - 0.5 mm (0.012 - 0.020 in) —
Carburetor Main jet #65 —
Float height 12 mm (0.47 in) —
Pilot screw opening Except SCG, LCG, SCHG, LCHG type: —
— 2 turns out
SCG, LCG, SCHG, LCHG type: —
2-1/4 turns out
* LOWER UNIT
Part Item Standard Service limit
Propeller shaft Holder O.D. 10.973 — 10.984 mm (0.4320 — 0.4324 in) | 10.930 mm (0.4303 in)
Propeller shaft Shaft bore 1.D. 11.000 - 11.018 mm (0.4331 — 0.4338 in) | 11.060 mm (0.4354 in)
holder
Holder-to-shaft clearance
0.016 — 0.045 mm (0.0006 - 0.0018 in)
Bushing-to-vertical shaft
clearance
0.16 - 0.23 mm (0.006 — 0.009 in)
Vertical shaft Gear case O.D. 10.97 - 10.99 mm (0.432 - 0.433 in) 10.93 mm (0.430 in)
Vertical bushing O.D. 10.97 — 10.99 mm (0.432 - 0.433 in) 10.93 mm (0.430 in)
Gear case Vertical shaft bore I.D. 11.000 — 11.018 mm (0.4331 — 0.4338 in) | 11.060 mm (0.4354 in)
Gear case-to-vertical shaft 0.010 — 0.048 mm (0.0004 — 0.0019 in) —
Vertical shaft Vertical shaft bore I.D. 11.15 — 11.20 mm (0.439 — 0.441 in) 11.70 mm (0.461 in)
bushing
HONDA
BF2D
6. TORQUE VALUES
Tighténing torque
item Thread dia. x pitch type Remark
N-m kgf-m Ibf-ft
Spark plug M10 x 1.0 12 1.2 9
Crankcase side cover M5 x 0.8 CT flange bolt 7.5 0.75 5.4
Crankcase M5 x 0.8 CT flange bolt 7.5 0.75 5,4
Connecting rod cap M5 x 0.8 flange bolt 6.0 0.6 4.3
Cylinder head cover bolt Mb x 0.8 CT flange bolt 6.0 0.6 4.3
Oil drain bolt M8 x 1.25 screw 6.5 0.65 4.7
Flywheel M10 x 1.25 flange nut 27.5 2.75 20 Apply oil to
threads and
seat.
Fuel tank M6 x 1.0 cap nut 8 0.8 5.8
Clutch stay M8 x 1.25 flange bolt 22.5 2.25 16
Clutch shoe bolt M8 x 1.25 special bolt 15.5 1.55 11
Ignition coil M5 x 0.8 CT flange bolt 6.0 0.6 4.3
Stud bolt M5 x 0.8 CT flange bolt 6.0 0.6 4.3
Carburetor joint plate M5 x 0.8 screw 4.5 0.45 3.3
Carburetor drain bolt M4 x 0.7 screw 1.5 0.15 1.1
Emergency stop switch M16 x 1.0 hex. nut 3.0 0.3 2.2
Exhaust pipe M5 x 0.8 flange bolt 6.0 0.6 4.3
Gear case M6 x 1.0 hex. bolt 10 1.0 7
Anode metal M6 x 1.0 hex. bolt 10 1.0 7
Propeller shaft holder M6 x 1.0 hex. bolt 10 1.0 7
Cavitation plate M6 x 1.0 hex. bolt 10 1.0 7
Oil check bolt M8 x 1.25 special bolt 3.5 0.35 2.5
Extension case M6 x 1.0 flange bolt 12 1.2 9
Extension separator M6 x 1.0 hex. boit 10 1.0
Water pipe M5 x 0.8 hex. bolt 5.3 0.53 3.8
Swivel case cap M8 x 1.25 hex. bolt 24 2.4 17
Stern bracket M8 x 1.25 hex. bolt/nut 24 2.4 17
Under case M6 x 1.0 flange bolt 13 1.3 9
Grease nipple M6 x 1.0 3.0 0.3 2.2
Steering handle M8 x 1.25 flange bolt 24 2.4 17
Throttle housing M5 x 0.8 screw 4.3 0.43 3.1
Throttle lever M6 x 1.0 hex. nut 10 1.0
Throttle arm M6 x 1.0 hex. nut 10 1.0
Cable holder M6 x 1.0 flange bolt 8 0.8
Throttle cable M10 x 1.25 hex. nut 4 0.4 2.9
* Use standard torque values (P.
2-6) for the fasteners that are not listed in this table.
* CT flange bolt indicates a self-tapping bolt.
2-5
HONDA
BF2D
STANDARD TORQUE VALUES
, Tightening torque
item . Thread dia.
N-m kgf-m Ibf-ft
Flange bolt, flange nut 4 mm. 3.5 0.35 2.5
5mm 5.5 0.55 4.0
6mm 10 1.0 7
8 mm 27 2.7 20
Screw 3 mm 1.0 0.10 0.7
4 mm 2.1 0.21 1.4
5mm 4.3 0.43 3.1
CT flange bolt 5 mm 5.5 0.55 4.0
* CT flange bolt indicates a self-tapping bolt.
7. SPECIAL TOOLS
FIONDA
BF2D
Application
Carburetor float level inspection
Clutch stay bolt removal/installation
2.5 mm spring pin removal/installation
Crankshaft oil seal installation
Gear case bearing installation
Clutch outer bearing installation
Crankshaft oil seal installation
Gear case bearing installation
Water seal removal
Used together with the tools (6) and (4) or
Clutch outer bearing removal
Water seal installation
Gear case bearing removal
Combustion chamber cleaning
No. Tool name Tool number
M | Float level gauge 07401 - 0010000
@ | Pin spanner 07702 - 0020001
© | Pin driver, 2.5 mm 07744 - 0010100
Outer driver, 24 x 26 mm 07746 - 0010700
® | Inner driver handle 07746 - 0020100
© | Pilot, 17 mm 07746 - 0040400
Pilot, 10 mm 07746 — 0040100
@ | Oil seal remover 07748 — 0010001
Driver handle 07749 — 0010000
Bearing separator 07631 - 0010000
Oil seal driver attachment 07947 - ZV00100
@) | Bearing remover shaft 07936 - GE00100
@ | Bearing remover head, 10 mm 07936 - GE00200
@ | Sliding weight 07741 - 0010201
dd | Cleaning brush 07998 - VA20100
® @
—
®
7
=
2-7
о BF2D
8. TROUBLESHOOTING
a. GENERAL SYMPTOMS AND POSSIBLE CAUSES
* Hard starting | т > CARBURETOR FLOAT CHAM- — Drain old fuel. Fill tank with
BER contains stale gasoline. | fresh gasoline.
—» SPARK PLUG WIRE discon- | Reconnect. |
nected. | |
—»| FUEL TUBE clogged. |—— Clean (P.3-7). |
—>| FUEL TANK FILTER clogged. |—— Replace (P. 3-7). |
—» FUEL TANK clogged. LH Clean (P. 3-7). |
—| THROTTLE CABLE out of adjust- |—#={ Readjust (P.3-6). |
ment.
">| CARBURETOR out of adjust- | Readjust (P. 3-5).
ment. | " | Disassemble and inspect
(P. 7-2).
— IGNITION COIL air gap incor- HP Readjust (P. 8-3). |
rect. o
—»| IGNITION COIL faulty. ———»| Replace (P. 8-3). |
— SPARK PLUG faulty. ___— | >| Верисе (Р. 3-3) |
—» EMERGENCY STOP SWITCH ——! Inspect (P. 13-4). |
faulty. | _ a
—»-| NO SPARK at plug. || Troubleshoot (P. 2-14). |
HONDA
BF2D
+ Engine lacks power.
>| SPARK PLUG faulty.
E» Inspect (P. 3-3). |
—» VALVE CLEARANCE incorrect. —>| Readjust (P. 3-4).
CYLINDER, PISTON or PISTON
RING worn.
Disassemble and
(section 11).
—
inspect
* Engine will not rev suffi-
ciently.
CARBURETOR out of adjust-
ment.
Readjust (P. 3-5).
Disassemble and
р
inspect
(P. 7-2).
THROTTLE CABLE out of adjust-
ment.
— Readjust (P. 3-6).
LS
IGNITION COIL faulty.
| > Inspect (P. 8-3).
* Poor performance at high
speed.
SPARK PLUG faulty.
= Replace (P. 3-3). |
>
- Poor performance at low
speed.
CARBURETOR clogged.
— Disassemble and clean (P. 7-2). |
—»| SPARK PLUG faulty.
— Inspect (P. 3-3). |
THROTTLE CABLE out of adjust-
ment.
—— || Readjust (P. 3-6). |
>
CARBURETOR clogged.
— Disassemble and clean (P. 7-2). |
THROTTLE CABLE out of adjust-
ment. |
| Readjust (P. 3-6). ||
—» VALVE CLEARANCE incorrect. [——®| Readjust (P. 3-4). |
2-9
HONDA
BF2D
b. ENGINE
* Hard Starting
| 1. First check the fuel level in the tank. — No fuel —— Add fuel and restart the engine.
Sufficient fuel
2. Loosen the drain screw and check whether | — Fuel not _ „| Check for blockage of the fuel tubes and/or
fuel reached the carburetor. reached. strainers. |
|
Fuel reached the
carburetor.
3. Remove the spark plug and inspect for wet Dry —»| Check for blockage in the carburetor port and
or fouled electrode. | nozzle.
Wet ——m| * Clean the electrode and restart, taking care
that the choke is not closed too much.
* If flooding is severe, check the carburetor
float valve.
— No sparkor
weak spark — See IGNITION SYSTEM TROUBLESHOOTING
4. Perform spark test (P. 2-14).
| | (P. 2-14).
Good spark
5. Check the cylinder compression (see High cylinder Check to see whether excessive carbon has
below). | | compression accumulated in the combustion chamber.
|
Normal compression Low cylinder < Check that the valve clearance is correct.
compression * Check for worn piston rings, piston or cylin-
| Install the spark plug and restart the engine. der.
« CYLINDER COMPRESSION CHECK
1) Remove the engine cover (P. 4-1). COMPRESSION GAUGE
(commercially available)
2) Remove the spark plug and install a compression gauge
in the spark plug hole. ‘
3) Pull the recoil starter several times with force and mea-
sure the cylinder compression.
Cylinder 0.88 MPa (9.0 kgf/cm?, 128 psi) at
compression 1,000 rpm
2-10
HONDA
BF2D
« Engine Starts But Then Stalls
| 1.
Check the fuel level in the tank.
|
Sufficient fuel
— No fuel —|
2.
Check for blockage of the fuel tube and fuel
Add fuel and restart.
Clogged —»
filter.
|
Not clogged
Remove the clogged foreign material from
the fuel tube.
Clean the fuel filter (P. 3-7).
. Check for the loose bolts on the carburetor,
or loose screws tightening the carburetor
joint plate. Check for secondary air sucked
through the damaged carburetor insulator
—— Abnormal —»
Tighten the carburetor mounting bolts and
joint plate mounting screws.
Replace the carburetor insulator (P. 7-1 and
10-3).
or packing.
Perform the IGNITION SYSTEM trou-
bleshooting (P. 2-14).
Normal
No spark
| 4. Perform the spark test (P. 2-14). or weak —»
spark
Good spark
5. Measure the cylinder compression (P. 2-10). -— Abnormal —»
Normal
6. Disassemble the carburetor and clean the
ports. Replace the pilot screw if necessary
and readjust the pilot screw (P. 7-3).
Check whether the valve clearance is cor-
rect (P. 3-4).
Check for worn piston, piston ring or cylin-
der.
Check for carbon deposits in the combus-
tion chamber.
Restart the engine following the starting pro-
cedure.
2-11
HONDA
BF2D
» Engine Lacks Power
| 1. Check whether the choke is closed. — Full close. — Open the choke fully.
Full open.
2. Check for blockage in the main jet or nozzle | Clogged —» Disassemble, and clean and replace if neces-
of the carburetor. sary.
+
3. Remove the spark plug and check the elec- |__ Abnormal — Clean the spark plug and adjust the plug gap,
trodes for carbon and spark plug gap. and replace if necessary.
Normal
No spark
4. Perform spark test (P. 2-14). — or weak —M| See IGNITION SYSTEM TROUBLESHOOTING
| spark (P. 2-14).
Good spark
| 5. Check the valve clearance. — Incorrect — Adjust the valve clearance (P. 3-4).
| |
Correct
| 6. Check the cylinder compression (P. 2-10). — Abnormal —»{ « Check for worn piston rings, piston or
| cylinder.
Normal | * Check to see whether excessive carbon has
accumulated in the combustion chamber.
Reinstall the spark plug securely.
Restart the engine following the starting pro-
cedure.
2-12
HONDA
BF2D
* Engine Speed Does Not Increase
1. Check that the throttle cable adjustment is Incorrect —» Adjust the throttle cable (P. 3-6).
correct (P. 3-6 grip throttle type only).
Correct
2. Check the valve clearance. О Incorrect —» Adjust the valve clearance (P. 3-4). |
|
Correct |
3. Remove the spark plug and check the elec- | Abnormal —» Clean the spark plug and adjust the plug gap,
trodes for carbon and spark plug gap. and replace if necessary (P. 3-3).
Normal
4. Check for blockage in the main jet or nozzle | Clogged —» Disassemble, and clean and replace if neces-
of the carburetor. sary (P. 7-2).
Not clogged
5. Check for the loose bolts on the carburetor, Abnormal —»{ ¢ Tighten the carburetor mounting bolts and
or loose screws tightening the carburetor joint plate mounting screws.
joint plate. Check for secondary air sucked * Replace the carburetor insulator.
through the damaged carburetor insulator
or packing.
|
Normal
6. Check the valve spring (P. 11-9).
Replace the valve spring if necessary (P.
11-5).
2-13
« SPARK TEST
* Do not pull the recoil starter rope while touching the
high tension wire. High voltage generates, which is
very dangerous. Be sure to ground the spark plug and
hold the plug cap to perform the spark test.
* Gasoline is extremely flammable and explosive. If
ignited, gasoline can burn you severely. Be sure there
is no spilled fuel near the engine.
- Unburnt gas can ignite if it is left in the cylinder. Be
sure to drain the carburetor thoroughly before spark
test, and release the unburnt gas from the cylinder by
pulling the recoil starter several times.
1) Remove the engine cover (P. 4-1) and remove the spark
plug cap. Clean any dirt from around the spark plug
base, then remove the spark plug.
2) Loosen the carburetor drain screw to drain the carbure-
tor thoroughly. Pull the recoil starter several times to
release the unburnt gas from the cylinder.
3) Install the spark plug in the plug cap.
4) Make sure that the emergency stop switch clip is
engaged with the emergency stop switch.
5) Ground the side electrode against the recoil starter
mounting cap nut as shown, pull the recoil starter and
check to see if sparks jump across the electrodes.
c. IGNITION SYSTEM
1. Measure the spark plug gap and perform
the spark test.
Plug gap:
0.6 - 0.7 тт (0.024 - 0.028 in)
|
No spark
spark plug.
|
No spark
3. Check the insulation of the high tension ——
wire for damage causing current leakage.
Ï
No spark
gency stop switch and retest.
!
No spark
Faulty ignition coil.
* Replace the ignition coil.
2. Check again after replacing with a new | Sparks — >
Faulty spark plug.
* Replace the spark plug.
Damaged
—» Replace the ignition coil (P. 8-1).
insulation
4. Disconnect the black wire from the emer- [| Sparks ——»
Faulty emergency stop switch.
* Replace the emergency stop switch (P. 13-2).
2-14
HONDA
BF2D
d. LOWER UNIT
| Gear case oil is milky. |-> WATER SEAL damaged or
worn.
»| Replace the water seal (P. 15-2). |
—» GEAR CASE bolt loose. |——— > Retighten the case bolts. |
PROPELLER SHAFT worn or Inspect and replace the pro-
———— |
damaged.
peller shaft (P. 15-1).
PROPELLER SHAFT HOLDER
PACKING faulty.
Replace the propeller shaft
gasket (P. 15-1).
— Replace the clutch (P. 9-1). |
— Inspect (P. 13-4). |
Engine speed increases but CLUTCH LINING worn.
the cruising speed does not
increase.
CLUTCH OUTER worn or dam-
aged.
PROPELLER faulty or stuck
with foreign material.
Inspect and replace the pro-
peller (P. 15-1).
—— —
— Replace the shear pin (P. 15-1).
PROPELLER SHEAR PIN dam-
aged.
2-15
BF2D_
9. CABLE & HARNESS ROUTING
[2] FUEL TUBE
Set in the cutout in the
engine under case.
[1] THROTTLE WIRE
Set underside the boss of |
the fan cover.
[3] THROTTLE WIRE
[12] FUEL TUBE
[11]
THROTTLE CABLE
(Grip throttie type only)
[4] CABLE CLAMPS
Secure the high ten-
sion cord.
[10] [5]
EMERGENCY STOP SWITCH HIGH TENSION
WIRE CORD
Set along the groove in the A
| => [6]
fan cover.
STOP SWITCH WIRE
Set the connectors
in the groove of the
[9]
EMERGENCY STOP SWITCH fan cover.
WIRE
Set in the cutout in the
fan cover. 90° :
[71HIGH TENSION CORD
[8] The cord must not be slack
EMERGENCY STOP SWITCH between the grommet and
GROUND TERMINAL the clamp of the fan cover.
Install in the direction
shown.
2-16